90-863080002 JANUARY 2001
Printed in U.S.A. -
2001, Mercury Marine
Page 1 of 58
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, RideGuide and MMPP.
GASOLINE ENGINE 8.1S INBOARD MODELS
INSTALLATION MANUAL
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owner’s Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information
2
. . . . . . . . . . . . . . . . . . . .
Notice to Installer
2
. . . . . . . . . . . . . . . . . . . . .
Quicksilver Products
3
. . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives
3
. . . . . . .
Torque Specifications
3
. . . . . . . . . . . . . . . . .
Serial Number Decal Placement
4
. . . . . . . .
Engine Rotation
4
. . . . . . . . . . . . . . . . . . . . . .
Transmissions
4
. . . . . . . . . . . . . . . . . . . . . . . . .
Velvet Drive Transmissions
4
. . . . . . . . . . . .
ZF / Hurth Transmissions
5
. . . . . . . . . . . . . .
Propeller Rotation
6
. . . . . . . . . . . . . . . . . . . .
Installation Requirements
9
. . . . . . . . . . . . . .
Engine Bed
9
. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Compartment
9
. . . . . . . . . . . . . . . . .
Exhaust System
12
. . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System
16
. . . . . . . . . . . . . . . . .
Battery
18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFI Electrical System Precautions
20
. . . . . .
Instrumentation
20
. . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection
21
. . . . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and Cables
22
Seawater Connections
22
. . . . . . . . . . . . . . . .
Hot Water Heater
23
. . . . . . . . . . . . . . . . . . . . .
Engine Installation
24
. . . . . . . . . . . . . . . . . . . . .
Engine Oil Dipstick Location
24
. . . . . . . . . . .
Battery Cable Connection
24
. . . . . . . . . . . . . .
Engine Mount Pre-Adjustment
25
. . . . . . . . . .
Initial Engine Alignment
26
. . . . . . . . . . . . . . .
Final Engine Alignment
29
. . . . . . . . . . . . . . . .
Engine Connections
34
. . . . . . . . . . . . . . . . . . . .
Seawater Pickup Pump Connection
34
. . . . .
Fuel Supply Connection
34
. . . . . . . . . . . . . . .
Audio Warning System Connection
35
. . . . .
Electrical Connections
36
. . . . . . . . . . . . . . . . .
Exhaust System
37
. . . . . . . . . . . . . . . . . . . . . .
Shaft Log Seal Connection
38
. . . . . . . . . . . . .
Shift Cable Installation And Adjustment
39
.
Velvet Drive Transmissions
- 5000 Series
39
. . . . . . . . . . . . . . . . . . . . . . .
Velvet Drive Transmissions - 72C In-Line
43
Hurth Transmissions
47
. . . . . . . . . . . . . . . . . .
Predelivery Preparation
52
. . . . . . . . . . . . . . . . .
Battery Connection
52
. . . . . . . . . . . . . . . . . . .
Test Running Engine
52
. . . . . . . . . . . . . . . . . .
Boat In The Water Tests
52
. . . . . . . . . . . . . . .
Cold Weather and
Extended Storage Draining
53
. . . . . . . . . . . .
Coolant And Water Flow Diagrams
56
. . . . . .
Predelivery Inspection
58
. . . . . . . . . . . . . . . . . .
