Service Manual: © MARCH 2016, Mercury Marine. All Rights Reserved. 90-8M0107213

X5
Service Manual
© MARCH 2016, Mercury Marine. All Rights Reserved. 90-8M0107213

Notice to Users of This Manual
Throughout this publication, warnings, cautions, and notices (accompanied by the International HAZARD Symbol !
) are
used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when
performing the service, plus common sense operation, are major accident prevention measures.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
This manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and
company service personnel when servicing the products described herein. We reserve the right to make changes to this
manual without prior notification.
It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they
have been trained in the recommended service procedures of MotorGuide products, including the use of mechanics’ common
hand tools and the special MotorGuide or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or
results of each method. Therefore, when using a service procedure and/or tool that is not recommended by the manufacturer,
be completely satisfied that neither your personal or product safety is endangered.
All information, illustrations, and specifications contained in this manual are based on the latest product information available at
the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service
these products.
Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent
information concerning the products described in this manual.
Precautions
It should be kept in mind, while working on the product, that the electrical systems are capable of violent and damaging short
circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or
touched by the mechanic, the battery cables should be disconnected at the battery.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as those
removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts
use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners
can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the
same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a
replacement that matches the original.
Replacement Parts
Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as
a result.
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected motor starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing motor components.
Page i © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Cleanliness and Care of Product
A MotorGuide product is a combination of many machined, honed, polished, and lapped surfaces with tolerances measured in
the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It should be
understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is
considered standard shop practice even if not specifically stated.
Whenever components are removed, they should be retained and marked for installation into their original locations. During the
assembly process, the marked parts are quickly identified for installation into the same locations they were removed from.
Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page ii

1
Manual Outline
General Information
1 - General Information
A - General Information
B - Wiring and Battery Information
2 - Troubleshooting
Troubleshooting
2
A - Troubleshooting
3 - Trolling Motor Disassembly and Assembly
A - Trolling Motor Parts Identification
Trolling Motor Disassembly and
Assembly 3
B - Top Housing and Column
C - Lower Unit
D - Foot Pedal
E - Mounts
Page iii © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page iv
General Information
General Information
1
Section 1A - General Information A
Table of Contents
Inspection and Maintenance Schedule.............................. 1A-2 Lubrication Points.............................................................. 1A-2
BEFORE EACH USE..................................................1A-2 Adjusting the Steering Cable Tension................................1A-3
AFTER EACH USE.....................................................1A-2 X5‑55/X5‑70/X5‑80/X5‑105 MotorGuide Trolling Motor.....1A-3
EVERY 100 HOURS OF USE OR ANNUALLY..........1A-2 Specifications.....................................................................1A-4
STORAGE PREPARATION....................................... 1A-2
90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1A-1

General Information
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
95 2-4-C with PTFE Latch pins, latch pin hooks, and bracket door knob threads 92-802859A 1
10W-30 4-Stroke Marine
110 Pivot pins 92-8M0078625
Engine Oil
Inspection and Maintenance Schedule

BEFORE EACH USE
• Check the trolling motor for tightness on the deck mount.
• Check the tightness of the battery lead connections.
• Visually inspect for loose or corroded wiring connections.
• Check the tightness of the propeller nut.
• Check the propeller blades for damage.
AFTER EACH USE

• Disconnect the battery cables from the power source.
• Check the propeller and the propeller shaft for debris such as weeds and fishing line. Remove all debris.
• Rinse the trolling motor with clean water to remove dirt and dust that may scratch the surface.
EVERY 100 HOURS OF USE OR ANNUALLY

• Periodically lubricate all the pivot points. Refer to Lubrication Points.
• Check the tightness of bolts, nuts, and other fasteners.
• Inspect the battery. Refer to Battery Inspection.
STORAGE PREPARATION
The major consideration in preparing the trolling motor for storage is to protect it from corrosion and damage caused by
freezing of trapped water.
Complete the appropriate care instructions to prepare the trolling motor for storage. Store the trolling motor in a dry location
where it will not be affected by temperatures below ‑29 °C (‑20 °F).
IMPORTANT: Trolling motors stored in temperatures below 0 °C (32 °F) should be operated slowly for a minimum of 15
minutes before going above 30% operation.
Lubrication Points
NOTE: Preferred lubricants can be obtained at any authorized MotorGuide or Mercury Marine service center.
To reduce friction and quiet squeaks, lubricate the specified locations periodically with the following lubricants:
• Bracket door knob threads ‑ 2‑4‑C with PTFE
• Latch pin hooks ‑ 2‑4‑C with PTFE
• Latch pins ‑ 2‑4‑C with PTFE
• Pivot pins ‑ 10W‑30 4‑Stroke Marine Engine Oil
IMPORTANT: Never use an aerosol lubricant to grease or oil any part of the unit. Many aerosol lubricants contain harmful
propellants that can cause damage to various parts of the trolling motor.
IMPORTANT: Do not allow any lubricant to contact the column sleeves in the door bracket halves as trolling motor steering
tension will be affected.
c c b a a- Latch pin hooks

a b- Pivot pins
d c- Latch pins
d- Bracket door knob threads
c c 58622
b
Page 1A-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

