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1 i - Brunswick Marine in EMEA Center

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2. ii o ee itm Ubi i ta Tt B Wf x am ea suf DEC 4 Maximum Spark Advance Screw Figure 2 Maximum Spark Advance Adjustment CARBURETOR ADJUSTMENT 1 Start engine and allow to warm up to normal operating temperature 2 With engine runningin forward gear adjust carburetor idle mixturescrew to attain best idle in forward gear Refer to carburetor adjustment infor mation preceding 3 Adjust engine idle RPM to specifications with engine running in forward gear Figure 3 Retighten nut on adjustment screw NUS SS VM gt oe E 7 P t i Pass Gans see 4 10963 a Idle RPM Screw Figure 3 idle RPM Adjustment 0 T Sis oie dunt 08395 a Maximum Neutral Speed Stop b Balt Figure 4 Maximum Neutral Speed Limiter Adjustment Only on Engines with a Tiller Twist Grip Handle MAXIMUM NEUTRAL RPM LIMITER ADJUSTMENT IMPORTANT Maximum neutral speed limiter adjustment stops the rotation of handle twist grip when throttle Is at specified maximum neutral speed This adjustment must be accurate to assure easy starting when engine Is cold and prevent engine from starting at maximum RPM 1 With engine idling in neutral loosen b
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4. dr s HI Sport TREE spk WEEE SE fet a FS Pea ad DEAE riora eT N 7 Bow 9 With engine running in forward gear advance engine speed so that timing pointer is aligned with specified maximum spark advance on timing decal Adjust maximum spark advance stop screw so that end of screw just touches spark lever as shown in Figure 5 Retighten nut on adjustment stop screw Move throttle back to idle and turn off engine Remove timing light 6 With engine not running advance throttle lever to wide open throttle WOT and adjust full throttle stop screw Figure to allow full carbu retor shutter opening at WOT Make sure that carburetor shutters do not act as a throttle stop Allow 010 to 015 75mm to 38mm clearance between throttle cam and pin on carburetor cluster when throttle is WOT as shown in Figure 7 Lo mBex m s p 4 pus ste Don a bee 09837 Throttle Lever Throttle Stop Screw Figure 6 Full Throttle Stop Screw Adjustment uu 4 PX M PS gt gv gt Dues 09838 Carburetor Cluster Pin b Throttle Cam Figure 7 Full Throtde Stop Adjustm
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6. SXO0SL pue 0051 006 ern cnin port u or d 955531 1uaunsn pe 2019480483 296 9 40 8 appt 2823 ur Zuruuni aurdua BUS HA ONILSQPOV HONAS ONIMALL S1N3W1SnrQv uo13unguvo PER s uid oni a n een Nee mere ng min a cepacia ae tone v n n eid inii b TRA eds C nci 2 Turn flywheel until single dot 3 dots on pre 1978 Mere 1150 and 1500 models on flywheel timing decal is aligned with center of distributor shaft as shown in Figure 1 3 Turn distributor pulley until arrow Figure 1 is aligned with single dot 3 dots on 1978 Merc 1150 and 1500 models on the timing decal then slip timing belt over pulley IMPORTANT When installing timing belt on engines with Thunderbolt Ignition on pulley may not align directly with dot s on flywheel If this should occur align arrow slightly counterclockwise This will appear to be approximately tooth otf If arrow is aligned slightly clockwise Instead of clockwise this will make engine synchronization difficult and r
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8. 10 8 Alternator and 12 LLI d 9 Internal Wiring Harness usus 16 5 m 10 Adjustments before Testing 16 LX 11 Boat Test 16 A 2158 12 Additional Checks and Adjustments 1 lt Spark Plug and ignition Data 45 Capacitor Module Test P Thunderbolt Ignition Stator Checks f Thunderbolt Ignition Coil Checks 22 1 gt Timing Synchronizing Adjusting TE 23 gt Spp ge Mare 40 2 22 2 EE E E d p d amp Merc 45 with Phase Maker Ignition 25 ez uu ud EE Merc 75and Merc 110 1 zb sp p d ep Mere 200 sese IG E Merc 402 d a Mere 500 0 eee GEIGER IE GE d E d Mere 650 z Se GE Merc 70O 0 sep py p epp pp b p Merc 800 and 850 s su sp quu Merc 900 1400 and 1500XS 1978 Models and e a 15 gt cpap Merc 1150 1500 In Line Models 91 5 HS p 481 V 6 Merc 1500 2000 1978
9. Actuator Plate Primary b Carburetor Cluster Primary Lever Just Touching Figure 2 Primary Throttle Pickup Adjustment Throttle Lever b Spark Lever c Maximum Spark Stop Screw Figure 3 Adjusting Maximum Spark Advance 8 vis E 4 D gin respi forward gear move throttle arm to retard 0560 to 600 RPM 5 Adjust idle throttle arm and uphten locknut Y 4 iam e throttle arm to align 77 9 BTDC marks on flywheel decal with taming pointer Loosen 2 throttle actuator plate retainer screws and rotate actuator plate so that the primary cam just touches primary pickup arm catburetor cluster Figures and 2 Tighten 2 retainer screws NOTE Due to electronic timing characteristics of this ignition system it is necessary to set the maximum spark advance at 32 BTDC as described in Step 6 to aitain 30 BTDC spark advance at 5000 RPM 6 Advance throttle arm to align 32 BTDC mark on flywheel decal with timing pointer adjust maximum spark stop screw to touch spark arm and tighten locknut Figure 3 MR REE i 4 e T 5 i mms P 4 09847 a Actuator Plate Secondary Screw b Carburetor Cluster Secondary Lever c Just Touching Figure 4 Secondary Throttle Pi
10. inv 8 10968 Timing Pointer Timing Pointer Attaching Screw Figure 2 Timing Pointer Alignment Reposition timing pointer if necessary so that timing pointer is aligned with 462 mark on timing decal Figure 2 Retighten pointer attaching screws 5 Remove dial indicator from cylinder and reinstall No 1 spark plug and spark plug lead TIMING ADJUSTMENTS IMPORTANT If link rod was disassembled make sure that 11 16 17 5mm dimension is retained as shown In Figure 4 eee meme p 3 f 09852 a Pickup Alignment Line Throttle Cam b Reed Block Housing Boss d Idle Siop Screw Figure 3 Idle Stop Screw Adjustment CAUTION Engine Is timed while cranking engine over wiih starter motor To prevent engine from starting when being cranked al spark plugs must be removed except No 1 plug 1 Remove all spark plugs except No 1 spark plug top cylinder starboard bank froin engine 2 Disconnect reinote fuel line from engine 3 Connect elerirical harness to engine 4 Remove throttle cable barrel from barrel retainer on cable anchor bracket Adjust idle stop screw so that top surface of throttle cam is aligned with edge on reed block housing boss as shown in Figure 3 Do not reinstall throttle cable at this time 5 Connect Timing Light to No
11. mt Le lut T PRI AA mt TREE i erre em ig me orem mense mo Throttle Actuator b Secondary Pickup Figure 8 Secondary Pickup 5 With engine not running move throttle lever to wide open throttle WOT and adjust throttle stop screw Figure 4 to allow full carburetor shutter opening at WOT Make sure that carburetor shutter does not act as a throttle stop Allow 010 6 015 25mm to 38mm clearance between throttle actuator cam and carburetor cluster pin at WOT as shown in Figure 5 Retighten nut on adjustment screw 6 Withengine ot running move spark lever to maximum spark then adjust secondary pickup adjustment screw Figure 6 so that carburetor cluster pin is on secondary pickup point on throttle actuator cam as shown in Figures 7 and B Retighten nut on adjustment screw 7 Move throttle lever to idle position CARBURETOR ADJUSTMENTS l Start engine and allow it to warm up in forward gear 2 Adjust carburetor mixture screws to attain best idle in forward gear See carburetor adjustment information preceding 3 Adjust engine idle RPM as follows a With engine in water connect electrical harness and fuel line 1o engine Start engine and allow to warm up b With throttle cable barrel removed from barrel retainer adjust idle RPM to 650 750 RPM with engine running in forward gear Figure 9 Retighten nut on adjustment screw
12. 99 4 5 1 1 dz V 6 Merc 1750 1976 77 105 8 pep IFTE 15 V 6 Merc 1750 1978 11 c fe z le y 2 51919 2 Schematic Wiring Diagrams 117 5 Jola 115 EJS a z SES 2 Merc 40 45 75 110 200 Models 117 Q 1212 BES HE 31593 4 Merc 500 129 515 61515 9 5 8 2 8 3 50 00 133 Sjo els 121815 2181981917 4 and 6 Merc 800 850 900 1150 1400 e 31212 13 8 3 S x 2 38 215159 1500 135 3 2 5 p es LLL 138 AME 5 2 lo 2 HEE SHRIRESEESRBEREEPEE MERCURY MARINE JEHESBREFEHEREESEE A DIVISION OF BRUNSWICK CORPORATION Biz 8 2 5 5 5 SSS FOND DU LAC WISCONSIN 54935 els 5 8 E ve amp rc Jac Snark Plug Leads All Electrical Connections Inspect Spark 5 Check Condition Description a C 92 66229 1 An engine tuneup is a service to put the maximum capability of economy power and performance back into the engine and at the same time assure the operator of a complete check and more lasting results i
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14. OER ERS E mmt to gr s tr TERES TIMING SYNCH ADJUSTING gt Jim f ight Merc 75 Below Serial CARBURETOR ADJUSTMENTS 431 4385 and Merc 110 Below Start engine and adjust idle mixture screw for best idle Refer to carburetor adjustment information preceding This is equipped with i i instructions integral fuel pump carburetor Follow proper idle mixture ins Serial No 4304785 Do not set carburetor leaner than necessary as a lean setting causes hard 1 starting Firing Order Alternate Firing 2 Set engine idle RPM stop screw to attain 650 to 750 RPM in forward gear Spark Plug AC V40FFK or Champion L78V Spark Plug Gap Not Adjustable Timing Maximum Advance 35 BTDC i MAXIMUM NEUTRAL RPM LIMITER Throttle Prim Pick j M Full Throttle SEM us eoo il With engine running in neutral gear loosen neutral RPM limiter screw Idle RPM 7 located in the bottom cowl Move limiter toward rear of engine and 650 750 RPM in Forward Gear tighten the screw only enough to place light tension on the limiter Figure Water Pressure at Tell Tale 4 to 8 psi 281 to 562kg cm 3 4500 RPM 2 Turn twist grip to attain 2400 to 2700 RPM then tighten the limiter screw Merc 75 s below 4131610 and Merc 110 below 4126460 securely Recheck limiter RPM by returning to idle then opening throttle 3 to the limit stop Readjust if necess
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21. 3 oo1l9vuv2 HiGH TENSION LEAD CYL Ben HIGH TENSION LEAD IGNITION COIL CYL NO 1 3t D MELOS U Green White Green Yellow TRIGGER COIL ii 8 o White White 5 I o Yellow Blue White Blue Orange Q Brown mm Brown Black Brown Brown p Black STOP SWITCH HIGH TENSION LEAD CYL NO 2 IGNITION HIGH TENSION COIL LEAD CYL x IGNITION COIL NOS reen White Green Blue White STATOR Wiring Yellow Red Yellow VOLTAGE REGULATOR Red m ons re STE Yellow gt rl 8 White White lt X o 2 o I STOP SWITCH Te Hp mmn cm PI RETE EUER emm Rm CT NH nmm HOLVNH3LTV LYVLS TVANVIN 34 22 9161 OLL pue 57 X m 2 e 3 gt c re gt X GUE HIGH TENSION LEAD Yellow m CYL 5 LIGHTING WINDING NO 2 White a IGNITION White A HIGH TENSION COIL 11 LEAD lt i 5 5 CYL 5 o 1 NO 1 2 gt gt 5 4 IGNITION Yellow RECTI
22. 1 Set selector switch on Position No 3 Continuity 2 Clip small red and black test leads together and turn meter adjustment knob for Scale No 3 until meter pointer hand lines up on set position on Scale 3 right side 3 Connect small red and black test leads from analyzer to positive terminal and ground stud 4 Note reading of figures on lower hand Scale No 3 5 Reverse test leads on rectifier and note readings again 14 6 Ratio of two readings should be 10 1 or greater 7 Remove analyzer test leads and connect to the two alternator terminals en rectifier Note reading of figures on lower hand Scale No 3 8 Reverse test leads on rectifier and note readings again 9 The ratio of the two readings should be no more than 2 1 10 This is only a preliminary test to determine condition of rectifier If ques tionable as a final test rectifier should be installed on engine and checked with ammeter while engine is running ies T 00042 Positive Terminal b Ground Stud Alternator Terminals Figure 9 Testing Plate Type Rectitier RECTIFIER OUTPUT CHECKS Net DC Amperage Output on All 2 4 and 6 Cylinder Engines Use VOA Tester C 91 52751 ONLY 1 With engine stopped disconnect red harness lead from positive ter minal of battery and connect negative ammeter terminal to red harness lead 2 Connect positive side of ammeter to positive terminal of battery Turn ignitio
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24. dis 91 o118q 51989 apio 15 dors Isulvde 1042 31110143 p i2euuoa equa jnosyp jo pus yny o Malus ju2unsnfpe uo Inu 31 51 928 4 1653 premioj duruuns Wd 009 065 091 Way jsnfpe 9128 91169 ajno qut dn pue aurdua ejg 1 pue ssouieq EMI 139803 yem ut auus YHA ce 5 appr isnfpy Butpavaid 1938159868 4013484483 229 1998 ut 159 01 APT 201241192 z ut dn 01 991293 pue ues 541 38 15 2 TOMON 8 61 yueunsn py Masog dois LL enbyd 9155 9018 91440441 e 58601 meer p i i 4 B TN 9PIO pue 2161 maios dois 6 941614 105 dois e 65080 o H mmn ees ment e n rsen 1 d 1 H E PERRA m qe mi EVE TIMING SYNCH ADJUSTING V 6 Merc 1500 2000 1978 1 2 3 4 5 6 60 Consecutive AC V40FFM or Champion L76V Not Adjus
25. not deformed or bent and will properly hold brushes against commutator 5 Check brush springs If tension is insufficient the brushes will arc and wear very rapidly 6 Check condition of brushes If pitted or worn to one half their original length they should be replaced 1 Check fit of armature shaft in bushing of drive end plate Shaft should fit snugly in bushing If bushing is worn it should be replaced Apply No 10 oil to this bushing before reassembly Avoid excessive lubrication 8 Check fit of bushing in commutator end plate If this bushing is damaged or worn excessively end plate bushing or assembly should be replaced Apply No 10 oil to this bushing before reassembly Avoid excessive lubri cation Lubricant forced onto commutator will gum and cause poor com mutation with resulting decrease in starter motor performance 9 Inspect armature commutator If commutator is rough or out of round it should be turned down and under cut Inspect points where armature conductors join commutator bars to make sure that it is a good firm con nection Burned commutator bar usually is evidence of a poor connection 10 To remedy any of preceding conditions refer to the Service Manual 11 Reassemble starter motor and lubricate pinion gear and screw shaft with No 10 oil 12 Check return spring for normal tension Pinion must return from engaged position smoothly and rapidly TESTING SOLENOID 1 Turn selector switch of
