6/8/9.9/10/15 6/8/9.9/10/15. Starting Model Year Serial Number 0A and Up (USA) and Up (Belgium)

Transcription

1 6/8/9.9/10/15 6/8/9.9/10/15 Strting Model Yer R02 Ferury 2003 Strting Model Yer 1986 Seril Numer 0A nd Up (USA) nd Up (Belgium)

2 Notice Throughout this puliction, Dngers, Wrnings nd Cutions (ccompnied y the Interntionl HAZARD Symol ) re used to lert the mechnic to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. OBSERVE THEM CAREFULLY! These Sfety Alerts lone cnnot eliminte the hzrds tht they signl. Strict complince to these specil instructions when performing the service, plus Common Sense opertion, re mjor ccident prevention mesures. DANGER DANGER - Immedite hzrds which WILL result in severe personl injury or deth. WARNING WARNING - Hzrds or unsfe prctices which COULD result in severe personl injury or deth. CAUTION Hzrds or unsfe prctices which could result in minor personl injury or product or property dmge. Notice to Users of This Mnul This service mnul hs een written nd pulished y the Service Deprtment of Mercury Mrine to id our delers mechnics nd compny service personnel when servicing the products descried herein. It is ssumed tht these personnel re fmilir with the servicing procedures of these products, or like or similr products mnufctured nd mrketed y Mercury Mrine, tht they hve een trined in the recommended servicing procedures of these products which includes the use of mechnics common hnd tools nd the specil Mercury Mrine or recommended tools from other suppliers. We could not possily know of nd dvise the service trde of ll conceivle procedures y which service might e performed nd of the possile hzrds nd/or results of ech method. We hve not undertken ny such wide evlution. Therefore, nyone who uses service procedure nd/or tool, which is not recommended y the mnufcturer, first must completely stisfy himself tht neither his nor the products sfety will e endngered y the service procedure selected. All informtion, illustrtions nd specifictions contined in this mnul re sed on the ltest product informtion ville t the time of puliction. As required, revisions to this mnul will e sent to ll delers contrcted y us to sell nd/or service these products. It should e kept in mind, while working on the product, tht the electricl system nd ignition system re cple of violent nd dmging short circuits or severe electricl shocks. When performing ny work where electricl terminls could possily e grounded or touched y the mechnic, the ttery cles should e disconnected t the ttery. Any time the intke or exhust openings re exposed during service they should e covered to protect ginst ccidentl entrnce of foreign mteril which could enter the cylinders nd cuse extensive internl dmge when the engine is strted R02 FEBRUARY 2003 Pge i

3 It is importnt to note, during ny mintennce procedure replcement fsteners must hve the sme mesurements nd strength s those removed. Numers on the heds of the metric olts nd on the surfces of metric nuts indicte their strength. Americn olts use rdil lines for this purpose, while most Americn nuts do not hve strength mrkings. Mismtched or incorrect fsteners cn result in dmge or mlfunction, or possily personl injury. Therefore, fsteners removed should e sved for reuse in the sme loctions whenever possile. Where the fsteners re not stisfctory for re-use, cre should e tken to select replcement tht mtches the originl. Clenliness nd Cre of Outord Motor A mrine power product is comintion of mny mchined, honed, polished nd lpped surfces with tolernces tht re mesured in the ten thousnds of n inch/mm. When ny product component is serviced, cre nd clenliness re importnt. Throughout this mnul, it should e understood tht proper clening, nd protection of mchined surfces nd friction res is prt of the repir procedure. This is considered stndrd shop prctice even if not specificlly stted. Whenever components re removed for service, they should e retined in order. At the time of instlltion, they should e instlled in the sme loctions nd with the sme mting surfces s when removed. Personnel should not work on or under n outord which is suspended. Outords should e ttched to work stnds, or lowered to ground s soon s possile. We reserve the right to mke chnges to this mnul without prior notifiction. Refer to deler service ulletins for other pertinent informtion concerning the products descried in this mnul. Pge ii R02 FEBRUARY 2003

4 Service Mnul Outline Section 1 - Generl Informtion & Specifictions A - Specifictions B - Mintennce C - Generl Informtion D - Outord Instlltion Section 2 - Electricl nd Ignition A - Ignition System B - Chrging & Strting System C - Timing/Synchronizing & Adjusting D - Wiring Digrms Section 3 - Fuel System A - Fuel Delivery System B - Emissions Section 4 - Powerhed Section 5 - Mid-Section A - Clmp/Swivel Brckets nd Driveshft Housing B - Power Trim Section 6 - Lower Unit Section 7 - Attchments/Control Linkge A - Throttle/Shift Linkge (Tiller Hndle Shift Models) B - Throttle/Shift Linkge (Side Shift Models) C - Tiller Hndle Section 8 - Mnul Strter Generl Informtion & Specifictions Electricl nd Ignition Fuel System Powerhed Mid-Section Lower Unit Attchments/ Control Linkge Mnul Strter R02 FEBRUARY 2003 Pge iii

5 Propeller Informtion For in-depth informtion on mrine propellers nd ot performnce written y mrine engineers see your Authorized Deler for the illustrted Wht You Should Know Aout Quicksilver Propellers... nd Bot Performnce Informtion (Prt No ). How To Use This Mnul Pge Numering The mnul is divided into SECTIONS which represents mjor components nd systems. Some SECTIONS re further divided into PARTS. Ech PART hs title pge. A Tle of Contents for the prticulr PART is printed on the ck of the title pge. SECTIONS nd PARTS re listed on the Service Mnul Outline sheet which immeditely follows the cover of this ook. Two numer groups pper t the ottom of ech pge. The exmple, elow, is self-explntory. EXAMPLE: R1 MAY 1998 Pge 2B-7 Revision No. 1 Month of Printing Yer of Printing Section Numer Prt of Section Letter Pge Numer Pge iv R02 FEBRUARY 2003