General Information

95 2-4-C with PTFE Latch pins, latch pin hooks, and bracket door knob threads 92-802859A 1
10W-30 4-Stroke Marine
110 Pivot pins 92-8M0078625
Engine Oil
Adjusting the Steering Cable Tension

! WARNING
Neglecting to inspect, maintain, or repair your trolling motor can result in product damage or serious injury or death. Do not
perform maintenance or service on your trolling motor if you are not familiar with the correct service and safety procedures.
The cable tension on the X5 trolling motor is preset at the factory. With time and use, the cables may stretch slightly, requiring
occasional adjustment. The following procedure explains how to adjust the steering cable tension.
Use care while adjusting the steering cable tension. Excessive cable tension will cause premature wear to the cables and
pulleys, while excessively loose tension may cause the cables to jump off of the pulleys, resulting in a loss of steering control.
1. Remove the foot pedal from the boat deck if it has been secured with screws.
2. Adjust the cable tension by turning the cable tension screw clockwise to increase tension, and counterclockwise to
decrease tension. Adjust the cable tension screw to the specified torque value.
Description Nm lb‑in. lb‑ft

Cable tension screw 1.7 15 –
Bottom of foot pedal

a - Cable tension screw
54574
X5‑55/X5‑70/X5‑80/X5‑105 MotorGuide Trolling Motor

a
a- Directional indicator
b- 53.3 cm (21 in.) mount bracket
c- Latch release handle
d- Foot pedal
e- Momentary button
b f- 3‑position switch
c g- Speed control knob
m
d h- Battery cables
i- 61 cm (24 in.) mount bracket (optional)
j- Propeller
k- Lower unit
l e l- Composite column
h m- Bracket door knob
g
k f
i
58588
j

General Information
Specifications
Freshwater/ Speeds Peak Shaft
Model Volts Sonar
Saltwater Forward/Reverse Thrust Length
X5‑55 FW Freshwater 12 V Variable No 24.9 kgf (55 lbf) 114.3 cm (45 in.)
X5‑55 FW Freshwater 12 V Variable Yes 24.9 kgf (55 lbf) 114.3 cm (45 in.)

Wiring and Battery Information
General Information
1
Section 1B - Wiring and Battery Information B
Table of Contents
Wiring and Battery Information.......................................... 1B-2 Establishing a Common Ground........................................ 1B-3
Wire Color Code Abbreviations..........................................1B-2 Electrolysis..................................................................1B-3
Battery Inspection.............................................................. 1B-2 Battery Connection............................................................ 1B-4
Recommended Practice and Procedures.......................... 1B-2 12‑Volt Battery Connection.........................................1B-4
Battery Recommendations.................................................1B-2 24‑Volt Battery Connection.........................................1B-4
Battery Precautions............................................................1B-3 36‑Volt Battery Connection.........................................1B-5
Battery Cutoff Voltage........................................................1B-3 X5 Wiring Diagram—Cable Steer Models..........................1B-6
Overvoltage........................................................................1B-3 Head Cover Assembly Wiring............................................ 1B-7
90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1B-1


! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
! WARNING
Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper trolling motor operation.
IMPORTANT: Read the safety and maintenance instructions which accompany your battery.
1. Ensure that the battery is secured to the vessel.
2. Ensure that the battery cable terminals are clean, tight, and correctly installed. For installation instructions, refer to Battery
Connection.
3. Ensure that the battery is equipped with a battery box to prevent accidental shorting of the battery terminals.
Recommended Practice and Procedures

IMPORTANT: Unplug the trolling motor after each use and when charging the battery.
• Do not use the main engine battery to power the trolling motor.
• Ensure that the batteries are enclosed within a battery box to prevent accidental shorting of the battery terminals.
• Route the trolling motor wires on the opposite side of the boat from other boat wiring.
• Connect boat accessories directly to the main engine battery.
• Do not charge the trolling motor batteries while the trolling motor is in the deployed (down) position.
Battery Recommendations
• Use 12‑volt, deep cycle marine batteries. The number of batteries required varies according to the model of your trolling
motor. Refer to Battery Connection.
• As a general rule, deep cycle batteries with a higher amp‑hour rating or reserve capacity rating will provide longer run
times and better performance.
• Install a manual reset circuit breaker in line with the trolling motor positive leads within 180 cm (72 in.) of the batteries.
These can be purchased from your local MotorGuide retailer or from www.motorguide.com.
• Do not extend the included 10‑gauge battery cables more than 1.8 m (6 ft) for a total of 3 m (10 ft). If longer battery cables
are required, MotorGuide offers accessory 8 mm² (8‑gauge) battery cables.
• Use nylock nuts to secure the battery cables to their terminals. Using wing nuts to secure the battery cables can cause
loose connections.
• Any depth sounders or fish finders must be powered from the engine starting battery. Connecting electronic equipment to
the trolling motor batteries can cause electrical interference and possible electrolysis.
Page 1B-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Recommended MotorGuide Accessory Description Part Number

