Mercury 150 EFI User manual

©2001, Mercury Marine. All rights reserved. Printed in U.S.A. 90-883728 MAY 2001
150/175/200
Electronic
Fuel Injection
Starting Model Year 2002
Starting Serial Number 0T409000
Starting Model Year 2002
Starting S/N 0T409000
150/175/200 EFI

90-883728 JULY 2001 Page i
Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention 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 in-
jury 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 personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these prod-
ucts, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which in-
cludes 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 service might be performed and of the possible hazards and/or results of each
method. We have not undertaken 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 contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe 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 internal damage when the engine is started.

Page ii 90-883728 JULY 2001
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the met-
ric bolts and on the surfaces of metric nuts indicate their strength. American 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. Therefore, fasteners removed should be saved for reuse in the same locations when-
ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
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 serviced, care and cleanliness are important. Throughout this manu-
al, 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 specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
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 information concerning the products de-
scribed in this manual.
Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explana-
tory.
EXAMPLE:
90-878079R1 OCTOBER 2000 LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Section Description
Section Number
Part of Section Letter
Page Number

1
2
3
4
5
6
7
General Information
& Specifications
Ignition System
Fuel System
Powerhead
Mid-Section
Gear Housing
Attachment/Control Linkage
8
Color Diagrams
90-883728 JULY 2001 Page iii
Service Manual Outline
Section 1 - General Information & Specifications
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 - Fuel Injection
C - Oil Injection
D - Emissions
Section 4 - Powerhead
A - Powerhead
B - Cooling
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim
Section 6 - Gear Housing
A - Right Hand Non-Ratcheting
B - Left Hand Non-Ratcheting
Section 7 - Attachments/Control Linkage
Section 8 - Color Diagrams

1
A
SPECIFICATIONS
90-883728 JULY 2001 Page 1A-1
IMPORTANT INFORMATION
Section 1A - Specifications
Table of Contents
Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury/Quicksilver Lubricants & Sealants 1A-4. . .
Specifications
Model 150XRI/175XRI/200XRI
HORSEPOWER
(KW) Model 150XRI Model 175XRI
Model 200XRI
Full Throttle RPM (150/175/200)
Idle RPM (In Gear) (150/175/200)
RPM Limiter
All Models
150 (111.8)
175 (130.5)
200 (149.1)
5250 – 5750
650 ±50
Refer to System Information in the
Digital Diagnostic Terminal (DDT) for
latest information
OUTBOARD
WEIGHT Model 150XRI/175XRI/200XRI Long Shaft
X-Long Shaft 425.0 lb (192.8 kg)
434.0 lb. (196.8 kg)
CYLINDER
BLOCK Model 150XRI/175XRI/200XRI Type
Displacement
Thermostat
V–6 Cylinder, Two Cycle, Loop
Charged
153.0 cu. in. (2507cc)
143°F (61.7°C)
STROKE Length (All Models) 2.650 in. (67.31 mm)
CYLINDER
BORE Diameter (Std) Models 150XRI/175XRI/200XRI
Taper/Out of Round/Maximum Wear
Bore Type
3.501 in. (88.925 mm)
0.003 in. (0.076 mm)
Cast Iron
CRANKSHAFT Maximum Runout 0.006 (0.152 mm)
PISTON Piston Type
Models 150XRI/175XRI/200XRI
Standard
0.015 in. (0.381 mm) Oversize
Aluminum
3.494 in. ±0.001 in.
(88.748 mm ±0.025 mm)
3.509 in. ±0.001 in.
(89.129 mm ±0.025 mm)
COMPRESSION All Models – Using a fully charged bat-
tery, 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 150XRI/175XRI/200XRI
Reed Type
Reed Stand 0pen (Max.)
Reed Stop (Max.)
Steel
0.020 in. (0.50 mm)
Not Adjustable

