Mariner Mercury 135 JET User manual

1992 Through 2000
105/140 Jet •135 •150 •
150 XR6 •150 Magnum III •150 EFI •
175 •175 EFI •200 •200 EFI
With Serial Numbers
0D082000 Through 0G960499
1992 Through 2000
150/200/225 Pro Max
150/200/225 Super Magnum
With Serial Numbers
0D082000 Through 0T105314
SERVICE
MANUAL
MODELS
105/140 JET •135 •150 •175 •
200 •225
Printed in U.S.A. 2002, Mercury Marine 90-824052R3 JUNE 2002

i90-824052R3 JUNE 2002
Notice
Throughout this publication, “Dangers”, “Warnings”
and “Cautions” (accompanied by the International
HAZARD Symbol ) are used to alert the mechanic
to special instructions concerning a particular service
or operation that may be hazardous if performed in-
correctly or carelessly. OBSERVE THEM CARE-
FULLY!
These “Safety Alerts” alone cannot eliminate the haz-
ards that they signal. Strict compliance to these spe-
cial instructions when performing the service, plus
“Common Sense” operation, are major accident pre-
vention measures.
DANGER
DANGER - Immediate hazards which WILL result
in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which
COULD result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result
in minor personal injury or product or property
damage.
Notice to Users of This
Manual
This service manual has been written and published
by the Service Department of Mercury Marine to aid
our dealers’ mechanics and company service per-
sonnel when servicing the products described here-
in.
It is assumed that these personnel are familiar with
the servicing procedures of these products, or like or
similar products manufactured and marketed by
Mercury Marine, that they have been trained in the
recommended servicing procedures of these prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone
who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the
products safety will be endangered by the service
procedure selected.
All information, illustrations and specifications con-
tained in this manual are based on the latest product
information available at the time of publication. As re-
quired, revisions to this manual will be sent to all deal-
ers contracted by us to sell and/or service these prod-
ucts.
It should be kept in mind, while working on the prod-
uct, that the electrical system and ignition system are
capable of violent and damaging short circuits or se-
vere electrical shocks. When performing any work
where electrical terminals could possibly be
grounded or touched by the mechanic, the battery
cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed
during service they should be covered to protect
against accidental entrance of foreign material which
could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
It is important to note, during any maintenance proce-
dure replacement fasteners must have the same
measurements and strength as those removed.
Numbers on the heads of the metric bolts and on the
surfaces of metric nuts indicate their strength. Ameri-
can bolts use radial lines for this purpose, while most
American nuts do not have strength markings. Mis-
matched or incorrect fasteners can result in damage
or malfunction, or possibly personal injury. There-
fore, fasteners removed should be saved for reuse in
the same locations whenever possible. Where the
fasteners are not satisfactory for re-use, care should
be taken to select a replacement that matches the
original.

ii 90-824052R3 JUNE 2002
Cleanliness and Care of
Outboard Motor
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten thousands of
an inch./mm. When any product component is serv-
iced, care and cleanliness are important. Throughout
this manual, it should be understood that proper
cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is
considered standard shop practice even if not specif-
ically stated.
Whenever components are removed for service,
they should be retained in order. At the time of instal-
lation, they should be installed in the same locations
and with the same mating surfaces as when re-
moved.
Before raising or removing and outboard engine from
a boat, the following precautions should be adhered
to:
1. Check that flywheel is secured to end of crank-
shaft with a locknut and lifting eye is threaded into
flywheel a minimum of 5 turns.
2. Connect a hoist of suitable strength to the lifting
eye.
In addition, personnel should not work on or under an
outboard which is suspended. Outboards should be
attached to work stands, or lowered to ground as
soon as possible.
We reserve the right to make changes to this manual
without prior notification.
Refer to dealer service bulletins for other pertinent in-
formation concerning the products described in this
manual.
Page Numbering
Two number groups appear at the bottom of each
page. The example below is self-explanatory.
EXAMPLE:
90-826148 R1 JANUARY 1993 LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Section Description
Section Number
Part of Section Letter
Page Number