26. 2 5 20154923 8 8 sequence TE Beco AS s E 590 a 5 op 6 8 95525 1 Compression Check 8 Alternator and Rectifier a 28 2 5 2 2 Spark Plug Inspection and Adjustment 9 Internal Wiring Harness dez IE E 56 55 3 522 3 Lower Unit and Water Pump 10 Adjustments Prior to Testing checks and adjustments shown in Tuneup Sequence immediately preceding 2 Changes to sequence 1 1 Complete tuneup should follow of service outlined should minimized whenever 5 5 E 3 3 2 5 R 3 Fd 3 25 2 S 2 amp pe 3 4 3 o E Tiller Handle Knuckle Pivot Gears Lubricate NOTE Complete list of maintenance is not applicable to all models E SAE 5W 30 or SAE 5W 20 Specification SE Automotive Oil al 3i E 8 m z possible SEE e 3 Tuneup is performed in 2 parts 418 1 3 Mai Se je 3s 5 Maintenance and adjustments Gi 3 i tot 5 5 8 A 5 b Additional checks and adjustments celeb 515 2 E 3 gt St 1 Includes added instrument checkouts performed with any of the olaj 9 5 8 modern units of service equipment available for this 51 3 55 uc purpose amp Hi E 3 5 2 Many checks an
27. 2 Remove centrifugal slinger from drive shaft 8 Check water pump failure may be cause of overheating 3 Remove water pump body assembly 4 Remove water pump and remove impeller and impeller drive pin and face plate 2 Spark Plugs Inspection and 5 impeller face plate and water pump insert closely for wear Adjustment 6 Remove water pump base assembly and water inlet tube if equipped 7 EXAMPLE gap measured is 010 25mm remove 012 30mm shim If gap measured is 005 13mm remove 007 18mm shim Merc 110 75 45 models do not use a gasket If gap measured is 005 remove 005 shim to give Zero gap Install ring on water pump base and install base to lower unit NOTE Lower units with tappered drive shaft bearings do not require shim ming of water pump base INSTALLING WATER PUMP 1 Install water pump base to face plate gasket stainless steel face plate and face plate to water pump cover gasket A f 2 Coat drive pin area of drive shaft with Multipurpose Lubricant C 92 9 If engine hesitates during acceleration after adjusting idle mixture it is 63250 too lean and idle mixture should be richened slightly until the engine 3 Position drive pin on drive shaft and install impeller Check that drive pin accelerates correctly does not s
28. H i 1 i 4 i H i 1 1 4 10 Adjust engine idle RPM as follows a With engine in water connect electrical harness and fuel line to eugine Start engine and allow to warm up b With throttle cable barrel removed from barrel retainer adjust idle RPM to specified idle RPM with engine running in forward Bear Figure 8 Retighten nut on adjustment screw With end of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place d Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed without tearing but has some drag on it Readjust cable barrel if necessary IMPORTANT Excessive preload on throttle cable will cause diffi culty when shliting from forwerd to neutral Readjust throttle cable barre if necessary NOTE Carburetor idle mixture is not equipped with adjustment screw as are other Mercury Outboards See carburetor Jet chart preceding for jet change NOTE If sufficient throttle cable barrel adjustment is not available a check must be made for correct installation of link rod located between the throttle lever and throttle cam Each end of this link rod must be threaded into its plastic barrel until it bottoms
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31. DYNAMIC TIMING PROCEDURE 1 Place engine in a test tank and remove engine cowl econtra eines Num ix 1092 b Maximum Spark Advance Screw Retard Cable Figure 2 Adjustment Locations a Trigger Link Rod 2 Connect Timing Light C 91 35507 to engine by connecting red lead to No 1 top spark plug and connecting black leads to 12 volt battery posi tive and negative terminals Connect tachometer to engine IMPORTANT Immediately after starting engine make certain that water pump is operating check for water discharge from ex haust reilef holes at rear of drive shaft housing 3 Start engine shift into forward gear and run at 2 throttle for approxi mately 5 minutes to warm up engine 4 Set idle timing as follows a With engine in gear and running at 1000 to 1500 RPM observe igni tion timing while quickly closing throttle against idle stop The timing will fully retard to approximately 18 to 20 ATDC then will advance slightly to 15 to 18 ATDC as the idle speed approaches 600 RPM b Adjust trigger link rod Figure 2 to set idle timing at 2 below the advance reading which is obtained as idle speed approaches 600 RPM EXAMPLE Timing fully retards to 18 as throttle is closed advances to 15 ATDC at 600 RPM set idle timing at 17 ATDC 5 Advance throttle grip until 22 to 26 BTDC is reached then adjust maxi mum spark advance screw Figure 2 to contact st
32. E 4 4 03795 Alignment Mark b Arrow on Pulley Figure 1 Distdbutor Drive Belt installation j ab b 5 sd t X 08122 Figure 2 Alignment Tooth Clockwise TIMING ADJUSTMENTS 1 Place engine in a test tank and connect engine electrical harness and fuel line 2 Pre set carburetor idle mixture screws at 1 turn out from seated position vee a gst tn tae 03799 Timing Mark Timing Light b Timing Decal Figure 3 Throttle Primary Pickup 1 SURE ica imas n RT n Ma css md Mr MM p 3 Install Timing Light C 91 35507 by connecting red lead to No 1 top spark plug and connecting black leads to 12 volt battery positive and negative pests Connect tachometer to engine With engine running in forward gear open throttle to align timing mark straight line on flywheel rim with throttle primary pickup specification Figure 3 LIEU et CES ca 03792 Throttle Actuator Plate Throttle Secondary Pickup Screw Figure 4 Throttle Actuator Plate Adjustment Screws With throttle positioned as in Step 4 loosen
33. Ne up B 2 Be e Co ics O98 Actuator Plate b Carburetor Cluster Primary Leve Primary Cam Just Touching Figure 2 Primary Throttle Pickup Adjustment 59 that the primary cam just touches primary pickup arm on carbureto _ cluster as shown in Figure 2 Retighten retainer screws and return engine speed back to idle IMPORTANT Electronic timing characteristics of this ignition system require that when adjusting maximum spark advance Ith necessary to set the maximum spark advance at 32 BTDC to attain 30 BTDC spark advance Pore RIM Ne OOP TE PEP ORR pem 7 3 E THEE Ne emis c MEME 4 M x M ao de cerise ea 1097 Maximum Spark Advance Screw Figure 3 Meximum Spark Advance Adjustment pE biur RIS Bove gre an forward gear advance engine speed until liming pointer pan with 42 BYDC mark on timing decal Adjust maximum spark stop sa that end of screw touches spark lever as shown in Figure 3 Re nut on adjustment screw move throttle back to idle and turn off engine Remove timing light comme ote 28 nis ons Ina La ii lined i a STER In 4 77 uin E acad 10960 a Secondary Pickup Screw
34. Orange LEAD on BACK SIDE MUST BE GROUNDED m Typical 3 Places n O fev O 2 ort 3 RECTIFIER STARTER MOTOR pGreen Whites oj e Black e H ce eo H 4 NO 2 e SOLENOID to Black U STARTER CABLE reen A eve no 1 gt o9 1 Red REMOTE UND nt IGNITION COIL CONTROL lt BATTERY 3 Required CHOKE ms 4 CHOKE SOLENOID o e Gray MN Red Brown NEUTRAL START Wo INTERLOCK SWITCH orange Red 5 P Black gt Brown Gray White ENGINE HARNESS EXTERNAL WIRING HARNESS TACHOMETER KEY SWITCH CONNECTOR Position 1 Off ED Position 2 A F Position 3 Run 567 AF 8 om lt UNTERTITEL US PSP ARTT WEISSEN TT P UK un CD ER jS pe m ER ALTERNATOR FLYWHEEL 12 VOLT BATTERY 5 x dud DISTRIBUTOR ADAPTOR to d FRONT COWL SUPPORT i zy C REMOTE CONTROL NEUTRAL START j INTERLOCK SWITCH 3 Bue 5 585 2 am iind 3 CONNECTOR 5 Lc EXTERNAL HARNESS GHY ENGINE HARNESS Position 1 Off E
35. Turn No 2 Scale meter adjustment knob to adjust meter needle with red line on right side of Scale No 2 Connect small red and black test leads to terminals of yellow or yellow red alternator leads 7 Read figures on Scale No 2 Refer to specification chart following for modcl being tested If alternator does not meet specifications it should be replaced a 8 5 10 5 7 9 7 9 9 7 9 3 5 78 7519 7510 7 9 6 8 7 9 7 9 __3 71214 at Rectifier 3 54 5 Average 1 Stator Part No Aver 74367 2 65 A 74367A3 A9 Rx1 5 A 398 5454A2 75 79 5 962 902599 13 RE At wide open throttle with somewhat discharged battery A 398 5919A3 75 3 A 398 4793 A 398 5232 A 398 4793 A 398 5255 A 298 2995 4 A 398 4634 A 398 5704A2 ALTERNATOR STATOR SPECIFICATIONS 1976 77 78 1976 77 78 1976 77 78 1975 1975 1976 77 78 1976 77 78 1975 76 77 800 850 850XS 1150 1500 V 6 s 900 1400 1500XS short is obtained this would be proper Copper wire is an excellent conductor but will have noticeable 1 Primary DC resistance of these windings generally is less than one 1 ohm If a reading resembling differences from cold to hot Reasonable variations from specified readings are acceptable 12 RECTIFIER CHECK on THUNDERBOLT IGNITION MODELS 1
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37. 1 cylinder posa and connecting black leads to 12 volt battery positive pegatise 6 posts Aah engine cunning in forward gear open throttle to align 39 5 marks on decal with timing pointer Adjust the screw between throttle and spark arm as necessary to cause the throttle actuator cam to just touch throttle lever pin Figure 2 Tighten locknut ERRANT 07351 Spark Advance Arm b Spark Stop Screw c Just Touching Figure 3 Adjusting Maximum Spark Advance AEN Ma nt E i d ME 1 Ad ATE a k Io 07352 Throttle Arm b Throttle Stop Screw Figure 4 Adjusting Full Throttle Stop Screw ERE SERRE BRE EE nda sia La taa sis a d eit wer d aa ts re 9196 196 Jojeorpur vayn pue 0192 0 18 126 391923 dor un astA50 o V ut uin prap doi 18 1 uoistd oN 9 1 one 25 88 4 5599 163 10162 rpug 15 pue s nd yseds 1 Snid eds wow 1 9 940 oj 5 ueunsn pg N2949 O 9098 Buun
38. Figure 9 as necessary to align Start with arrow c Reinstall tiller handle to engine with 2 screws Tighten screws securely i i mo 4 2 un EN 5 5 Figure 9 Tiller Handie Gear Realignment for Models with Tiller Handle xi 0789 AR TIMING SYNCH ADJUSTING Merc 402 Alternate Firing AC V40FFM or Champion L76V Not Adjustable Firing Order Spark Plug Spark Plug Gap Timing Maximum Advance Align Notch with Solid Line on Flywheel Throttle Primary Pickup Align Notch with 2 Dots on Flywhee Throttle Secondary Pickup See Step 6 Full Throttle RPM 5000 5500 RPM Idle RPM 550 650 RPM in Gear Water Pressure at Cylinder 6 to 14 psi 422 to 984kg cm at Block 5200 RPM IMPORTANT When timing engine use proper timing window as shown in Flgure 1 H Pd 4 it E 4 UU uet Y E 5 T 1 E KU E P 004 0X NM menu ado veio 10442 a Use This Timing Window on Merc 402 s below Serial No 4726798 b Use This Timing Window on Merc 402 s with Serial No 4726798 _ and Above Figure 1 Timing Location Merc 402 1 Place engine in test tank and connect fuel line Pre set carburetor idle mixture screw at 1 turns out from lightly seated
39. position Connect Timing Light to No 1 top spark plug Start engine and shift into forward gear Advance engine RPM until timing mark 2 dots are aligned with notch in timing window asshown in Figure 2 Adjust turnbuckle so that throttle cam just touches the primary pickup wm on carburetor cluster Figure 3 Retighten turnbuckle locknuts and Teturn engine speed back to idle RR oomen m AMT Mtm mince e RTT 5 SOR 76 1 With engine running in forward gear advance engine speed to full throttle 5000 5200 RPM Adjust maximum spark advance screw Figure 5 until b timing mark straight line on flywheel is aligned with notch in timing P window as shown in Figure 4 Return engine speed back to idle and turn B ox x off engine Disconnect timing light Nu ti i B 5 i EN oco 0738 Timing Marks with Notch Timing Window Figure 2 Throtile Pickup Timing Marks Aligned CT eel lll Ee temere PEE ere 10989 a Maximum Spark Advance Screw 5 iod Advance Adjustment 07378 Just Touching b Turnbuckle Figure 3 Throttle Pickup Adjustment mmm i Forme uei iK 24 i 11 X 14 jT 4 EX i s E NR ATE DUE ono tend 10987 b XE 0738 Secondary Pic
40. 381mm Clearance between er Pin and Throttle Cam at Closed Position 1 3 to 4 Threads 1 8 Exposed on Retard Cabie Figure 1 Adjustment Locations TIMING SYNCH ADJUSTING Merc 40 2 Timing Maximum Advance WOT 22 to 26 BTDC E gt jns 5 5 22 5 2 5 19 2 lt ccc Ai ale lt DIE 28g wk 2856 act 5 5 5 2 ue ES x lt ox 22 SEF 25 8 n exo xm ocu Ss 2 Ey Efe 5285 o nso O 5 0 a gt d Sus oy gt 555 85525 aes ny 2 epqnidooan aap sSuiproa parfivads 104 0 pjo 94 ut aouazaffip ajqvaoyoU 0 up anm 124407 ag snjj 419 11095 0 v 1 auo 55 s1 spos 25991 fo 291 o zvevisece v 62 17 9260 tx 8829 68 pue 504 1 2 pue ION 10 punoar 25 568 867291 S
41. Allen lead Screws One Hidden Figure 5 Tiller Handle Gear Reallgnment TIMING SYNCH ADJUSTING Merc 200 All Models except Electric Models Serial No 4709593 and Above Alternate Firing Spark Plug AC V40FFK or Champion L78V Spark Plug Gap Not Adjustable Timing Maximum Advance 133 BTDC 5000 RPM Throttle Pickup Below Serial No 4102790 2 BTDC to 2 ATDC Above Serial No 4102789 3 to 7 BTDC 4800 5500 RPM idle RPM 550 650 in Gear Approx 10 Water Pressure at Tell Tale 6 to 8 psi 422 to 562kg cm at 5000 RPM Full Throttle RPM Place engine in test tank and connect fuel line 2 Pre set carburetor idle mixture screw at 1 turns out from lightly seated position 3 Connect Timing Light to No 1 top spark plug pu EN 07839 CPT o UO uu 2 pe An E a H s 72 D o EV ym MAS mm enar tmt etii eme 1 SEV hd RA mu 10964 Elastic Stop Nuts 2 b Link Rod Figure 1 Maximum Spark Advance Adjustment Model with Adjust Elastic Stop Nuta Komm ISO ME i t d anti n ac 3 i d atas a Aui amp 11025 Link Rod Flgure 2 Maximum Spark Advance Adjustment Model with Adjust able Link Rod Sta
