service bulletin 1990 Index

Transcription

1 1990 Index 90-1 Panel Mount Pro 120 Remote Control -- Mariner 175 Ski 90-2 Rubber Retainer--Bleed Check Valve Mariner/Mercury Reed Block Gasket -- Mariner/Mercury 100/ Top Cowl Unlatching And 1990 Mariner/Mercury Service/Repair of Electrical Test Equipment 90-6 Excessive Exhaust Smoke/Spark Plug Fouling -- Mariner 40 Magnum/Mercury Electric Start (4 Cyl.) 90-7 Voltage Regulator Wire Interference Mariner/Mercury Obstructed Fuel Line Connector -- Mariner/Mercury Models 90-9 Lean Above Idle Mariner/Mercury High Elevation Gear Ratio Exchange Program -- Mariner/Mercury/Sea Ray Models US and Canada Gasoline Recommendations -- Mariner and Mercury Models Textured Decals -- Mercury Reversed Steering Control Cables -- Thruster R33 and R45 Models ECU and TPI Setting Change Magnum/XRi Lower End Cap Seal Improvement (4 Cyl.) Overheating Sea Ray 135 and Carburetor Main Jet Replacement Models 1990 SERVICE BULLETIN

2 1991 Index Mark on Cast Iron Flywheel thru Low Ignition Output: w/40 Amp Charging System 91-3 Starter Drive Material Change thru Friction Nut Assembly -- Co--Pilot P/N A1 Increased Friction Holding Capacity 91-5 Air Leak/Fuel Restriction -- Plastic Fuel Tank Gallon 91-6 Throttle Cam Change /115 Models 91-7 Hesitation and/or Surge -- Mariner and Mercury Intake Manifold Leak Mariner/Mercury 50 & CID (849cc) 91-9 Autoblend Inlet Check Valve -- P/N Voltage Regulator Test Thicker Fuel Pump Check Valves thru Replacement Speedometer Tube thru Top Cowl Air Deflector Kit thru Relocation of Gear Housing Vent Hole thru Oil Injection Crankcase Pressure Valve thru Cylinder Block Bearing Shoulder Bore Depth thru Outboard Chrome Bore Replating -- 2, 2.4 and 3.4 Liter Thermostat Change thru Cylinder Head Dome Size Flywheel Replacement Flywheel Puller P/N A Galvanic Corrosion / Linkage Swivel Bushing thru Shipping Damage to Outboard -- 3 thru Two Cable Steering -- Tube Alignment thru Top Cowl Unlatching thru Crankshaft Sealing Ring Change Power Trim Relay Inspection and SERVICE BULLETIN

3 1992 Index 92-1 WMH Carburetor Kit P/N thru Oil Tank Leak - 50/ Power Steering Actuator Repair Kit - P/N Alignment/Memory Piston Removal Tool - P/N Power Steering Kits P/N 17443A2, A3, A7, A8, and A thru Lower End Cap Seal Change (4 Cylinder) 92-7 Improved Cylinder Head thru Slow Trim/Tilt Rate thru Required Fuel Filter Replacement - 40 thru Sta-Strap and Link Rod Interference - 75 thru Battery Isolator Kit P/N A3-70 thru Power Trim Rocker Arm - 75 thru Gearcase Oil Slinger Eliminated thru Stronger Spark Advance Spring P/N thru Bleed Restrictor P/N and Previous 135 thru Timing Decal and HP Carburetor Models Voltage Regulator Failures thru Quicksilver Propeller Failures and Guidelines Trigger Modification - 250/ Modified Propellers for Troubleshooting thru Outboard Wiring Color Chart Outboard Installation thru 200 HP 1992 SERVICE BULLETIN

4 1993 Index 93-1 Remote Control Handle Change - P/N 92744A Flywheel Replacement thru 200 HP Models 93-3 Fuel Recommendations - 2 thru Fuel Filter P/N Installed - 150/175/200 EFI 93-5 Carburetor Main Jet Replacement Models 93-6 High Elevation Gear Ratio/Gear Housing Exchange Program Mariner/Mercury Models 93-7 Paralift P/N A-4 Pivot Bushing Replacement 93-8 Sport Jet 90 Flushing Kit 93-9 Shift Cable Lost Motion and Attachment Soft Rewind Starter Pawls - 6 thru 25, Improved Manual Tilt Assist - Speed/Effort thru Detonation Sensor and Module Magnum EFI/XRi Voltage Regulator Failures thru Service/Repair Of Electrical Test Equipment Cylinder Head Bolt Torque thru Cylinder Head Change thru Spark Plug Change Carburetor Main Jet Change /115 Models Lean Condition Between 2000 and 3500 RPM thru Update Fuel Pump Replacement - 40 thru Power Trim Leak Down - 40 thru Rich Idle Condition - Sport Jet Ride Plate Damage - Sport Jet SERVICE BULLETIN