Important
Information
Electrical
Fuel System
Powerhead
Mid-Section
Lower Unit
Attachments/
Control Linkage
1
2
3
4
5
6
7
iii
90-824052R3 JUNE 2002
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
C - Fuel Injection 1995 and Prior
D - Fuel Injection 1996 and Up
E - Oil Injection
F - Emissions
Section 4 - Powerhead
A - Powerhead
B - Cooling
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim
Section 6 - Lower Unit
A - Right Hand Rotation
B - Left Hand Rotation
C - 1.78:1 Ratio (4-1/4″Dia.)
D - Right Hand Non-Ratcheting
E - Left Hand Non-Ratcheting
F - Jet Outboards
Section 7 - Attachments/Control Linkage

1
A
IMPORTANT
INFORMATION
SPECIFICATIONS

90-824052R3 JUNE 20021A-0 - IMPORTANT INFORMATION
Table of Contents Page
Master Specifications 1A-1. . . . . . . . . . . . . . . . . . . . .

90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-1
Master Specifications
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
HORSEPOWER
(KW) Model 135 Model 105 Jet/150/150XRI
Model XR6/MAGIII
Model 175/175XRI
Model 140 Jet/200/200XRI
Model Pro Max/Super Magnum 150
Model Pro Max/Super Magnum 200
Model Pro Max/Super Magnum 225
135 (100.6)
150 (111.8)
150 (111.8)
175(130.5)
200(149.1)
150 (111.8)
200(149.1)
225(167.9)
OUTBOARD
WEIGHT Model 135/150 Model Pro Max/Super Magnum
150/200/225
Model XR6/MAGIII/175/200
Model 150XRI/175XRI/200XRI
Model 105 Jet
Model 140 Jet
404.0 lbs. (184.0kg)
350.0 lbs. (159.0kg)
395.0 lbs. (180.0kg)
410.0 lbs. (186.0kg)
428.0 lbs. (195.0kg)
408.0 lbs. (185.5kg)
CYLINDER
BLOCK Model 105 Jet/135/150 Type
Displacement
Model 140 Jet/XR6/MAGIII/I75/200
150XRI/175XRI/200XRI/Pro Max/
Super Magnum 150/200/225
Type
Displacement
V–6 Cylinder, Two Cycle, Loop Charged
121.9 cu. in. (1998cc)
V–6 Cylinder, Two Cycle, Loop Charged
153.0 cu. in. (2507cc)
STROKE Length (All Models) 2.650 in. (67.31mm)
CYLINDER
BORE Diameter (Std) – Models 105 Jet/135/150
– Models XR6/MAGIII/175/200
150XRI/175XRI/200XRI/140 Jet
Pro Max/Super Magnum
150/200/225
Taper/Out of Round/Maximum Wear
Bore Type
3.125 in. (79.375mm)
3.501 in. (88.925mm)
0.003 in. (0.076mm)
Cast Iron
PISTON Piston Type
Models 105 Jet/135/150
Standard
0.015 in. (0.381mm) Oversize
0.030 in. (0.762) Oversize
Models XR6/MAGIII/175/200/140 Jet
150XRI/175XRI/200XRI/ProMax/
Super Magnum 150/200/225
Standard
0.015 in. (0.381mm) Oversize
Aluminum
3.115 in. ±0.002 in.
(79.121mm ±0.051mm)
3.130 in. ±0.002 in.
(79.502mm ±0.051mm)
3.145 in. ±0.002 in.
(79.883mm ±0.051mm)
3.494 in. ±0.001 in.
(88.748mm ±0.025mm)
3.509 in. ±0.001 in.
(89.129mm ±0.025mm)

