Mercury Optimax 115 User manual

115/135/150/175

OptiMax

Direct Fuel Injection

Starting Model Year 2000

Starting Serial Number OG960500

Starting Model Year 2000

Starting S/N OG960500

115/135/150/175 OptiMax

90-859494R1 JUNE 2000 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 90-859494R1 JUNE 2000

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:

90-859494 R1 MAY 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

90-859494R1 JUNE 2000 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 - Direct 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 – Design I (Showa)

C - Power Trim – Design II (Oildyne)

Section 6 - Gear Housing

A - Right Hand (Standard) Rotation Non-Ratcheting

B - Left Hand (Counter) Rotattion Non-Ratcheting

Section 7 - Attachments/Control Linkage

Section 8 - Color Diagrams

1

A

SPECIFICATIONS

90-855347R1 JANUARY 1999 Page 1A-1

IMPORTANT INFORMATION

Section 1A - Specifications

Table of Contents

Master Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . .

Master Specifications

Model 135/150 DFI

HORSEPOWER

(KW)

Model 135

Model 150

Full Throttle RPM (135/150)

Idle RPM (In Gear) (135/150)

RPM Limiter

1998 Model 135/150

1999 Model 135

1999 Model 150

135 (100.7 kw)

150 (111.8 kw)

5000 - 5600

550 ± 25

5750

5950

OUTBOARD

WEIGHT

Model 135/150

– 20 in. (50.8cm) Shaft

– 25 in. (63.5cm) Shaft

440.0 lbs. (200.0 kg)

452.0 lbs. (206.0 kg)

CYLINDER

BLOCK

Type

Displacement

V-6 Cylinder, Two Cycle, Direct Injected

153 cu. in. (2508 cc) 60° Vee

STROKE Length (All Models) 2.65 in. (67.3 mm)

CYLINDER

BORE

Diameter (Std)

Diameter 0.015 in. Oversize

Taper/Out of Round/Wear Maximum

Bore Type

3.501 in. (88.925 mm)

3.516 in. (89.306 mm)

0.003 in. (0.076 mm)

Cast Iron

CRANKSHAFT Maximum Runout 0.006 in. (0.152 mm)

PISTON Piston Type

Diameter Standard

Diameter 0.015 in. Oversize

Aluminum

3.4925 in. ± .0005 in. (88.7095 mm ±

0.0127 mm)

3.5075 in. ± 0.0005 in.

(89.0905 mm ± 0.0127 mm)

PISTON

DIAMETER

Dimension

“A” at Right

Angle (90

°)

to Piston

.700

17.78mm

3.4925 in. ± .0005 in.

(88.7095 mm ± .0127 mm)

Using a micrometer, measure dimension

“A” at location shown. Dimension “A”

should be 3.4925 in. ± .0005 for a STAN-

DARD size piston (new) Dimension “A”

will be 0.001 – 0.0015 less if coating is

worn off piston (used)

REEDS Reed Stand 0pen (Max.) 0.020 in. (0.50 mm)

SPECIFICATIONS

Page 1A-2 90-855347R1 JANUARY 1999

Model 135/150 DFI

MID

SECTION

Power Trim (Total Tilt Range)

Power Trim (Tilt Range)

Steering Pivot Range

Tilt Pin Adjustment Positions

Allowable Transom Thickness

73°

19°

60°

4

2-3/8 in. (6.03 cm)

GEAR

HOUSING

Gear Ratio

Standard Ratio – 135

Standard Ratio – 150

Optional High Altitude Ratio

– 135

– 150

Gearcase Capacity

Pinion Height

Forward Gear Backlash

– 1.87:1

– 2.00:1

– 2.30:1

Reverse Gear Backlash

– Standard/Counter Rotation

Water Pressure @ RPM

2.00:1 12/24 Teeth

1.87:1 15/28 Teeth

2.30:1 13/30 Teeth

2.00:1 12/24 Teeth

22.5 fl. oz. (665.4 ml)

0.025 in. (0.635 mm)

.

0.017 in. – 0.028 in.

(0.431 mm – 0.711 mm)

0.015 in. – 0.022 in.

(0.381 mm – 0.558 mm)

0.018 in. – 0.023 in.

(0.460 mm – 0.584 mm)

0.030 in. to 0.050 in.