5 1994 Index 94-1 Power Steering Actuator Seal Failures 94-2 Cast Iron Cylinder Sleeve Liter 200 and Trim Gauge Reading Opposite 94-4 Missing Data - Digital Diagnostic Terminal Screen Water Pump Base Replacement - 30/ Oil Injection Conversion Kit - Sport Jet Locking Tab, Pivot Bolt and Starter Solenoid - Sport Jet Shift Interrupt Diode Replacement Kit P/N 17461A Sport Jet 90 Information Update Power Trim Shaft Not Engaging Sender - 75 thru Powerhead Water Ingestion Ring Gear Mounting Screws Thru 25 Electric Start Models Power Trim Partial Leak Down At Maximum Trim - 75 thru Pre-Loaded Reeds - 6 thru Manual Starter Interlock Lever Replacement - 30/40 and 55/60 Marathon/Sea Pro 1994 SERVICE BULLETIN

6 1995 Index 95-1 Accumulator Removal -- Manual Tilt Assist (4 Cylinder), 50/60, 55 Marathon/Sea Pro and Jet 30 & Gearhousing Exchange Program thru Outboard Serial Number Decal and Shipping Carton Information 95-4 Powerhead Lower End Cap , 225 EFI, 3 Liter 95-5 Reformulated Gasoline (USA) 95-6 Thruster Service and Parts 95-7 Driveshaft Replacement -- 30/40 and 50 (FourStroke) 95-8 Propeller Hub Slipping -- Small Hub Trophy 95-9 Exhaust Manifold Bolts -- Sport Jet Product Information -- Sport Jet 95XR and 120XR Quicksilver Digital Diagnostic Terminal (DDT) and Accessories 150 thru 220 EFI, 225/250 3 Liter Hard Shifting -- 20/25 Tiller Handle Shift Models Service/Repair of Electrical Test Equipment Merctach Interface Module P/N A Shift Shaft Seal & Power Trim Manual Release Valve Tip Breakage thru Mechanics Precautions , 225 EFI, 250 EFI, 3 Liter Marathon/Sea Pro Compression Tests -- Sport Jet Turn Key Start Kit -- Sport Jet New Stator -- Sport Jet SERVICE BULLETIN

7 1996 Index 96-1 Power Trim Relay thru Voltage Regulator V Reduced Wide Open Throttle RPM HP, (3 Liter) EFI 96-4 Key Switch Replacement 96-5 Detonation Control Module Replacement HP, EFI 96-6 Oil Pump Tubing thru Fuel Pump Replacement -- 45/50 (FourStroke) 96-8 Maintenance Recommendations 96-9 Cowl Decals -- 6 thru 250 HP Oil Injection Pump -- Sport Jet Crankshaft Replacement -- 45/50 (FourStroke) Camshaft Oil Seal Replacement -- 45/50 (FourStroke) Commander 3000 Remote Control Counter Rotation Gearcase Installation thru Idle Relief Restriction thru 250 HP Gear Failures -- 30/40 (2--Cylinder), 45/50 (FourStroke) Clutch Failers thru High Elevation Gear Ratio/Gear Housing Exchange Program HP Models CDM Ground Wire Breaking thru Poppet/Relief Valve Spring Liter Overheating -- 3 Liter 1996 SERVICE BULLETIN

8 1997 Index 97-1 Replating Chrome, Nikasil, Ni--com Cylinders -- V Bearing Carrier Nut Low Torque Big Foot, 75 thru Starter Motor Failures -- 6 thru Special Adjustment for Startor Failures thru 125, Sport Jet 90/ Adaptor Plate Improvements Liter V Warranty and Registration of Unsold Non--Current Outboards 97-7 Gearhousing Modification 97-8 Reverse Gate Adjustment -- Sport Jet 175 XR@ 97-9 Water Pump Base Cracked thru Special Tools Emissions Information Gear Failures -- 40/50 and 45/ Stainless Steel Propellers thru Hard Starting of Hot Engine -- 45/50 (FourStroke) Paint Codes and Part Numbers Nozzle Assembly -- Sport Jet Cross Pins Missing -- Single Ram Power Trim thru Oil Injection Gear Failures thru L, 2.4L & 2.5L V Engine Shipping Damage and Missing Parts Modified Test Propellers For Troubleshooting thru 3.4L Propeller Shaft Seal -- 25, 45/50 (FourStroke) and 30/40, 40/50, 55/60 (TwoStroke) Important Break--In Information Propeller Selection thru 250 (3 Liter) 1997 SERVICE BULLETIN