90-824052R3 JUNE 20021A-2 - IMPORTANT INFORMATION
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
COMPRESSION All Models – Using a fully charged
battery, throttle shutters wide open
and cylinder block warm
110 – 135 psi
(753.3 – 924.5 kPa)
Variance between cylinders should not
exceed 15 psi (102.7 kPa)
REEDS Model 105 Jet/135/150
Model XR6/MAGIII/175/200
Model 150XRI/175XRI/200XRI
Reed Type
Reed Stand 0pen (Max.)
Reed Stop (Max.)
Model Pro Max/Super Magnum
150/200/225
Reed Type
Reed Stop (Max.)
Steel
0.020 in. (0.50mm)
Not Adjustable
2 Stage Plastic
No Stop
MID
SECTION Power Trim (Total Tilt Range) Power Trim (Trim Range)
Steering Pivot Range
Tilt Pin Adjustment Positions
Allowable Transom Thickness
75°
20°
60°
5
2-3/8 in. (6.03cm) Maximum
GEAR
HOUSING Gear Ratio – Models 135/150
– Models XR6/MAGIII/150XRI
– Models XR6/MAGIII (4-1/4″dia.)
– Models 175/200/175XRI/200XRI
– Model Pro Max/Super Magnum
200/225
Gear Ratio – High Altitude
– Models 135/150
– Models XR6/MAGIII/175/200
150XRI/175XRI/200XRI
– Model Pro Max/Super Magnum
150
Gearcase Capacity
– 1.87:1/2.00:1/2.30:1
– 1.78:1
Pinion Height
– All Models
Forward Gear Backlash
– 1.78:1 Ratio
– 1.87:1 Ratio
– 2.00:1 Ratio
– 2.30:1 Ratio
Water Pressure @ RPM
2.00:1 (14/28 teeth)
1.87:1 (15/28 teeth)
1.78:1 (14/25 teeth)
1.87:1 (15/28 teeth)
1.87:1 (15/28 teeth)
2.30:1 (13/30 teeth)
2.00:1 (14/28 teeth)
2.00:1 (14/28 teeth)
22.5 fl. oz. (665.4ml)
21.0 fl. oz. (621.0ml)
0.025 in. (0.64mm)
0.016 in – 0.019 in. (0.406mm –
0.482mm)
0.018 in. – 0.027 in. (0.460mm –
0.686mm)
0.015 in. – 0.022 in. (0.381mm –
0.558mm)
0.018 in. – 0.023 in. (0.460mm –
0.584mm)
12 PSI Minimum @ 5500 RPM

90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-3
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
FUEL
SYSTEM Fuel Recommended Gasoline
Model 105/140 Jet/135/150
Model XR6/MAGIII/175/200
Model 150XRI/175XRI/200XRI
Model Pro Max/Super Magnum
150/200/225
Recommended Oil
All Models
Gasoline/Oil Ratio
Fuel Pressure – @ Idle
– @ WOT
Gasoline w/Oil Injection
Unleaded 87 Octane Minimum
Unleaded 92 Octane Minimum
Quicksilver TC-W3 2 Cycle Outboard Oil
Only
50:1 (25:1 Break-In)
Normal – 2-3 psi (14-21 kPa)
Minimum – 1 psi (7 kPa)
Maximum – 10 psi (69 kPa)
Normal – 8-10 psi (55–69 kPa)
Minimum – 3 psi (21 kPa)
STARTING
SYSTEM Manual Start – All Models
Electric Start – All Models
Starter Draw (Under Load)
Starter Load (No Load)
Battery Rating
Emergency Start Rope
175 Amperes
40 Amperes
Min. Reserve Cap. Rating of 100 Min.
and CCA of 490
(MCA of 630 Amperes)
IGNITION
SYSTEM Type Spark Plug Type (Except 225 ProMax
and 225 Super Magnum
Spark Plug Type (225 ProMax
and 225 Super Magnum only)
Spark Plug Gap
Capacitor Discharge
NGK BU8H
Surface Gap
NGK BUZHW
Surface Gap
CHARGING
SYSTEM Alternator Output (Regulated) 40 Amperes @ 5000 RPM
F
U
E
L
I
N
J
E
C
T
I
O
N
Idle RPM
– All Models
Wide Open Throttle (WOT) RPM
– Model 150XRI/175XRI
– Model 200XRI
– Pro Max/Super Magnum
Float Adjustment (Vapor Separator)
Float Level
Injectors
– All Models (Quantity)
– Inner Switch Box Controls:
– #1 Primary Circuit
– #3 Primary Circuit
– #5 Primary Circuit
Line Pressure @ Injectors
– 150XRI/175XRI/200XRI
– Pro Max/Super Magnum
– (S/N 0G303045 and below)
– (S/N 0G303046 and above)
650 ±50
5000 – 5600
5000 – 5800
6200 – 6500
Preset @ Factory
6
#3 and #4 Injectors
#5 and #6 Injectors
#1 and #2 Injectors
34 PSI - 36 PSI (234 kPa - 248 kPa)
36 PSI - 39 PSI (248 kPa - 269 kPa)
34 PSI - 36 PSI (234 kPa - 248 kPa)

