90-10216040 JANUARY 2003
Printed in U.S.A. -
2003, Mercury Marine
Page 1 of 18
INSTALLATION MANUAL
75, 90 AND 115 HP (4-Stroke)
NOTICE TO INSTALLER: After completing assembly, these instructions should be
placed with the product for the owner’s future use.
IMPORTANT: If the boat is to be water tested, the operator should be familiar with the
operation procedures in the Operation and Maintenance Manual.
Electric Fuel Pump
1
. . . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity
1
. . . . . . . . . . . . . . . . . .
Start in Gear Protection
2
. . . . . . . . . . . . . . . . . . . . .
Selecting Accessories For The Outboard
2
. . . . . .
Installation Specifications
2
. . . . . . . . . . . . . . . . . . . .
Lifting Outboard
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod
4
. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard
5
. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical, Hoses and Control Cables
7
. . . . . . . . .
Front Cowl Grommet
7
. . . . . . . . . . . . . . . . . . . . . .
Remote Wiring Harness
7
. . . . . . . . . . . . . . . . . . . .
Battery Cable Connections
8
. . . . . . . . . . . . . . . . .
Fuel Hose
9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer (Optional) Water Pick-up
9
. . . . . .
75 and 90 Hp Shift Cable Installation
10
. . . . . . .
75 and 90 Hp Throttle Cable Installation
12
. . . . .
115 Hp Shift Cable Installation
13
. . . . . . . . . . . . .
115 Hp Throttle Cable Installation
15
. . . . . . . . . .
Propeller Installation
16
. . . . . . . . . . . . . . . . . . . . . . .
Trim-In Stop Adjustment
17
. . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment
18
. . . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If
necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY
XXX
U.S. COAST GUARD CAPACITY
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can:
1. cause loss of boat control 2. place too much weight at the transom, altering
the designed flotation characteristics of the boat or 3. cause the boat to break
apart, particularly around the transom area. Overpowering a boat can result in
serious injury, death, or boat damage.
