SPECIFICATIONS

IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Master Specifications . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants and
Propeller Information Charts . . . . . . . . . . . . . . . . 1A-7 Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10

Master Specifications
Model 75/90/115 DFI
HORSEPOWER Model 75 55.2 kw (75)
(HP) Model 90 66.2 kw (90)
Model 115 84.6 kw (115)
Full Throttle RPM (75/90/115) 5000 - 5750

Idle RPM (In Gear) (75/90/115) 625 – 675

RPM Limiter
Model 75/90/115 5800
OUTBOARD Model 75/90/115
WEIGHT – 20 in. (50.8cm) Shaft 163.3 kg (360.0 lbs.)
– 25 in. (63.5cm) Shaft 168.7 kg (372.0 lbs.)
CYLINDER Type 3 Cylinder, Two Cycle, Direct Injected
BLOCK Displacement 1523.5 cc (92.9 cu. in.) In-line
Thermostat 61°C (142°F)
Water Pressure
Idle 20.6 – 41.3 kPa (3 – 6 psi)
Poppet Valve Opening 48.3 – 62.1 kPa (7 – 9 psi)
W.O.T. 75.8 – 96.5 kPa (11 – 14 psi)
STROKE Length (All Models) 76.2mm (3.00 in.)
CYLINDER Diameter (Std) 92.1131 mm (3.6265 in.)
BORE Diameter 0.038 mm (0.015 in.) Over- 92.4941 mm (3.6415 in.)
size
Diameter 0.076 mm (0.030 in.) Over- 92.875 mm (3.6565 in.)
size
Taper/Out of Round/Wear Maximum 0.076 mm (0.003 in.)
Bore Type Cast Iron
Compression 620 – 758 kPa (90 – 110 psi)♦
CRANKSHAFT Maximum Runout 0.0508 mm (0.002 in.)

♦When performing cylinder compression test, place lanyard switch in the OFF position to pre-
vent operation of direct injectors or remove fuse controlling fuel and direct injectors.

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SPECIFICATIONS

Model 75/90/115 DFI

PISTON Piston Type Aluminum
Diameter Standard 91.9226 mm ± 0.0127 mm (3.619 in. ±
.0005 in.)
Diameter 0.038 mm (0.015 in.) Over- 92.3036 mm ± 0.0127 mm
size (3.634 in. ± 0.0005 in.)
92.6846 mm ± 0.0127 mm
Diameter 0.076 mm (0.030 in.) Over- (3.649 in. ± 0.0005 in.)
size
PISTON
DIAMETER 91.9226 mm ± .0127 mm
(3.619 in. ± .0005 in.)Using a microme-
Dimension
“A” at Right ter, measure dimension “A” at location
Angle (90°) shown. Dimension “A” should be 3.619
to Piston Pin in. ± .0005 for a STANDARD size piston
(new) Dimension “A” will be 0.001 -
1.0 in. 0.0015 less if coating is worn off piston
25.4 mm
(used)

REEDS Reed Stand 0pen (Max.) 0.50 mm (0.020 in.)

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Model 75/90/115 DFI

Gear Ratio 2.33:1
Gearcase Capacity 655 ml (22.5 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 28 Spiral/Bevel
Pinion Gear
Number of Teeth 12 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Pinion Gear Locating Tool (91-12349A2)
MODEL 75/90 Flat #8
GEARCASE Disc #3

Forward Gear Backlash 0.012-0.019 in. (0.30-0.48mm)

Backlash Indicator Tool (91-78473)
Mark #4
Water Pressure
@ 750 RPM (Idle) 20.6 - 41.3 kPa (3.0-6.0 psi)
@ 5750 RPM (WOT) 75.8 - 96.5 kPa (11.0-14.0 psi)
Prop Shaft Runout (Maximum) 0.23 mm (0.009 in.)
Gear Ratio 2.07:1
Gearcase Capacity 655 ml (22.5 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 29 Spiral/Bevel
Pinion Gear
Number of Teeth 14 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Pinion Gear Locating Tool (91-12349A2)
MODEL 115 Flat #8
GEARCASE Disc #3

Forward Gear Backlash 0.33-0.48 mm (0.013-0.019 in.)