6 GENERAL INFORMATION & SPECIFICATIONS Section 1A Specifictions Tle of Contents SPECIFICATIONS 1 A Generl Specifictions A-1 Propeller Informtion Chrt - 6 HP A-6 Propeller Informtion Chrt - 8 HP A-6 Propeller Informtion Chrt -9.9/10 HP A-7 Propeller Informtion Chrt -15 HP A-7 Mercury/Quicksilver Luricnts nd Selnts 1A-8 Generl Specifictions PERFORMANCE KW (HP) OUTBOARD WEIGHT FUEL SYSTEM Models 6/8/9.9/10/15 Model 6 Model 8 Model 8 Silmte Model 9.9 Model 9.9 Silpower XR/MAG/Viking10 Model Se Pro/Mrthon 10 Model 15 Model Se Pro/Mrthon 15 Mnul Strt Silmte Silpower XR/MAG/Viking10 Se Pro/Mrthon Se Pro/Mrthon 15 Electric Strt Silpower 15 Recommended Gsoline Recommended Oil Rtio Fuel Tnk Cpcity 6/8/9.9/Silpower, XR/MAG10 10 Se Pro Mrthon/ (6) 5.9 (8) 5.9 (8) 7.4 (9.9) 7.4 (9.9) 7.5 (10) 7.5 (10) 11.2 (15) 11.2 (15) 33.1 kg (73.0 l) 33.1 kg (73.0 l) 33.8 kg (74.5 l) 33.8 kg (74.5 l) 34.2 kg (76.5 l) 33.8 kg (74.5 l) 33.8 kg (74.5 l) 34.0 kg (75.0 l) 34.0 kg (75.0 l) 36.1 kg (79.5 l) 36.1 kg (79.5 l) 36.7 kg (81.0 l) 37.7 kg (83.0 l) 37.0 kg (81.5 l) Automotive Unleded with Minimum Pump Posted Octne Rting of 86 2 Cycle Outord Oil 25:1 (During rek-in) 50:1 (After rek-in) 12.0 L, 2.7 Imp Gl., 3.2 U.S. Gl L, 5.5 Imp Gl., 6.6 U.S. Gl R02 FEBRUARY 2003 Pge 1A-1

7 SPECIFICATIONS CYLINDER BLOCK Type Displcement (1994 Model) Silpower 10 Se Pro/Mrthon XR10/MAG10 15 Displcement (1995 nd Newer) Silpower 10 Se Pro/Mrthon XR/MAG/Viking Se Pro/Mrthon Two-Stoke Cycle Cross Flow 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in. 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) CYLINDER BORE Dimeter (Stndrd)(1994 Model) Silmte Silpower 10 Se Pro/Mrthon XR/Mg Dimeter (Stndrd)(1995 Model) Silpower 10 Se Pro/Mrthon XR/Mg/Viking Se Pro/Mrthon Tper/Out of Round Mximum Bore Type mm (2.125 in.) mm (2.125 in.) mm (2.125 in.) mm (2.125 in.) mm (2.125 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (2.375 in.) mm (0.004 in.) Cst Iron STROKE Length 45.7 mm (1.800 in.) CRANKSHAFT CONNECTING ROD PISTON REEDS Top Min Bering Journl Center Min Bering Journl Bottom Bll Bering Journl Connecting Rod Journl Runout Piston Pin End (I.D.) Crnkpin End (I.D.) Piston Type Ring End Gp Reed Stnd Open (Mximum) All Models Reed Stop Opening (Mximum) All Models 19.1 mm ( in.) 20.6 mm ( in.) 20.0 mm ( in.) 20.6 mm ( in.) mm (0.003 in.) 20.8 mm ( in.) 27.0 mm ( in.) Aluminum 0.25 mm mm (0.010 in in.) mm (0.007 in.) 7.54 mm (0.296 in.) Pge 1A R02 FEBRUARY 2003

8 GEAR HOUSING MID SECTION FUEL SYSTEM STARTING SYSTEM CHARGING SYSTEM Ger Rtio Gercse Cpcity Luricnt Type Forwrd Ger - Tooth count - Type Pinion Ger - Tooth count - Type Pinion Height Forwrd Ger Bcklsh Reverse Ger Bcklsh Wter Pressure With W.O.T (5000 Idle (750 RPM) W/O W.O.T (5000 Idle (750 RPM) Trnsom Height Short Shft Long Shft Extr Long Shft Steering Pivot Rnge Tilt Pin Positions Totl Tilt Angle Allowle Trnsom Thickness Fuel Recommended Gsoline Recommended Oil Gsoline/Oil Rtio Fuel Tnk Cpcity 6/8/9.9/9.9 Silpower XR/MAG/10 Se Pro/ Mrthon/15 Mnul Strt Electric Strt Strter Drw (Under Lod) (No Lod) Alterntor Output BLACK Sttor - 2 Mgnet Flywheel (8 Pole)(4 Pulses) RED Sttor - 4 Mgnet Flywheel (10 Pole)(5 Pulses) SPECIFICATIONS 2.0:1 200 ml (6.8 fl. oz.) Quicksilver Ger Lue Premium Blend 26 Spirl/Bevel 13 Spirl/Bevel Floting No Adjustment No Adjustment kp (5-7 PSI) kp ( PSI) kp (5 7 PSI) 0-7 kp (0 1 PSI) 38 cm (15 in.) 51 cm (20 in.) 63.5 cm (25 in.) Shllow Wter mm (2-3/8 in.) Pre-Mixed Gsoline nd Oil Automotive Led-Free 2 Cycle Outord Oil 25:1 (During Brek-In) 50:1 (After Brek-In) 12.0 L, 3.2 U.S. Gl L, 6.6 U.S. Gl. Recoil 12 Volt 55 Amperes 15 Amperes 4 Amp. ( RPM 6 mp ( RPM R02 FEBRUARY 2003 Pge 1A-3

9 SPECIFICATIONS BATTERY IGNITION SYSTEM Bttery Rting Type SPARK PLUG (1994) 6/8/9.9 10/15 SPARK PLUG GAP (1994) 6/8/9.9 10/15 SPARK PLUG (1995 AND NEWER) 6/8 9.9/10/15 SPARK PLUG GAP (1995 AND NEWER) 6/8 9.9/10/15 Firing Order Sttor High Speed Winding Sttor Low Speed Winding Diode Test Ignition Coil Resistnce: Primry Secondry Trigger 465 Mrine Crnking Amps (MCA) or 350 Cold Crnking Amps (CCA) Cpcitor Dischrge NGK BP8H-N-10 NGK BP8HS-15 NGK BPZ8H-N-10* 1.0 mm (0.040 in.) 1.5 mm (0.060 in.) NGK BP8H-N-10 NGK BP8HS-15 NGK BPZ8H-N-10* 1.0 mm (0.040 in.) 1.5 mm (0.060 in.) Ω (BLACK/WHITE - GROUND) Ω (BLACK/YELLOW - GROUND) Ω (BLACK/YELLOW - BLACK/WHITE) Ω Ω Ω NOTE: *Use NGK-BPZ8H-N-10 where rdio frequency interference (RFI) suppression is required. Pge 1A R02 FEBRUARY 2003