8‑gauge battery cable and terminals with 50‑amp manual reset circuit breaker MM309922T
50‑amp manual reset circuit breaker MM5870
60‑amp manual reset circuit breaker 8M0064076
Battery Precautions
! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
When charging batteries, an explosive gas mixture forms in each cell. Part of this gas escapes through holes in the vent plugs
and may form an explosive atmosphere around the battery if ventilation is poor. This explosive gas may remain in or around the
battery for several hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion, which
may shatter the battery.
The following precautions should be observed to prevent an explosion:
1. Do not smoke near batteries being charged or which have been charged very recently.
2. Do not break live circuits at terminals of batteries, because a spark usually occurs at the point where a live circuit is broken.
Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of
electrical arcs which cause explosions.
3. Do not reverse polarity of battery terminal to cable connections.
Battery Cutoff Voltage

The battery cutoff voltage level is the voltage at which the trolling motor will not operate.
• 9 volt minimum cutoff for 12 volt systems.
Overvoltage
! CAUTION
Failure to operate the trolling motor within the recommended voltage specifications can cause product damage. Do not
exceed the maximum supply voltage.
Overvoltage occurs when the voltage is raised above the motor's rated maximum supply voltage.
• 16 volt maximum for 12 volt systems.
Establishing a Common Ground

A common ground (–) connection increases sonar sensitivity, improves sonar display, avoids the ground circuit as a possible
source of corrosion or electrolysis, and reduces interference with other electronic equipment. For 12‑volt trolling motor
applications, connect the negative (–) terminal on the trolling motor battery to the negative (–) terminal on the engine starting
battery with a common ground cable to establish a common ground.
For 24‑volt and 36‑volt trolling motors, a common ground (–) connection cannot be established with the 12‑volt electrical
system in the boat due to the different circuit voltages. As a general rule to reduce interference with other electronics on your
boat, route all battery wiring away from other boat wiring (opposite side of the boat if possible), keep the battery cable length as
short as possible, and always use battery cables of the appropriate size (gauge).
Electrolysis
Using the main engine battery as a power source for the trolling motor may cause electrolysis on metallic parts. If the motor and
battery wiring are installed correctly and electrolysis issues continue, separate the trolling motor from any other boat
electronics. Using the main engine battery as a power source for the trolling motor is not recommended. Refer to Battery
Connection for correct installation.

Battery Connection
! WARNING
Before working around electrical system components, disconnect the battery cables from the battery to prevent injury or
damage to the electrical system due to an accidental short circuit.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
NOTICE
Failure to operate the trolling motor within the recommended voltage specifications can cause product damage. Do not
exceed the maximum supply voltage.
IMPORTANT: Refer to the decal on the head of the trolling motor to determine the voltage requirements of your trolling motor.
12‑Volt Battery Connection

1. Starting with the negative (–) lead, disconnect the battery cables from the engine starting battery.
2. Install a 50‑amp (good) or 60‑amp (best) manual reset circuit breaker in line with the trolling motor power cable positive (+)
lead and the trolling motor battery positive (+) terminal.
3. Connect the positive (+) trolling motor lead to the positive (+) trolling motor battery terminal.
4. Connect the negative (–) trolling motor lead to the negative (–) trolling motor battery terminal.
5. Connect a jumper cable (common ground bond) from the trolling motor battery negative (–) terminal to the engine battery
negative (–) terminal.
NOTE: Vessels using 12‑volt trolling motors with multiple batteries must have a common ground bonding circuit. Not
establishing a common ground between the vessel batteries may cause severe corrosion, electrolysis, or electrical shock.
NOTE: The common ground bond cable should be no more than one wire size (gauge) smaller than the battery cables, nor
smaller than 16‑gauge (AWG). The common ground bond cable must be insulated, and secured to the negative (–) battery
terminals with ring‑style connectors.
6. Starting with the positive (+) lead, reconnect the battery cables to the engine starting battery.
a e
12-volt battery connection with common ground bond
a - Power cables to trolling motor
b - Manual reset circuit breaker
RED
RED
BLK
c - Trolling motor battery

BLK
d - Engine starting battery

e - Power cables to engine
b f - Common ground (–) bond cable
c d
f
44291

lead and the trolling motor battery B positive (+) terminal.
3. Connect the positive (+) trolling motor lead to the positive (+) terminal on trolling motor battery B.
4. Connect a jumper wire (reference gray) between the negative (–) terminal on battery B to the positive (+) terminal on
battery A.
IMPORTANT: The jumper wire should be the same wire gauge as the negative (–) and positive (+) power cables.
5. Connect the trolling motor negative (–) lead to the negative (–) terminal on battery A.

a
d 24-volt battery connection
c - Jumper wire (not supplied)
BLACK
d - Negative (–) battery terminal
AY
GR
RED
Battery A c
Battery B
c
b 37824
IMPORTANT: Do not connect a common ground bond cable between 24‑volt and 12‑volt electrical circuits.

lead and the trolling motor battery C positive (+) terminal.
3. Connect the positive (+) trolling motor lead to the positive (+) terminal on trolling motor battery C.
4. Connect a jumper wire (reference gray) between the negative (–) terminal on battery C to the positive (+) terminal on
battery B.
IMPORTANT: The jumper wire should be the same wire gauge as the negative (–) and positive (+) power cables.
5. Connect a jumper wire (reference gray) between the negative (–) terminal on battery B to the positive (+) terminal on
battery A.
6. Connect the trolling motor negative (–) lead to the negative (–) terminal on battery A.
a
d 36-volt battery connection
c - Jumper wire (not supplied)
BLK
d - Negative (–) battery terminal
Y
GR
Battery A c Y
GR
RED
Battery B c
Battery C
c
b 37825
IMPORTANT: Do not connect a common ground bond cable between 36‑volt and 12‑volt electrical circuits.