42. Figure 3 Retighten screw to lock vertical lever in position 10 Rotate crankshaft clockwise to place piston at 005 127mm 11 With VOA meter connected as in Step 6 close the throttle with twist grip until meter indicates points closed 12 Adjust throttle cam to just touch vertical throttle lever Figure 4 13 Remove dial indicator and install spark plug 14 Pre set carburetor idle mixture screw to one turn turn from ligatly seated position 15 Start engine and allow it to warm up in forward gear Set idle mixture scre for best idle refer to Fuel System in Section 5 AT ua 09850 com louem WA vU 1 Y tu Veg Tet que eye d 09875 Carburetor Vertical Shaft d idle RPM Screw b Throttle Cam e Locknuts c Maximum Spark Advance Screw f Vertical Shaft Lockscrew Figure 3 Adjusting Maximum Spark Advance 16 Check that twist grip decal Start aligns with cast arrow running at 2500 3000 RPM in neutral 17 Set idle RPM screw to attain 650 800 RPM in forward and tighten locknu eoe Cte me Na ARRA TUN with engine t ep m r 3 MD Ut M nee nate a 09874 8 Throttle Cam b Just Touching C Throttle Lever Figure 4 Adjusting Throttle Pickup
43. Figure 4 Secondary Pickup Screw Adjustment UE fe i 3 mr 4 i E Eos sth 5 FM 3 i 4 x 1 ra m i DRESS Xu 10976 Full Throttle Stop Screw Figure 5 Full Throttle Stop Screw Adjustment Ren due d maximum spark advance stop screw then adjust secondary pickup scres Figure 4 so that end of screw just touches secondary lever 7T With engine not running move throttle lever to wide open throttk WOT Adjust full throttle stop screw Figure 5 to allow full carburetor shutter opening at WOT Make sure that carburetor shutters do not act a a throttle stop Allow 010 to 015 25mmto 38mm clearance between secondary pickup screw and carburetor cluster sccondary lever as shown in Figure 6 5 8 p x PEN lt 22 d 534 0984 b Carburetor Cluster Secondary Lover 010 to 015 Clearance Figure 6 Full Throttle Stop Adjuatment CARBURETOR ADJUSTMENTS 1 Start engine and allow it to warm up in forward gear 2 Adjust carburetor idle mixture screw to attain best idle in forward gear See carburetor adjustment information preceding 3 Adjust engine idle RPM as follows a With engine in water connect electrical harness and fuel line to engine S
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45. Merc 500 1975 with Lightning Energizer Ignition System Firing Order Firing Sequence Spark Plug Spark Plug Gap Timing Maximum Advance Throttle Primary Pickup Throttle Secondary Pickup Full Throttle RPM Idie RPM 1 3 2 4 90 Consecutive AC V40FFM Champion L76V Not Adjustable 35 BTDC 5200 RPM 7 9 BTDC At 35 BTDC Stop 4800 5500 RPM 550 600 3 5 ATDC in Forward Gear 3 to 5 psi 211 to 352kg cm 2000 RPM Water Pressure at Cylinder Block DISTRIBUTOR DRIVE BELT INSTALLATION l Rotate flywheel until Alignmeni Mark straight line on flywheel rim is aligned with center of distributor shaft Figure 1 2 Rotate distributor pulley until arrow cas wheel alignment mark Slip drive belt ove washers and bolt Torque cover bolt to t into pulley is pointing at fly r pulley and install pulley cover 60 in lbs 69kg cm Figure 1 NOTE When installing timing belt on 4 and 6 cylinder outboards with Thunderbolt Ignition the arrow on the pulley may not align directly with the mark on the flywheel If this should occur align the arrow slightly clockwise as viewed from front of outboard This will appear to be approximately Va tooth off Figure 2 Installing the belt V tooth to the left counterclockwise will make engine synchronization difficult and result in rough engine operation Lo E a 77 m E
46. With distributor adaptor held against maximum spark stop screw but not actuating economizer collar spring adjust throttle secondary pickup screw Figure 4 to just touch secondary pickup arm on carburetor cluster Figure 7 Tighten locknut PEG M c ANA 7 _ M d iy cai Po 1 sor AT TH bv xi ipie SD nes ARK ETC ulmi veut gt t RR Cus boo 03790 ROMS E Maximum Spark Stop Screw b Full Throttle Stop Screw Idle RPM Screw Figure 6 Stop Screw Locations int E ie iit d i 10 Rotate throttle to WOT position and adjust throttle stop screw Figure 5 to allow full carburetor opening but not to allow throttle shutters to acta Ti Ni i N G SYMCH ADJ USTI NG a stop or the carburetor cluster to hit carburetor filter cover CARBURETOR ADJUSTMENTS Merc 506 Up to Serial No l Start engine and adjust idle mixture screw for best idle in forward gear Se 4576236 with Distributor Less carburetor adjustmeni information preceding 2 Set idle RPM within specifications while in forward gear ign ition System N XU 1 Firing Order Firing Sequence Spark Plug Spark Plug Ga
47. With engine not running move throttle lever to wide open throttle WOT and adjust full throttle stop screw Figure 5 to allow full carbu retor shutter opening at WOT Make sure that carburetor shutter does not act as a throttle stop Allow 010 to 015 25mm to 38mm clearance between throttle pickup screw and carburetor cluster pin a Full Throttle Stop Screw Figure 5 Full Throttle Stop Screw Adjustment CARBURETOR ADJUSTMENT l Start engine and allow to warm up to normal operating temperature 2 With engine running in forward gear adjust carburetor idle mixture screw to attain best idle in forward gear Refer to carburetor adjustment infor mation preceding 3 Adjust idle RPM to specifications with engine running in forward ges Figure 6 Retighten nut on adjustment screw a f TERK en E vw Idle RPM Screw Figure 6 Idle RPM Adjustment MAXIMUM NEUTRAL SPEED LIMITER ADJUST MENT for Models with Tiller Twist Grip Handle IMPORTANT Maximum neutral speed ilmiter adjustment stops the rotation of tiller handle twist grip when throttle Is at specified maximum neutral speed This adjustment must be accurate to assure easy starting when engine I cold and prevent engine from starting at maximum RPM 7 pur RE 07821 8 Maximum Neutral Speed Stop b Bolt figure 7 Maximum Neutral Speed Limiter Adjustment for Models with Tiller H
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49. arse 10979 idle RPM Screw Figure 8 Engine idle RPM Adjustment EET Damna nts tna eid AM E Mee AP ak s Alia dl minia s i ae ics xum ai e TU o TIMING SYNCH ADJUSTING 850 Below Serial 4366801 Firing Order 1 3 2 4 Firing Sequence 90 Consecutive Spark Plug AC 40FFM or Champion L76V Spark Plug Gap Not Adjustable Timing Maximum 27 BTDC Throttle Primary Pickup 3 5 BTDC Throttle Secondary Pickup 27 BTDC Full Throttle RPM 4800 5500 RPM idle RPM 50 600 RPM Water Pressure at Cylinder 2 to 5 psi 141 to 352kg cm Block 2000 RPM DISTRIBUTOR DRIVE BELT INSTALLATION 1 Rotate flywheel until 3 dots on flywheel timing decal are aligned with center of distributor shaft Figure 1 8 a Arrow Figure 1 Distributor Drive 598 Installation gante distributor pulley until arrow cast into pulley is pointing at 3 dots Cn fiewheel decal Slip drive belt over pulley and install pulley cover washer and bolt Torque cover bolt to 60 in lbs 69kg cm NOTE When installing timing belt on 4 and 6 cylinder outboards with Thun derbolt Ignition the arrow on the pulley may not align directly with the mark on the flywheel If this should occur align the arrow slightly c
50. as necessary to align Start with arrow Reinstall allen screws TIMING ADJUSTMENTS 1 Place engine in a test tank and connect fuel line 2 Pre set carburetor idle mixture screw 1 turns out from lightly seated M position m 3 Connect Timing Light 91 35507 to No 1 top spark plug amp x emen et nm emnes 22 Io eum 2 X x CL MG E amp NNUS m Re LN e L E EON A x x Maximum Timing Mark on Flywheel b Timing Alignment Mark Se Figure 1 Maximum Spark Advance Timing Marks Aligned x a Start engine and shift into forward gear Advance engine RPM until maxi 28 L 07839 mum timing mark on flywheel is aligned with timing alignment mark Son Haad Screws starter housing as shown in Figure 1 Adjust maximum spark advance screw Figure 2 so that end of screw just touches throttle lever Retighten Figure 4 Tiller Handie Gear Realignment nut on adjustment screw Return throttle back to idle and turn off engine Disconnect timing light mergan a mones jme RRL tee tre e mnt mti nm sie ites qe Leti m Rd is
51. c With end of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place d Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed without tearing but has some drag on it Readjust cable barrel if necessary IMPORTANT Excessive preload on throttle cable will cause diffi culty when shifting from forward to neutral Readjust throttle cable barrel if necessary QUIS P uae D aa SD reves 5 Idie RPM Screw Figure 9 Idle RPM Adjustment TIMING SYISCH ADJUSTING Merc 800 and 850 Serial 4366802 and Above with Distributor Less Ignition 1 3 2 4 90 Consecutive AC V40FFK or Champion L78V Not Adjustable 27 2 4 BTDC Below Serial No 4423112 2 BTDC to 2 Serial No 4423112 and Above Not Adjustable 5000 5500 RPM 550 650 RPM 5 8 in Gea 2 to 5 psi 141 to 352kg cm 2000 RPM Firing Order Firing Sequence Spark Plug Spark Plug Gap Timing Maximum Throttle Primary Pickup Throttle Secondary Pickup Full Throttle RPM Idle RPM Water Pressure at Cylinder Block TIMING POINTER ADJUSTMENT SAFETY WARNING Englne possibly could
52. limiter Readjust limiter if necessary 3 Check that neutral RPM limiter does not interfere with throttle operation in forward gear If limiter interferes move its back edge toward cylinder block then recheck neutral RPM NOTE This adjustment MUST BE accurate to assure easy starting when engine is cold Mme ibo ose die 08365 8 Neutral RPM Limiter b Adjustment Screw Figure 2 Neutral RPM Limiter Adjustment m9 YAN SHIT TED A m M c Eadcm i ane i ania Sarl PER rid 5 sais aor TILLER HANDLE DECAL PLACEMENT 1 TIMING SYNCH ADJUSTING ith engine i ist gri i RPM limiter Star en mist deca musi age wih arrow Figure 75 Above Serial No 4397537 and Merc 110 Above Serial No 4387437 Firing Order Alternate Firing E Spark Plug or Champion L78V Spark Plug Gap Not Adjustable 07822 Timing Maximum Advance Align Timing Marks Arrow b Start Throttle Pickup Not Adjustable Figure 3 Tiller Handle and Decal Alignment j Full Throttle 4500 5500 RPM Idle RPM 650 750 RPM in Gear Water Pressure at Tell Tale 4 to 8 psi 281 to 562kg cm at 5000 RPM 2 Reposition twist grip if necessary by removing 2 allen head screws at tiller handle knuckle Figure 4 and realign gears
53. necessary IMPORTANT Excessive preload on throttle cable will cause diffi a i E culty when shitting from forward to neutral Readjust throttle MET nee teste 7 07377 cable barrel if necessary Just Touching b Secondary Throttle Pickup Screw lt Secondary Cluster Arm Figure 7 Adjusting Secondary Throttle Pickup 6 With engine not running position spark advance lever against maximum spark stop DO NOT actuate throttle lever Adjust secondary throttle pick up screw Figure so that end of screw just touches secondary pickup arm on carburetor cluster as shown in Figure 7 Retighten nut on adjustment Screw With engine not running move throttle lever to wide open throttle WOT and adjust throttle stop screw Figure 8 to allow full carburetor shutter opening at WOT Make sure that carburetor shutter does not act as throttle stop Allow 010 to 015 25mm to 38mm clearance between secondary pickup screw and secondary pickup arm on carburetor cluster e ett Il 088 DE UN PNE d ai bret pw i 1 a n EE 4 di 10986 Idle RPM Screw Figure 9 Idle RPM Adjustment yy enero e a n ai 10988 a Full Throttle Stop Screw Figure 8 Full Throtile Stop Adjustment En rm RE TIMING SYNCH ADJUSTING
54. oar aa Vei er lar onini pee 2 Return engine to idle and stop engine Remove Timing Light 8 With engine stopped advance throttle lever to maximum spark advance screw but not actuating the economizer collar spring adjust the secondary throttle pickup screw Figure 6 so that the secondary pickup just touches secondary lever on carburetor cluster Figure 7 Tighten locknut 9 Advance throttle lever to wide open throttle WOT position Adjust throttle stop screw Figure 6 to allow full carburetor shutter opening but not to allow shutters to act as a stop Allow approximately 1 32 8mm clearance between throttle secondary pickup and secondary lever on car buretor cluster tighten locknut and recheck adjustment 2 mie tere mu Vr pense tenes e Tia ew 1 EET 1 PISTON EF M T Timing Pointer Figure 5 Aligning 27 BTDC Mark with Timing Pointer memorie T P a To Specification Figure 3 Adjusting Throttle Primary Pickup 0847 ys 5 fi Bes x 3 aA p 2 i i MC D eA 08099 ane x 1 Throttle Actuator b Secondary Throttle Pickup Screw pores 08097 Economizer Collar Spring Prim
55. re etn t RR m NO COIL NO 2 COIL CHOKE SCLENCIO o L DAL T y FLYWHEEL z 3 TILT STOP STARTER STARTE Red SWITCH MOTOR S01 TRIGGER Clip Under Rubber Mount Nun REMOTE CONTROL PLATE m alow Black Red 2 5522 5 i i lack i wnitetarown SS Brown whee RECTIFIER men E Salmon KEY SWITCH i 0 6 1 TACHOMETER Red E CONNECTOR EXTERNAL HARNESS lt View of Terminal thru Back of Plug f NEUTRAL START bs Red Red INTERLOCK SWITCH Black meon PLATE _ CYL NO 1 a White Green Brown IGNITION COIL 2 Required CYL NO 2 Groen White CONNECT at TERMINAL BLOCK C D For REMOTE SHUTOFF STOP SWITCH MAY BE LEFT in PLACE TACHOMETER TERMINAL CONNECTOR BLOCK gt Orange STOP SWITCH Orange MERCURY SWITCH E REMOTE STOP SWITCH J Black LYVLS 215103713 5261 LYVLS 1v NVM 82 22 9261 Zor BUSH MIC
56. start when tuming flywheel to check timing pointer adjustment Re move all spark plugs from engine to prevent engine from starting Remove all spark plugs and install Dial Indicator C 91 58222A1 Figure 1 into No cylinder top 2 Turn flywheel in a clockwise direction until No 1 piston isat top dead cen ter TDC then set dial indicator at 0 zero and tighten indicator set screw ta bii Jf Ges 4 RR 4 10969 a Dial Installed into No 1 Cylinder Figure 1 Dial Indicator Installed into No 1 Cylinder Hm ooucApy s 648614 6 5 61 15 2 96960 dois weds q 7 a Y 49 9 05 jueunsn py A p etia Je e 90141 75960 pM amm Vemm mecnm mel FA 4 ll Oy 1 TV 8 M S juswisnipy A E uf 81 70153 dnysiq Lewd 15 o 2915119 e 6 960 MM MM p magos juaunsn pe uo INU uo dnyotd amory payroads st utum