10 CARBURETOR SPECIFICATIONS TIMING SPECIFICATIONS Type Idle RPM (In Ger) /9.9 Silpower 10 Se Pro/Mrthon XR/MAG/Viking Wide Open Throttle RPM /9.9 Silpower 10 Se Pro/Mrthon XR/MAG/Viking Se Pro/Mrthon Idle Mixture Screw (Initil Setting) Flot Setting (All Models) Min Jet Thred size /9.9 Silpower 10 Se Pro/Mrthon XR/MAG /9.9 Silpower 10 Se Pro/Mrthon XR/MAG 10 15/Viking Se Pro/Mrthon Idle 6 8/8 Silmte 9.9/9.9 Silpower 10 Se Pro/Mrthon XR/MAG/Viking Se Pro/Mrthon Mximum 4500 RPM All Models SPECIFICATIONS Center Bowl, Integrl Fuel Pump 650 ± ± ± ± ± ± Refer to Section 3 for Specifics 25.4 mm (1 in.) Model Yer nd Newer BTDC ± 1 8 BTDC ± 1 8 BTDC ± 1 8 BTDC ± 1 8 BTDC ± 1 8 BTDC ± 1 8 BTDC ± 1 36 BTDC R02 FEBRUARY 2003 Pge 1A-5

11 SPECIFICATIONS Propeller Informtion Chrt - 6 HP Wide Open Throttle RPM: Recommended Trnsom Height: 15, 20, 25 Right Hnd Rottion Stndrd Ger Reduction: 2:1 Dimeter Pitch No. Of Bldes Mteril Typicl Gross Bot WGT. (LBS) Typicl Bot Length Speed Rnge (MPH) Propeller Prt Numer Alum. Up To 1400 Up To A Alum A12 9-1/4 7 3 Alum A12 9-3/4 6-1/2 3 Alum High Reverse Thrust A12 9-3/4 5-1/2 3 Alum Workot A12 Thrust Hu: Propeller Drive Hu: Diffuser Ring: (Forwrd) T (Aluminum) Propeller Informtion Chrt - 8 HP Wide Open Throttle RPM: Recommended Trnsom Height: 15, 20, 25 Right Hnd Rottion Stndrd Ger Reduction: 2:1 Dimeter Pitch No. Of Bldes Mteril Typicl Gross Bot WGT. (LBS) Typicl Bot Length Speed Rnge (MPH) Propeller Prt Numer Alum. Up To 1200 Up To Alum A12 9-1/4 7 3 Alum A12 9-3/4 6-1/2 3 Alum High Reverse Thrust A12 9-3/4 5-1/2 3 Alum Workot A12 Thrust Hu: Propeller Drive Hu: Diffuser Ring: (Forwrd) T (Aluminum) Pge 1A R02 FEBRUARY 2003

12 Propeller Informtion Chrt -9.9/10 HP Wide Open Throttle RPM: Recommended Trnsom Height: 15, 20, 25 Right Hnd Rottion Stndrd Ger Reduction: 2:1 SPECIFICATIONS Dimeter Pitch No. Of Bldes Mteril Typicl Gross Bot WGT. (LBS) Typicl Bot Length Speed Rnge (MPH) Propeller Prt Numer Alum. Up To 1200 Up To A Alum A12 9-1/4 7 3 Alum A12 9-3/4 6-1/2 3 Alum High Reverse A12 Thrust 9-3/4 5-1/2 3 Alum Workot A12 Thrust Hu: Propeller Drive Hu: Diffuser Ring: (Forwrd) T (Aluminum) Propeller Informtion Chrt -15 HP Wide Open Throttle RPM: Recommended Trnsom Height: 15, 20, 25 Right Hnd Rottion Stndrd Ger Reduction: 2:1 Dimeter Pitch No. Of Bldes Mteril Typicl Gross Bot WGT. (LBS) Typicl Bot Length Speed Rnge (MPH) Propeller Prt Numer /2 3 Alum. Up To 1000 Up To A Alum A Alum A12 9-1/4 7 3 Alum A12 9-3/4 6-1/2 3 Alum High Reverse Thrust A12 Thrust Hu: Propeller Drive Hu: Diffuser Ring: (Forwrd) T (Aluminum) R02 FEBRUARY 2003 Pge 1A-7

13 SPECIFICATIONS Mercury/Quicksilver Luricnts nd Selnts Tue Ref. No Description Needle Bering Assemly Luricnt Dielectric Grese Loctite 271 Thred Locker Loctite 567 PST Pipe Selnt Loctite Mster Gsket Kit 2 Cycle Premium Outord Oil Mercury Prt Numer Quicksilver Prt Numer A1 N/A A Q1 19 Perfect Sel Liquid Neoprene Bellows Adhesive N/A Q1 33 Loctite 680 Retining Compound Specil Luricnt A Q U-Joint nd Giml Bering Grese Loctite 222 Thred Locker Loctite 242 Thred Locker 4 Cycle 25W40 Engine Oil Premium Ger Luricnt High Performnce Ger Lue Engine Coupler Spline Grese A Q A Q A Q A Q A Q1 94 Anti-Corrosion Grese A Q C with Teflon A Q Stroke 10W30 Outord Oil Power Trim & Steering Fluid A Q A Q1 Pge 1A R02 FEBRUARY 2003

14 Tue Ref. # Description Mercury Prt Numer SPECIFICATIONS Quicksilver Prt Numer Premium Plus 2 Cycle TC-W3 Outord Oil A Q1 RTV 587 Silicone Seler Loctite 7649 Primer N Storge Sel Rust Inhiitor Q Corrosion Gurd Q W40 4-cycle Diesel Engine Oil Extended Life Antifreeze/Coolnt K Q K K1 123 Mrine Engine Coolnt NA A Fuel System Tretment nd Stilizer Concentrte Het Trnsfer Compound A Q Liquid Gsket NA 127 T442 Selnt NA Loctite 5900 Ultr Blck RTV Silicone Selnt Loctite Gsket Remover Seler Kit, Two Prt Epoxy 131 Anti-seize Compound K1 132 Torco MTF Ger Oil Optimol Longtime PD 2 Dexron III Automtic Trnsmission Fluid NA NA NA Otin Loclly Otin Loclly 135 Loctite 592 Otin Loclly Otin Loclly 136 Loctite Quick Tite Otin Loclly Otin Loclly 137 Isopropyl Alcohol Otin Loclly Otin Loclly 138 Hot Glue Otin Loclly Otin Loclly 139 Loctite 609 Otin Loclly Otin Loclly 140 Loctite 405 Otin Loclly Otin Loclly R02 FEBRUARY 2003 Pge 1A-9