SPECIFICATIONS
Page 1A-2 90-883728 JULY 2001
MID
SECTION Power Trim (Total Tilt Range) Power Trim (Tilt Range)
Maximum Allowable Leak down in 24
hrs.
Tilt Pin Adjustment Positions
Steering Pivot Range
Allowable Transom Thickness
75°
20°
1 in. (25.4 mm)
5
60°
2-3/8 in. (6.03 cm) Maximum
FUEL
SYSTEM Fuel Recommended Gasoline
Recommended Oil
Gasoline/Oil Ratio
Gasoline w/Oil Injection
Unleaded 87 Octane Minimum
Quicksilver or Mercury Precision Lubri-
cants NMMA/BIA Certified TC-W3
2 Cycle Outboard Oil
50:1 (25:1 Break-In) ECM Controlled –
no premix
STARTING
SYSTEM Electric Start – All Models
Centrifugal Bendix
Starter Draw (Under Load)
Starter Load (No Load)
Minimum Brush Length
Solenoid Driven Bendix
Starter Draw (Under Load)
Starter Load (No Load)
Minimum Brush Length
Battery Rating
165 Amperes
30 Amperes
0.25 in. (25.4 mm)
175 Amperes
60 Amperes
0.25 in. (25.4 mm)
Min. 630 Marine Cranking Amps
(MCA) or 490 Cold Cranking Amps
(CCA)
IGNITION
SYSTEM Type Spark Plug Type
Spark Plug Gap
Firing Order
Idle Timing
Maximum Timing
Throttle Position Sensor
Digital Inductive
NGK BPZ8HS-10
0.040 in. (1.0 mm)
1-2-3-4-5-6
Not Adjustable; Controlled by ECM
Not Adjustable; Controlled by ECM
Not Adjustable; Controlled by ECM
CHARGING
SYSTEM Alternator Output (Regulated)
Brush Length
Voltage Output
Regulator Current Draw
42 – 48 Amperes @ 2000 rpm @ Bat-
tery
52 – 60 Amperes @ 2000 rpm @ Al-
ternator
Std. Exposed Length: 0.413 in. (10.5
mm)
Min. Exposed Length: 0.059 in. (1.5
mm)
13.5 to 15.1 Volts
0.15 mA (Ign, Switch Off)
30.0 mA (Ign. Switch On)

SPECIFICATIONS
90-883728 JULY 2001 Page 1A-3
GEAR
HOUSING Gear Ratio – Models 150XRI
– Models 175XRI/200XRI
Gear Ratio – High Altitude
– Models 150XRI/175XRI/200XRI
Gearcase Capacity
– 1.87:1/2.00:1
Pinion Height
– All Models
Forward Gear Backlash
– 1.87:1 Ratio
– 2.00:1 Ratio
Water Pressure @ rpm
2.00:1 (14/28 teeth)
1.87:1 (15/28 teeth)
2.00:1 (14/28 teeth)
22.5 fl oz (665.4 ml)
0.025 in. (0.64 mm)
0.018 in. – 0.027 in.
(0.460 mm – 0.686 mm)
0.015 in. – 0.022 in.
(0.381 mm – 0.558 mm)
12 psi Minimum @ 5500 rpm
OIL
INJECTION Recommended Oil
Oil Tank Capacity
Approx. Time
– Model 150XRI/175XRI/200XRI
Reserve Capacity/Approx. Time
Oil Pump Output
– Model 150XRI/175XRI/200XRI
Quicksilver or Mercury Precision Lubri-
cants NMMA/BIA Certified TC-W3
2 Cycle Outboard Oil
3 gal. (11.4 Liter)
6.6 hrs. Approx.
0.74 qt. (0.70 Liter) 20 – 25 min.
26cc during auto prime time period
FUEL
INJECTION Idle RPM – All Models
Wide Open Throttle (WOT) RPM
– Model 150XRI/175XRI/200XRI
Float Adjustment (Vapor Separator)
Float Level
Injectors
– All Models (Quantity)
– Injectors are Crank Angle
Driven by ECM
– #1 Cylinder
– #2 Cylinder
– #3 Cylinder
– #4 Cylinder
– #5 Cylinder
– #6 Cylinder
Line Pressure @ Injectors
Injector Resistance
Electric Fuel Pump Resistance
Electric Fuel Pump Amperage Draw
625 ±50
5250 – 5750
Preset @ Factory
6
RED + BRN Leads
RED + WHT Leads
RED + ORG Leads
RED + YEL Leads
RED + LT BLUE Leads
RED + PUR Leads
41 psi – 45 psi (283 kPa – 310 kPa)
12.3 ohms ±0.5 ohms
0.7 ±0.3 ohms
4 amperes ±0.5 amperes