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59. 1 spark plug top starboard bank SAFETY WARNING Before cranking engine keep clear of propellor as it mey rotate With engine in neutral hold throttle arm so that idle stop screw Figure 4 is against idle stop Crank engine with starter motor and adjust throttle primary pickup screw Figure 4 to align specified throttle primary pickup mark on timing decal with timing pointer Retighten nut on adjustment screw eu 1 P 1 3 t Serer aren anu 7 4410990 Primary Pickup Screw d Idle Stop Screw Position 5 Maximum Spark Advance Lever against Stop When Throttle Lever Adjusting Primary Pickup e Link Rod Figure 4 Throttle Primary Pickup Adjustment oe y EN SRI 09830 idle Stop Screw e Picku gt Timi Throttle Cam i Holler ARES Screw 6 Full Throttle Stop Screw Boss g Synchronization Screws d 1 8 3 2mm Upper Screw Not in View Figure 5 Carburetor Synchronizing TN _ DEUM fo nus once 10991 Maximum Spark Advance Screw Figure 6 Maximum Spark Advance Adjustment 7 Loosen 3 carburetor synchronizing screws Figure 5 Position throttle lever against idle stop Move roller arm Figure 5 until roller just touches throttle cam Without moving roller arm retighten 3 carburetor synchro ni
60. 2 actuator plate screws Figure 4 and rotate actuator plate as necessary so that primary cam just touches primary pickup lever on carburetor cluster Figure 5 then tighten screws Due to the electronic timing characteristics of this ignition it is necessary to run the engine at wide cpen throttle WOT and to know the approxi mate RPM while adjusting the maximum spark advance Refer to the chart following for maximum spark advance settings at differing RPM while at wide open throttle Engine RPM will vary depending upon pro peller pitch and water level in test tank NOTE The engine may be timed on a boat but it must be timed at wide open throttle Engine RPM at Wide Open Throttle 2000 4000 4000 4800 200 5500 Maximum Spark Advance Setting 382 392 BTDC 37 38 BTDC 35 BTDC 3 TT WM 103797 b Actuator Plate c Just Touching Figure 5 Throttle Primary Pickup Adjustment a Carburetor Cluster 7 With engine running in forward gear at WOT determine engine RPM with tachometer Use this RPM to select correct maximum spark advance from the preceding chart With engine running in forward gear at WOT adjust maximum spark stop screw to align timing mark on flywheel rim with cor responding degree mark on timing decal Tighten locknut Figure 6 Close throttle to idle position Shut engine off and remove Timing Light
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62. 26L SX00531 0081 IXH Teud 1 968 5 06 1 0511 006 CV88C86 E V ONS68t CEE V 0 LVS68t CEE V CVSvVIGGEE V 60 8 PS 88298 Asepuosas 10102 uaap OOLXH Asepuosas pue 121614 10 punog Seui B N pU SOq 490 109 PUNO J 123614 20 1 8 5 1 9454 PUP SOd 48 1 pue PRUNON ION J 20 punossy SJ UIUUJ8 PUB SOd HOD pue Palunoyy Ji 13814 20 5 8 1 491 pue SOd 109 pue PalUNoy 10 punog 0 spe 19159 SERM D TT TEE nc dem M aac Ro arca otl a Chirac Wa e Adjust retard cable Figure 1 so that approximately 3 to 4 threads 3 2mm are exposed as shown in Figure 1 Tighten jam nuts securely With twist grip held against idle stop adjust advance cable Figure 1 until no slack exists in cable Tighten jam nuts securely Remove remote idle lever from idle screw on carburetor and preset car buretor idle screw at 1 turns turn out from lightly seated position
63. 5000 5500 5300 5800 4800 5800 5300 5800 5300 5800 4800 6000 4800 5800 Thelower RPM is recommended for large heavy slow boats or for commercial applications The higher RPM is recommended for light fast boats The wide RPM range will result in greater satisfaction derived from maximum per formance and maximum fuel cconomy If the engine speed is too high try a higher pitch or the same pitch cupped Likewise if engine speed is low try a lower pitch prop There normally is a 300 500 RPM change between propeller pitches For dual installation the next higher pitch propeller may be best For water skiing it may be desirable to use the next lower pitch however use caution do not operate at full throttle when using ski propeller and not pulling skiers In this case the propeller has too little pitch for the application and dangerous overspeed of the engine may result If the propeller has too much pitch for the application acceleration will be slow Spark Piug and ignition Data 1975 6 7 8 1975 6 7 8 Spark Plug Type M Spark Flug Type NOTE Turn in all spark plugs finger tight before applying torque wrench Torque plugs to 20 ft lbs 2 76mkg Champion QL7 5 QL7J for countries other than U S Merc 45 Capacitor Module Test us erer Red to Red Terminal and X 1000 Black to Capacitor DIEM Black Lead to Ground and A 336 4463 Re
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65. AD HOLIMS 3 38 y gt p 9 41 38 1snw 71102 jo 391 HOVE 31 V ON TAD 130 ALTERNATOR STATOR Orange fn CYL NO 1 x 5 TRIGGER PLATE m Black MERCURY SWITCH 2 x LEAD on BACK SIDE of MUST BE CYL NO 2 SWITCH BOX GROUNDED Typical A Black 5 4 Places E e areen White 3 CYL NO 3 5 Viet STARTER MOTOR 2 Start White o 5 1 Finish Violet RECTIFIER 4 gt 3 Start Brown SOLENOID to 4 Finish White Black STARTER CABLE Green Black IGNITION COIL Red Grown BATTERY gt m a Black m amp 4Y gt STARTER SOLENOID m CHOKE Black 6 CHOKE SOLENOID KEY SWITCH SWITCH Position 1 ED jazi j Position 2 Run 2 Position 3 8 5 8 A F B 6 NEUTRAL START 55 INTERLOCK SWITCH o 5 2 Red gt 285 lack TACHOMETER i Orange CONNECTOR gt it As 25 Brown BAT Yalow 34 ENGINE HARNESS WIRING HARNESS and SWITCHES REMOTE CONTROL ALTERNATOR STATOR 0 Yellow Red TRIGGER PLATE Yellow Red MERCURY SWITCH
66. Ad usting for articular models ng Adjusting P following Importance of correct timing and synchronization cannot be over 16 imp g y 1 e emphasized as a motor even in excellent mechanical condition will not perform satisfactorily unless timing and synchronization are correct 11 Boat Test 1 2 Mount motor on boat Install remote control cables and check for proper adjustment Electric Models Inspect battery and cables and perform necessary service on these components b Inspect for signs of corrosion on battery cables and surrounding area loose or broken carriers cracked or bulged cases dirt and acid elec trolyte leakage and low electrolyte level c Fill cells to proper level with distilled water or water passed thru a demineralizer d Top of battery should be clean and battery fastened securely in posi tion Particular care should be taken so that tops of 12 volt batteries are kept clean of acid film and dirt because of high voltage between battery terminals e For best results when cleaning batteries wash first with a dilute ammonia or soda solution to neutralize any acid present then flush off with clean water f Keep vent plugs tight so that neutralizing solution does not enter cell Hold down device should kept tight enough to prevent battery from shaking around in its holder but it should not he tightened to 8 peint where battery case will be placed under a seve
67. D Position 2 Position 3 Run Start 8 ALTERNATOR FLYWHEEL ok ALTERNATOR STATOR I STARTER GROUND d DISTRIBUTOR ASSEMBLY GROUND ASSEMBLY upra RE S 5 229 COWL FRAME GROUND REMOTE Li CONTROL TACHOMETER KEY SWITCH CONNECTOR Off O E Run A F Stet A F A EXTERNAL HARNESS VIEW OF TERMINALS THRU BACK OF PLUG COWL FRAME Red GROUND Yellow C D Black BATTERY um 5261 142 059 5261 00S1 051 1 0S59 MERC 900 1150 1400 and 1500 1976 77 78 MERC 850 1976 77 and 800 1978 tin Line 0 de 3 MOIRA Bn WHE 9 WOVE 51 34 JO 1 8 LONE SSINHVH 1VNU31X3 p 2 SS3NHVH 3WvHUi MOD aNIiDN3 HOIO3NNOO 2 H313WOH2V171 15 TWHLNIN 82 sums e 20 H21IMS A33 7081409 340438 WM I
68. DENEN 10964 E a Elastic Stop Nuts 2 b Link Rod 2 5 P 10962 4 th Adjust a Maximum Spar vance Timing Mark Figure 1 Silo Elasto Step Nuls Adjustment Model wl b Throttle Pickup Timing Mark 6 Timing Pointer Figure 3 Timing Mark Alignment Starten RPM an wi that 1 Eine and shift into forward gear Advance throttle to full throttle d adjust 2 elastic stop nuts Figure 1 or adjust link rod Figure 2 iming pointer is aligned with maximum spark advance mark inter line on flywheel Figure 3 Retighten elastic stop nuts Figure 1 7 nut Figure 2 and return throttle back to idle us EN ee Ae m ea ear a pt ue 3 an k v 5 Cn VE assu 10975 8 Throttle Pickup Screw b Carburetor Cluster Pin Flgure 4 Throttle Pickup Adjustment 5 With engine runring in forward gear advance engine speed so that timing pointer is aligned with throttle pickup mark solid line on flywheel Figure 1 then adjust throttle pickup screw Figure 4 so that end of screw just touches carburetor cluster pin as shown in Figure 4 Retighten nut on adjustment screw Return engine speed back to idle turn off engine and disconnect timing light 6
69. FIER ge Red a o x lt m Green Whit m Green Oo Blue White i 1 4 2 Orange Brown lt lt Yellow Brown lt Brown e STARTER Black STARTER NJ SWITCH STOP SWITCH STARTER STARTER SOLENOID REMOTE CONTROL with MOTOR do LP e SHIFT and THROTTLE FLYWHEEL J CHOKE SOLENOID 0 Yellow Lid rli EXTERNAL Black volt 3 TC mE STATOR Red TRIGGER x nt E e 22 E 2 aa TEE 2 c ALTERNATE atow S Yellow 601 Le a 25 _ EXTERNAL NEUTRAL START eg Z HARNESS CONTROLS SWITCH KEY CHOKE m 5 gt SWITCH SWITCH 55 rA m SWITCH BOX 9 12 01 3 REMOTE CONTROL with 9 BATTERY SWITCH and CHOKE PANEL 3 1 8 Orange Es 1 IGNITION COIL d CYL iE Red o 9 NO STOP SWITCH Yellow A 1 7773 EXTERNAL WIRING HARNESS 2 A NOTE When Electric Starter Kit Is Installed Disconnect Stop Switch Orange Lead from Terminal 30 Glock Instali Neoprene Sleeve over End of Lead and Connect Lead to Short Orange Lead in Engine F ite To SPARK PLUGS Harness Using Screw and Nut Provided Slide Neoprene Sleeve over Connection Remove Boot Orange Lead in Harness and Connect to Terminal Block WIRING TACHOMETER v BATTE
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72. Magneto Analyzer to Position No 2 Distributor Resistance and clip small red and black lead together 8 Connect Small Red Test Lead b S Terminal Terminal d Connect Small Black Test Lead Figure 5 Terminals on Solenold 2 Turn meter adjustment knob for Scale No 2 until meter pointer lines up with set position on left side of OK block on Scale No 2 3 Unclip small red and black leads Figure 5 Connect small red test lead to one large terminal of solenoid and connect small black test lead to other large terminal as shown in Figure 1 CAUTION Do not connect battery leads to large terminals of solenold or meter will be damaged Using 12 volt battery and jumper leads connect positive lead to small 5 terminal of solenoid Connect negative battery lead to T terminal of solenoid Meter pointer hand must move into the block or solenoid is open circuited and must be replaced 8 With lead apart zero meter to right side of Scale 2 Check between S and I terminal 2 1 to 2 7 ohms Ara ae 2 Cra AM Cu e ail ike KA 8 Alternator and Rectifier TESTING ALTERNATOR Alternator may be tested without removing flywheel Disconnect 2 yellow alternator leads from rectifier Turn selector switch of Magneto Analyzer to Position No 2 DO NOT clip small red and black leads together
73. RY HARNESS CONNECTOR Gray amp i Orange Blk 9 5 9_02 Brown Red 5 2 White KEY CHOKE SWITCH SWITCH STATOR IGNITION TRIGGER SWITCH BOX Green Bive Orange L__ Black ic Orange Bisck mH STOP SWITCH STATOR STARTER MOTOR STARTER SOLENOID Yellow etlow Red Rad RECTIFIER IGNITION STATOR STATOR B CYL NO 2 AT CYL NO 314 H Black 55 pi NT Biue White Biue SWITCH BOX Green White Blue White CYL NO 2 CYL NO 1 HIGH TENSION SPARK PLUG CABLE HIGH TENSION SPARK PLUG CABLE IGNITION COIL 2 Req Alternator Wiring STATOR LIGHTING CHOKE SOLENOID IGNITION COIL 2 Required VOLTAGE REGULATOR ALTERNATE EXTERNAL X CONTROLS EXTERNAL WIRING H REMOTE CONTROL with KEY SWITCH and CHOKE PANEL Yeltow Red gt Yellow Red gt LIGHTING HARNESS 12 VOLT BATTERY zip NHY EXTERNAL 2 WIRING TACHOMETER HARNESS CONNECTOR Yellow NEUTRAL START SWITCH KEY SWITCH CHOKE SWITCH REMOTE CONTROL with SHIFT and THROTTLE 12 VOLT BATTERY ARNESS Le Whiti CHOKE SWITCH SWITCH 15 82 24 9161 002 JYAW LUVLS 21910373 87 47 9461 002 ATO ER S JU IHE Sos ISIN IT HOTELS OI TP Y RH rn V s e
74. The rectifier will protect the switch box from damage if the harness plug becomes loose or is removed during engine operation however the recti fier will become damaged 2 Disconnecting battery leads during engine operation or reversing the battery leads also will damage the rectifier 3 An open circuit such as a broken wire or loose connection on internal engine harness can cause rectifier failure 4 Leaving battery leads connected to the wrong terminals will damage the switch box NOTE The engine can be operated without the rectifier if the alternator leads are disconnected and properly insulated Tape each lead wire so that it cannot touch the other lead or engine ground Mercury Marine will not honor warranty on rectifiers and switch boxes which are damaged under conditions described above Rectifier can be tested without removing it from engine by removing alternator stator leads and disconnecting external engine harness and red lead from rectifier terminals AE VE m uu SIG Woo EU ud X VS mi A SE iur UE e 1 TEC E vn P 02194 07300 Terminal No 1 Alternator b Terminal No 2 Positive Terminal No 3 Alternator Figure 7 Diode Type Rectifler Terminals Merc 402 Terminal No 1 2 No 3 Figure 6 Diode Type Terminals 6 Cyl In Lines TESTING DIODE TYPE RECTIFIERS Figures 6 7 8 NOTE Use VOA Electrical Tes