9 1998 Index 98-1 Power Trim Piston/Rod Replacement P/N 43397A Over Torque of Flywheel Bolt -- 20/25 (TwoStroke) & 20 Jet /150 OptiMax Update 98-4 Manual Venting Fuel Tank Conversion -- Plastic 6.6 Gallon Tank 98-5 Starter Motor P/N Tempset and Trophy Propeller Flo--Torque II Bushing (A45/A46 Series) 98-7 Propeller Failures and Guidelines -- 6 thru /150 OptiMax Update 98-9 Burned Propellers Hubs & Shaft Seals Liter High Oil Consumption Liter EFI V Siphon Break -- Sport Jet CDM Ignition Systems Reverse Lock Link Rod Replacement (FourStroke) Upper Motor Mount Replacement /15 (FourStroke) Additional Warning Signal -- Sport Jet 175 XR@ Hose Replacement -- 6 thru Engine Shipping Damage and Missing Parts Ground -- Ignition Components Plated -- Force 75, 90, Service Tools thru Service/Repair of Electrical Test Equipment Paralift Usage Liter Quicksilver Digital Diagnostic Terminal (DDT) Check Valve Kit /150 OptiMax 1998 SERVICE BULLETIN

10 1999 Index 99-1 V--6 Power Trim Motor Harness 99-2 Propeller Whine thru Special Aluminum Propellers Required for 40 BigFoot (FourStroke) Models 99-4 Break--In Procedure 3.0 Liter 99-5 Fuel Starvation 99-6 End Cap OptiMax Air Compressor 99-7 Steering Arm 3.0 Liter 99-8 Red Stator -- 6 thru 25 (TwoStroke) 99-9 Gearcase Sleeve (FourStroke) & 20/25 (TwoStroke) Tilt Release -- Bigfoot 50 (FourStroke) & 60 (TwoStroke) Vapor Separator Cover (VST) -- Fitting Liter Mounting Height thru DDT Data Worksheet New Service Tools Engine Battery and Battery Cable Requirements Commander 3000 Classic Panel Mount Remote Control Decal 1999 SERVICE BULLETIN

11 2000 Index Steering Link Rod Attaching Bolt -- V SmartCraft Gauge Trouble Shooting and Service Tips Shifting Effort -- 75/90 (FourStroke) Shift Link -- 75/90 (FourStroke) Manual Tilt Cross Pin Loose -- 55/60 (TwoStroke) Wire Harness Shunt Resistor -- 25, 30/40/40 Bigfoot (FourStroke) Air Compressor End Cap Oil Leak Oil Control -- 25, 30/40, 40/45/50 (FourStroke) Special Aluminum Propellers Required for 50/60 Bigfoot (FourStroke) Models Oil Coupler/Bearing -- Sport Jet Analog Gauge Connections for Digital OptiMax Models DDT Cartridge and Worksheet -- OptiMax 2001 Models Fuel Sender Connection Modification (OptiMax) Hard Starting EFI Jet Drive Voltage Regulator HP Jet Drive Shift Link 3.0 Liter 2000 SERVICE BULLETIN

12 2001 Index Direct Injector Replacement Reference Voltage Circuit Fuel Hose Routing Tachometer Signal -- 75/90 FourStroke Spark Plug Boot Removal & Installation Flywheel Nut Retorque EFI FourStroke In--Line Fuel Filter -- 75/90 FourStroke Running Engine Without the Gearcase -- 75/90, 115 FourStroke Voltage Regulators HP Jet Drives Fuel Filter /210/240 Jets Liter Driveshaft Oil Seal Carrier Kit Fuel Additive Recommendation (Quickleen) SmartCraft Troubleshooting Spark Plug Fouling Liter OptiMax Rocker Arm Failure Outboard Replacement -- 30/40 & 40/50/60 FourStroke Tach Adapter -- 6 thru 25 HP Electric 2002 MY Fuel Starvation Spark Plug Fouling, 3.0 Liter OptiMax (Revised) Oil Pump Replacement & 115 FourStroke New Special Tools and Service Aids Water Tube Guide Causing Engine Overheating (3 Cyl.) Bigfoot & 40 thru 60 FourStroke 2001 SERVICE BULLETIN