15 SPECIFICATIONS Tue Ref. # Description Cyncrylte Adhesive 3M Permond #3M08155 Mercury Prt Numer Otin Loclly Otin Loclly Quicksilver Prt Numer Otin Loclly Otin Loclly 143 Loctite 262 Otin Loclly Otin Loclly 144 Loctite 290 Otin Loclly Otin Loclly 145 Loctite 598 RTV Selnt Otin Loclly 146 Insulting Compound Otin Loclly Pge 1A R02 FEBRUARY 2003

16 GENERAL INFORMATION & SPECIFICATIONS Section 1B Mintennce Tle of Contents MAINTENANCE 1 B Tle of Contents B-1 Gercse Luricnt Cpcity B-2 Specil Tools B-2 Inspection nd Mintennce Schedule B-3 Before Ech Use B-3 After Ech Use B-3 Every 100 Hours of Use or Once Yerly, Whichever Occurs First B-3 Every 300 Hours of Use or Three Yers. 1B-3 Flushing The Cooling System B-4 Fuel System B-5 Fuel Line Inspection B-5 Engine Fuel Filter B-5 Corrosion Control Anode B-6 Sprk Plug Inspection B-6 Bttery Inspection B-7 Fuse Replcement Electric Strt Remote Control Models B-7 Luriction Points B-8 Gercse Luriction B-10 Gercse Luricnt Cpcity B-10 Drining Gercse B-10 Checking Luricnt Level nd Refilling Gercse B-11 Storge Preprtions B-12 Fuel System B-12 Protecting Externl Engine Components 1B-12 Protecting Internl Engine Components. 1B-12 Gercse B-12 Positioning Outord for Storge B-13 Bttery Storge B R02 FEBRUARY 2003 Pge 1B-1

17 MAINTENANCE Gercse Luricnt Cpcity Specil Tools Ger Cse Rtio Cpcity 2.00: ml (6.8 fl. oz.) 1. Flushing ttchment 12612Q2 2. Grese gun Q2 Pge 1B R20 FEBRUARY 2003

18 Inspection nd Mintennce Schedule MAINTENANCE Before Ech Use After Ech Use 1. Check tht lnyrd stop switch stops the engine. 2. Visully inspect the fuel system for deteriortion or leks. 3. Check outord for tightness on trnsom. 4. Check steering system for inding or loose components. 5. Visully check steering link rod fsteners for proper tightness. 6. Check propeller ldes for dmge. 1. Flush out the outord cooling system if operting in slt or polluted wter. 2. Wsh off ll slt deposits nd flush out the exhust outlet of the propeller nd gercse with fresh wter if operting in slt wter. Every 100 Hours of Use or Once Yerly, Whichever Occurs First 1. Luricte ll luriction points. Luricte more frequently when used in slt wter. 2. Inspect nd clen sprk plugs. 3. Check fuel line filter for contminnts. 4. Check cruretor djustments, if required. 5. Check corrosion control nodes. Check more frequently when used in slt wter. 6. Drin nd replce gercse luricnt. 7. Luricte splines on the drive shft. 8. Electric strt models Inspect ttery. 9. Remote control models Check control cle djustments. 10. Remove engine deposits with Power Tune Engine Clener. 11. Check tightness of olts, nuts, nd other fsteners. 12. Clen fuel tnk pick up filter. Every 300 Hours of Use or Three Yers 1. Replce wter pump impeller (more often if overheting occurs or reduced wter pressure is noted).* These items should e serviced y n uthorized deler R02 FEBRUARY 2003 Pge 1B-3

19 MAINTENANCE Flushing The Cooling System Flush the internl wter pssges of the outord with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent uildup of deposits from clogging the internl wter pssges. Use Quicksilver ccessory or equivlent flushing ttchment. WARNING To void possile injury when flushing, remove the propeller. Refer to Propeller Replcement. 1. Remove propeller (refer to Propeller Replcement). Instll the flushing ttchment so the ruer cups fit tightly over the cooling wter intke holes. CAUTION Never strt or run your outord (even momentrily) without wter circulting through the cooling wter intke in the gercse to prevent dmge to the wter pump (running dry) or overheting of the engine. 2. Attch wter hose to the flushing ttchment. Turn on the wter nd djust the flow so wter is leking round the ruer cups to ensure the engine receives n dequte supply of cooling wter. 3. Strt the engine nd run it t idle speed in neutrl shift position. 4. Adjust wter flow if necessry so excess wter continues leking out from round the ruer cups to ensure the engine is receiving n dequte supply of cooling wter. 5. Check for stedy strem of wter flowing out of the wter pump indictor hole. Continue flushing the outord for 3 to 5 minutes, crefully monitoring wter supply t ll times. 6. Stop the engine, turn off the wter, nd remove the flushing ttchment. Reinstll the propeller. Pge 1B R20 FEBRUARY 2003

20 Fuel System MAINTENANCE Fuel Line Inspection Engine Fuel Filter REMOVAL WARNING Avoid serious injury or deth from gsoline fire or explosion. Crefully follow ll fuel system service instructions. Alwys stop the engine nd DO NOT smoke or llow open flmes or sprks in the re while servicing ny prt of the fuel system. Before servicing ny prt of the fuel system, stop engine nd disconnect the ttery. Drin the fuel system completely. Use n pproved continer to collect nd store fuel. Wipe up ny spillge immeditely. Mteril used to contin spillge must e disposed of in n pproved receptcle. Any fuel system service must e performed in well ventilted re. Inspect ny completed service work for sign of fuel lekge. Visully inspect the fuel line nd primer ul for crcks, swelling, leks, hrdness or other signs of deteriortion or dmge. If ny of these conditions re found, the fuel line or primer ul must e replced. Inspect the sight owl for wter ccumultion nd inspect the filter element for sediment. Clen filter s follows. 1. Hold onto the filter cover cover to prevent it from turning. 2. Turn off the sight owl. 3. Pull out the filter element nd wsh it with clening solvent. INSTALLATION 4. Push the open end of the filter element, into cover. 5. Plce the O-ring sel into the sight owl nd screw the sight owl hnd tight into the cover. c d -Filter cover -Filter c -O-ring d-sight owl 6. Visully inspect for fuel lekge round the sight owl y squeezing the primer ul until firm, forcing fuel into the sight owl R02 FEBRUARY 2003 Pge 1B-5

21 MAINTENANCE Corrosion Control Anode The outord hs corrosion control node instlled to the ger cse. An node helps protect the outord ginst glvnic corrosion y scrificing its metl to e slowly eroded insted of the outord metls. 1. The node requires periodic inspection especilly in slt wter which will ccelerte the erosion. To mintin this corrosion protection, lwys replce the node efore it is completely eroded. Never pint or pply protective coting on the node s this will reduce effectiveness of the node. -Anode Sprk Plug Inspection Inspect sprk plugs t the recommended intervls. 1. Remove the sprk plug leds y twisting the ruer oots slightly nd pull off. 2. Remove the sprk plugs to inspect nd clen. Replce sprk plug if electrode is worn or the insultor is rough, crcked, roken, listered or fouled. 3. Set the sprk plug gp. See Specifiction Chrt in Generl Informtion Section. 4. Before reinstlling sprk plugs, clen wy dirt on the sprk plug sets. Instll plugs finger tight, nd tighten 1/4 turn or torque to 27 N m (20 l. ft.). Pge 1B R20 FEBRUARY 2003