75. Throttle Primary Pickup 3 5 BTDC Throttle Secondary Pickup Not Adjustable Full Throttle RPM Idle RPM 550 600 RPM Water Pressure at Cylinder 3 to 5 psi 211 to 352kg cm Block 2000 RPM 4800 5300 RPM DISTRIBUTOR DRIVE BELT INSTALLATION 1 Place timing pointer packed in emergency start rope poucb into notch in cylinder block as shown in Figure 1 Rotate flywheel to align Belt Alignment Mark with timing pointer Align cast tab on distributor pulley with raised area on distributor adaptor Figure 1 Place distributor drive belt over distributor pulley Install pulley cover screw and washer Torque screw to 60 in Ibs 69kg cm emen meret tam RH Ee ti nager mo MINA qnt et sae nmm mt mr ree m een t pere oT pm yero M WW TI SERERE Mtt te B 1 nae Merde z a Belt Alignment Mark Figure 1 Distributor Drive Belt Alignment TIMING ADJUSTMENTS place engine in a test tank and connect electrical harness and fuel Pre set carburetor idle mixture screws at one turn out from seated position jer MEOE T EOS a Just Touching C Throttle Lever b Throttle Actuator Cam d Adjustment Screw Figure 2 Throttle Primary Pickup Adjustment p wy 07350 ees Lada 6291 35507 by connecting red lead to No
76. aced to improper choke shutter operation Adjust choke linkage and choke return spring for fast positive action of the choke shutters 5 Fuel System FUEL PUMPS VACUUM TYPE Figure 3 Wash all parts thoroughly and use compressed air to dry Inspect each par carefully for wear damage Replace pulsator diaphragm with new if old diaphragm shows the least sign of deterioration Ive di Be sure that valve seats provide flat contact area for valve disc Tighten elbows and check valve connections firmly when replacing Do not use Permatex on valve retainer gasket Check valves after reassembling fuel pump cover by blowing thru outlet hole Air should blew thru valve but should close immediately whe attempting to draw air thru it nons a Fuel Outlet b Diaphragm Check Valves d Fuel Inlet Figure 3 Fuel Pump tor Most Models 8 Check inlet valve by reverse procedure If leakage is encountered check for free operation arid accurate setting of valves 9 Worn or slightly warped valve will eause leakage Replace with new valves for more accurate seating 10 When installing fuel line fittings we recommend aviation Permatex for sealing Apply sparingly to avoid clogging of fuel lines CAUTION Do not use Liquid Neoprene on fuel line fittings Neoprene Is recommended only for exposed electrical con nections Permatex is available thru all local hardware stores 11 Reassemble fuel pump
77. against the throttle lever or throttle cam casting then turned out only far enough to obtain correct orientation of link rod less than one turn All timing adjustments must be reset after this procedure mM na TIMING SYNCH ADJUSTING V 6 Merc 1750 1976 77 1 2 3 4 5 6 60 Consecutive AC V40FFM or Champion L76V Not Adjustable 15 One Punch Mark BTDC 8 10 3 Punch Marks Not Adjustable 4800 5800 RPM 550 650 RPM in Gear 8 to 11 psi 56 to 77kg cm 3000 RPM Firing Order Firing Sequence Spark Plug Spark Plug Gap Timing Maximum Throttle Primary Pickup Throttle Secondary Pickup Full Throttle RPM Idle RPM Water Pressure IMPORTANT Timing procedure has been changed for Merc 1750 1976 77 models 88 shown in Figure 1 one punch mark replaces 2 punch marks on flywheel timing change has not been mace to engine being timed complete Step 1 following before timing engine New timing change Figure 1 a Remove ALL spark plugs Install a dial indicator C 91 58222A1 or equivalent in No 1 spark plug hole b Rotate flywheel until top dead center TDC is found and set the dial indicator to zero c Rotate the flywheel counterclockwise to approximately 100 2 54mm before top dead center BTDC then rotate the flywheel clockwise until 069 1 75mm BTDC is located DO NOT locate 069 BTDC by rotating flywheel counte
78. andle 2 323 NAMED EI E i 1 With engine idling in neutral loosen bolt Figure 7 just enough to enahh maximum neutral speed stop Figure 7 to slide back and forth then turr twist grip advance engine RPM to 2400 2700 RPM Without turnin twist grip position and secure neutral speed stop against neutral spee limiter as shown in Figure 7 This will stop throttle at maximum neutra speed Recheck adjustment to see if maximum neutral speed stop stops th throttle at 2400 2700 RPM Readjust if necessary Shift engine into forward and check that neutral speed stop docs not inter fere with throttle operation in forward gear If stop interferes move edge of stop toward cylinder 0782 Arrow b Start Figure 8 Throttle Handle and Throttle Decal Alignment for Models with Tiller Handle TILLER HANDLE and THROTTLE DECAL ALIGN MENT l With engine not running shift into neutral position and turn twist grip until throttle is against maximum neutral stop The word Start on throttle decal must be aligned with arrow on tiller handle as shown in Figure 8 If Start does not align with arrow refer to steps following a Remove and retain 2 screws Figure 9 which secure tiller handle to engine b Realign gears
79. ary ET 3 Check that neutral RPM limiter does not interfere with throttle operation TIMING ADJUSTMENTS forward gear If it should interfere move end of limiter toward cylinder l Place engine in test tank and attach fuel line block and recheck neutral RPM 2 Install Timing Light C 91 35507 by connecting large red lead to No 1 i spark plug then connect one small lead to battery negative post and NOTE This adjustment must be accurate to assure easy starting when engine a4 other lead to positive post is cold 3 Start engine and shift into forward gear Turn twist grip to full throttle T 4 Adjust maximum spark advance screw Figure 1 until timing line on wheel aligns with timing specification on starter housing decal Figure 2 ues SET NM lt 4 gt t V gt a it d Adi 08397 Timing Decal b Timing Mark era Lour E Figure 2 Timing Mark Alignment ME m ed 08396 Maximum Spark Advance Screw die Mixture Screw Locknuts d Idle RPM Screw s Figure 1 Maximum Spark Screw and 116 Speed Screw _ yer E Me xS 2 sd 4 4 Dots i 08395 Neutral RPM Limiter b Screw c Figure 3 Neutral RPM Limiter Adjustment 8 A
80. ary Pickup Lever Throttle Cam d Throttle Stop Screw b Actuator Piate Retainer Just Touching Maximum Spark Stop Screw Bolts Out of Sight f Idle RPM Screw Figure 4 Throttie Cam Just Touching Carburetor Primary Lover Figure 6 Adjusting Secondary Throttle Pickup uv Hag an 49 4 p 10g 4 H Q 1585 18601 Eum eub p wem 4 6 395 6 85 94 614 Buryonoy 15 Aiepuosag q dnyoig A1repucoes P jueAoad 6 94043494 GAUP 599 81 Buuin 9 HES Aiqissod ONINHVAA 13495 dH 0002 490g 5 3 6 99 p 139 5 012 19 4 55944 188M 1299 U dH 009 056 Wdy 880091 0029 0085 0051 0071 dH 0085 0025 091 2460 WdH 0099 0009 006 2464 0005 0057 Wd 911024 30148 12 02 6 DOLE 9 dn21g 911091 2018 15 eougApy eiqeisnipy det Bnig y eds A943 uoIdweyd 10 WA40bpb 2V Bnig xreds BAINDBSUCD 09 e uenbeg 9 58868 591 0091 pue 0 me 0911 pue sjepoi 8 61
81. ble a check o amp 3 j must be made for correct installation of link rod located between the throttle 2 lever and throttle cam Each end of this link rod must be threaded into its 1 3 j Plastic varrel it bottoms against the throttle lever or throttle cam casting ae 1 then turned out only far enough to obtain correct orientation of link rod less 9 than ons turn timing adjustments must be reset after this procedure 5 5 5 Sg 52 E 5 T 5 Ss 1 f E S 1 5 9 gt g o 3 1 1 i 6 i c amp 220600 iM art 5 0 05 o E i s 1 i 1 4 P Oxo 5 on2z E d S MERC 75 and 110 1975 MANUAL START MERC 45 1975 76 77 78 MANUAL START xii icm 26 m E HOLIMS 4045 HOLIMS eis 048 078 9345 HH 91 M U324E anig fs amp Ll LJ 0 a LONAD umo g 2 NOISN3 HOIH E __8355 41 318V2 NOISNAL H5IH lL HOLLIS Tj T IPPON 9 61 jeuondo tt HOLIMS 4015 ai 378V5 NOISN31 49225
82. cator C 91 58222 into spark plug hole Rotate crankshaft clockwise to find piston TDC top dead center Set dial indicator at zero and lock set screw Figure 2 MEE crankshaft counterclockwise to place piston at 198 5 03mm PDC Using VOA Meter C 91 52751 set meter on R x 1000 scale Clip test leads together and zero meter to right side of scale Connect red test lead to ignition white wire terminal and black lead to engine ground Turn twist grip throttle to open throttle to maximum spark advance point Figure 3 2 prem E in ORE rei meme TAA SES ASI aai ae pere ei EU nS a 2 Bats on A bet BUM Cia al nee mat h ta d a ora use DE AOL a Feeler Gauge 020 Figure 1 Setting Point Gap A Central M 4 06144 b Set Screw Figure 2 Dial Indicetor installed q P 8 Use twist grip to keep throttle against maximum spark advance screw while adjusting screw until meter indicates points just close meter needle swings down scale to right Tighten stop screw locknut 9 Adjust carb retor vertical shaft to allow approximately 050 1 27mm play between vertical shaft and throttle cam
83. ckup Adjustment Stop engine Advance throttle to position spark arm against spark stop screw and adjust actuator plate secondary pickup screw Figure 1 to just touch secondary lever on carburetor cluster Figure 4 Tighten locknut Advance throttle arm 10 wide open throttle WOT Adjust full throttle stop screw to allow full carburetor shutter opening but not to allow carbu retor shutters to act as a stop Allow 010 to 015 25mm to 38mm clearance between secondary pickup screw and carburetor cluster second ary lever Figures 5 and 6 CARBURETOR ADJUSTMENTS 1 Start engine and adjust idle mixture screw for best idle in forward gear See carburetor adjustment information preceding Set idle RPM within specifications while in forward gear d ey a Throttle Lever b Stop Screw Figure 5 Throttle Lever against Full Throttle Stop E h 7 Lc a Fre e s 2 0988 Secondary Pickup Screw b Carburetor Cluster Secondary Lever 6 010 to 015 Clearance Figure 6 Throttle Step Adjustment TIMING SYNCH ADJUSTING Merc 500 Serial No 4576237 end Above 1 3 2 4 90 Consecutive AC V40FFK or Champion L78V Not Adjustable 30 5000 RPM 7 9 BTDC Firing Order Firing Sequence Spark Plug Spark Plug Gap Ti
84. d Ground A 339 5312A_ 75 110 A 339 5313A__ 1975 76 77 78 BA 339 5589A Wear A 339 5590A Rx 100 Between Yellow and White Coil Wires 339 6119 __ A 339 6120A__ 200 1975 76 BIA 338 4992A__ Between Red and Blue Coil Wires 180 340 S N 4377556 and BA 1000 Between White and Blue Coil Wires 5 2 7 2 200 1976 77 78 p Between Yellow Stator Lead and Ground 15 20 S N 4403787 and 339 6119 Between Yellow and White Coil Wires 7 5 10 Above 84 359 61204 Continued on Next le 398 4770 402 A A 398 4799 Between Blue Stator Lead and Groun 1975 76 77 78 398 5255 R 398 5256 x1 Between Red Stator Lead and Ground MA 333 3175 Low Speed Between Red and White Ignition Driver Leads 500 WA 333 3176 High Speed Between Blue and White ignition Leads 10 11 is ignition x 1000 Between Red Lead and Ignition Driver Case ground Nc Cont Driver 1000 Between White Lead and Ignition Driver Case ground Coils Rx 1290 Between Blue Lead and ignition Driver Case ground No Cont Low Speed Between Blue Stator Wire and SARI Stator Wire 5 7 8 0 500 398 5919 __ High Speed Between Red Stator Wire and Red White Stator Wire 1976 77 76 Between Blue Stator Wire and Engine Ground No Cont 2 Between Red Stator Wire and Engine Ground No Cont 650 700 398 5704 _ e x 2568 Low Speed Between Blue Stator Wire and Red Stator Wire 5 4 6 2 4 5 4 6 2 2 1976 77 78 Hi
85. d adjustments are included to isolate and correct als 5 2 ziej 5 Sa 8 o trouble located during tuneup m n a a g 5 5 5 5 5 3 Always follow instructions for use of equipment as provided by oils co 3 3 i manufacturer 3 2 8 62 lt 33453 4 When conditions are uncovered which require major corrective action 51915 519 exa refer to Service Manual for detailed service information 25 5 following item numbers correspond with item numbers in Tuneup 5 6 oir le 2 me E Sequence preceding 1 Compression Check Inspect each spark plug for make and heat range All plugs must be of the same make and number or heat range Remove spark plugs clean and inspect If center electrode is eroded Figure 1 replace with new spark plug listed Timing Synchronizing Adjusting section following prey emer Ne i mo 299996 nd pe v DR ac 4 june SANSA TT Argo E 1 32 0 8mm b Center Electrode Figure 1 Thunderboit Plug 3 Inspect spark plug hole threads and clean before installing plugs CAUTION Crank engine several times to blow out any Remove ring and oil seal from base plate assemb
86. d to Green Cap Lead 45 55 Black Lead to Ground and EE Red to Green Cap Lead Left Side TEST METERS 8 Zero meter before using 1 VOA Meter 21 52751 black case 8 2 Thunderbolt Ignition nalyzer Meter 91 62563 1 red case 8 3 Merc O Tronic Ignition Analyzer C 91 25213 Scale T est Leads to Reading 336 4516 2 1 or 2 Black to Red Terminal and Red to Blue Terminal and Black to Blue Terminal and a ESTAS Ed SER Li Gi x rn S D REN A emi oii a CR oet T Thunderbolt ignition Stator and Siator Coil Checks IMPORTANT Disconnect Stator Leads before Testing Stator Assembly Disconnect Stator Coil Wires before Testing 2683 Scale Reading Part No AStator Assembly Stator Coll Merc and Year Tester Leade to 40 A339 5566A_ Between Yellow Stator Wire and Ground 1976 77 78 9 5589 ETT H339 5590A Rx100 Between Yeliow and White Coil Wires 45 HA 336 4470A High Speed Between Yellow and Blue Coil Leads 1975 76 77 78 336 4469 _ Low Speed Between Yeilow and Red Coil Leads 5 3 6 1 2 339 5209 gt 339 5566 __ Between Yellow Stator Lead an
87. efore testing Any marine growth or a hook a rocker in boat bottom can greatly reduce performance 12 Additional Checks and Adjustments Following tests are described herein for use as required where either an abnor mal condition requiring further checking has been detected during Tuneup 9r 8 specific complaint exists Water Pressure Use Water Pressure Gauge 4 5566441 46561441 Fuel Pressure Use Fuel Pressure Gauge 91 30692 uda ti m WATER PRESSURE TEST A 55664A1 or A 65614A1 1 Water pressure at the cylinder block should be checked whenever an over heating condition is detected or suspected 2 A large keel or other accessories located on the boat bottom forward of the motor can cause what is mistakenly diagnosed as water pump failure 3 A motor mounted unusually high on the transom also can cause over heating solid unrestricted water flow must be delivered to the gear housing for maximum cooling and engine efficiency 4 Install necessary fitting and water pressure hose on the cylinder block and place water pressur gauge in convenient position for viewing while operating boat Water pressure at full throttle under any running condi tions ie turning maneuvering etc must 5 psi lbs per sq in 0 35kg cm or more FUEL PRESSURE C 91 30692 1 Fuel pressure at the top carburetor should be checked whenever insuffi cient fuel i
