Service Bulletin - Amazon Web Services
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1. DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 6 7 2005 Mercury Marine SEPTEMBER 2005 2005 11 30 60 Horsepower FourStroke Voltage Regulator Replacement Non USA customers Return any 883071T1 voltage regulator to the appropriate distribution center for credit Follow the normal return parts procedure Please make reference to Service Bulletin 2005 11 Owner Notification All registered owners within the affected serial number range will receive a letter from Mercury Marine The letter will explain the situation and request that they contact their local dealer to set up a time to have this repair performed Warranty Mercury Marine will credit the dealer for the cost of parts and labor until September 30 2008 Complete the warranty claim listing US AND CANADA Complete process the claim via MercNET or return a warranty claim form INTERNATIONAL Outboard engine serial number Qty 1 P N 893640A01 or 893640A02 1 0 hour labor Warranty Flat Rate Code SB10 Part Code 330 Failure Code 00 Follow instructions issued by the Marine Power International office or by an authorized Marine Power Distributor THE INFORMATION IN THIS DOCUMENT IS CONFIDEN2. EMBER 2005 2005 Mercury Marine Page 1 7 30 60 Horsepower FourStroke Voltage Regulator Replacement Repair Identification Inspect the engine for the installation of a fuse harness c required for the use of this new kit If the fuse harness is installed the bulletin has been performed on the engine and no further action is necessary i o LY A _ Dp aces ae e A IN oS a Voltage regulator b Fuse harness connector to voltage regulator c Fuse harness connector to wiring harness d Cable tie securing fuse and harness e 25 ampere fuse assembly Correction If the repair has not been previously completed install the appropriate voltage regulator kit per the following instructions 1 Disconnect the battery leads from the battery Remove the top cowl Remove the spark plug leads from the spark plugs Remove the bottom cowls Disconnect the voltage regulator wire connectors Or ani i THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 2 7 2005 Mercury Marine SEPTEMBER 2005 2005 11 30 60 Horsepower FourStroke Voltage Regulator Re
3. MERCURY amarr Service Bulletin Bulletin No 2005 11 Circulate to O Sales Manager O Accounting IM service Manager f Technician IM Parts Manager 30 60 Horsepower FourStroke Voltage Regulator Replacement Models Affected Models Covered Serial Number Or Year Model Year 2002 and 2003 Mercury Mariner 30 40 3 Cylinder FourStroke 0T438281 through OT800906 Belgium 0P156468 through 0P269818 Model Year 2002 and 2003 Mercury Mariner 40 50 60 4 Cylinder FourStroke 0T416659 through OT800906 Belgium 0P 156559 through 0P270043 Situation Mercury Marine has received reports of voltage regulator failures on the above identified models A failure of the voltage regulator will prevent the battery from maintaining a proper charge Included in the observed failure modes is electrical arcing within the regulator which can be an ignition source Mercury Marine has made changes to the voltage regulator and related components to address this issue The models identified above will be upgraded at no cost to the customer with a kit described below which includes a new voltage regulator THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2005 11 SEPT
4. TIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2005 11 SEPTEMBER 2005 2005 Mercury Marine Page 7 7 Dear Mercury Marine Owner Thank you for your purchase of a Mercury Outboard We at Mercury Marine are dedicated to providing superior reliability and customer satisfaction As part of our commitment to superior customer satisfaction we have determined that it is necessary to replace the voltage regulator on your engine to insure the durability of your Mercury Outboard What is the condition On a small number of engines it is possible that the voltage regulator may fail resulting in the loss of battery charging capacity Included in the observed failure modes is electrical arcing within the regulator which can be an ignition source To eliminate the possibility of this occurring Mercury Marine will replace the voltage regulator and other related components which have been redesigned to address this issue at no charge to you What will Mercury Marine do Any authorized Mercury Marine dealer will inspect and if necessary replace your voltage regulator at no charge to you What should you do Please contact your Mercury Outboard dealer to schedule an appointment to have the volta
5. f the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2005 11 SEPTEMBER 2005 2005 Mercury Marine Page 5 7 30 60 Horsepower FourStroke Voltage Regulator Replacement 17 Route and secure wiring as shown i o A p X p J GES J a Voltage regulator b Fuse harness connector to voltage regulator c Fuse harness connector to wiring harness d Cable tie securing fuse and harness e 25 ampere fuse assembly IN 18 Reinstall bottom cowls 19 Reinstall spark plug leads 20 Reconnect battery cables 21 Test run outboard and inspect exhaust cover for leakage 22 Reinstall the top cowl Parts Required Qty 1 of the appropriate voltage regulator kit 30 40 3 cylinder FourStroke carburetor or EFI 893640A01 40 50 60 4 cylinder FourStroke carburetor or EFI 893640A02 Dealer Parts Inventory USA customers Return any 883071T1 voltage regulators in your inventory using the Mercury Precision Parts UNDER 30 DAYS RETURNS PROGRAM You may use the form on the back of any parts and accessories packing list Please note on the form that the return is part of Service Bulletin 2005 11 All returns must be sent freight prepaid to Mercury Marine Attn Return Goods W6250 20C Pioneer Road Fond du Lac WI 54935 THE INFORMATION IN THIS
6. ge regulator replaced Your dealer is able to determine how long the repair will take on your engine Please present this notice to your dealer when you bring your engine in for your service appointment What if you have other questions or if you no longer own this engine Please contact your Mercury Outboard dealer or call Mercury Outboard Customer Service at 1 920 929 5040 between 7 30 AM and 5 30 PM CST We have sent this notice in the interest of your continued satisfaction with our product and we sincerely regret any inconvenience this may cause you Thank you for boating with Mercury Marine Mercury Marine Service
7. placement 6 Remove the mounting screws and remove the voltage regulator TT LT 16931 b Wire connectors a Screws 7 Remove the temperature sensor from the exhaust cover Retain for installation into the new exhaust cover 8 Remove the thermostat cover Retain for installation into the new exhaust cover 9 Remove the exhaust cover 10 Properly clean the gasket surface of the exhaust chest 11 Install the new exhaust cover with the gasket provided 12 Install the new thermostat thermostat cover and new thermostat gasket to the new exhaust cover THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2005 11 SEPTEMBER 2005 2005 Mercury Marine Page 3 7 30 60 Horsepower FourStroke Voltage Regulator Replacement NOTE The installation of this kit requires the replacement of the engine exhaust cover Refer to the appropriate service manual for removal and installation instructions 18525 a Exhaust cover gasket g Screw M6 x 40 2 each b Exhaust cover h Thermostat c Thermostat cove
8. r gasket i Thermostat cover d Voltage regulator j Elbow e Pipe plug drive tight k Temperature sensor f Screw M6 x 35 12 each l Thermostat gasket Description Screw M6 x 35 Screw M6 x 40 THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 4 7 2005 Mercury Marine SEPTEMBER 2005 2005 11 30 60 Horsepower FourStroke Voltage Regulator Replacement 13 Torque the exhaust cover and thermostat cover screws in the proper torque sequence Reference the correct sequence below 11 Q O 4 3 1 2 O 5 6 3 O 2 2 10 18501 12 18509 Three cylinder exhaust cover Four cylinder exhaust cover er 14 Install the new plastic fitting and pipe plug to the exhaust cover drive tight 15 Install the temperature sensor Torque to specifications e er Pts Pd 16 Install the new voltage regulator Description Nm tint Voltage regulator rectifier mounting screw torque oes ee Jooo o THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use o
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