22 Bttery Inspection MAINTENANCE The ttery should e inspected t periodic intervls to ensure proper engine strting cpility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your ttery. 1. Turn off the engine efore servicing the ttery. 2. Add wter s necessry to keep the ttery full. 3. Mke sure the ttery is secure ginst movement. 4. Bttery cle terminls should e clen, tight, nd correctly instlled. Positive to positive nd negtive to negtive. 5. Mke sure the ttery is equipped with nonconductive shield to prevent ccidentl shorting of ttery terminls. Fuse Replcement Electric Strt Remote Control Models The electric strting circuit is protected from overlod y SFE 20 AMP fuse. If the fuse is lown, the electric strter motor will not operte. Locte nd correct the cuse of the overlod. If the cuse is not found, the fuse my low gin. Replce the fuse with fuse of the sme rting. 1. Replce with new SFE 20 AMP fuse. -SFE 20 mp fuse R02 FEBRUARY 2003 Pge 1B-7

23 MAINTENANCE Luriction Points 1. Luricte the following with 2-4-C with Teflon or Specil Luricnt 101. Tilt tue. Trnsom clmp screws. Swivel rcket. Steering friction djustment shft (tiller hndle models). -Swivel rcket -Steering friction djustment shft Pge 1B R20 FEBRUARY 2003

24 MAINTENANCE Tilt lock pins (Mke sure this pin is free to push in nd out). Luricte long the entire tilt pin trck on oth trnsom rckets. -Tilt lock pins -Tilt pin trck Luricte the throttle nd shft cles, moving components nd pivot loctions. WARNING The end of the steering cle must e fully retrcted into the outord tilt tue efore dding luricnt. Adding luricnt to steering cle when fully extended could cuse steering cle to ecome hydruliclly locked. An hydruliclly locked steering cle will cuse loss of steering control, possily resulting in serious injury or deth. Rotte steering wheel (if so equipped) to fully retrct the steering cle end into the outord tilt tue. Luricte steering cle through grese fitting nd cle end. -Grese fitting -Steering cle end R02 FEBRUARY 2003 Pge 1B-9

25 MAINTENANCE 2. Luricte the following with light weight oil. Steering Link Rod Pivot Points. 3. Luricte the following with nti-corrosion grese or 2-4-C with Teflon. Cot the entire propeller shft with luricnt to prevent the propeller hu from corroding to the shft. Gercse Luriction Gercse Luricnt Cpcity Drining Gercse Ger Cse Rtio Cpcity 2.00: ml (6.8 fl. oz.) When dding or chnging gercse luricnt, visully check for the presence of wter in the luricnt. If wter is present, it my hve settled to the ottom nd will drin out prior to the luricnt, or it my e mixed with the luricnt, giving it milky colored ppernce. If wter is noticed, hve the gercse checked y your deler. Wter in the luricnt my result in premture ering filure or, in freezing tempertures, will turn to ice nd dmge the gercse. Whenever you remove the fill/drin plug, exmine the mgnetic end for metl prticles. A smll mount of metl filings or fine metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte norml ger wer nd should e checked y n uthorized deler. Pge 1B R20 FEBRUARY 2003

26 1. Plce outord in verticl operting position. 2. Plce drin pn elow outord. 3. Remove fill/drin plug nd vent plug nd drin luricnt. MAINTENANCE -Fill/Drin Plug -Vent plug Checking Luricnt Level nd Refilling Gercse 1. Plce outord in verticl operting position. 2. Remove vent plug from vent hole. 3. Plce luricnt tue into the fill hole nd dd luricnt until it ppers t the vent hole. 4. Stop dding luricnt. Instll the vent plug nd seling wsher efore removing the luricnt tue. -Fill/Drin plug -Vent plug 5. Remove luricnt tue nd reinstll clened fill/drin plug nd seling wsher R02 FEBRUARY 2003 Pge 1B-11

27 MAINTENANCE Storge Preprtions Fuel System IMPORTANT: Gsoline contining lcohol (ethnol or methnol) cn cuse formtion of cid during storge nd cn dmge the fuel system. If the gsoline eing used contins lcohol, It is dvisle to drin s much of the remining gsoline s possile from the fuel tnk, remote fuel line, nd engine fuel system. Fill the fuel system (tnk, hoses, fuel pumps, nd fuel injection systems) with treted (stilized) fuel to help prevent formtion of vrnish nd gum. Proceed with following instructions. 1. Portle fuel tnk Pour the required mount of fuel system/stilizer concentrte (follow instructions on continer) into fuel tnk. Tip fuel tnk ck nd forth to mix stilizer with the fuel. 2. Permnently Instlled Fuel Tnk Pour the required mount of fuel system/stilizer concentrte (follow instructions on continer) into seprte continer nd mix with pproximtely one liter (one qurt) of gsoline. Pour mixture into fuel tnk. 3. Plce the outord in wter or connect flushing ttchment. Run the engine for ten minutes to llow treted fuel to fill the fuel system. Protecting Externl Engine Components 1. Luricte ll outord components listed in the Inspection nd Mintennce Schedule. 2. Touch up ny pint nicks. 3. Spry Corrosion Gurd on externl metl surfces (except corrosion control nodes). Protecting Internl Engine Components Gercse NOTE: Before performing Steps 1 nd 2, mke sure the fuel system hs een prepred for storge. 1. Plce the outord in wter or connect flushing ttchment. Strt the engine nd let it run in neutrl to wrm up. 2. With engine running t fst idle, stop the fuel flow y disconnecting the remote fuel line. When engine egins to stll, quickly spry Storge Sel Rust Inhiitor into cruretor until engine stops from lck of fuel. 3. Remove the sprk plugs nd inject five second spry of Storge Sel Rust Inhiitor round the inside of ech cylinder. 4. Rotte the flywheel mnully severl times to distriute the Storge Sel in the cylinders. Reinstll sprk plugs. Drin nd refill the gercse luricnt. Refer to Refilling Gercse Pge 1B R20 FEBRUARY 2003

