TABLE OF CONTENTS
1 SAFETY " FUEL
INTRODUCTION 1-1 INTRODUCTION 4-1
CLEANING, WAXING, &: POLISHING 1-1 GENERAL CARBURETION
CONTROLLING CORROSION 1-1 INFORMA TION 4-1
PROPELLERS 1-2 TROUBLESHOOTING 4-5
FUEL SYSTEM 1-7 "Sour" Fuel 4-6
LOADING 1-9 Leaded Gasoline &: Gasohol 4-6
HORSEPOWER 1-10 Removing Fuel From System 4-7
FLOTATION 1-10 Fuel Pump Test 4-9
EMERGENCYEQUWMENT 1-12 Fuel Line Test 4-11
COMPASS 1-14 Rough Engine Idle 4-12
STEERING 1-16 Excessive Fuel Consumption 4-12
ANCHORS 1-16 Engine Surge 4-13
MISCELLANEOUS EQUIPMENT 1-17 CARB URE TOR IDE NTIFICA TION 4-13
BOATING ACCIDENT REPORTS 1-17
NAVIGATION 1-18 CARBURETOR "A" - SIDE BOWL
AND BACK DRAG 4-14
2 TUNING Removal &: Disassembling 4-14
Cleaning &: Inspecting 4-16
INTRODUCTION 2-1 Assembling &: Installation 4-20
TUNE-UP SEQUENCE 2-2 Adjustments 4-24
COMPRESSION CHECK 2-3
SPARK PLUG INSPECTION 2-3 CARBURETOR liB" V6 POWERHEADS
IGNITION SYSTEM 2-4 DUAL FLOAT CENTER BOWL 4-25
TIMING AND SYNCHRONIZING 2-5 Removal &: Disassembling 4-25
CARBURETOR ADJUSTMENT 2-7 Cleaning &: Inspecting 4-27
FUEL PUMPS 2-9 Assembling &: Installation 4-29
CRANKING MOTOR
AND SOLENOID 2-10 CARBURETOR "C" - CENTER
INTERNAL WIRING HARNESS 2-11 SQUARE BOWL 4-33
WATER PUMP CHECK 2-12 Removal &: Disassembling 4-33
PROPELLER 2-13 Cleaning &: Inspecting 4-37
LOWER UNIT 2-15 Assembling &: Installation 4-37
BOAT TESTING 2-16
FUEL PUMP 4-42
3 MAINTENANCE Theory of Operation 4-42
Pump Pressure Check 4-43
INTRODUCTION 3-1 Pump Removal 4-44
OUTBOARD SERIAL NUMBERS 3-2 Cleaning &: Inspecting 4-45
LUBRICATION - COMPLETE UNIT 3-2 Assembling 4-45
PRE-SEASON PREPARA TION 3-6
FIBERGLASS HULLS 3-10 ELECTRONIC FUEL
BELOW WATERLINE SERVICE 3-10 INJECTION (EFI) 4-47
SUBMERGED ENGINE SERVICE 3-11 General Infor ma tion 4-47
PROPELLER SERVICE 3-13 System Description 4-47
POWER TRIM/TILT 3-15 Troubleshooting EFI 4-55
INSIDE THE BOAT 3-16
LOWER UNIT 3-16 EFI MAINTENANCE 4-62
WINTER STORAGE 3-18 Removing Fuel from System 4-63
FUEL (Continued) Assembling 5-37
" SERVICING EFI 4-64
ELECTRONIC "BLACK BOX"
MODULES 5-38
Intake Manifold &. Injectors 4-64 Operation 5-39
Cleaning &. Inspecting 4-70 Troubleshooting 5-39
Assembling &. Installation 4-70
Fuel Filter Service 4-75 6 TIMING AND SYNCHRONIZING
Fuel Pressure Regulator
&. Vapor Separator Service 4-77 INTRODUCTION &. PREPARATION 6-1
Throttle Sensor Service 4-81 IGNITION TIMING AND
OIL INJECTION SYSTEM 4-83 CARB SYNCHRONIZATION 6-3
"Auto Blend" System 4-84 ELECTRONIC IDLE STABILIZER AND
Description 4-84 SPARK ADVANCE MODULES 6-6
Troubleshooting 4-85 MODEL 900 - 1965
Storing the System 4-88 MODEL 950 - 1966
Prep. for Use 4-88 MODEL 100 - 1965
Advanced Oil Injection 4-89 MODEL 1100 - 1966 6-7
Description 4-89
Operation 4-92 MODEL 950SS - 1966
Filling System 4-93 MODEL 1100SS - 1966 6-9
Purging Air 4-93
Oil Pump Adjustment 4-94 MODEL 950SS &. 1100SS - 1967 6-10
Troubleshooting 4-94
Servicing 4-94 MODEL 1000SS - 1968-69 6-12
MODEL 1250SS - 1968-69 6-14
5 IGNITION MODEL 1150 - 1970-73
MODEL 1350 - 1970-71