X5 Wiring Diagram—Cable Steer Models
g
d
RED/BLK
RED/BLK
f e
58580
a- Lower unit
b- Directional arrow light
c- Connectors—inside top housing
d- Digital speed control module
e- Battery cables
f- Momentary switch
g- Speed control switch

Head Cover Assembly Wiring

a a- Red (+) wiring connection
b b- Black (–) wiring connection
c- Directional arrow light
d- Bullet connector
e- Motor wires to lower unit
e
c
d 58339

Notes:

Troubleshooting
Troubleshooting
Section 2A - Troubleshooting
Table of Contents 2
A
Troubleshooting Guide.......................................................2A-2 Interference Troubleshooting............................................. 2A-4
Testing............................................................................... 2A-4 Checking for Interference........................................... 2A-4
Checking the Armature for Short Circuits................... 2A-4 Mercury Marine Service Offices.........................................2A-5
Checking the Armature for Ground.............................2A-4

Troubleshooting
Special Tools
DMT 2004 Digital Multimeter 91‑892647A01
Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

V Hz
H z TEMP
mA
A
voltages; records maximums and minimums simultaneously, and accurately
reads in high RFI environments.
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Troubleshooting Guide
Symptom Possible Cause Resolution
Propeller is loose, damaged, or off Tighten the propeller nut. If the propeller is
balance damaged or off balance, replace it.
Check the power supply for proper voltage.
For battery voltage cutoff and overvoltage
Incorrect supply voltage
information, refer to Section 1B ‑ Wiring
and Battery Information.
Check for faulty wiring, corrosion, reversed
Weak battery battery polarity, or other battery issues.
Repair or replace defective components.
Refer to the safety and maintenance
Loose or corroded battery connections
instructions that accompany your battery.
Wire gauge from the battery to the trolling
Wiring or electrical connection is faulty
motor is insufficient. Six‑gauge wire is
from the boat to the trolling motor
recommended.
Wiring or electrical connection is faulty Check the battery lead connections for
from the power supply to the control damage. Replace the top housing if
board necessary.
Loss of power
The motor control wires could be damaged.
Wiring damage inside the column
Replace the lower unit if necessary.
Remove the top housing and connect the
motor control wires to the proper power
supply to verify. Refer to Section 1B ‑
Battery Cutoff Voltage for minimum voltage
requirements.
If the motor works, install a new speed
Internal wiring or electrical connection control switch in the top housing
(hand‑operated models) or replace the
speed knob potentiometer (foot pedal
models).
If the motor does not work, the wires could
be damaged. Recrimp the wires. If the motor
still does not work, replace the lower unit.
Weeds, fishing line, or debris wrapped Remove weeds, fishing line, or debris from
around the propeller the propeller.
Excessive noise, vibration
Replace the armature or the lower unit as
Bent armature shaft
necessary.

Troubleshooting

Check the power supply for proper voltage.
For battery voltage cutoff and overvoltage
Incorrect supply voltage
information, refer to Section 1B ‑ Wiring
and Battery Information.
Check for faulty wiring, corrosion, reversed
Weak battery battery polarity, or other battery issues.
Repair or replace defective components.
Refer to the safety and maintenance
Loose or corroded battery connections
instructions that accompany your battery.
Reverse battery connections. Refer to
Reverse polarity Section 1B ‑ Battery Connection for the
correct wiring diagram.
Motor failure motor control wires to the proper power
Motor does not run supply to verify. Refer to Section 1B ‑
Motor runs at full speed only Battery Cutoff Voltage for minimum voltage
Motor does not turn off requirements.
Internal wiring or electrical connection control switch in the top housing
models).
Locate and correct the cause of the
Fuse or circuit breaker is open overload. Then replace the fuse or reset the
circuit breaker.
motor control wires to the proper power
supply to verify. Refer to Section 1B ‑
Battery Cutoff Voltage for minimum voltage
requirements.
Speed adjustment failure Internal wiring or electrical connection control switch in the top housing
models).
Motor column is bent Replace the motor column.
Hard to steer
Tension collar is overtightened Loosen the tension collar.
Cracked tension collar Replace the tension collar.
Steering is loose Tension collar threads are stripped Replace the tension collar.
(transom and bow mount) Dirt or grime in the tension collar Clean thoroughly with mild soap and water.
Damaged bow mount friction tube Replace the mount.
Motor will not maintain depth Depth collar failure Replace the depth collar.
Bolts or nuts are seized, loose, or Replace the necessary part and torque to
defective specification.
Top housing rotates on column Height pin missing Replace the height pin.
Engage the height pin. Refer to Section 3B ‑
Height pin not engaged
Top Housing and Column Assembly.
Handle extension will not secure Missing O‑ring Replace the O‑ring.