28 Positioning Outord for Storge Bttery Storge Store outord in n upright position to llow wter to drin out of outord. CAUTION MAINTENANCE If outord is stored tilted up in freezing temperture, trpped cooling wter or rin wter tht my hve entered the propeller exhust outlet in the gercse could freeze nd cuse dmge to the outord. 1. Follow the ttery mnufcturers instructions for storge nd rechrging. 2. Remove the ttery from the ot nd check wter level. Rechrge if necessry. 3. Store the ttery in cool, dry plce. 4. Periodiclly check the wter level nd rechrge the ttery during storge R02 FEBRUARY 2003 Pge 1B-13

29

30 GENERAL INFORMATION GENERAL INFORMATION & SPECIFICATIONS Section 1C Generl Informtion Tle of Contents 1 C Tle of Contents C-1 Seril Numer Loction C-1 Conditions Affecting Performnce C-2 Wether C-2 Bot C-3 Engine C-4 Following Complete Sumersion C-5 Sumerged While Running C-5 Fresh Wter Sumersion C-5 Slt Wter Sumersion C-5 Propeller Selection C-6 Propeller Removl/Instlltion C-7 Compression Check C-9 Pinting Procedures C-9 Clening & Pinting Aluminum Propellers & Ger Housings C-9 Decl Appliction C-11 Decl Removl C-11 Instructions for Wet Appliction C-11 Seril Numer Loction The Outord seril numer is locted on the lower strord side of the engine lock. A seril numer is lso locted on the strord side of the swivel rcket. OGXXXXXX 19XX XXXX c -Seril numer -Model yer c -Model description d-yer mnufctured e -Certified Europe insigni e XX d R02 FEBRUARY 2003 Pge 1C-1

31 GENERAL INFORMATION Conditions Affecting Performnce Wether Rted hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondry Loss Due to Propeller Becoming To Lrge for Summer Horsepower RPM Drop Due to Wether ENGINE RPM Rted RPM It is known fct tht wether conditions exert profound effect on power output of internl comustion engines. Therefore, estlished horsepower rtings refer to the power tht the engine will produce t its rted RPM under specific comintion of wether conditions. Corportions interntionlly hve settled on doption of I.S.O. (Interntionl Stndrds Orgniztion) engine test stndrds, s set forth in I.S.O stndrdizing the computtion of horsepower from dt otined on the dynmometer. All vlues re corrected to the power tht the engine will produce t se level, t 30% reltive humidity, t 25 C (77 F) temperture nd rometric pressure of inches of mercury. Summer conditions of high temperture, low rometric pressure nd high humidity ll comine to reduce the engine power. This, in turn, is reflected in decresed ot speeds--s much s 3 or 5 Km per-hour (2 or 3 miles-per-hour) in some cses. (Refer to previous chrt.) Nothing will regin this speed for the oter, ut the coming of cool, dry wether. In pointing out the prcticl consequences of wether effects, n engine--running on hot, humid summer dy--my encounter loss of s much s 14% of the horsepower it would produce on dry, risk spring or fll dy. The horsepower, tht ny internl comustion engine produces, depends upon the density of the ir tht it consumes, nd in turn, this density is dependent upon the temperture of the ir, its rometric pressure nd wter vpor (or humidity) content. Accompnying this wether-inspired loss of power is second ut more sutle loss. At rigging time in erly spring, the engine ws equipped with propeller tht llowed the engine to turn within its recommended RPM rnge t full throttle. With the coming of the summer wether nd the consequent drop in ville horsepower, this propeller will, in effect, ecome too lrge. Consequently, the engine opertes t less thn its recommended RPM. Pge 1C R02 FEBRUARY 2003

32 Bot WEIGHT DISTRIBUTION BOTTOM GENERAL INFORMATION Due to the horsepower/rpm chrcteristics of n engine, this will result in further loss of horsepower t the propeller with nother decrese in ot speed. This secondry loss, however, cn e regined y switching to smller pitch propeller tht llows the engine to gin run t recommended RPM. For oters to relize optimum engine performnce under chnging wether conditions, it is essentil tht the engine hve the proper propeller to llow it to operte t or ner the top end of the recommended mximum RPM rnge t wide-open-throttle with norml ot lod. Not only does this llow the engine to develop full power, ut eqully importnt is the fct tht the engine lso will e operting in n RPM rnge tht discourges dmging detontion. This, of course, enhnces overll reliility nd durility of the engine. 1. Proper positioning of the weight inside the ot (persons nd ger) hs significnt effect on the ot s performnce, for exmple:. Shifting weight to the rer (stern) (1.) Generlly increses top speed. (2.) If in excess, cn cuse the ot to porpoise. (3.) Cn mke the ow ounce excessively in choppy wter. (4.) Will increse the dnger of the following - wve splshing into the ot when coming off plne.. Shifting weight to the front (ow) (1.) Improves ese of plning off. (2.) Generlly improves rough wter ride. (3.) If excessive, cn mke the ot veer left nd right (ow steer). For mximum speed, ot ottom should e nerly flt plne where it contcts the wter nd prticulrly stright nd smooth in fore-nd-ft direction. 1. Hook: Exists when ottom is concve in fore-nd-ft direction when viewed from the side. When ot is plning, hook cuses more lift on ottom ner trnsom nd llows ow to drop, thus gretly incresing wetted surfce nd reducing ot speed. Hook frequently is cused y supporting ot too fr hed of trnsom while huling on triler or during storge. 2. Rocker: The reverse of hook nd much less common. Rocker exists if ottom is convex in fore-nd-ft direction when viewed from the side, nd ot hs strong tendency to porpoise. 3. Surfce Roughness: Moss, rncles, etc., on ot or corrosion of outord s ger housing increse skin friction nd cuse speed loss. Clen surfces when necessry. WATER ABSORPTION It is impertive tht ll through hull fsteners e coted with qulity mrine seler t time of instlltion. Wter intrusion into the trnsom core nd/or inner hull will result in dditionl ot weight (reduced ot performnce), hull decy nd eventul structurl filure R02 FEBRUARY 2003 Pge 1C-3

33 GENERAL INFORMATION CAVITATION Engine DETONATION Cvittion is cused y wter vpor ules forming either from shrp edge or ngle on the ger cse or from n irregulrity in the propeller lde itself. These vpor ules flow ck nd collpse when striking the surfce of the propeller lde resulting in the erosion of the propeller lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Detontion in 2-cycle engine resemles the pinging herd in n utomoile engine. It cn e otherwise descried s tin-like rttling or plinking sound. Detontion is n explosion of n unurned portion of the fuel/ir chrge fter the sprk plug hs fired. Detontion cretes severe shock wves in the engine, nd these shock wves often find or crete wekness: The dome of piston, cylinder hed/gsket, piston rings or piston ring lnds, piston pin nd roller erings. A few of the most common cuses of detontion in mrine 2-cycle ppliction re s follows: Over-dvnced ignition timing. Use of low octne gsoline. Propeller pitch too high (engine RPM elow recommended mximum rnge). Len fuel mixture t or ner wide-open-throttle. Sprk plugs (het rnge too hot - incorrect rech - cross-firing). Indequte engine cooling (deteriorted cooling system). Comustion chmer/piston deposits (result in higher compression rtio). Detontion usully cn e prevented if: 1. The engine is correctly set up. 2. Diligent mintennce is pplied to comt the detontion cuses. Dmged Piston Resulting from Detontion Pge 1C R02 FEBRUARY 2003