SPECIFICATIONS
Page 1A-4 90-883728 JULY 2001
Mercury/Quicksilver Lubricants and Sealants
Description Mercury Part Number Quicksilver Part Number
Needle Bearing Assy. Lubricant
[8 oz. (226.8 grams)] tube 92-802868A1 N/A
Dielectric Grease
[8 oz. (226.8 grams)] can 92-823506-1 92-823506-1
Loctite 271 – Thread Locker
(10 ml) tube 92-809819 92-809819
Loctite 567 PST Pipe Sealant
(50 ml) tube 92-809822 92-809822
Loctite Master Gasket Kit 92-12564-2 92-12564-2
2 Cycle Premium Outboard Oil
[1 Gallon (3.7 liter)] 92-802815A1 92-802815Q1
Perfect Seal
[16 oz. (0.45 kg)] can 92-34227-1 92-34227-1
Liquid Neoprene
[8 oz. (226.8 grams)] can 92-25711-3 92-25711-3
Cyanacrylate Adhesive Obtain Locally Obtain Locally
Bellows Adhesive N/A 92-86166Q1
Loctite 680 Retaining Compound
(10 ml) tube 92-809833 92-809833
Loctite 222 Thread Locker
(10 ml) tube 92-809818 92-809818
3M Permabond #3M08155 Obtain Locally Obtain Locally
Loctite 242 Thread Locker
(10 ml) tube 92-809821 92-809821
Loctite 609 Obtain Locally Obtain Locally
Loctite 405 Obtain Locally Obtain Locally

SPECIFICATIONS
90-883728 JULY 2001 Page 1A-5
Description Mercury Part Number Quicksilver Part Number
RTV 587 Silcone Sealer
[3 oz. (85.05 grams)] 92-809825 92-809825
Loctite 262 Obtain Locally Obtain Locally
Premium Gear Lubricant
[1 Quart (0.94 liter)] 92-802846A1 92-802846Q1
Loctite 7649 Primer
[4.5 oz (127.57 grams)] 92-809824 92-809824
Anti-Corrosion Grease
[8 oz. (226.8 grams)] tube 92-802867A1 92-802867Q1
2-4-C with Teflon
[8 oz. (226.8 grams)] tube 92-802859A1 92-802859Q1
Loctite Quick Tite Obtain Locally Obtain Locally
Isopropyl Alcohol Obtain Locally Obtain Locally
Hot Glue Obtain Locally Obtain Locally
Special Lubricant 101
[8 oz. (226.8 grams)] tube 92-802865A1 92-802865Q1
4 Stroke 10W30 Outboard Oil
[1 Quart (0.94 liter)] 92-802833A1 92-802833Q1
4 Cycle 25W40 Engine Oil
[1 Quart (0.94 liter)] 92-802837A1 92-802837Q1
Power Trim & Steering Fluid
[8 oz. (226.8 grams)] 92-802880A1 92-802880Q1
Engine Coupler Spline Grease
[14 oz. (0.39 kg)] cartridge 92-802869A1 92-802869Q1

1
B
MAINTENANCE
90-883728 JULY 2001 Page 1B-1
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity 1B-1. . . . . . . . .
Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury/Quicksilver Lubricants and Sealants 1B-2
Inspection and Maintenance Schedule 1B-3. . . . .
Before Each Use 1B-3. . . . . . . . . . . . . . . . . . . . .
After Each Use 1B-3. . . . . . . . . . . . . . . . . . . . . . .
Every 100 Hours of Use or Once Yearly,
Whichever Occurs First 1B-3. . . . . . . . . . . . . . .
Flushing Engine 1B-4. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System –
Using Cowl Flush Plug 1B-4. . . . . . . . . . . . . . . .
Flushing Cooling System –
Using Flushing Attachment 44357A2 1B-4. . . .
Fuel System 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Line Inspection 1B-5. . . . . . . . . . . . . . . . . .
Water Separating Fuel Filter – EFI Models 1B-5
Corrosion Control Anode 1B-6. . . . . . . . . . . . . . . . .
Spark Plug Inspection and Replacement 1B-6. . .
Battery Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement 1B-7. . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 1B-8. . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-9. . . . . . . . . . . . . . .
Gear Case Lubrication 1B-10. . . . . . . . . . . . . . . . . . .
Storage Preparation 1B-11. . . . . . . . . . . . . . . . . . . . .
Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.87:1 22.5 fl. oz. (717 ml)
2.00:1 22.5 fl. oz. (717 ml)

MAINTENANCE
Page 1B-2 90-883728 JULY 2001
Special Tools
1. Grease Gun 91-37299A1
2. Flushing Attachment 44357A2
Mercury/Quicksilver Lubricants and Sealants
NOTE: See section 1A for lubricants and sealants chart.