Troubleshooting

Hold one blade and lightly tap the opposite
blade with a rubber mallet.
Bent propeller pin
Difficulty removing propeller Use a putty knife on both sides of the
propeller to apply equal pressure.
Bent armature shaft Replace the lower unit.
Lubricate the lock pins on the mount bracket
Mount bracket squeaks Lock pins need lubrication
with 2‑4‑C with PTFE.
Testing
Checking the Armature for Short Circuits
a a - Hacksaw blade
b
b - Armature
44125
1. Place the armature in a growler. Turn on the growler.

2. Hold a hacksaw blade over the armature core while rotating the armature.
3. If the hacksaw blade vibrates, the armature is shorted.
4. Clean the armature between the commutator bars.
5. Test the armature in a growler after cleaning between the commutator bars. If the hacksaw blade still vibrates, replace the
armature.
Checking the Armature for Ground
b c a - Armature core
a
b - Commutator
c - Shaft
42462
1. With an ohmmeter set on the Rx100 scale, place one probe on the commutator and the other probe on the armature core
or the armature shaft.
2. If the meter indicates continuity (current flow), the armature is grounded and must be replaced.
DMT 2004 Digital Multimeter 91‑892647A01
Interference Troubleshooting
Interference may occur due to a variety of causes on the boat such as the manufacturer of the depth finder, its location, the
transducer location, the boat wiring configuration, and the condition of the boat wiring or boat connections. Interference is most
prevalent when the trolling motor transducer is turned on, the depth finder is in high manual gain mode, and the trolling motor is
operating at a slow speed.
Checking for Interference

The potential exists for interference to occur with some sonars due to a trolling motor's pulse width modulation (PWM) speed
control.
• LCD models – the display may turn solid black or blank out the display when the trolling motor is turned on. When the
trolling motor is stopped the display returns to normal operation.

Troubleshooting
• Flashers – the flasher may "bloom" (a bright light appears on a dark scene) then turns blank (no flash at all) when the
motor is turned on.
To locate the interference source:
1. Deploy the trolling motor and then turn the motor on to speed 10.
2. If the interference continues or decreases slightly, the trolling motor may be shorted or there is a problem with the boat
wiring.
Mercury Marine Service Offices

For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.
United States, Canada

English +1 920 929 5040 Mercury Marine
Telephone
Français + 905 636 4751 W6250 Pioneer Road
English +1 920 929 5893 P.O. Box 1939
Fax Fond du Lac, WI 54936-1939
Français +1 905 636 1704
Website www.mercurymarine.com
Australia, Pacific
Telephone +61 3 9791 5822 Brunswick Asia Pacific Group
41–71 Bessemer Drive
Fax +61 3 9706 7228 Dandenong South, Victoria 3175
Australia
Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe
Parc Industriel de Petit-Rechain
Fax +32 87 31 19 65 B-4800 Verviers,
Belgium
Mexico, Central America, South America, Caribbean

Telephone +1 954 744 3500 Mercury Marine
11650 Interchange Circle North
Fax +1 954 744 3535 Miramar, FL 33025
U.S.A.
Asia, Singapore, Japan

Telephone +65 65466160 Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
Fax +65 65467789 29 Loyang Drive
Singapore, 508944

Troubleshooting
Notes:

Trolling Motor Parts Identification
Trolling Motor Disassembly and Assembly

Section 3A - Trolling Motor Parts Identification
Table of Contents
3
Trolling Motor Assembly.................................................... 3A-2 Lower Unit Assembly—FW80.......................................... 3A-12
Upper Mount...................................................................... 3A-4 Lower Unit Assembly—FW80 Sonar............................... 3A-14
Lower Mount...................................................................... 3A-6 Lower Unit Assembly—FW105........................................ 3A-16
Lower Unit Assembly—FW55............................................ 3A-8
Lower Unit Assembly—FW55 Sonar............................... 3A-10
Lower Unit Assembly—FW105 Sonar............................. 3A-18 A

Trolling Motor Assembly

2 e
3 15 13
uid
x 3
rG
oto
M
15
14
12
1
16
15
10
15 15
21
11
4
18
5 17
10
4 10
19
6 19
19
7 20
59045

Trolling Motor Assembly

Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
1 1 Head assembly with decals
2 1 Top cover indicator kit
3 1 Decal set
4 2 Bearing assembly
Tube
5 1
Tube (XL)
6 1 Clamp assembly
Column, 91.4 cm (36 in.)
7 1
Lower unit assembly—55 lbs, fresh water
Lower unit assembly—55 lbs, fresh water, sonar
8 1
9 1 Propeller kit, black (Safari)—with propeller nut and pin
Harness assembly
Harness assembly (XL)
10 1
Harness assembly (sonar)
Harness assembly (XL, sonar)
11 1 Pedal kit
12 1 Pedal tread (NSS)
13 1 Button kit
14 1 Speed knob (NSS)
15 1 Hardware kit
16 1 Harness assembly
Board assembly, 12 V
17 1 Board assembly, 24 V
Board assembly, 36 V
18 1 Button
19 1 Screw kit
20 1 Bow mount (NSS)
21 1 Pinion assembly