88. ent CARBURETOR ADJUSTMENTS 1 Start engine and allow engine to warm up in forward gear 2 Adjust carburetor idle mixture screws to attain best idle in forward gear Sec carburetor adjustment information preceding 3 Adjust engine idle RPM as follows a With engine in water connect clectrical harness and fuel line to engine Start engine and allow to warm up b With throttle cable barrel removed from barrel retainer adjust idle RPM to 550 650 RPM with engine running in forward gear Figure 8 Retighten nut on adjustment screw c With end ef tlirottle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place d Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed without tearing but hassome dragon it Readjust cable barrel if necessary IMPORTANT Excessive preload on throttle ceble will cause diffi culty when shif ng from forward to neutral Read just throttle cable barrel necessary a DA E A INE TN E gt rj uc m 1 M 3 S x Du X REE il Vi tad aia e
89. esult in rough engine operation TIMING POINTER ADJUSTMENT SAFETY WARNING Engine could start when turning fly wheel io check timing pointer adjustment Remove spark plugs from engine to prevent engine from starting E 1 p 1 E E Ex ue Mis 10969 8 Dial Installed into No 1 Cylinder Figure 2 Dial Indicator Installed into No 1 Cylinder zi E 3 mid Eel apis MW LET 10982 Tirning Pointer b Timing Pointer Attaching Bolt Figure 3 Timing Pointer Alignment 1 Remove all spark plugs from engine and install Dial Indicator C 91 58222A1 No 1 cylinder as shown in Figure 2 2 Turn flywhecl clockwise until No 1 piston isat top dead center TDC Set dial indicator at 70 zero and tighten indicator set screw 3 Turn flywheel counterclockwise until dial indicator needle is approx turn beyond 464 12mm then turn flywheel clockwise so that dial indi cator reads 464 exactly 4 Reposition timing pointer if necessary so that timing pointer is aligned with 464 mark on timing decal as shown in Figure 3 Retighten pointer attaching screw 5 Remove Dial Indicator from cylinder and reinstall spark plugs and spark plug leads moms ay 190 Throttle Actuator Plate b Actuator Plate Retaining Bolts Figure 4 Throttle Actuator Pla
90. gh Speed Between Red Stator Wire and Engine Ground 125 175 iE x Hel Low Speed Between Blue Stator Wire and Biue White Stator Wire 5 7 8 0 800 850 850XS 398 591943 High Speed Between Red Stator Wire and Red White Stator Wire 56 76 1976 77 78 1000 Between Blue Stator Wire and Engine Ground Between Red Stator Wire and Engine Ground Low Speed Between Blue Stator Wire and Red Stator Wire 1500 V 6 x 1000 Low Speed Between Blue White Stator Wire and Red White 5 4 6 2 1750 2000 398 5454 Stator Wire QS 1976 77 78 High Speed Between Red Stator Wire and Engine Ground 125 175 Rx i High Speed Between Red White Stator Wire and Engine Ground 125 175 8 Not necessary to disassemble ignition driver Leads must be disconnected from switch box MEN atom a Champion L7J AC M43FF United States Only 4300 to 4700 RPM 600 to 700 RPM in Gear 9 to 1 0 psi at Idle in Gear psi at WOT in Gear For countries other than the United States use Champion QL7J5 or which is obtained as c 9 c 5 lt 2 0 to 3 0 djustment screw Figure 1 and adjust to 015 clearance between throttle cam and position and carburetor shutter plate cluster pin Figure 1 Retighten throttle cam adjustment screw securely C Throttie Cam Adjustment Screw d Cluster Pin to 015 127mm to
91. ints which show slight resistance may affect idle operation Points which show high resistance may cause a malfunction of ignition system and subsequent loss of spark 3 Complete Timing Synchronizing Adjusting following to assure cor rect engine operation See Troubleshooting Thunderbolt Ignition information following 7 Starter Motor and Solenoid STARTER MOTOR Testing Starter Motor 1 Be sure that battery is fully charged and at least 70 ampere hour capacity before testing starter motor Many starter motors are needlessly dis assembled when battery actually is at fault E 2 Using a voltmeter connected to the starter motor positive terminal and ground check battery voitage under load as follows With voltmeter con nected turn ignition switch to Start position while observing voltmeter If voltage 15 9 volts or more and starter motor fails to operate repair replace starter motor Cleaning and Inspection of Starter Motor 1 Remove starter motor and disassemble 2 With starter motor completely disassembled except for removal of field coils component parts should be cleaned and inspected DO NOT use grease dissolving solvent for cleaning armature or field coils as insulation will be damaged 3 Test pinion gear and screw shaft Pinion gear must move freely on screw Check pinion gear to sec 31 it is not chipped worn excessively Check for bent armature shaft 4 Check that brush holders
92. kup Screw a Maximum Timing Mark with Notch in Timing Window Figure 6 Secondary Pickup Screw Adjustment Figure 4 Maximum Timing Marks Aligned gt r T t sn TEACH Ya cha EA xs Jis at enc n o A OR GR FE eh ert METER a aee CARBURETOR ADJUSTMENTS i 1 Start engine and allow jt to warm up in forward gear 2 Adjust carburetor idle mixture screw to attain best idle in forward gear See carburetor adjustment information preceding 3 Adjust engine idle RPM as follows a With engine in water connect electrical harness and fuel line to engine Start engine and allow to warm up b With throttle cable barrel removed from barrel retainer adjust idle RPM to 500 650 RPM with engine running in forward gear Figure9 f Retighten nut on adjustment screw c With end of throttle cable connected to throttle lever hold throttle f lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place d Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed without tearing but has drag on it Readjust cable barrel if
93. lation and or loose connections between wires and termina ends The harness connector should also be checked for possible corrosion and or bent or broken electrical prongs If any of these conditions exist they must be corrected before proceeding with the following tests Be sure that prongs of harness connector are clean and free of corrosion for a good electrical connection between harness connector and remote control harness SHORT TEST See Wiring Diagram at End of This Book 1 2 3 4 Disconnect internal wiring harness from electrical components Using Magneto Analyzer Scale No 3 check for continuity between any of the wires in the harness Use Scale No 3 and check for continuity between any wire and ground If continuity exists harness will have to be repaired or replaced RESISTANCE TEST See Wiring Diagrams Following 1 Turn selector switch of Magneto Analyzer to Position 2 Distributor Resistance and clip small red and black leads together Turn meter adjustment knob for Scale No 2 until meter pointer lines up with set position on left side of OK block on Scale No 2 Unclip small red and black leads Using wiring diagram a guide c eck each wire for resistance between harness connection and terminal ends If resistance exists meter reading is outside OK block and harness must repaired or replaced 10 Adjustments before Testing Refer to Tim ng Synchronizing
94. ler chart 1976 77 78 4357640 and Up Try a size larger or smaller if in doubt See jet sizes in chart following 4382056 amp Below 2 No change in spark advance is recommended for elevation operation Pro pellers of lower pitch should be used at high elevations to allow proper 4304235 and Up engine RPM 4382057 and Up 4382057 and U HIGH SPEED ADJUSTMENT tud High speed has a fixed jet similar to those used in automobiles Main Vent 066 IDLE ADJUSTMENT Integral Fuel Pump Type Carburetor Only 4366801 amp Below Main 076 1 Idle mixture and idle speed have been set at the factory Due to local con 1976 ditions it ray be necessary to readjust the carburetor in the test tank or on the boat 1976 77 2 Set idle mixture screw specified turns open from a lightly seated position See specified setting in following Timing Synchronizing Adjusting 1978 4845301 and Up Main 070 by model Start engine and allow it to warm up to operating temperature in forward gear 4112635 and Up Main NOTE All carburetor settings must be made in FORWARD gear with the engine properly warmed up 3 With engine running slowly turn the idle mixture screw counterclock Mes Up wise until the affected cylinders start to load up or fire unevenly due to an 121435 and Up over rich mixture 4 Slowly turn idie mixture screw clockwise until the cylinders fire evenly and engine picks up speed 5 Continue tur
95. lide out of flat area as this will cause the impeller to be forced 10 Idle engine and adjust idle stop screw on stop bracket so that engine against the insert after assembly and result in premature impeller wear idles at recommended RPM sec Timing Synehronizing Adjusting 4 Coat insert area of water pump cover with Perfect Seal C 92 34227 and following by models in forward gear install insert Be sure that tab on insert enters location hole in water pump 11 Run engine in forward gear 4000 to 5000 RPM to clear engine and re cover Clean off any excess Perfect Seal that was displaced while installing check idle RPM insert CARB MAIN JET SIZES for ELEVATIONS 5 Lubricate insert with Multipurpose Lubricant Slide water pump cover over drive shaft and down onto impeller while turning the drive shaft in a clockwise direction viewed from top of drive i shaft Be sure that impeller drive pin is in position and impeller turns with drive shaft 7 Install washers lockwashers nuts and bolt as required and torque to 1975 specifications as follows 1975 76 1976 77 78 14 bolts 20 in lbs 23kg cm 5 16 studs 40 in lbs 46kg cm 14 studs 30 Ibs 35kg cm 1575 1976 77 7 8 Install water guide tube and drive shaft slinger 4 Carbu retors 1975 4280269 amp Below 1975 4280270 and Up CARBURETOR ADJUSTMENT 1 Jet size recommendations are intended as guide like a propel
96. llen Head Screws Figure 5 Tiller Handle Adjustment eren mmm Th rir E n Si pija 07822 Arrow b Start Figure 4 Tiller Handle and Twist Grip Alignment TILLER HANDLE DECAL PLACEMENT 1 With engine running in neutral gear turn twist grip to attain 2400 to 2700 RPM At this point the Start position on twist grip should align with indicator arrow on tiller handle Figure 4 2 Reposition twist grip if necessary by removing 2 allen head screws at tiller handle knuckle Figure 5 3 Pull handle apart far enough to clear teeth of gears Turn twist grip to alig marks and install screws NOTE This adjustment must be accurate to assure eusy starting when engin is cold 2n meme neto einen i is a ins d o n TIMING SYNCH ADJUSTING Merc 75 Serial No 4314385 thru 4397536 and Merc 110 Serial No 4304785 thru 4387436 Firing Order Alternate Firing Spark Plug AC VAOFFK or Champion L78V Spark Plug Gap Not Adjustable Timing Maximum 30 BTDC 35 BTDC Advance Throttle Pickup Full Throttle RPM jidle RPM Not Adjustable 4500 5500 RPM 650 750 RPM in Gear l650 750 RPM in Gear Approx 10 Approx 15 4 to B psi 281 to 562kg cm at 5000 RPM Water Pressure at Tell Tale TIMING ADJUSTMENTS l Place engine in a te
97. lockwise as viewed from front of outboard This will appear to be approximately Ha tooth off Figure 2 Installing the belt tooth to the left counterclockwise will make engine synchronization difficult and result in rough engine operation CE d 0812 Figure 2 Alignment Tooth Clockwise 4 TIMING ADJUSTMENTS l Place engine in a iest tank and connect electrical harness and fuel line Press carburetor idle mixture screws 1 turns out from seated position 3 Install Timing Light C 91 35507 by connecting red lead to No 1 top spark plug and connecting black leads to 12 volt battery positive and negative posts With engine running in forward gear move the throtile lever to align 3 to 5 BTDC on timing decal with timing pointer Figure 3 With throttle positioned as in Step 4 loosen2 actuator plate retainer bolts Figure 4 aud rotate actuator plate as necessary so that primary cam just touches primary pickup lever on carburetor cluster Figure 4 Tighten 2 bolts Advance throttle lever to align 27 BTDC mark on timing decal with timing pointer Figure 5 and adjust maximum spark stop screw Figure 6 to just touch distributor adaptor Tighten locknut and recheck maximum spark advance N e pap Sint rad ice er CLAIM Iu ide or anita ke rait oem
98. low 010 to 0157 25 mm to 38mm clearance between throttle pickup screw and carburetor cluster pin An NER CARBURETOR ADJUSTMENT Start engine and allow to warm up to normal operating temperature didi ass 28 10974 Full Throttle Stop Screw Figure 5 Full Throttle Stop Adjustment 2 With engine runningin forward gear adjust carburetor idle mixture screw to attain best idle in forward gear Refer to carburetor adjustment infor mation preceding Adjust idle RPM to specifications with engine running in forward gear Figure 6 Retighten nut on adjustment screw d 5 y ase crees Idle RPM Screw Figure 6 Idle RPM Adjustment nue NEUTRAL SPEED LIMITER ADJUST IMPORTANT Maximum neutral speed limiter adjustment the rotation of tilfer handle twist grip when throttie ai spacified maximum neutral speed This adjustment must be accurate to easy starting when engine cold and prevent engine from string at maximum RPM At Lm rerea o mons MENO maximum neutral speed stop Figure 7 to slide back and forth then turn twist grip advance engine RPM to 2400 2700 RPM Without turning twist grip position and secure neutral speed stop against neutral speed limiter follower as shown in Figu