Backlash Indicator Tool (91-19660--1)
Mark #1
Water Pressure
@ 750 RPM 20.6 - 41.3 kPa (3 - 6 psi)
@ 5750 RPM (WOT) 75.8 - 96.5 kPa (11 - 14 psi)
Prop Shaft Runout (Maximum) 0.23 mm (0.009 in.)

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SPECIFICATIONS

Model 75/90/115 DFI

MID Power Trim (Total Tilt Range) 75°
SECTION Power Trim (Tilt Range) 20°
Maximum amount of acceptable leak
down in 24 hrs. 25.4 mm (1 in.)
Steering Pivot Range 60°
Tilt Pin Adjustment Positions 5
Allowable Transom Thickness 6.03 cm (2-3/8 in.)
DIRECT Injectors
INJECTION – Quantity 3
– Injectors are Crank Angle Driven
by ECM
– #1 Cylinder Fuel Injector RED/BLUE + BROWN/PINK Leads
– #1 Cylinder Air Injector RED/BLUE + BROWN/WHT Leads
– #2 Cylinder Fuel Injector RED/BLUE + RED/PINK Leads
– #2 Cylinder Air Injector RED/BLUE + RED/WHT Leads
– #3 Cylinder Fuel Injector RED/BLUE + ORANGE/PINK Leads
– #3 Cylinder Air Injector RED/BLUE + ORANGE/WHT Leads

Fuel Line Pressure @ Injectors 744.6 ± 13.8 kPa (108 ± 2 psi)*

Air Pressure 648.1 ± 13.8 kPa (94 ± 2 psi)*
High and Low Pressure Electric Fuel
Pump Amperage Draw 10 - 14 Amperes

Low Pressure Electric Fuel Pump 1 - 2 Amperes

Output 165.5 - 179.3 kPa (24 - 26 psi)

Fuel Pump Ohm Resistance 1.0 – 1.8 Ω

Fuel Injector Ohm Resistance 1.8 ± 0.1 Ω
Direct Injector Ohm Resistance 1.3 ± 0.3 Ω
Fuel/Air Differential 96.5 ± 6.9 kPa (14.0 ± 1.0 psi)

*The fuel/air differential must remain at 96.5 kPa (14.0 psi). If this differential is not main-
tained, the engine will exhibit poor running characteristics; i.e. – poor idling, spark plug
fouling etc. Example: if the fuel pressure is 744.6 kPa (108.0 psi), air pressure should be
648.1 kPa (94.0 psi).

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 SPECIFICATIONS

Model 75/90/115 DFI

FUEL Fuel Gasoline with Oil Injection
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil TC-W3 Premium Plus or Optimax 2
Cycle Outboard Oil
Gasoline/Oil Ratio
– @ Idle 300 - 400:1
– @ WOT 50:1
Fuel Pressure

Crankcase Pump
– @ Idle Normal – 13.7 - 20.5 kPa (2-3 psi)
Minimum – 6.8 kPa (1 psi)
– @ WOT Normal – 41.0 - 54.8 kPa (8-10 psi)
Maximum – 68.5 kPa (10 psi)
Minimum – 27.4 kPa (4 psi)
STARTING Starter Draw (Under Load) 150 Amperes
SYSTEM Starter Draw (No Load) 60 Amperes
Minimum Brush Length 65.4 mm (0.25 in.)
Battery Rating* 1000 (Minimum) Marine Cranking Amps
750 (Minimum) Cold Cranking Amps
105 (Minimum) Ampere Hours
IGNITION Type Digital Inductive
SYSTEM Firing Order 1-2-3
Spark Plug Type NGK PZFR6H
Spark Plug Gap 0.8 mm (0.030 in.)
Maximum Timing Not Adjustable; Controlled by ECM
Idle Timing Not Adjustable; Controlled by ECM
Throttle Position Sensor
@ Idle 0.17 - 1.05 vdc
@ W.O.T 3.76 - 4.64 vdc
Crank Position Sensor
Air Gap 0.635 mm - 1.01 mm
(0.025 in. - 0.040 in.)
CHARGING Alternator Output (Regulated) 32 - 38 Amperes @ 2000 RPM @ Bat-
SYSTEM tery
52 - 60 Amperes @ 2000 RPM @
Alternator
Brush Length Standard Exposed Length: 10.5 mm
(0.413 in.)
Minimum. Exposed Length: 1.5 mm
(0.059 in.)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw** 0.585 mA (Ignition Switch Off)
150.0 mA (Ignition Switch On)