Upper Mount
5
3 3
3 4
3
2
3
3 3 60349

Upper Mount
Torque
Top channel
1 1
Top channel (XL)
Arm kit
2 1
Arm kit (XL)
3 1 Hardware kit
4 1 Lockslide pin
5 1 Rope assembly
6 1 Complete door kit
NS 1 Front door kit
7 1 Knob kit
8 1 Clutch channel
9 1 Spring kit

Lower Mount
60351

Lower Mount
Torque
1 1 Decket kit
Lockslide assembly
2 1
Lockslide assembly (XL)
Bottom channel
3 1
Bottom channel (XL)

Lower Unit Assembly—FW55
1 7 7
2 3
46416


FW55—Variable Speed
Torque
1 1 Nose cone assembly (with bushing and thrust washer)
2 1 Housing assembly (with magnet and wire retainer)
3 1 Armature kit (with Nylatron® washer)
4 1 Commutator cap assembly (with seals and bushings)
5 1 Brush card kit (with springs and screws)
6 1 Through bolt assembly 5.1 45 –
7 1 Seal kit (for magnet housing and through bolts)

Lower Unit Assembly—FW55 Sonar

6
3 4 2 5
8 8
46465


FW55—Variable Speed Sonar
Torque
3 1 Nose cone assembly (sonar, with screws)
4 1 Spacer assembly (with screws, washers, and bearing)

1 7 7
2 3
46417


Torque


6
3 2 5
4
8 8
46466


Torque
4 1 Spacer assembly (with screws, spacers, and bearing)


5
1
7 7
2
3
56622


Torque

4
6
8 8
3
2
5
56621


Torque
4 1 Spacer assembly (with screws, washers, and bearing)

Notes:

Top Housing and Column

Section 3B - Top Housing and Column
Table of Contents
3
Top Housing and Column Disassembly.............................3B-2 Top Housing and Column Assembly..................................3B-4


86 Loctite 262 Column clamp screw threads Obtain Locally
95 2-4-C with PTFE Bearing races 92-802859A 1
Top Housing and Column Disassembly

1. Remove the three top cover attaching screws and remove the top cover.
a - Top cover attaching screws (3)

a
a
a
56489
2. Carefully pull the wire bundle loose from the top housing.
3. Disconnect the bullet connector for the battery light from the harness.

d- Bullet connector
e
c
d 58339
4. Use an appropriate tool to remove the wire connectors from the following wire pairs:
• Black to black
• Red to red
NOTE: The wire connectors may be difficult to remove. However, removing the wire connectors is preferable to cutting the
wires. Cut wires may be too short to be properly reattached, or may limit steering travel.
41629
5. Inspect the wires for damage. Repair or replace as necessary.

6. Cut the wire tie for the sonar cable, if equipped.

7. Remove the wire bushing from the top housing.
8. Remove the cable pulley from the column shaft splines.
9. Remove the screw from the strain relief bracket.
10. Remove the cable grommet, wiring, strain relief bracket, and steering cables from the top housing as an assembly.
b a- Wire bushing
c
d b- Cable pulley
a e c- Column shaft splines
d- Strain relief bracket screw
f e- Strain relief bracket
f- Cable grommet
g- Sonar cable (optional)
g
59305
11. Remove the column clamp screws.

12. Remove the column clamp.
a - Column clamp screws

b - Column clamp
a
a 56492
13. Push the column upwards to free the upper and lower column bearings.
14. Remove the two screws to remove the spline drive from the trolling motor. Retain the nylon locking nuts.
a - Screws
b - Nylon locking nuts (hidden)
c - Spline drive
b a
c
b
56491

15. Remove the bearing cups and races from the column.
a
b
56493
a - Upper column bearing

b - Lower column bearing
Top Housing and Column Assembly

1. Lubricate the bearing races with 2‑4‑C with PTFE.
a a - Bearing cup
b - Bearing race
56497
2. Install the bearing cups and races into the column.
a
b
56493
a - Upper column bearing

b - Lower column bearing

95 2-4-C with PTFE Bearing races 92-802859A 1
3. Install the top column assembly onto the steering column.

4. Route the motor wiring (and sonar cable, if equipped) through the spline drive, then install the spline drive onto the steering
column. Ensure that the nylon locking nuts are installed into the recesses on the spline drive.
5. Align the spline drive so the retaining screws will fit into the machined grooves in the steering column.
NOTE: The spline drive screws can only be installed once they are aligned with the machined grooves in the steering
column.
6. Tighten the two spline drive retaining screws evenly and securely.
a - Spline drive retaining screws (2)

b - Nylon locking nuts (hidden)
c - Spline drive
b a
c
b
56491
7. Apply Loctite 262 to the column clamp screw threads.