13 2002 Index :1 Gear Ratio -- 75/90 (FourStroke) Water Intrusion (Top Cowl) Expired Fix Campaigns Idle Relief Noise thru 60 FourStroke Warranty and Preparation of New, Unsold, Non--current Product Discharged Battery Following Periods of Extended Non--Use -- 75/90 (FourStroke) Spark Plug Fouling 3.0 Liter OptiMax New Thermostats and Thermostat Covers Liter Corrosion Prevention and Maintenance Fusible Link -- V6 Charging System Mercury Side Mount Control (MSC) 4000 with Power Trim Switch High Idle RPM EFI (FourStroke) Cylinder Bore Seals Liter Outboards and Sport Jet Uneven or Increased Effort After Control Installation -- Commander 3000 Classic Panel Mount Remote Control SmartCraft Communication Problem Testing Alternators Key Switch Harness (859722A16) -- Sea Doo Boats Carburetor Fuel Inlet Clamp FourStroke Voltage Regulator Wire Contact -- 40/50/60 EFI FourStroke Electric Fuel Pumps (Seized) Powerhead & Adaptor Plate Bolt Torque thru 60 FourStroke New Spark Plug (OptiMax) 2002 SERVICE BULLETIN

14 2003 Index Carburetor Vent House FourStroke HP EFI, 3.0 Liter Outboard (New Model) Aftermarket Replacement Aluminum Anodes Electric Fuel Pump Harness Connection Engine Shipping Damage and Missing Parts /4500 Gen II Control Box FourStroke Stalling below 1200 RPM Electric Oil Pump No Longer Available (NLA) Official Recall Notification United States Federal Boat Safety Act 225 EFI FourStroke Throttle Sticking Hairpin Cotter is NLA Electric Fuel Pump Troubleshooting Propeller Failures and Guidelines -- Outboards 2.5 Thru 250, Alpha, Bravo One, Bravo Two, Bravo Three Sterndrives Propellers Commander Remote Control Replacement Parts Crankcase Oil Entering the Breather FourStroke FourStroke 9.9/15HP Camshaft Washer Failure Service/Repair of Electrical Test Equipment 2003 SERVICE BULLETIN

15 2004 Index Official Recall Notification U.S. Federal Boat Safety Act Gen II Throttle/Shift Remote Control Cables Sport Jet -- False Overheat Warning Computer Diagnostic System Testing Remote Control System EFI FourStroke Top Cowl Remote Control Requirement for 2005 Model Year 8/9.9 HP FourStroke Outboards Installation of Neoprene Wrap 1.5L OptiMax HP (TwoStroke) EPA Decal -- Incorrect Information / Model Year FourStroke Reverse Hook Replacement Official Recall Notification United States Federal Boat Safety Act 8/ Model Year FourStroke Tiller Tube Replacement Gearcase Warranty Claims Prop Rattle & Flo--Torq III Propeller Hub Powerhead & Adaptor Plate Bolt Torque thru 60 FourStroke Pro XS OptiMax Service Manual Release 2004 SERVICE BULLETIN

16 2005 Index Official Recall Notification United States Federal Boat Safety Act Throttle Linkage Rod Replacement Fuel Level Sender Accuracy EFI FourStroke Fuel Cooler Hose Replacement Pin Adapter and Control Harnessess Engine Shipping Damage and Missing Parts Shipping of Hazardous Material (HazMat) and Engine/Components Containing Hazardous Material Digital Throttle and Shift (DTS) Changes Mercury 4000 Series Panel Mount Control -- Pistol Grip Voltage Regulator T1 No Longer Available (NLA) Torque Change -- Propeller Hub Bushing Q Horsepower FourStroke Voltage Regulator Replacement Transom Bolt Torque/Engine Mounting Choke Function Pin Key/Choke Harness FourStroke Wire Harness Replacement HP (TwoStroke) Service Manual Correction New 14 Pin Key/Choke and Engine Harness Features (non--dts) 2005 SERVICE BULLETIN

17 2006 Index Steering Tie Bart Kit Enhancements /225/250/275 Verado Mercury Panel Mount Electronic Remote Control (ERC) used with Digital Throttle and Shift (DTS) Engines Model Year 25/30 EFI FourStroke Accessory Kits Outboard Service Manual Colored Diagrams Fuel Supply Module (FSM) Float Switch Replacement /225/250/275 Verado Ground Strap Kit /225/250/275 Verado 2006 SERVICE BULLETIN