(0.076 mm to 0.127 mm)

12 PSI Minimum @ 5500 RPM

DIRECT

INJECTION

Injectors

– Quantity

– Injectors are Crank Angle Driven

by ECM

– #2 Cylinder

– #4 Cylinder

– #6 Cylinder

– #1 Cylinder

– #3 Cylinder

– #5 Cylinder

Fuel Line Pressure @ Injectors

Air Pressure

High Pressure Electric Fuel Pump

Amperage Draw

Low Pressure Electric Fuel Pump

Amperage Draw

Low Pressure Electric Fuel Pump

Output

Fuel Injector Ohm Resistance

Direct Injector Ohm Resistance

Fuel/Air Differential

6

WHT/RED + RED/WHT Leads

WHT/YEL + YEL/WHT Leads

WHT/PPL + PPL/WHT Leads

WHT/BRN + BRN/WHT Leads

WHT/ORG + ORG/WHT Leads

WHT/DRK BLU + DRK BLU/WHT

Leads

89 ± 2 psi (613.5 ± 13.8 kPa)

79 ± 2 psi (544.0 ± 13.8 kPa)

5 – 9 Amperes

1 – 2 Amperes

6 – 9 psi (41.37 – 62.04 kPa)

1.8 ± 0.1 Ω

1.3 ± 0.3 Ω

10 psi (68.5 kPa)

SPECIFICATIONS

90-855347R1 JANUARY 1999 Page 1A-3

Master Specifications

Model 135/150 DFI

FUEL

SYSTEM

Fuel

Recommended Gasoline

Recommended Oil

Gasoline/Oil Ratio

– @ Idle

– @ WOT

Fuel Pressure

Crankcase Pump

– @ Idle

– @ WOT

Gasoline w/Oil Injection

Unleaded 87 Octane Minimum

Quicksilver TC-W3 Premium Plus 2

Cycle Outboard Oil

300 – 400:1

60:1

2 psi (13.8 kPa)

8 psi (55.2 kPa)

STARTING

SYSTEM

Electric Start – All Models

Starter Draw (Under Load)

Starter Draw (No Load)

Minimum Brush Length

Battery Rating

165 Amperes

30 Amperes

0.25 in. (65.4 mm)

1000 (Minimum) Marine Cranking Amps

(MCA)

750 (Minimum) Cold Cranking Amps

(CCA)

IGNITION

SYSTEM

Type

Spark Plug Type

Spark Plug Gap

Maximum Timing

Idle Timing

Throttle Position Sensor 1 (Inner

TPS)

@ Idle

@ W.O.T

Throttle Position Sensor 2 (Outer

TPS)

@ Idle

@ W.O.T

Crank Position Sensor

Air Gap

Digital Inductive

NGK PZFR5F-11

NGK ZFR5F-11 or

Champion RC12MC4

0.040 in. (1.0 mm)

Not Adjustable; Controlled by ECM

3.70 – 4.90 VDC

0.30 – 1.80 VDC

0.10 – 1.50 VDC

3.20 – 4.90 VDC

0.025 in. – 0.040 in.

(0.635 mm – 1.01 mm)

CHARGING

SYSTEM

Alternator Output (Regulated)

Brush Length

Voltage Output

Regulator Current Draw

32 - 38 Amperes @ 2000 RPM

@ Battery*

52 - 60 Amperes @ 2000 RPM

@ Alternator

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)

*Amperage listed is when battery is in a discharged state. If battery is fully charged, amperage readings will

be less.

1

B

MAINTENANCE

90-855347R1 JANUARY 1999 Page 1B-1

IMPORTANT INFORMATION

Section 1B - Maintenance

Table of Contents

Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Case Lubricant Capacity 1B-1. . . . . . . . . . . . . .

Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quicksilver Lubricant/Sealant 1B-2. . . . . . . . . . . . . . . . . .

Inspection and Maintenance Schedule 1B-4. . . . . . . . . .

Before Each Use 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . .

After Each Use 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 100 Hours of Use or Once yearly,

Whichever occurs first 1B-4. . . . . . . . . . . . . . . . . . . . .

Flushing Engine 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Cooling System – Using Cowl

Flush Plug 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Cooling System – Using Flushing

Attachment 44357A2 1B-5. . . . . . . . . . . . . . . . . . . . . .

Fuel System 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Line Inspection 1B-6. . . . . . . . . . . . . . . . . . . . . . .

Water Separating Fuel Filter 1B-6. . . . . . . . . . . . . . . .

Corrosion Control Anode 1B-7. . . . . . . . . . . . . . . . . . . . . .

Spark Plug Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . . . .

Battery Inspection 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Air intake Filter 1B-9. . . . . . . . . . . . . . . . . . .

Removal 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Points 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Power Trim Fluid 1B-11. . . . . . . . . . . . . . . . . . .

Gear Case Lubrication 1B-12. . . . . . . . . . . . . . . . . . . . . . .

Storage Preparation 1B-13. . . . . . . . . . . . . . . . . . . . . . . . .

Specifications

Gear Case Lubricant Capacity

Gear Case Ratio Capacity

1.87:1

22.5 fl. oz. (665ml)

2.00:1

22.5 fl. oz. (665ml)

2.30:1

22.5 fl. oz. (665ml)

MAINTENANCE

Page 1B-2 90-855347R1 JANUARY 1999

Special Tools

1. Grease Gun 91-37299A1

2. Flushing Attachment 44357A2

Quicksilver Lubricant/Sealant

1. Gear Lubricant - Premium Blend 92-19007A24

MAINTENANCE

90-855347R1 JANUARY 1999 Page 1B-3

2. Anti-Corrosion Grease 92-78376A6

3. 2-4-C Marine Lubricant with Teflon 92-825407A12

4. SAE 30W Motor Oil (Obtain Locally)

5. Quicksilver Power Trim and Steering Fluid 91-90100A12)

MAINTENANCE

Page 1B-4 90-855347R1 JANUARY 1999

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

4. Replace compressor air intake filter.

5. Check corrosion control anodes. Check more frequently 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. Check control cable adjustments.

∗

11. Remove engine deposits with Quicksilver Power Tune Engine Cleaner.

12. Check tightness of bolts, nuts, and other fasteners.

13. 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

90-855347R1 JANUARY 1999 Page 1B-5

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. (12.7mm) 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.

a. Water must be discharged thru “tell tale.”

IMPORTANT: Prevent engine overheating. If water flow is insufficient, stop engine

and determine cause before continuing.

b. Flush until discharge water is clear. In salt-water areas, run outboard 3 to 5 min-

utes.

c. Stop engine before turning off water.

6. Stop engine, turn water off and remove flushing attachment from gear housing.

MAINTENANCE

Page 1B-6 90-855347R1 JANUARY 1999

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.

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.

Water Separating Fuel Filter

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.

Remove and replace filter as follows:

a. Turn ignition key switch to OFF position.

b. Disconnect wire at bottom of filter.

c. Remove filter by turning the filter in the direction of the arrow (clockwise). Tip the

filter to drain fluid in a suitable container.

d. 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.

IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the prim-

er bulb until firm, forcing fuel into the filter.

MAINTENANCE

90-855347R1 JANUARY 1999 Page 1B-7

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

Inspect spark plugs at the recommended intervals.

1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect

spark plug boots and replace if cracked.

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 in General Information Section.

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 N·m).

MAINTENANCE

Page 1B-8 90-855347R1 JANUARY 1999

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 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:

a. Electric Fuel Pump Circuit – SFE 20 AMP Fuse.

b. Fuel/Air Injector Circuits – SFE 20 AMP Fuse.

c. Starting Circuit – SFE 20 AMP Fuse.

d. Ignition Coil/Oil Pump Circuit – SFE 20 AMP Fuse.

a

b

c

d

MAINTENANCE

90-855347R1 JANUARY 1999 Page 1B-9

Compressor Air intake Filter

The filter should be changed every 100 hours of operation, or once a season. Never run

the engine without the air filter.

Removal

1. Remove flywheel cover from the engine. Snap out the retainer (a) and remove filter

(b).

a

b

Installation

Install filter (b) into the cover. Secure filter into cover with retainer (a).

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.

1

MAINTENANCE

Page 1B-10 90-855347R1 JANUARY 1999

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.

5

MAINTENANCE

90-855347R1 JANUARY 1999 Page 1B-11

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-12 90-855347R1 JANUARY 1999

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.

Whenever you remove the fill/drain plug, examine the magnetic end for metal particles.

A small amount of metal filings or fine metal particles indicates normal gear wear. An ex-

cessive amount of metal filings or larger particles (chips) may indicate abnormal gear

wear and should be checked by an authorized dealer.

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.

2

1

3

GEAR CASE LUBRICANT CAPACITY

Gear case lubricant capacity is approximately 22.5 fl. oz. (666 ml).

MAINTENANCE

90-855347R1 JANUARY 1999 Page 1B-13

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

c

d

b

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.

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