86 Loctite 262 Column clamp screw threads Obtain Locally
8. Install the column clamp onto the column.
a. Preload the column clamp downward against the bearing before tightening the screws.
Description N lbf
Column clamp preload force 355.9 80
b. Tighten the column clamp screws to the specified torque.

Column clamp screws 20.3 180 –
IMPORTANT: Do not overtighten the column clamp screws or damage to the column or column clamp may occur.
a - Column clamp screws

b - Column clamp
a
a 56492
9. Install the cable grommet, wiring, strain relief bracket, and steering cables into the top housing as an assembly.
10. Install the strain relief bracket screw and tighten it securely.

11. Install the wire bushing.
12. Ensure that the lower unit and the top housing align, and that the foot pedal is in the straight‑ahead position (pedal tread
level).
13. Install the cable pulley onto the column shaft splines.
a - Lower unit direction of

c d e travel
f b - Wire bushing
a
c - Cable pulley
d - Column shaft splines
e - Strain relief bracket
screw
b f - Strain relief bracket
g - Cable grommet
56498
14. Connect the bullet connector to the directional arrow light.
15. If the sonar cable is not being used, bundle the sonar cable and secure it with a cable tie.
16. Route the wires into the top housing and install new wire connectors on the following wire pairs. Use an appropriate tool to
fully crimp the connectors. Ensure that no wiring will interfere with the steering cables or cable pulley.

d- Bullet connector
e
c
d 58339
17. Align the direction indicator on the top cover with the lower unit direction of travel.
b a - Lower unit direction of travel

a b - Direction indicator
59308
18. Install the top cover onto the top housing. Ensure that no wiring is pinched or contacting the steering cables or pulley.

19. Install the three screws securing the top cover to the top housing. Tighten the screws evenly and securely.
a - Top cover attaching screws (3)

a
a
a
56489

Notes:

Lower Unit

Section 3C - Lower Unit
Table of Contents
3
Remove the Lower Unit from the Column..........................3C-2 Commutator Cap Subassembly.......................................3C-10
Assemble the Lower Unit to the Column........................... 3C-2 Brush Board Assembly Removal..............................3C-10
Lower Unit Disassembly.................................................... 3C-3 Brush Board Assembly Installation...........................3C-11
Wire Pull Method........................................................ 3C-3
Nonwire Pull Method.................................................. 3C-4
Lower Unit Assembly....................................................... 3C-11
Armature and Brush Board Assembly...................... 3C-11
C
Sonar Nose Cone Subassembly........................................3C-6 Assemble Commutator Cap to Lower Unit Housing
Sonar Cable Removal................................................ 3C-6 .............................................................................. 3C-12
Bearing Housing and Nose Cone Removal................3C-7 Propeller Replacement.................................................... 3C-13
Nose Cone and Bearing Housing Installation.............3C-7 Removing the Propeller............................................ 3C-13
Sonar Cable Installation............................................. 3C-8 Installing the Propeller.............................................. 3C-14
90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 3C-1

Lower Unit

Loctite 9460 Column threads Obtain Locally
117 Loctite 7649 Primer N Column threads 92-809824
Special Tools
Brush Spring Compression Tool 91‑MXC6031T
Holds the motor brush in the brush housing when removing and installing the
armature
43131
Remove the Lower Unit from the Column

IMPORTANT: Do not use a pipe wrench to remove the lower unit from the column. A pipe wrench may allow corrosion to occur,
or the friction collar and depth collar may fail. Use a strap wrench.
1. Disassemble the top housing. Refer to Section 3B ‑ Top Housing and Column Disassembly.
2. Clamp the lower unit into a padded vice.
3. Secure a strap wrench to the column approximately 8 cm (3 in.) from the column collar.
! CAUTION
Heating the motor column can melt the insulation of the wires inside the column. When removing the lower unit from the
column, apply heat only to the column collar.
4. Use a heating torch to apply heat only to the column collar to loosen the adhesive.
a
a - Heating torch
b - Column collar
b
43515
5. Use a strap wrench to rotate the column counterclockwise to loosen the column from the lower unit. When the column is
loose, turn off the heating torch.
6. Unscrew the column from the lower unit.
Assemble the Lower Unit to the Column

NOTE: The column collar thread specification is 1.250‑12 UNC‑2B.
1. Ensure the column collar and threads on the lower unit are clean. Remove the old thread adhesive using a wire bristle
brush.
Page 3C-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Lower Unit
IMPORTANT: Failure to thoroughly clean the column collar and threads may cause cross threading when assembling the
lower unit to the column.
a - Excess thread adhesive
43517
2. Slide the column over the motor lead wires.

3. Apply Loctite 7649 Primer N to the column threads. Allow the primer to dry.

117 Loctite 7649 Primer N Column threads 92-809824
4. Rotate the column while applying Loctite 9460 to fully coat the first half of the threads.
a
a - Loctite 9460 on column threads
b b - Lower unit collar
43516

Loctite 9460 Column threads Obtain Locally
5. Insert the column into the collar of the lower unit and turn the column to start the threads.
6. Screw the column into the lower unit and tighten to the specified torque.