90-824052R3 JUNE 20021A-4 - IMPORTANT INFORMATION
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
C
A
R
B
U
R
E
T
O
R
Idle RPM
– Model 105/140 Jet
135/150/175/200
– Model Pro Max/Super Magnum
150/200/225
– Model XR6/MAGIII
Wide Open Throttle (WOT) RPM
– Model 105/140 Jet
135/150/175/200
– Model XR6/MAGIII
– Model Pro Max/Super Magnum
150/200/225
Idle Mixture Screw Adjustment
(Preset - Turns Out)
– All Carburetor Models
– All EFI Models
Float Adjustment
Float Level
WMH Carburetor Jets
– Model 135 (WMH 30)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model 105 Jet/150 (WMH 31)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model XR6/MAGIII (WMH 32)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model 175 (WMH 33)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model 140 Jet/200 (WMH 34/39)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
650 ±50
650 ±50
650 ±50
675 ±50
5000 – 5600
5000 – 5500
5000 – 5500
6200 – 6500
1-1/2 ±1/8
Not Adjustable
Float Even with Bowl Edge w/Bowl
Inverted
.066
.050
.054
.084
.062
.050
.052
.086
.062
.040
.058
.090
.064
.050
.048
.084
Cyl. 1,2 – .066
Cyl. 3,4,5,6 – .064
.050
.046
.084

90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-5
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
C
A
R
B
U
R
E
T
O
R
WMV Carburetor Jets
– Model 135 (WMV 1/1A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model 105 Jet/150 (WMV 2/2A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model XR6/MAGIII (WMV 3/3A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model 175 (WMV 4/4A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model 140 Jet/200 (WMV 5/5A)
– Main Jet
– Idle Air Jet
– Vent Jet
.072
Cyl. 1,2,3,4,6 – .036; Cyl. 5 – .040
.086
.074
Cyl. 1,2,3,4,6 – .034; Cyl.5 – .038
.086
.074
Cyl. 1,2,3,4,6 – .044; Cyl.5 – .048
.082
.078
Cyl. 1,2,3,4,6 – .030; Cyl.5 – .034
.086
Cyl 1,2 – .082
Cyl. 3,4,5,6 – .080
Cyl 1,2 – .052
Cyl. 3,4,6 – .028
Cyl. 5 – .032
.096