♦Electric fuel pump pressure, if used in conjunction with engine mechanical fuel pump, must be limited to
no more than 27.4 kPa (4 psi).
*Refer to Section 2B for additional information concerning battery selection.
**All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in
the OFF position and an amperage draw of not more than 350.0 mA with ignition key in the ON position.

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SPECIFICATIONS

Model 75/90/115 DFI

Air Compressor Type Reciprocating Piston
(1.14 to 1 ratio with engine RPM)
Compressor Output @ Idle – 648.1 kPa (94 psi)
Cylinder Block Displacement 60 cc (3.66 cu. in.)
Cylinder Bore Diameter (Standard) 52.0 mm (2.0472 in.)
Taper/Out of Round/Wear Maxi-
mum 0.025 mm (0.001 in.)
Bore Type Cast Iron
Stroke Length 27.9 mm (1.100 in.)
Piston Piston Type Aluminum
Piston Diameter 51.95 ± 0.010 mm
(2.0453 ± .0004 in.)
Dimen-
sion “A”
at Right
Angle
(90°) to
Piston Pin
0.300 in.

Piston Ring End Gap

Top Ring 0.15 - 0.30 mm
(0.0059 - 0.0118 in.)
Middle Ring 0.15 - 0.30 mm
(0.0059 - 0.0118 in.)
Bottom Ring 0.10 - 0.35 mm
(0.0039 - 0.014 in.)
Reeds Reed Stand Open 0.25 mm (0.010 in.)

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 SPECIFICATIONS

Propeller Information Charts

Optimax 75
Wide Open Throttle RPM : 5000-5750
Recommended Transom Heights : 20 in. (50.8 cm) and 25 in. (63.5 cm)
Right Hand Rotation Standard
Gear Reduction : 2.33:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13-1/2″ 26″ 3 Steel Up to 1500 Up to 16′ 44-57 48-16996A46
13-1/2″ 24″ 3 Steel Up to 1800 Up to 17′ 40-51 48-16994A46
12-1/2″ 23″ 3 Alum 1400-1900 16-17′ 38-48 48-77350A45
13-1/2″ 22″ 3 Steel 1500-2000 16-17′ 35-46 48-16992A46
12-3/4″ 21″ 3 Alum 1600-2200 16-18′ 33-43 48-77348A45
13-1/4″ 20″ 3 Steel 1800-2400 16-18′ 31-40 48-16990A46
13″ 19″ 3 Alum 1900-2600 17-19′ 29-38 48-77346A45
13″ 18″ 3 Steel 2100-2900 17-19′ 27-35 48-16988A46
13-1/4″ 17″ 3 Alum 2300-3200 18-20′ 25-32 48-77344A45
13-1/8″ 16″ 3 Steel 2500-3500 19-21′ 23-31 48-16986A46
13-1/4″ 16″ 3 Alum 2500-3500 19-21′ 23-31 48-854360A45
13-3/4″ 15″ 3 Alum 2800-3900 20-22′ 21-29 48-77342A45
13-3/8″ 14″ 3 Steel 3100-4400 21-23′ 19-26 48-17314A46
14″ 13″ 3 Alum 3500-5000 21-24′ 15-23 48-77340A45
14″ 12″ 3 Steel 4000+ work boat 11-19 48-17312A46
14″ 11″ 3 Alum 4500+ pontoon/work 1-16 48-77338A45