99. ly and watch for shims under base assembly SHIMMING of WATER PUMP BASE Lower units with a ball bearing on the drive shaft must be shimmed to Zero clearance between drive shaft ball bearing and water pump base as follows 1 2 3 7 8 Position a new gasket to lower unit over water p mp studs Install original shims plus 020 51mm additional shims above drive shaft bearing This will result in an over shim condition Lubricate seals in water pump base Remove O ring from water pump base to ease installation for measurement only Position water pump base into lower unit push down firmly Measure gap between water pump base gasket and water pump base with a feeler gauge The gap measured plus 002 051 mm is the correct amount of shims to remove This will result in Zero gap between water pump base and drive shaft bearing which is correct and will result in 002 compression of the gasket 3 4 1 Remove spark plug wires and all spark plugs and check condition material which might dislodged during cleaning 2 Disconnect or install a ground wire as instructed on wiring diagram see operation Wiring Diagram by model following to render ignition system i operative while performing compression hecki 4 Install spark plugs in engine with new gaskets and tighten to 17 ft Ibs 1 3 Install compression gauge in spark plug hole t 2 35mkg torque Impr
100. ming Maximum Advance Throttle Primary Pickup Throttle Secondary Pickup At 30 Maximum Stop Full Throttle RPM 5000 5500 RPM idle RPM 550 6C0 RPM 5 ATDC Water Pressure at Cylinder 3 to 5 psi 211 to 352kg cm Block 2000 RPM TIMING ADJUSTMENTS 1 Place engine in a test tank or if engine is mounted on boat place boat and engine in water Connect electrical harness and fuel line to engine 2 carburetor idle mixture screw at one turn out from lightly seated position 3 Connect Timing Light to No 1 top spark plug MUS 3 jd C VT tg PO HI N HP dem i eo MV p 28 1 1 E D V p A TEM 2 22 E r e ood orm M a 4 09844 8 Actuator Plate Secondary Throttle Pickup Screw 5 Screws 2 d Top Carburetor Figure 1 Throttle Actuator Plate ith engine running in forward inter is aligned with 79 99 gear advance engine speed until timing BTDC mark on timing decal then loosen 2 actuator plate retainer screws Figure 1 and rotateactuator plate n e mmt m iae eon eet AE eje iis Sate aser Na oh ERUNT m SEPE
101. n efficiency and trouble free operation 2 Each year tuneup of the modern outboard engine has become increasingly important with improved power and performance Today this increase in power and performance has meant higher compression ratios and new and improved electrival systems among other advances in design 3 It is advisable that the service technician follow a definite and thorough procedure of analysis and correction of all items which affect power C 92 68623 C 92 C 92 63290 C 92 63260 C 92 63214 C 92 65183 C 92 65193 C 92 63250 C 92 34227 C 92 63233 C 92 68617 OUTBOARD TUNEUP 85 9 o 859267 QUICKSILVER LUBRICANTS i 4 Carburetors 11 Boat Test i 5 Fuel System 6 Ignition System 7 Starter Motor and Solenoid TUNEUP SERVICE SEQUENCE 12 Additional Checks and Adjustment 6 performance and economy to assure lasting results 5 4 The extent of engine tuneup usually is determined by the amount of time 8 ra t since the last servicing of the engine however specific servicing of items 5 3 9 on the engine should be performed at regular intervals depending upon wor 2 2255 5 conditions under which the engine operates 5 2228 Er i 5 Check for satisfactory water pump operation prior to tuneup or repairs 3 o Og gt 9 5 m E 9 5
102. n key to On position START ENGINE and read ammeter 3 With a partially discharged battery ammeter should change from dis charge to charge at between 800 to 1000 RPM With a fully charged battery this RPM may be somewhat higher Increase engine RPM to 5200 10 5500 at which time reading should be approximately 10 to 12 amperes with partially discharged battery With fully charged battery a somewhat lower reading will be obtained because of self regulating characteristics of generating systems See chart preceding for output by model Gross DC Amperage Output of Rectifiers on 2 4 and 6 Cylinder Englnes Use VOA Tester C 91 52751 ONLY 1 Connect an ammeter between red output lead from the rectifier and elec trical internal harness red lead 1000007 Open disconnects and connect ammeter attaching lead from rectifier to one terminal of ammeter and lead from internal harness to second terminal Start engine and check amperage output See chart preceding for output by model RECTIFIER REPLACEMENT CAUTION Make sure that battery is disconnected before connecting or disconnecting any wires In electrical System replacement is a nut and bolt operation 9 Internal Wiring Harness If trouble has been experienced with any of the electrical componenis the internal wiring harness should be checked carefully Check for frayed or chafed insu
103. ning clockwise slowly until too lean a mixture is obtained and engine slows down and misfires 6 Set idle mixture screw one to 1 turns counterclockwise from lean out position to gain approximate true 7 Do not adjust leaner than necessary to attain reasonably smooth idling Too lean a setting is a major cause of hard starting 8 When in doubt it is preferable to have idle mixture set too rich rather than Main Main Fuel Jen Vou 2 too lean Metric 1 305m 1 Vent Float Bowl Cover Idle Idle Air Jet i Inch 2 54 2 1 i 3 REPAIRS and ADJUSTMENTS For carburetor repair procedures disassembly cleaning adjustments and reassembly refer to Fuel Systems in Service Manual by carburetor type y Cs eM T E id Fol po el Veo 7 T Vo 08582 Screen b Idle Mixture Screw Figure 2 Idie Adjustment Typical MARD STARTING 2 Cylinder Models 1 When starting a cold engine choke shutter must be fully closed Adjust choke linkage and choke return spring for fast positive action of choke shutter 21 may be necessary to readjust the carburetor idle mixture screw up to Ys turn with each change in brand of gasoline to compensate for varying volatility and differences in refining process 3 4 and 6 Cylinder Models Hard starting is often tr
104. olt Figure 4 just enough to enable maximum neutral speed stop Figure 4 to slide back and forth then turn twist grip advance engine RPM to 2400 2700 RPM Without turning twist grip position and secure maximum neutral speed stop against neutral speed limiter follower Figure 5 This will stop throttle at maximum neutral speed Recheck adjustment to see if maximum neutral speed stop stops the throttle at 2400 2700 RPM Readjust if necessary Shift engine into forward and check that neutral speed stop does not inter fere with throttle operation in forward gear If stop interferes move back edge of stop toward cylinder block 07822 Arrow b Start Figure 4 Throttle Handle and Throttle Decal Alignment HANDLE and THROTTLE DECAL ALIGN With engine not running until throttle is throttle decal Figure 4 If n shift into neutral position and turn twist grip against maximum neutral stop The word Start on 1 must be aligned with arrow on tiller handle as shown in Start does not align with arrow refer to steps following ea tag ee n Firing Order a Remove and retain 2 screws Figure 5 which secure tiller handle to engine b Realign gears Figure 5 as necessary to align Start with arrow 6 Reinstall tiller handle to engine with 2 screws Tighten screws se curely E N nes Y T
105. op Tighten jam nut on spark advance screw sccurely 6 Turn twist throttle grip against idle stop Advance throttle grip until throttle cam contacts cluster pin then check timing Timing should be 14 2 If throttle pickup is incorrect readjust throttle cam as re quired to obtain throttle pickup at 14 2 ATDC 7 Adjust carburetor setting as outlincd preceding 8 With the idle adjustment knob Figure 3 in Run position reinstall the remote idle lever onto carburetor idle screw in the 9 o clock position 9 Disconnect timing light and tachometer from engine and reinstall engine cowl 2 4 Figure 3 idle Adjustment Knob Locatlon TIMING SYNCH ADJUSTING Merc 45 with Phase Maker Ignition Firing Order Spark Plug Spark Plug Gap Single Cylinder AC V40FFK amp Champion L78V Not Adjustable Timing Maximum Advance 198 BTDC Throttle Pickup 5 ATDC 4500 5500 RPM 650 800 RPM in Forward Gear Approximately 9 to 12 ATDC Water Pressure at Tell Tale 4 to 7 psi 281 to 492kg cm at 5000 RPM Full Throttle RPM Idie RPM TIMING ADJUSTMENTS 1 Remove top cowl flywheel and module cover to expose maker point set Figure 1 Rotate crankshaft to place cam follower at high point on cam Figure 1 Adjust point gap to 020 51 and reinstall flywheel Torque fly wheel nut to specification in Specifications section of Service Manual Remove spark plug and install Dial Indi
106. oper installation is one of the greatest single 1 4 Crank engine thru at least 4 compression Wideropen throttle causes of unsatisfactory spark plug performance WOT to obtain highest possible reading 3 3815 5 Always use new gasket and wipe seats in head clean Gasket inust be fully 5 Check and record compression of each cylinder Var ation ol morethan compressed on clean seats to complete heat transfer and provide a gas lbs per sq in 1 050kg cm between cylinders indicates tight seal in the cylinder For this reason as well as the necessity of main pr ssion eyligders are in som way taining correct plug gap the use of correct torque is extremely important 1 piston rings and or scored pistons and cylinders during installation 6 Compression check is important because an engine Mod een compression cannot be tuned successfully to give peak performance is esential therefore that improper compression be corrected before pro 3 Water Pump Installation 1 ceeding with an engine tuncup 7 powerhead shows any indications of overheating such as REMOVE WATER PUMP scorched paint inspect cylinders visually thru transfer ports OF possible 1 Set gear housing in vise in upright position with skeg held between blocks 4 scoring It is possible for a cylinder be scored slightly and still have com of wood i paratively good compression
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108. ottle cable barrel removed from barrel retainer adjust idle RPM to 600 700 RPM with engine running in forward gear Figure Retighten nut on adjustment screw With end of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed without tearing but has some drag on it Readjust cable barrel if necessary uf 4 NH 4 i e i Xeon 3 t f a 4 feb E 1 zu 20341012 idle Stop Screw Figure 7 idle RPM Adjustment 1 IMPORTANT Excessive preload on throttle cable will cause ditti MERC 40 2 CYL MANUAL START cully when shifting from forwerd to neutral Readjust throttle cable barrel If necessary beeen NOTE Carburetor idle mixture is not equipped with adjustment screw as are other Outboards See carburetor Jet chart preceding for jet change zu i NOTE If sufficient throttle cable barrel adjustment is not availa
109. p Timing Maximum Advance Throttle Primary Pickup Throttle Secondary Pickup Full Throttle RPM 1 3 2 4 90 Consecutive AC V4OFFM or Champion L76V Not Adjustable 30 5000 RPM 7 9 BTDC At 309 Maximum Stop 4800 5500 RPM tmt 1 RPM 550 600 RPM 5 j Water Pressure at Cylinder 3 to 5 psi 211 to 352kg cm j Block 2000 RPM E TIMING ADJUSTMENTS E x 1 Place engine in a test tank and connect engine electrical harness and fuel line E 5 2 Pre set carburetor idle mixture screws at one turn out from seated position 23 3 Connect Timing Light C 91 35507 by connecting red lead to No 1 top ZR spark plug and connecting black leads to 12 volt battery positive and 1 ert em ME negative posts Connect tachometer to engine UTC i Rem eee asas 16110379 Secondary Arm b Secondary Pickup Screw c Just Touching Figure 7 Throttle Secondary Pickup pu d VN o 7 405644 Actuator Plate Secondary Throttle Pickup Screw b Screws 2 d Top Carburetor Figure 1 Actuator Plate Screw Location me mtr MAII ES TH e nmm bomi is D i Gd ij E
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111. r REFUS MUR Ri a re O M mu si a a K rm e mw a im cate Oe TIMING SYNCH ADJUSTING Mierc 200 Electric Model Serial No 4709593 and Above Firing Order Spark Plug Spark Plug Gap Timing Maximum Advance Alternate Firing AC V40FFK or Champion L78V Not Adjustable Align Interrupted Line with Timing Pointer Align Solid Line with Timing Pointe 4800 5500 RPM 550 650 in Gear 6 to 8 psi 422 to 562kg cm at 5000 RPM Throttle Pickup Full Throttle RPM Idie RPM Water Pressure at Tell Tale l Place engine in test tank and connect fuel line 3 2 Pre set carburetor idle mixture screw at 1 turns out from lightly seate PE 11025 position Jam Nut b Link Rod 3 Connect Timing Light to No 1 top spark plug Figure 2 Maximum Spark Advance Adjustment Model with Adjust able Link Rod gt F1 m Dd t An EE Df tg UNES rt lt a 6 id d i E Mi E Pod 590 8 i we be F 1 uu i BM _ 7 A DU E V ML
112. rclockwise d With center punch and using the existing timing reference mark on flywheel cover as a guide make a new punch mark on flywheel in cen ter of timing mark as shown in Figure 1 e Remove dial indicator and install spark plug in No 1 cylinder only f Remove or paint over with black paint the 119 22 BTDC timing decal on the front air box cover 8 Reference Point Figure 1 New Punch Mark on Flywheel b Punch Mark on Flywheel mE TE EE I TI GATE oF OEE nn aulua 1021 ju2unsn pe uo mu Vay way 1 Jo aoueape siy iuiojsks siy jo y reds jo asneoag 34n3 J 12405 19 up Ut YOU p uo pund auo ue 9 9 211914 mans yaeds 15888 pue 7517915 2urduo Yura 4015 9105 yreds 539190 19491 91110143 QUA 56 posn 2800 s1 4 yound 2 yao Sunny 108 Zurziu 01Qou s 1 99 8 19 WED apor 5942101 19 04 tun 21081 J 96 9 91 4015 191989 42431 uorisoq c 210914 589425 Surziuo1qou s 1912414199 uosoo