INTRODUCTION 5-1 MODEL 1400 - 1972
SPARK PLUG EVALUATION 5-2 MODEL 1500 - Early 1973 6-16
POLARITY CHECK 5-4
WIRING HARNESS 5-5 MODEL 1150 - 1974 SIN 3761035
MODEL 1500 - Late 1973-74
TYPE I SYSTEM - DISTRIBUTOR SIN 3628318 to 3752840 6-17
WITH POINTS
Description 5-5 MODEL 900 - 1978-79
Troubleshoo ting 5-7 MODEL 1150 - 1975-79
Servicing 5-10 MODEL 140 - 1979
Removal 5-10 MODEL 1500 - 1975-77
Distributor Disassembly 5-11 MODEL 1500XS - 1978
Cleaning &. Inspecting 5-14 (UNITS WITH DISTRIBUTOR) 6-19
Distributor Assembling 5-14
Installat ion 5-19 MODEL 90 - 1980 &. ON
TYPE D SYSTEM - DISTRIB UTOR MODEL 115 - 1980 &. ON
CD - POINTLESS MODEL 140 - 1980 &. ON
Description 5-20 (UNITS WITHOUT DISTRIBUTOR) 6-21
Troubleshoo ting 5-22
Servicing 5-23 MODEL 1750 V6 - 1976-77 6-24
Distributor Removal 5-24
Cleaning &. Inspecting 5-25 MODEL 1750 V6 - 1978 ONLY
Distributor Assembling 5-25 MODEL 175 V6 - 1979-81 6-27
TYPE mSYSTEM - CD
COIL PER CYLINDER MODEL 1500 &. 150 V6
Description 5-28 SIN 5203428 AND BELOW
Troubleshooting 5-29 MODEL 2000 &. 200 V6
Servicing 5-35 SIN 5363917 AND BELOW 6-31
MODEL 200 SIN 6073192 &: ABOVE 8 POWERHEAD
MODEL 225 ALL 6-34
CHAPTER ORGANIZATION 8-1
MODEL -135 SIN A907777 &: ABOVE GENERALPOWERHEAD
MODEL 150 SIN 5203429 &: ABOVE INFORMATION 8-1
MODEL 200 SIN 5363918
TO 6073191 L6 POWERHEAD
MODEL 175 SIN 6618751 Removal and Disassembling 8-5
&: ABOVE 6-37 Cleaning and Inspecting 8-11
Thermostat Service 8-11
MODEL 250, 275, 300 Reed Block Service 8-12
AND 3.4 LITRE 6-40 Crankshaft Service 8-13
V6 POWERHEADS End Cap Bear ings 8-14
WITH EFI 6-43 Connecting Rod Service 8-14
Piston Service 8-16
Honing Procedures 8-20
7 ELECTRICAL Cylinder Block Service 8-21
Assembling &: Installation 8-21
INTRODUCTION 7-1 L6 With Oil Injection 8-37
BATTERIES 7-1
V6 POWERHEAD
GAUGES AND HORNS 7-7 Removal and Disassembling 8-35
Temperature Gauges 7-8 Crankshaft Disassembling 8-40
Warn ing Ugh ts 7-8 Piston Disassembling 8-42
Fuel Gauges 7-9 End Cap Disassembling 8-43
Tachometer 7-11 Cleaning and Inspecting 8-46
Horns 7-11 Thermosta t Service 8-46
ELECTRICAL SYSTEM 7-12 Reed Block Service 8-47
General Information 7-12 Crankshaft Service 8-48
CHARGING CIRCUIT SERVICE 7-13 End Cap Bearings 8-48
Troubleshooting 7-14 Connecting Rod Service 8-48
Rectifier Removal 7-15 Piston Service 8-50
Rectifier Installation 7-17 Cylinder Block Service 8-51
STATOR SERVICE 7-17 Honing Procedures 8-52
Removal 7-18 Assembling 8-55
Installation 7-18 Piston &: Rod 8-58
CHOKE CIRCUIT AND Crankshaft Installation 8-61
ENRICHENER SYSTEM 7-19 Crankcase Cover 8-67
CRANKING MOTOR CIRCUIT 7-20 Powerhead Build-up 8-71
Description &: Operation 7-20
Troubleshooting 7-21
Removal 7-25
Disassembling - Pinion Gear
with Rubber Cushion 7-26
Assembling 7-26 9 LOWER UNIT
Disassembling - Pinion Gear
with Snap Ring or Nut 7-27 DESCRIPTION 9-1
Assembling 7-28 CHAPTER COVERAGE 9-1
Disassembling - Pinion Gear TR OUBLESHOOTIN G 9-5
with Top Spring 7-29 LOWER UNIT REMOVAL
Assembling 7-30 ALL UNITS 9-6