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SPECIFICATIONS

Propeller Information Charts

Optimax 90
Wide Open Throttle RPM : 5000-5750
Recommended Transom Heights : 20 in. (50.8 cm) and 25 in. (63.5 cm)
Right Hand Rotation Standard
Gear Reduction : 2.33:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13-1/2″ 26″ 3 Steel Up to 1900 Up to 16′ 44-57 48-16996A46
13-1/2″ 24″ 3 Steel Up to 2100 Up to 17′ 40-51 48-16994A46
12-1/2″ 23″ 3 Alum 1700-2300 16-17′ 38-48 48-77350A45
13-1/2″ 22″ 3 Steel 1800-2400 16-18′ 35-46 48-16992A46
12-3/4″ 21″ 3 Alum 1900-2600 16-18′ 33-43 48-77348A45
13-1/4″ 20″ 3 Steel 2100-2800 17-19′ 31-40 48-16990A46
13″ 19″ 3 Alum 2200-3100 17-20′ 29-38 48-77346A45
13″ 18″ 3 Steel 2400-3400 18-20′ 27-35 48-16988A46
13-1/4″ 17″ 3 Alum 2600-3800 19-21′ 25-32 48-77344A45
13-1/8″ 16″ 3 Steel 2900-4200 20-22′ 23-31 48-16986A46
13-1/4″ 16″ 3 Alum 2900-4200 20-22′ 23-31 48-854360A45
13-3/4″ 15″ 3 Alum 3300-4600 21-23′ 21-29 48-77342A45
13-3/8″ 14″ 3 Steel 3600-5200 21-24′ 19-26 48-17314A46
14″ 13″ 3 Alum 4000-5900 22-25′ 15-23 48-77340A45
14″ 12″ 3 Steel 5000+ work boat 11-19 48-17312A46
14″ 11″ 3 Alum 5500+ pontoon/work 1-16 48-77338A45

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 SPECIFICATIONS

Optimax 115
Wide Open Throttle RPM : 5000-5750
Recommended Transom Heights : 20 in. (50.8 cm), 25 in. (63.5 cm)
Right Hand Rotation Standard
Gear Reduction : 2.07:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13-1/2″ 26″ 3 Steel Up to 1800 Up to 17′ 51-65 48-16996A45
13-1/2″ 24″ 3 Steel Up to 2100 Up to 18′ 45-58 48-16994A45
12-1/2″ 23″ 3 Alum 1800-2400 16-18′ 43-55 48-77350A45
13-1/2″ 22″ 3 Steel 1900-2600 16-18′ 40-52 48-16992A45
12-3/4″ 21″ 3 Alum 2100-2800 16-19′ 38-49 48-77348A45
13-1/4″ 20″ 3 Steel 2200-3100 17-19′ 36-46 48-16990A45
13″ 19″ 3 Alum 2400-3400 17-19′ 33-43 48-77346A45
13″ 18″ 3 Steel 2600-3700 18-20′ 31-40 48-16988A45
13-1/4″ 17″ 3 Alum 2900-4100 18-21′ 29-37 48-77344A45
13-1/8″ 16″ 3 Steel 3200-4500 19-22′ 26-34 48-16986A45
13-3/4″ 15″ 3 Alum 3600-5000 19-23′ 24-31 48-77342A45
13-3/8″ 14″ 3 Steel 4000-5700 21-25′ 22-29 48-17314A45
14″ 13″ 3 Alum 4400-6400 22-26′ 20-27 48-77340A45
14″ 12″ 3 Steel 5200+ pontoon 17-23 48-17312A45
14″ 11″ 3 Alum 6000+ pontoon/work 15-20 48-77338A45
14″ 10″ 3 Steel 8000+ houseboat/ 1-18 48-17310A45
work