34 Following Complete Sumersion GENERAL INFORMATION Sumerged While Running Fresh Wter Sumersion Slt Wter Sumersion When n engine is sumerged while running, the possiility of internl engine dmge is gretly incresed. If, fter engine is recovered nd with sprk plugs removed, engine fils to turn over freely when turning flywheel, the possiility of internl dmge (ent connecting rod nd/or ent crnkshft) exists. If this is the cse, the powerhed must e disssemled. 1. Recover engine s quickly s possile. 2. Remove cowling. 3. Flush exterior of outord with fresh wter to remove mud, weeds, etc. DO NOT ttempt to strt engine if snd hs entered powerhed, s powerhed will e severely dmged. Disssemle powerhed if necessry to clen components. 4. Remove sprk plugs nd get s much wter s possile out of powerhed. Most wter cn e eliminted y plcing engine in horizontl position (with sprk plug holes down) nd rotting flywheel. 5. Pour lcohol into cruretor throts (lcohol will sored wter). Agin rotte flywheel. 6. Turn engine over nd pour lcohol into sprk plug openings nd rotte flywheel. 7. Turn engine over (plce sprk plug openings down) nd pour engine oil into throt of cruretors while rotting flywheel to distriute oil throughout crnkcse. 8. Agin turn engine over nd pour pproximtely one tespoon of engine oil into ech sprk plug opening. Agin rotte flywheel to distriute oil in cylinders. 9. Remove nd clen cruretors nd fuel pump ssemly. 10. Dry ll wiring nd electricl components using compressed ir. 11. Disssemle the engine strter motor nd dry the rush contcts, rmture nd other corrodile prts. 12. Reinstll sprk plugs, cruretors nd fuel pump. 13. Attempt to strt engine, using fresh fuel source. If engine strts, it should e run for t lest one hour to eliminte ny wter in engine. 14. If engine fils to strt, determine cuse (fuel, electricl or mechnicl). Engine should e run within 2 hours fter recovery of outord from wter, or serious internl dmge my occur. If unle to strt engine in this period, disssemle engine nd clen ll prts. Apply oil s soon s possile. Due to the corrosive effect of slt wter on internl engine components, complete disssemly is necessry efore ny ttempt is mde to strt the engine R02 FEBRUARY 2003 Pge 1C-5

35 GENERAL INFORMATION Propeller Selection For in-depth informtion on mrine propellers nd ot performnce see your Authorized Deler for the illustrted Wht You Should Know Aout Quicksilver Propellers... nd Bot Performnce Informtion (Prt No ). For est ll round performnce from your outord/ot comintion, select propeller tht llows the engine to operte in the upper hlf of the recommended full throttle RPM rnge with the ot normlly loded (refer to Section 1A - Specifictions). This RPM rnge llows for etter ccelertion while mintining mximum ot speed. If chnging conditions cuse the RPM to drop elow the recommended rnge (such s wrmer, more humid wether, opertion t higher elevtions, incresed ot lod or dirty ot ottom/ger cse) propeller chnge or clening my e required to mintin performnce nd ensure the outord s durility. Check full-throttle RPM using n ccurte tchometer with the engine trimmed out to lnced-steering condition (steering effort equl in oth directions) without cusing the propeller to rek loose. Refer to Mercury Precision Prts/Quicksilver Accessory Guide for complete list of ville propellers. 1. Select propeller tht will llow the engine to operte t or ner the top of the recommended full throttle RPM rnge (refer to Section 1A - Specifictions preceding) with norml lod. Mximum engine speed (RPM) for propeller selection exists when ot speed is mximum nd trim is minimum for tht speed. (High RPM, cused y n excessive trim ngle, should not e used in determining correct propeller.) Normlly, there is RPM chnge etween propeller pitches. 2. If full throttle opertion is elow the recommended rnge, the propeller must e chnged to one with lower pitch to prevent loss of performnce nd possile engine dmge. 3. After initil propeller instlltion, the following common conditions my require tht the propeller e chnged to lower pitch:. Wrmer wether nd gret humidity will cuse n RPM loss.. Operting in higher elevtion cuses n RPM loss. c. Operting with dmged propeller or dirty ot ottom or ger housing will cuse n RPM loss. d. Opertion with n incresed lod (dditionl pssengers, equipment, pulling skiers, etc.). Pge 1C R02 FEBRUARY 2003

36 Propeller Removl/Instlltion GENERAL INFORMATION WARNING If the propeller shft is rotted while the engine is in ger, there is the possiility tht the engine will crnk over nd strt. To prevent this type of ccidentl engine strting nd possile serious injury cused from eing struck y rotting propeller, lwys shift outord to neutrl position nd remove sprk plug leds when you re servicing the propeller. 1. Shift outord to neutrl position. N N 2. Remove the sprk plug leds to prevent engine from strting. 3. Plce lock of wood etween ger cse nd propeller to hold propeller nd remove propeller nut. 4. Pull propeller stright off shft. If propeller is seized to the shft nd cnnot e removed, hve the propeller removed y n uthorized deler. 5. Cot the propeller shft with Anti-Corrosion Grese or 2-4-C with Teflon. IMPORTANT: To prevent the propeller hu from corroding nd seizing to the propeller shft, especilly in slt wter, lwys pply cot of the recommended luricnt to the entire propeller shft t the recommended mintennce intervls nd lso ech time the propeller is removed R02 FEBRUARY 2003 Pge 1C-7

37 GENERAL INFORMATION 6. Instll forwrd thrust hu, propeller, rer thrust hu nd propeller nut onto the shft. d c -Forwrd thrust hu -Propeller c -Rer thrust hu d-propeller nut 7. Plce lock of wood etween ger cse nd propeller nd tighten propeller nut. Pge 1C R02 FEBRUARY 2003