90-824052R3 JUNE 20021A-6 - IMPORTANT INFORMATION
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
T
I
M
I
N
G
Idle Speed/Pickup Timing
– 105 JET/135/150 Carb Models
– XR6/MAG III/175 Carb
– 140 Jet/200 Carb
– All Pro Max/Super Magnum
– 150XRI/175 XRI Models
– 200 XRI Model
Maximum BTDC
– Model 105 Jet/135/150
@ Cranking Speed
@ WOT RPM
– XR6/MAG III/175 Carb
– 175 XRI
– Pro Max/Super Magnum 150
@ Cranking Speed
@ WOT RPM
– 150 XRI
@ Cranking Speed
@ WOT RPM
– 140 Jet/200 Carb
Models with Spark Advance
Module
@ Cranking Speed
@ WOT RPM
Models with Idle Stabilizer
Module
@ Cranking Speed
@ WOT RPM
– Model 200XRI
@ Cranking Speed
@ 5800 RPM
– Pro Max/Super Magnum 200
@ Cranking Speed
– Pro Max/Super Magnum 225
@ 3000 RPM
2°– 9°ATDC
0°– 9°ATDC
21°BTDC
19°BTDC
20°BTDC
19°BTDC
15°BTDC
16°BTDC
21°BTDC
25°BTDC
22°BTDC
20°BTDC
16°BTDC
22°BTDC
With Spark Advance Box – 20°BTDC
Without Spark Advance Box – 25°BTDC
23°BTDC
NOTE: Timing specifications listed are for 1998 model year engines. Refer to timing decal on engine for previous
model year timing specifications.

90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-7
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
OIL
INJECTION Recommended Oil (All Models) Hi-Perf. Pro Max/Super Magnum
Oil Tank Capacity
Approx. Time
– Model 105 Jet/135/150
– Model 140 Jet/XR6/MAGIII/175/200
– Model 150XRI/175XRI/200XRI/Pro
Max/Super Magnum 150/200/225
Reserve Capacity/Approx. Time
Output @ 1000 RPM for 3 Minutes
with Pump @ Full Open
– Model 105 Jet/135/150
– Model 140 Jet/XR6/MAG III/175/200
– Model 150XRI/175XRI/200XRI/Pro
Max/Super Magnum 150/200/225
Quicksilver TC-W3
Quicksilver TC-W3
3 gal. (11.4Liter)
8.7 hrs. Approx.
6.6 hrs. Approx.
6.6 hrs. Approx.
.94 qt. (0.89Liter) 30 – 35 min.
12cc @ 1000 RPM
15cc @ 1000 RPM
15cc @ 1000 RPM

1
B
IMPORTANT
INFORMATION
MAINTENANCE

1B-0 - IMPORTANT INFORMATION 90-824052R3 JUNE 2002
Table of Contents Page
Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity 1B-1. . . . . . . . . . .
Special Tools 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricant/Sealant 1B-1. . . . . . . . . . .
Inspection and Maintenance Schedule 1B-1. . . . . .
Lubrication Points 1B-2. . . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-4. . . . . . . . . . . . . . . .
Gear Case Lubrication 1B-5. . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity 1B-5. . . . . . . . . . .
Draining Gear Case 1B-5. . . . . . . . . . . . . . . . . . . .
Checking Lubricant Level and Refilling
Gear Case 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Replacement 1B-6. . . . . . . . . . . . . . . . . . . .
Removal 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion Control Anode 1B-7. . . . . . . . . . . . . . . . . .
Flushing Engine 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System with Engine NOT
Running (Using Cowl Flush Plug) 1B-8. . . . . . . .
Flushing Cooling System with Engine
Running (Using Flushing Attachment
44357A2) 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting External Outboard
Components 1B-8. . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine
Components 1B-8. . . . . . . . . . . . . . . . . . . . . . .
Gear Case 1B-9. . . . . . . . . . . . . . . . . . . . . . . . .
Positioning Outboard for Storage 1B-9. . . . . .
Battery Storage 1B-9. . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION - 1B-190-824052R3 JUNE 2002
Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.78:1 21 fl. oz. (625ml)
1.87:1 24-1/4 fl oz. (717ml)
2.00:1 24-1/4 fl oz. (717ml)
2.30:1 24-1/4 fl oz. (717ml)
Special Tools
Description Part No.
Flushing Attachment 44357A2
Grease Gun 91-37299A1
Quicksilver Lubricant/Sealant
Description Part No.
Gear Lubricant -
Premium Blend 92-19007A24
Anti-Corrosion Grease 92-78376A6
2-4-C Marine Lubricant
with Teflon 92-825407A12
SAE 30W Motor Oil Obtain Locally
Inspection and Maintenance
Schedule
Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration
or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose com-
ponents.
5. Visually check steering link rod fasteners for
proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operat-
ing in salt or polluted water.
2. Wash off all salt deposits and flush out the ex-
haust outlet of the propeller and gear case with
fresh water if operating in salt water.
Every 100 Hours of Use or Once
yearly, Whichever occurs first
1. Lubricate all lubrication points. Lubricate more
frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Check engine fuel filter for contaminants – Car-
buretor models.
4. Replace Water separating fuel filter – EFI mod-
els.
5. Check corrosion control anodes. Check more fre-
quently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft.∗
8. Check power trim fluid.
9. Inspect battery.
10. Adjust carburetors (if required).∗
11. Check engine timing setup.∗
12. Check control cable adjustments.∗
13. Remove engine deposits with Quicksilver Power
Tune Engine Cleaner.