113. re 7 This will stop throttle at maximum neutral speed Recheck adjustment to see if maximum neutral speed stop stops the throttle at 2400 2700 RPM Readjust if necessary 2 Shift engine into forward and check that neutral speed stop does not inter fere with throttle operation in forward gear f stop interferes move back edge of stop toward cylinder block mu rod md Por oer Re Re ae gon a Maximum Neutral Speed Stop b Boit Figure 7 Neutral RPM Limiter Adjustment TILLER HANDLE and THROTTLE DECAL ALIGN MENT 1 With engine not running shift into neutral position and turn twist grip until throttle is against maximum neutral stop The word Start on throttle decal must be aligned with arrow on tiller handle as shown in Figure 8 Start does not align with arrow refer to steps following J 0782 1 metet Arrow b Start Figure 8 Throttle Handle and Throttle Decal Alignment An With engine idling in neutral loosen bolt Figure 7 just enough to enable a Remove and retain 2 screws Figure 9 which secure tiller handle to engine b Realign gears Figure 9 as necessary to align Start with arrow c Reinstall tiller handle to engine with 2 screws Tighten screws securely Figuro 9 Tiler Handle Gear Realignment S 3 in PR peer E ra p Allen Head Screws 07839 Par
114. re strain To ensure good contact battery cables should be tight on battery posts If battery posts or cable terminals are corroded cables should be cleaned separately with a soda solution and wire brush After cleaning and before installing clamps apply a thin coating of Multipurpose Lubricant 92 63250 to posts and cable clamps to help retard corrosion i If battery has remained under charged check for high resistance in charging circuit j If battery has been using too much water it may be defective or under size Check fuel tank s for dirt water and or stale fuel NOTE If any doubt exists clean fuel tanks and refill with fresh fuel before continuing test If other than Mercury Marine fuel tanks are used see 12 Additional Checks and Adjustments If possible boat should be tested with average gross load Check motor tilt angle adjustment Boat should ride on even keel If motor is equipped with adjustable trim tab tab should be adjusted so that boat steers with equal ease in either direction Check engine RPM at full throttle RPM should be within specified range If RPM is not within specified range check propeller pitch Higher pitch propeller will decrease RPM lower pitch propeller will in crease RPM For optimum low speed inotor performance we recommend that idle mix ture and idle RPM be readjusted under actual operating conditions HOOK and ROCKER Check boat bottom carefully b
115. rt engine and shift into forward gear Advance throttle to full throttle RPM and adjust 2 elastic stop nuts Figure 1 or adjust link rod Figure2 so that timing mark on flywheel is aligned with 33 BTDC mark on rewind slarter housing as shown in Figure 3 letighten elastic stop nuts Figure 1 or jam nut Figure 2 and return throttle back to idle ENSE ER S Rene ie s Rum Rei eR me Mist qu Timing Mark on Flywheel Figure 3 Timing Mark Alignment d AT 1 4 i x CN Ae 5 s EE Wd OW 10975 Throttle Pickup Screw b Carburetor Cluster Pin Figure 4 Throttle Pickup Adjustment D 5 With engine running in forward gear advance engine speed so that timing mark on flywheel is aligaed with specified throttle pickup then adjust throttle pickup screw Figure 4 so that end of screw just touches carbu retor cluster pin as shown in Figure 4 Hetighten nut on adjustment screw Return engine speed back to idle turn off engine and disconnect timing light 6 With engine not running movethrottle arm to wide open throttle WOT and adjust full throttle stop screw Figure 5 to allow full carburetor shutter opening at WOT Make sure that carburetor shutter does not act af a throttle stop Al
116. s using new gasket s FUEL LINES and FILTERS l Inspect fuel lines for kinks leaks and restrictions and correct any defects found If necessary remove fuel lines and blow out with compressed air to remove any foreign material When reinstalling lines be sure that they are not twisted or kinked thereby causing restrictions 2 Clesn or replace fuel line filter element s as follows a Remove filter cover s and element s b Wash parts in solvent and dry with compressed air 3 Reinstall eleinent s NOTE If a complaint of poor high speed performance exists fuel pump sure test should be performed FUEL PUMP DIAPHRAGM defective fuel pump diaphragm Figure 4 is often mistakingly diagnosed 55 ignition trouble tiny pin hole in diaphragm will permit gas to enter crank 6856 causing that particular cylinder to wet foul the spark plug at idle speed At higher speeds quantity is limited and plug will fire normally Gasket b Check Valves d Filter Screen 1 Cover Figure 4 Fuel Pump A 66530A2 Screw e O Ring 9 Diaphragm h Base 6 Ignition System 1 Use Mercury Marine Thunderbolt Ignition Analyzer C 91 62563A1 All ignition components must be checked 2 Maker Points 1975 Merc 45 Maker points with some time on them will show discoloration but this is not a reason for replacement Points that show zero resistance across contacts are satisfactory Maker po
117. s suspected or if other than Mercury Marine fuel tank is used Check foreign fuel tanks for the following a Adequate air vent in fuel cap b Fuel line large enough 5 16 to 3 8 8 to 9 5mm c Filter on end of pickup too small or clogged or fuel pickup tube too small Use A 32 33909A4 Fuel Pickup Assembly as a comparison 2 Insufficient fuel supply will cause engine to run lean lose RPM or cause piston scoring 3 The fuel pressure gauge should be installed at the end of the fuel line that leads to the upper carburetor Fuei pressure must be 2 psi Ibs per sq in 0 141kg cm or more at full throttle LOW SPEED PERFORMANCE For optimum low speed motor performance we recommend that idle mixture and idle RPM be readjusted under actual operating conditions OPERATION at RECOMMENDED RPM The correct propeller should be installed on the engine so that it will run at recommended RPM Max RPM Range 4300 4700 4500 5500 4500 5500 4500 5500 4800 5500 4800 5500 4800 5300 4800 5300 4800 5500 4800 5500 4800 5300 4800 5300 6000 7000 4300 4700 4900 5500 4500 5500 4500 5500 4500 5500 4500 5500 4500 5500 4800 5500 4800 5500 5000 5500 4800 5300 5000 5500 4800 5500 4500 5500 4500 5500 4500 5500 5000 5500 4800 5500 5000 5500 5000 5500 5000 5500 5000 5500 5000 5500 5000 5500 4500 5000 5000 5500 4800 5300 5300 5800 4800 5300 4800 5300 5300 5800 5300 5800 5800 6300 4800 6000
118. st tank and connect fuel line Pre set idle mixture screw at 1V turns 4 turn out from seated position 2 Install Timing Light C 91 35507 by connecting red lead to No 1 top spark plug and connecting black leads to battery positive and negative posts 3 Start engine and place shift lever in forward gear Feast Pepe urpis ipe goi riti NP RI d ww uem Ld 1 083 Maximum Spark Advance Screw Idle Mixture Screv b Locknuts d Idle RPM Screw Flgure 1 Maximum Sperk Advance Adjustment 4 Advance twist grip until timing line on flywheel aligns with maximum timing mark sce specification above on starter housing Adjust maxi mum advance screw Figure 1 until end of screw just touches throttle lever Tighten jam nut 5 Close throttle with twist grip Shut engine off and remove Timing Light CARBURETCR ADJUSTMENT 1 Restart engine and adjust idle mixture for best idle in forward gear See carburetor adjustment information preceding 2 Set idle RPM to specification in forward gear MAXIMUM NEUTRAL RPM LIMITER ADJUSTMENT 1 With engine running in neutral loosen neutral RPM limiter screw Figure 2 Move limiter toward rear of engine and tighten screw only enough to place light tension on limiter 2 Turn twist grip to attain 2400 2700 RPM then tighten limiter screw securely Recheck RPM returning to idle then open throttle against
119. t on adjustment screw 8 With engine in neutral move throttle lever to place maximum spark screw against stop Crank engine with starter motor and adjust maximum spark serev Figure 5 to 20 BTDC mark on timing decal with the pointer Due to the advance characteristics of this ignition system this adjustment will result in a spark advance of 18 at maximum RPM Retighten nut on adjust nent screw Remove timing light from engine cce rn nep RTT Te p ext s lil a Xr eA Sa Sima Tq eR ud Maximum Spark Advance Screw Figure 5 Maximuin Spark Advance Adjustment 9 With not running move throttle lever to wide open throttle WOT and adjust full throttle stop screw Figure to allow full throttle shutter opening WOT Make sure that throttle shutters do not act asa throttle stop Allow 0107 015 0 25mm to 0 38mm clearance between roller and throttle cam at WOT as shown in Figure 6 Retighten nut on adjustment screw 10 Adjust engine idle RPM as follows a With engine in water connect electrical harncss and fuel line 10 engine Start engine and allow to warm up a b PX dui 1 15 Y YE Vie RE cni Cancel 09833 Full Throttle Stop Screw 010 to 015 Clearance d Roller e Throttle Cam Figure 6 Full Throttle Stop Adjustment Push Downward With thr
120. table 16 BTDC 16 BTDC 7 5 8 5 8 to 10 ATDC Throttle Secondary Pickup Not Adjustable Full Throttle RPM 5000 to 5500 5300 to 5800 Idle RPM in Forward Gear 600 700 at 7 5 550 650 at 12 to 85 ATDC to 15 ATDC 18 to 25 psi 5000 RPM T lt 1 Firing Order Firing Sequence Spark Plugs Spark Plug Gap Timing Maximum Throttle Primary Pickup TO Water Pressure P dais s Idle RPM Screw Figure 12 Engine Idle Adjustment SITE TIMING POINTER ADJUSTMENT SAFETY WARNING Engine could start when turning fly wheel to check timing pointer adjustment therefore re move all spark plugs to prevent engine from starting 1 Remove all spark plugs and install Dial Indicator C 91 58222A1 Figure 1 into No 1 cylinder top cylinder starboard bank 2 Turn flywheel in a clockwise direction until No 1 piston isat top dead cen ter TDC Set dial indicator at 0 zero and tighten indicator set screw 3 Turn flywheel counterclockwise until dial indicator needle is approx turn beyond 462 12mm then turn flywheel clockwise so that dial indi cator reads 462 exactly dedu ct au 10961 Dial Indicator Installed in No 1 Cylinder Figure 1 Dial Indicator Installed in Cylinder ORE nup te cite
121. tart aud allow to warm up With throttle cable barrel removed from barrel retainer adjust idle RPM to 550 600 RPM with engine running in forward gear Figure 7 Retighten nut on adjustment screw With end of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed without tearing but has some drag on it Readjust cable barrel if necessary IMPORTANT Excessive preload on throttle cable will cause diffi culty when shiiting from forward to neutral Readjust throttle cable barrel If necessary Secondary Pickup Screw b aoi NOTE Carburetor idle mixture is not equipped with adjustment screw as at other Mercury Outboards See carburetor jet chart preceding for jet change With engine not running move throttle lever so that spark lever is agains IDEM OF pU 1 e 1 V ue es orones 10978 a Idle RPM Screw Figure 7 Engine Idle RPM Adjustment TIMING SYNCH ADJUSTING Merc 650 1975 Firing Order 1 2 3 Firing Sequence 120 Consecutive Spark Plug AC V40FFM or Champion L76V Spark Plug Gap Not Adjustable Timing Maximum 23 BTDC
122. te V V t TA f 8 v c f gt 6 v E f 5 8 MEAE EARE O AO tre it nance ans 4 08097 8 Primary Pickup Lever C Throttle Cam 5 Actuator Plate Retainer Bolts Out of Sight d Just Touching Figure 5 Primery Throttle Pickup Adjustment say St RET d sna le Sie nha RUN A Nat ram a RN i _ Wa 9139 1999 5 uo mu TO 18 211041 U2 AA uo 5 dnyotd 2 101 4 ULILA 10 93010 dois opor jou op 101210162 jeu aans aye 18 Sutuodo 1211s 11J 01 11 40 01 6940814 mass dois LOM 01 Jou juaunsu pe uo pmu cg ut umos 58 uo 1epuooas snl pip 08 7 210214 2198 dnxotd 211044 isnlpy z 214 91 09 soz 00339 3ul jou 3 3138 93 en 150188 st 10jnqujsip 08 HOI
123. ter 91 52751 to test rectifier Red and yellow red wires must be removed from rectifier before testing IMPORTANT Beforo making any tests with VOA Tester tum meter selector to range specified and adjust pointer to ohms set Position with small red and black leads clipped together set position MUST BE readjusted each time meter range Is changed NOTE Refer to F igures 6 7 8 for rectifier terminal identification 12 _ Range Reading EIE NOTE If rectifier test readings are not attained replace the rectifier Failure to obtain stated readings in Tests 1 and 3 in chart above indicates that diodes are open circuited Failure to obtain stated readings in Tests 2 and 4 indicates that diodes are short circuited 1 Red VOA lead to ground black lead alternately to terminals one 1 and 3 2 Black VOA lead to ground red lead alternately to terminals one 1 and 3 3 Black VOA lead to terminal 2 red lead alternately to termi nals one 1 and 3 4 Red VOA lead to terminal 2 black lead alternately to termi nals one 1 and 3 22 23 d A m 07300 Terminal No 1 Alternator Terminal No 3 Alternator b Terminal No 2 Positive d Ground Figure 8 Diode Type Rectifer Terminals Merc V 6 s and 850 800 700 650 500 200 110 75 TESTING PLATE TYPE RECTIFIER Figure 9 By Measuring Direct Current Resistance on Magneto Analyzer
124. zing screws amp in neutral move throttle lever to place maximum spark screw agans stop Crank engine with starter motor and adjust maximum spark screw Figure to align 20 Mere 2000 or 18 Merc 1500 BTDC mark on timing decal with timing pointer Because of spark advance character istics of this ignition system this adjustment will result in a spark advance of 189 Merc 2000 or 169 Merc 1500 at maximum RPM Retighten nut on adjustment screw Remove timing light from engine 9 With engine not running move throttle lever to wide open throttle WOT and adjust full throttle stop screw Figure 7 to allow full throttle shutter opening at WOT Make sure that throttle shutters do not act 88 a throttle stop Allow 010 015 25mm to 38mm clearance between roller and throttle cam at WOT as shown in Figure 7 Retighten nut on adjustment screw puer ud PIO Cw eM fes i D 1 7 amp E at dul NA ar zi 27 2 u bon 09833 8 Full Throttle Push Downward d Roller Stop Screw 010 to 015 Clearance Throttle Cam Figure 7 Fuil Throttle Stop Adjustment Ar i P n docni T 1 f pons x Idle Stop Screw AR 8 Idle RPM Adjustment i

1 i - Brunswick Marine in EMEA Center

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