MAINTENANCE
90-883728 JULY 2001 Page 1B-3
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 components.
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 operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust 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. Replace water separating fuel filter – EFI models.
4. Check corrosion control anodes. Check more frequently when used in salt water.
5. Drain and replace gear case lubricant.
6. Lubricate splines on the drive shaft and shift shaft.∗
7. Check power trim fluid.
8. Inspect battery.
9. Check control cable adjustments.∗
10. Check tightness of bolts, nuts, and other fasteners.
11. Replace water pump impeller (more often if overheating occurs or reduced water
pressure is noted).∗
∗
These items should be serviced by an authorized dealer.

MAINTENANCE
Page 1B-4 90-883728 JULY 2001
Flushing Engine
Flushing Cooling System – Using Cowl Flush Plug
Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted or muddy water. This will help prevent a buildup of deposits from clogging the
internal water passages.
NOTE: Engine can be stopped or running at idle speed when flushing the cooling system.
Do not flush engine using a water system that exceeds 45 psi.
1. Remove the plug from fitting in the bottom cowl.
2. Attach a water hose to the fitting. Turn water on and flush for 3 to 5 minutes.
Flushing Cooling System – Using Flushing Attachment 44357A2
WARNING
When flushing, verify that area in vicinity of propeller is clear and that no person
is standing nearby – to avoid possible injury. It is recommended to remove pro-
peller as a precautionary measure.
1. Install Quicksilver Flushing Attachment 44357A2 (or equivalent tool) on the gear
housing from the FRONT side, positioning the rubber cups over the water intake
openings.
2. Connect hose [1/2 in. (12.7 mm) I.D. or larger] between flushing attachment and water
tap.
IMPORTANT: To prevent water pump damage, do not start or run engine unless
cooling water is flowing.
3. With the outboard in the normal operating position (vertical), partially open water tap
(IT IS NOT NECESSARY to use full water pressure) and adjust water flow so that
there is a significant water loss around the rubber cups.
4. Start engine and idle in NEUTRAL. Increase engine speed, not to exceed 2500 RPM.
5. Flush or service engine as required. Verify adequate cooling water is provided.
6. Water must be discharged thru “tell tale.”
IMPORTANT: Prevent engine overheating. If water flow is insufficient, stop engine
and determine cause before continuing.
7. Flush until discharge water is clear. In saltwater areas, run outboard 3 to 5 min-
utes.
8. Stop engine before turning off water.
9. Stop engine, turn water off and remove flushing attachment from gear housing.
IMPORTANT: While and after flushing, keep outboard in upright position until all
water has drained from drive shaft housing to prevent water from entering the pow-
erhead via drive shaft housing and exhaust ports.

MAINTENANCE
90-883728 JULY 2001 Page 1B-5
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel sys-
tem.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of deterioration or damage. If any of these conditions is found, the fuel line or primer
bulb must be replaced.
IMPORTANT: Visually inspect for fuel leakage from the filter connections by
squeezing the primer bulb until firm, forcing fuel into the filter.
Water Separating Fuel Filter – EFI Models
NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
1. This filter removes moisture and also debris from the fuel. If the filter becomes filled
with water, the water can be removed. If the filter becomes plugged with debris, the
filter must be replaced with a new filter.
a
58800
a-Fuel/Water Separator Filter
Remove and replace filter as follows:
2. Turn ignition key switch to OFF position.
3. Disconnect wire at bottom of filter.
4. Remove filter by turning the filter in the direction of the arrow (clockwise). Tip the
filter to drain fluid in a suitable container.
5. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten se-
curely by hand. Reconnect the wire to the filter.

MAINTENANCE
Page 1B-6 90-883728 JULY 2001
Corrosion Control Anode
The gear case has two corrosion control anodes (a). Another anode (b) is installed on the
bottom of the transom bracket assembly. An anode helps protect the outboard against
galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard
metals.
a
b
Each anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is com-
pletely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
Spark Plug Inspection and Replacement
Inspect spark plugs at the recommended intervals.
WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark
plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel
vapors under the engine cowl. To avoid damaging spark plug boots, do not use
any sharp object or metal tool such as pliers, screwdriver, etc. to remove spark
plug boots.
1. Remove the spark plug leads by twisting the rubber boots slightly and pulling off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs
finger tight, and tighten 1/4 turn or torque to 20 lb-ft (27 Nm).