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SPECIFICATIONS

Mercury/Quicksilver Lubricants, Sealants, and Adhesives

Tube Mercury Part Quicksilver Part
Description
Ref. No. Number Number
Needle Bearing
4 92-802868A1 N/A
Assembly Lubricant
6 Dielectric Grease 92-823506-1 92-823506-1
Loctite 271
7 92-809819 92-809819
Threadlocker
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2-cycle Premium
14 92-802813A1 92-802813Q1
Outboard Oil
19 Perfect Seal 92-34227-1 92-34227-1

25 Liquid Neoprene 92-25711-3 92-25711-3

27 Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining
33 92-809833 92-809833
Compound
34 Special Lubricant 101 92-802865A1 92-802865Q1
U-joint and Gimbal
42 92-802870A1 92-802870Q1
Bearing Grease
Loctite 222
51 92-809818 92-809818
Threadlocker
Loctite 242
66 92-809821 92-809821
Threadlocker
4-cycle 25W40
79 92-802837A1 92-802837Q1
Engine Oil
Premium Gear
82 92-802846A1 92-802846Q1
Lubricant
High Performance
87 92-802854A1 92-802854Q1
Gear Lube
Engine Coupler
91 92-802869A1 92-802869Q1
Spline Grease
Anti-Corrosion
94 92-802867A1 92-802867Q1
Grease
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
Power Trim and
114 92-802880A1 92-802880Q1
Steering Fluid

Page 1A-10 90-889785 APRIL 2003

 SPECIFICATIONS

Tube Mercury Part Quicksilver Part

Description
Ref. No. Number Number
Premium Plus
115 2-cycle TC-W3
92-802824A1 92-802824Q1
Outboard Oil
RTV 587 Silicone
116 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust
119 92-802878-56 92-802878Q56
Inhibitor
120 Corrosion Guard 92-802878-55 92-802878Q55
15W40 4-cycle Diesel
121 92-877695K1 92-877695Q1
Engine Oil
Extended Life
122 92-877770K1 92-877770K1
Antifreeze/Coolant
Marine Engine
123 NA 92-813054A2
Coolant
Fuel System
124 Treatment and 92-802876A1 92-802876Q1
Stabilizer Concentrate
Heat Transfer
125 92-805701-1 NA
Compound
126 Liquid Gasket 92-808137 NA
127 T442 Sealant 92-862258 NA
Loctite 5900 Ultra
128 Black RTV Silicone 92-809826 NA
Sealant
Loctite Gasket
129 92-809828-1 NA
Remover
Sealer Kit, Two Part
130 NA 92-65150-1
Epoxy
131 Anti-seize Compound 92-881091K1 NA
Torco MTF Gear Oil
132 (For Dry Sump 92-849684-1 NA
Drives)
Optimol Longtime PD
133 92-848767 NA
2
Dexron III Automatic
134 Obtain Locally Obtain Locally
Transmission Fluid
135 Loctite 592 Obtain Locally Obtain Locally
136 Loctite Quick Tite Obtain Locally Obtain Locally
137 Isopropyl Alcohol Obtain Locally Obtain Locally
138 Hot Glue Obtain Locally Obtain Locally
139 Loctite 609 Obtain Locally Obtain Locally

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SPECIFICATIONS

Tube Mercury Part Quicksilver Part

Description
Ref. No. Number Number
1
140 Loctite 405 Obtain Locally Obtain Locally
Cyanacrylate
1
141 Obtain Locally Obtain Locally
Adhesive
3M Permabond
142 Obtain Locally Obtain Locally
#3M08155
143 Loctite 262 Obtain Locally Obtain Locally
144 Loctite 290 Obtain Locally Obtain Locally
Loctite 598 RTV
145 Obtain Locally Obtain Locally
Sealant
146 Insulating Compound 92-41669-1 NA
Hydraulic Helm
147 NA 92-862014Q1
Steering Fluid
Optimol White T
148 92-847206 NA
Grease
2-cycle Performance
149 92-813743A2 NA
Blend Outboard Oil

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