1B-2 - IMPORTANT INFORMATION 90-824052R3 JUNE 2002
14. Check tightness of bolts, nuts, and other fasten-
ers.
15. Replace water pump impeller (more often if over-
heating occurs or reduced water pressure is
noted).∗
∗
These items should be serviced by an authorized
dealer.
Before Periods of Storage
FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid
during storage and can damage the fuel system.
If the gasoline being used contains alcohol, it is
advisable to drain as much of the remaining gas-
oline as possible from the fuel tank, remote fuel
line and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, carbure-
tors and fuel injection systems) with treated (stabi-
lized) fuel to help prevent formation of varnish and
gum. Proceed with following:
1. Portable Fuel Tank – Pour the required amount of
Quicksilver Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank
back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Quicksilver Gasoline Stabilizer
(follow instructions on container) into a separate
container and mix with approximately one quart
(one liter) of gasoline. Pour this mixture into fuel
tank.
3. Place the outboard in water or connect flushing
attachment for circulating cooling water. Run the
engine for ten minutes to allow treated fuel to fill
the fuel system.
Lubrication Points
Item
No. Descrip- tion Type of Lubricant Fresh Water
Frequency
Salt Water
Frequency
1 Throttle/
Shift Link-
age Pivot
Points
2-4-C
w/Teflon 100 Hours of Use or Once in Season
2Upper Shift
Shaft
3 Tilt Lock
Lever
4Swivel Pin
5Ride Guide
Steering
Cable
6Tilt Tube
7 Steering
Link Rod
Pivot
Points
SAE 30W
Motor Oil 100 Hours of Use or Once in Season
8Trim Rod
Ball Ends 2-4-C w/Teflon
Anti-Corro-
sion
Grease
100 Hours of Use or
Once in Season
9 Propeller
Shaft 2-4-C w/Teflon 100 Hours of Use or Once in Season
10 Gear Hous-
ing Bearing
Carrier and
Cover Nut
2-4-C
w/Teflon 100 Hours of Use or Once in Season
◊Gear Hous-
ing Quicksilver Premium
Blend Gear
Lube
100 Hours of Use or
Once in Season
°Engine Dri-
veshaft
Splines
2-4-C
w/Teflon Once in Season Once in Season
◊Refer to “Gear Housing Lubrication”
°Refer to Gear Housing Removal and Installation”
(Section 6)

IMPORTANT INFORMATION - 1B-390-824052R3 JUNE 2002
1
1 - Throttle/Shift Linkage Pivot Point Lubrication
52183
2
2 - Upper Shift Shaft Lubrication
4
3
3 - Tilt Lock Lever Grease Fitting
4 - Swivel Pin Grease Fittings
RIDE-GUIDE STEERING CABLE AND PIVOT
POINTS LUBRICATION
WARNING
Core of steering cable (transom end) must be
fully retracted into cable housing before
lubricating cable. If cable is lubricated while
extended, hydraulic lock of cable could occur.
With core of Ride-Guide Steering cable (transom
end) fully retracted, lubricate transom end of steering
cable thru grease fitting and exposed portion of cable
end with Quicksilver 2-4-C w/Teflon. Lubricate all
pivot points with SAE 30W engine oil.
7
5
6
5 - Ride-Guide Steering Cable Grease Fitting
6 - Tilt Tube Grease Fitting
7 - Steering Link Rod Pivot Point Lubrication