MAINTENANCE
90-883728 JULY 2001 Page 1B-7
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting
capability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to posi-
tive and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Fuse Replacement
IMPORTANT: Always carry spare SFE 15 and 20 AMP fuses.
The electrical wiring circuits on the outboard are protected from overload by fuses in the
wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is
broken, replace the fuse. Replace fuse with a new fuse with the same rating.
2. The fuses and circuits are identified as follows:
1. Smart Craft Data Bus Circuit – SFE 15 Ampere Fuse
2. Fuel Injector Harness, Electric Fuel Pump and Oil Pump
3. Main Power Relay, Remote Control Harness and Power Trim
4. Ignition Coils
58802
1
2
3
4

MAINTENANCE
Page 1B-8 90-883728 JULY 2001
Lubrication Points
Lubricate Point 1 with Quicksilver Special Lubricant 101.
1. Trim Rod Ball Ends – Turn the ball ends to work the lubricant into the ball sockets.
11
Lubricate Point 2 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
2. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the
propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub
from corroding and seizing to the shaft.
2
Lubricate Points 3 thru 6 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special
Lubricate 101.
3. Swivel Bracket – Lubricate through fitting.
4. Tilt Support Lever – Lubricate through fitting.
3
4
5. Tilt Tube – Lubricate through fitting.
57834
5

MAINTENANCE
90-883728 JULY 2001 Page 1B-9
6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the
steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b).
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube
before adding lubricant. Adding lubricant to steering cable when fully extended
could cause steering cable to become hydraulically locked. An hydraulically
locked steering cable will cause loss of steering control, possibly resulting in se-
rious injury or death.
Lubricate Points 7 With Light Weight Oil.
7. Steering Link Rod Pivot Points – Lubricate pivot points.
7
6-b 6-a
Checking Power Trim Fluid
8. Tilt outboard to the full up position and engage the tilt support lock.
8
9. Remove fill cap and check fluid level. The fluid level should be even with the bottom
of the fill hole. Add Quicksilver Power Trim & Steering Fluid. If not available, use auto-
motive (ATF) automatic transmission fluid.
9

MAINTENANCE
Page 1B-10 90-883728 JULY 2001
Gear Case Lubrication
When adding or changing gear case lubricant, visually check for the presence of water
in the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer.Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
DRAINING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Place drain pan below outboard.
3. Remove vent plug and fill/drain plug and drain lubricant.
3
21
GEAR CASE LUBRICANT CAPACITY
Gear case lubricant capacity is approximately 22.5 fl. oz. (665 ml).
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Remove vent plug (a).
3. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent
hole (c).
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer (a) before removing
the lubricant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer (d).
1-5
a
b
cd

MAINTENANCE
90-883728 JULY 2001 Page 1B-11
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust,
corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of
season storage or prolonged storage (two months or longer).
CAUTION
Never start or run your outboard (even momentarily) without water circulating
through all the cooling water intake holes in the gear case to prevent damage to
the water pump (running dry) or overheating of the engine.
FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a for-
mation of acid during storage and can damage the fuel system. If the gasoline be-
ing used contains alcohol, It is advisable to drain as much of the remaining gaso-
line as possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (sta-
bilized) fuel to help prevent formation of varnish and gum. Proceed with following instruc-
tions.
1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (fol-
low instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabiliz-
er with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline
Stabilizer (follow instructions on container) into a separate container and mix with ap-
proximately 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 at 2000 rpm for 10 minutes to allow treated fuel to fill the fuel
system.
PROTECTING INTERNAL ENGINE COMPONENTS
Electronic Fuel Injection (EFI) Models
NOTE: Make sure the fuel system has been prepared for storage.
1. Remove the spark plugs and add approximately one ounce (30ml) of engine oil into
each spark plug hole. Rotate the flywheel manually several times to distribute the oil
in the cylinders. Reinstall spark plugs.
2. Remove the water separating fuel filter and empty contents into a suitable container.
Refer to Maintenance Section for removal and installation of filter. Replace fuel filter
annually, or every 100 Hours of operation, or if large amount of fuel contamination is
present.
PROTECTING EXTERNAL OUTBOARD COMPONENTS
1. Lubricate all outboard components listed in the Inspection and Maintenance Sched-
ule.
2. Touch up any paint nicks. See your dealer for touch-up paint.
3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion con-
trol anodes).
GEAR CASE
Drain and refill the gear case lubricant (refer to maintenance procedure).