CRANKING MOTOR REPAIR 7-30 Propeller Removal 9-7
Disassembling 7-31
Testing Parts 7-32 WATER PUMP SERVICE
Cleaning &: Inspecting 7-34 Removal and Disassembling
Assembling a Bosch 7-39 High Pressure Type Pump 9-9
Assembling a Delco Remy 7-39 High Volume Type Pump 9-10
9 LOWER UNIT (Continued) SERVICING E-Z SHIFT
MODELS SINCE ABOUT 1979
SERVICING CAM-SHIFT TYPE I Special Word s 9-53
UNITS MATCHED WITH EARL Y Removal
L6 AND V6 POWERHEADS Bearing Carrier 9-53
TO ABOUT 1979 9-12 Propeller Shaft 9-.5.5
Removal 9-12 Driveshaft & Bearing 9-56
Bearing Carrier and Separate Forward Gear
Propeller Shaft 9-13 from Bearing 9-60
Driveshaft & Bearing 9-14 Disassembling
Forward Gear & Bearing 9-16 Driveshaft 9-60
Disassembling Separate Reverse Gear
Bearing Carrier 9-17 from Bearing Carrier 9-61
Propeller Shaft 9-18 Assembling & Installation
Driveshaft 9-18 Lower Driveshaft Bearing 9-61
Assembling Bearing Carrier 9-61
Lower Driveshaft Bearing 9-23 Forward Gear & Bearing 9-64
Shift Shaft 9-23 Forward Bearing Race 9-65
Bearing Carrier 9-24 Propeller Shaft 9-66
Forward Gear & Bearing 9-25 Driveshaft 9-71
Forward Bearing Race 9-26 Shimming
Driveshaft 9-27 Pinion Gear Depth 9-75
Shimming & Backlash Forward Gear Backlash 9-76
Pinion Gear Depth 9-29 Alpha Drive 9-78
Forward Gear Backlash 9-30
Assembling & Installation
Bearing Carrier 9-33 WATER PUMP ASSEMBLING AND
Reverse Gear Backlash 9-34 INSTALLATION 9-81
High Pressure Type Pump 9-81
SERVICING CAM-SHIFT TYPE II Shimming (Certain Units) 9-81
UNITS MATCHED WITH LATE High Volume Type Pump 9-85
MODEL L6 POWERHEADS FROM
ABOUT 1980 CLEANING AND INSPECTING
AND l50XR4 V6 POWERHEAD 9-35 ALL UNITS 9-86
Removal and Disassembling LOWER UNIT INSTALLATION
Bear ing Carr ier 9-36 Filling Lower Unit 9-88
Propeller Shaft 9-37 Assembling & Installation 9-89
Shift Shaft 9-38 Propeller Installation 9-93
Pinion Gear 9-39
Driveshaft 9-39
Forward Gear 9-40 10 TRIM/TILT
Pinion Gear Bearing Race 9-41
Forward Bearing Race 9-41 INTRODUCTION 10-1
Driveshaft Bearing 9-41 CHAPTER ORGANIZATION 10-2
Assembling and Installation MECHANICAL TILT PIN 10-2
Driveshaft Bearing 9-44
Pinion Gear Bearing Race 9-45 SYSTEM "A"
Forward Bearing Race 9-45 TWO TRIM/TILT CYLINDERS
Shift Shaft 9-46 Description and Operation 10-3
Forward Gear 9-46 Special Instructions 10-5
Driveshaft 9-47 Bleeding System "A" 10-6
Pinion Gear 9-47 Troubleshooting 10-7
Propeller Shaft 9-48 Cleaning and Inspecting 10-9
Bearing Carrier 9-49 System "A" Service 10-12
Pinion Gear Depth 9-50 Pump Service 10-14
Forward Gear Backlash 9-51 Electric Motor Service 10-17
SYSTEM "B" CARBURETOR JET SIZE/ELEV ATION
TWO TRIM CYLINDERS CHARTS A-13
ONE TILT CYLINDER PISTON AND CYLINDER SPECS. A-19
Description and Operation 10-21 REED STOP OPENING A-20
Bleeding System "B" 10-22 LOWER UNIT OIL CAPACITY
Flushing 10-23 AND GEAR CHART A-21
Troubleshooting 10-24 LOWER UNIT BACKLASH TABLE A-22
System "B" Service 10-31 TORQUE VALUE SPECIFICATIONS A-23
Preliminary Tasks 10-31
Removal 10-33 WIRE IDENTIFICATION DWGS.