1B-4 - IMPORTANT INFORMATION 90-824052R3 JUNE 2002
8
8 - Trim Rod Ball Ends
9
9 - Propeller Shaft Lubrication
Checking Power Trim Fluid
The power trim system is filled at the manufacturer
and is ready for use.
Trim outboard through entire trailing range several
times to remove any air from the system.
The trim system is pressurized and is not externally
vented.
The outboard can be raised or lowered manually by
loosening the manual release valve 3 to 4 turns.
The trim “out” angle of this outboard is not adjustable.
The trim system has an internal valve which will
automatically stop the outward trim travel at 20°
when engine RPM is approximately 2000 RPM or
higher; outboard also has to be in water and in gear.
The outboard can be operated beyond the 20°trim
limit for operating outboard in shallow water if engine
RPM is kept below approximately 2000 RPM.
a
a - Manual Release Valve

IMPORTANT INFORMATION - 1B-590-824052R3 JUNE 2002
Gear Case Lubrication
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.78:1 21 fl. oz. (621ml)
1.87:1 22.5 fl. oz. (665ml)
2.00:1 22.5 fl. oz. (665ml)
2.30:1 22.5 fl. oz. (665ml)
Draining Gear Case
WARNING
If gear housing is installed on outboard, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before work-
ing near the propeller.
CAUTION
Do not use automotive grease in the gear hous-
ing. Use only Quicksilver Gear Lubricant.
1. Tilt outboard so that lubricant in gear housing will
drain toward front of housing, out fill hole and into
clean container.
IMPORTANT: Inspect FILL and VENT screw seal-
ing washers for damage. Use new washers as
needed.
2. Remove lubricant FILL screw and sealing
washer. Note amount of metal particles on
magnetic fill screw.
3. Remove VENT screw with sealing washer and al-
low sufficient time for all lubricant to drain.
a
b
a - Vent Screw w/Sealing Washer
b - Fill Screw w/Sealing Washer
4. Inspect gear lubricant for metal particles (lubri-
cant will have a “metal flake” appearance). Pres-
ence of a small amount of fine metal particles (re-
sembling powder) on the fill screw bar magnet
indicates normal gear wear. An excessive
amount of metal filings or larger particles (chips)
may indicate abnormal wear and requires gear
housing disassembly and component inspection.
5. Note color of gear lubricant. White or cream color
indicates presence of water in lubricant. Gear lu-
bricant which has been drained from a gear case
recently in operation will have a yellowish color
due to lubricant agitation/aeration. This is normal
and should not be confused with the presence of
water.
6. Presence of water in gear lubricant indicates the
need for disassembly and inspection of oil seals,
seal surfaces, o-rings, water pump gaskets as
well as gear housing components for damage.
Checking Lubricant Level and
Refilling Gear Case
IMPORTANT: Never add lubricant to gear hous-
ing without first removing VENT screw, as
trapped air will prevent housing from being filled.
Fill gear housing only when outboard is in oper-
ating position.
1. With outboard in vertical position, insert lubricant
tube into fill hole.
2. Slowly fill housing thru “FILL” hole with Quicksil-
ver Gear Lubricant until lubricant flows out of
“VENT” hole and no air bubbles are visible.
3. Install “VENT” screw into “VENT” hole.
IMPORTANT: DO NOT lose more than one fluid
ounce (30cc) of gear lubricant while reinstalling
“FILL” screw.
4. Remove grease tube (or hose) from “FILL” hole
and quickly install “FILL” screw into “FILL”
hole.
a
b
a - Vent Screw
b - Fill Screw