38 Compression Check GENERAL INFORMATION Norml Compression (All Models) kp ( psi) Pinting Procedures 1. Remove sprk plugs. 2. Instll compression guge in sprk plug hole. 3. Hold throttle plte t W.O.T. 4. Crnk the engine over until the compression reding peks. 5. Check nd record compression of ech cylinder. The difference in compression redings etween ech cylinder should not vry more thn 15%. If compression vries y more thn 15% or compression for oth cylinders is less thn 685kP (100psi), the powerhed should e disssemled nd inspected. 6. Compression check is importnt ecuse n engine with low or uneven compression cnnot e tuned successfully to give pek performnce. It is essentil, therefore, tht improper compression e corrected efore proceeding with n engine tuneup. 7. Cylinder scoring: If powerhed shows ny indiction of overheting, such s discolored or scorched pint, visully inspect cylinders for scoring or other dmge. Refer to Section 4 Powerhed. Clening & Pinting Aluminum Propellers & Ger Housings PROPELLERS WARNING Avoid serious injury from flying deris. Avoid serious injury from irorne prticles. Use eye nd rething protection with proper ventiltion. 1. Snd the entire re to e pinted with 3M 120 Reglite Polycut or corse Scotch-Brite, disc or elts. 2. Fether edges of ll roken pint edges. Try not to snd through the primer. 3. Clen the surfce to e pinted using PPG Industries DX330 Wx nd Grese Remover or equivlent (Xylene or M.E.K.). 4. If re metl hs een exposed, use Mercury/Quicksilver s Light Gry Primer. 5. Allow minimum of 1 hour dry time nd no more thn 1 week efore pplying the finish cot. 6. Apply the finish cot using Mercury/Quicksilver s EDP Propeller Blck R02 FEBRUARY 2003 Pge 1C-9

39 GENERAL INFORMATION GEAR HOUSINGS The following procedures should e used in refinishing ger housings. This procedure will provide the most durle pint system ville in the field. The mterils recommended re of high qulity nd pproximte mrine requirements. The following procedure will provide repint jo tht compres with properly pplied fctory pint finish. It is recommended tht the listed mterils e purchsed from locl Ditzler Automotive Finish Supply Outlet. The minimum pckge quntity of ech mteril shown following is sufficient to refinish severl ger housings. Procedure: 1. Wsh ger housing with muritic cid se clener to remove ny type of mrine growth, nd rinse with wter, if necessry. 2. Wsh ger housing with sop nd wter, then rinse. 3. Snd listered re with 3M 180 grit sndpper or P180 Gold Film Disc to remove pint listers only. Fether edge ll roken pint edges. 4. Clen ger housing thoroughly with (DX-330) wx nd grese remover. 5. Spot repir surfces where re metl is exposed with (DX-503) lodine tretment. IMPORTANT: Do not use ny type of erosol spry pints s the pint will not properly dhere to the surfce nor will the coting e sufficiently thick to resist future pint listering. 6. Mix epoxy chromte primer (DP-90LF) with equl prt ctlyst (DP-402LF) per mnufcturers instructions, llowing proper induction period for permetion of the epoxy primer nd ctlyst. 7. Allow minimum of one hour drying time nd no more thn one week efore top coting ssemlies. 8. Use Ditzler Urethne DU9300 for Mercury Blck, DU34334 for Mriner Grey, nd DU35466 for Force Chrcol, nd DU33414 for Se Ry White. Ctlyze ll three colors with Ditzler DU5 ctlyst mixed 1:1 rtio. Reduce with solvents per Ditzler lel. CAUTION Be sure to comply with instructions on the lel for ventiltion nd respirtors. Using spry gun, pply one hlf to one mil even film thickness. Let dry, flsh off for five minutes nd pply nother even cot of one hlf to one mil film thickness. This urethne pint will dry to the touch in mtter of hours, ut will remin sensitive to scrtches nd rsions for few dys. 9. The type of spry gun used will determine the proper reduction rtio of the pint. IMPORTANT: Do not pint scrificil zinc trim t or zinc node. 10. Cut out crdord plug for trim t pocket to keep pint off of mting surfce to mintin good continuity circuitry etween trim t nd ger housing. Pge 1C R02 FEBRUARY 2003

40 Decl Appliction GENERAL INFORMATION Decl Removl 1. Mrk decl loction efore removl to ssure proper lignment of new decl. 2. Crefully soften decl nd decl dhesive with het gun or het lower while removing old decl. 3. Clen decl contct re with 1:1 mixture of isopropyl lcohol nd wter. 4. Thoroughly dry decl contct re nd check for completely clened surfce. Instructions for Wet Appliction NOTE: The following decl instlltion instructions re provided for wet instlltion. All decls should e pplied wet. TOOLS REQUIRED 1. Plstic Squeegee* 2. Stick Pin 3. Dish Wshing liquid detergent without mmoni. Do not use sop tht contins petroleum sed solvents. ** Automotive ody filler squeegee. SERVICE TIP: Plcement of decls using the wet ppliction will llow time to position decl. Red entire instlltion instructions on this technique efore proceeding. TEMPERATURE IMPORTANT: Instlltion of vinyl decls should not e ttempted while in direct sunlight. Air nd surfce temperture should e etween 15 C (60 F) nd 38 C (100 F) for est ppliction. SURFACE PREPARATION IMPORTANT: Do not use sop or ny petroleum sed solvents to clen ppliction surfce. Clen entire ppliction surfce with mild dish wshing liquid nd wter. Rinse surfce thoroughly with clen wter R02 FEBRUARY 2003 Pge 1C-11

41 GENERAL INFORMATION DECAL APPLICATION 1. Mix 16 ml ( 1 / 2 ounce) of dish wshing liquid in 4 literes (1 gllon) of cool wter to use s wetting solution. NOTE: Leve protective msking, if present, on the fce of decl until finl steps of decl instlltion. This will ensure tht the vinyl decl keeps it s shpe during instlltion. 2. Plce the decl fce down on clen work surfce nd remove the pper cking from dhesive side of decl. 3. Using spry ottle, flood the entire dhesive side of the decl with the pre-mixed wetting solution. 4. Flood re where the decl will e positioned with wetting solution. 5. Position pre-wetted decl on wetted surfce nd slide into position. 6. Strting t the center of the decl, lightly squeegee out the ir ules nd wetting solution with overlpping strokes to the outer edge of the decl. Continue going over the decl surfce until ll wrinkles re gone nd dhesive onds to the cowl surfce. 7. Wipe decl surfce with soft pper towel or cloth. 8. Wit minutes. 9. Strting t one corner, crefully nd slowly pull the msking off the decl surfce t 180 ngle. NOTE: To remove ny remining ules, pierce the decl t one end of the ule with stick pin nd press out the entrpped ir or wetting solution with your thum (moving towrd the puncture). Pge 1C R02 FEBRUARY 2003