Component Service 10-34 L6 Models 900, 950, 1000
Manual Release Valve 10-34 and 1100 -- 1965-66 A-24
Oil Reservoir Cover 10-35 L6 Models 950, 1000, 1100,
Trim Cylinder 10-35 and 1250 -- 1967-69 A-25
Til t Cylinder 10-36 L6 Models 1150, 1350, 1400
Electric Motor 10-36 and 1500 - 1970-78 A-26
Cleaning and Inspecting 10-37 L6 Models 900, 11.50,
Assembling &: Installation 10-38 and 1.500 -- 1976-78 A-27
L6 Models 90, 11.5,
SYSTEM "C" and 140 -- 1979 only A-28
ONE TRIM/TILT CYLINDER V6 Models SIN 4301235
Description and Opera tion 10-53 to 5129480 A-29
Bleeding System "C" 10-.54 V6 Models 1.50, 17.5 &: 200
Troubleshooting 10-.54 SIN 5129481 to 5363918 A-30
System "C" Service 10-55
Pump Removal &: Service 10-.5.5 V6 Models 150,17.5, &: 200
Cylinder Service 10-.5.5 SIN 5363919 to .5464484 A-32
V6 Models 1.50, 17.5, &: 2,00
SIN .5464485 to C100860 A-34
11 REMOTE CONTROLS V6 Model 22.5 SIN .561.5282
and higher 0 A-36
INTRODUCTION 11-1 V6 Models with 74 block A-38
STEERING SYSTEMS 11-1 L6 Models 90, 1 j.5, &:
DIRECTIONAL INDICATOR 11-2 140 -- 1980-89 A-40
ROTARY STEERING SERVICE 11-5 V6 Models 135, 1.50, and 175
Disassembling 11-.5 SIN CI00861 &: higher A-41
Cleaning &: Inspecting 11-.5 V6 Mode1150XR4
Assembling 11-6 with 40-amp stator A-42
V6 Model 200 WITHOUT EFI
STANDARD RIDE GUIDE KIT 11-8 SIN CI00861 &: higher A-43
CUSTOM RIDE GUIDE KITS 11-8 V6 Model 220 XRi WITH EFI A-44
MERCONTROL PANEL V6 Model 200 XRi WITH EFI A-4.5
EARLY MODEL 11-9 Early V6 remote control WITH
Disassembling 11-9 temperature horn A-46
Assembling 11-12 Early remote control WITH
power trim/tilt A-47
COMMANDER CONTROL BOX "Commander" side mount controls
Removal &: Disassembling 11-13 WITHOUT power tr im A-48
Cleaning &: Inspecting 11-20 "Commander" side mount controls
Assembling &: Installation 11-22 WITH power trim/tilt
CABLE ADJUSTMENTS 11-31 and WITHOUT warning horn A-49
"Commander" side mount controls
APPENDIX WITH warning horn
to 1989 A-.50
METRIC CONVERSION CHART A-I "Commander" side mount controls
ENGINE SPECIFICATIONS WITH warning horn
AND TUNE-UP ADJUSTMENTS A-3 1989 and on A-.51
'WIRE IDENTIFICAnON (Continued) Type "A" power trim/ tilt
system - two trim/tilt
cylinders -- with OLD style
"Commander" side mount controls single solenoid A-62
WITH trim indicator gauge Type "A" power trim/tilt
and tri m sender A-52 system - two trim/tilt
Panel mount con trol A-53 cylinders -- with NEW style
Tachometer WITHOUT adjustable single solenoid A-63
dial, trim indicator gauge, Type "A" power trim/tilt
and alar m horn A-54 system - two trim/tilt
Tachometer WITH adjustable dial, cylinders -- with DUAL
trim indicator gauge and solenoids A-64
temperature gauge - Model Type "B" power trim/tilt
200 &: 220 WITH EFI only A-55 system -- two trim cylinders
Instrument panel - single ou tboard and one tilt cylinder A-65
installation using "Commander" Type "C" power trim/tilt
2000 remote control A-56 system -- WITHOUT fuse -
Visual warning system single cylinder -
installation A-57 pump mounted in boat A-66
Oil level gauge installation A-58 Type "C" power trim/tilt
Dual outboard synchronizer system - WITH fuse -
system A-59 single cylinder -- pump
Dual outboard instrument moun ted in boat A-67
setup for PORT Type "C" power trim/ tilt
outboard uni t A-60 system WITH fuse -
Dual outboard instrument 1990 and on A-68
setup for STARBOARD Trim indicator gauge
outboard unit A-61 and alarm horn A-69