Assemble column to lower unit 81.3 – 60
7. Wipe off the excess Loctite 9460 from the lower unit and column.
Lower Unit Disassembly

NOTE: There are two methods for removing the lower unit from the column. Refer to Wire Pull Method to remove the lower
unit and wires from the column. Refer to Nonwire Pull Method if the wiring harness does not need to be removed.
Wire Pull Method

1. Disassemble the top housing. Refer to Section 3B ‑ Top Housing and Column Disassembly.

Lower Unit
2. Loosen and remove both through bolts. Retain the washers and seals.
a - Through bolts
55785
3. Carefully pull the commutator cap away from the lower unit housing assembly approximately 1.27 cm (0.50 in.).
a - Commutator cap
b
a b - Lower unit housing assembly
42616
4. Insert one brush spring compression tool on each brush housing to hold the brushes firmly in place. Pull the commutator
cap away from the lower unit.
IMPORTANT: The brushes must be held back when removing the armature or serious damage may occur to the brushes
and armature shaft.
a - Brush spring compression tools
55819

5. Pull the armature straight out from the lower unit housing assembly. If necessary, insert a metal rod into the propeller pin
hole on the armature shaft to aid in removing the armature from the lower unit housing assembly.
Nonwire Pull Method

NOTE: The motor lead wires and cable assembly wires yield little slack between the top housing and the commutator cap. To
fully remove the commutator cap without removing the wiring harness, it is necessary to remove all of the cable ties in the top
housing. To disassemble the top housing to access the cable ties, refer to Section 3B ‑ Top Housing and Column
Disassembly.

Lower Unit
1. Loosen and remove both through bolts. Retain the washers and seals.
a - Through bolts
55785
2. Remove the nose cone.
a - Nose cone
a
43529
3. Carefully pull the commutator cap away from the lower unit housing assembly approximately 1.27 cm (0.50 in.).
a - Commutator cap
b
a b - Lower unit housing assembly
42616
4. Insert one brush spring compression tool on each brush housing to hold the brushes firmly in place.
IMPORTANT: The brushes must be held back when removing the armature or serious damage may occur to the brushes
and armature shaft.
55819

Lower Unit
5. Push against the armature shaft with a blunt object while continuing to hold the commutator cap to maintain the 1.27 cm
(0.50 in.) gap. Continue pushing on the armature shaft until the commutator cap can be removed by hand.
c
d a- Blunt object
b- Armature shaft
c c- Commutator cap
b d- Brush compression tools
a
55787
6. Remove the brush compression tools to release the brushes.
7. Remove the brushes and brush springs from the brush housings.
a a - Brush
b - Brush spring inside brush housing ‑ not visible
c - Brush housing
c
42656
Sonar Nose Cone Subassembly

Sonar Cable Removal
1. Remove the armature from the magnet housing.
2. Disconnect the sonar cable connector in the top housing. Refer to Section 3B ‑ Top Housing and Column Disassembly.
3. Remove the lower unit power wires from the column. For instructions on the wire pull method, refer to Lower Unit
Disassembly.
4. After removing the commutator cap and armature from the magnet housing, remove the sonar cable from the cable
retainer. Use a screwdriver to remove the retaining ring. Use care not to damage the sonar cable.
d a- Retaining ring
b- Cable retainer
c- Tab on retaining ring
d- Lower unit power wires
b
a c
55821

Lower Unit
Bearing Housing and Nose Cone Removal

1. After removing the sonar cable, the nose cone and bearing housing will detach from the magnet housing.
a - Nose cone and bearing housing
a
43531
2. Remove the four screws from the bearing housing. Remove the bearing housing from the nose cone. Inspect the nose
cone and bearing for damage.
a - Bearing housing screws
a
a
43532
Nose Cone and Bearing Housing Installation

1. Install a new O‑ring onto the nose cone.
2. Insert the sonar cable through the bearing housing hole as shown.
a
a - O‑ring
b - Sonar cable
43537

Lower Unit
3. Align the nose cone to the bearing housing. Ensure the flat surface of the nose cone faces down and that the temperature
sensor faces up. Ensure that the bearing housing is aligned to the nose cone as shown.
c f
b d c d d
e
a
55788
a- Flat surface of the nose cone

b- Temperature sensor
c- Nose cone
d- Bearing housing
e- Through bolt holes
f- Sonar cable
4. Install the four bearing housing screws to secure the bearing housing to the nose cone. Tighten the screws to the specified
torque.
a - Bearing housing screws
a
a
43532

Bearing housing screws 3.1 27.5 –
Sonar Cable Installation

IMPORTANT: If the sonar cable retainer is already installed in the magnet housing, go to step 3.
1. Remove the old cable retainer and acrylic adhesive, if applicable.

Lower Unit
2. Using the specified acrylic adhesive, apply a thin line of adhesive on the right side of the top magnet as shown.
a - Top magnet
b - Adhesive
a
b 43540

3M DP-805 Magnet housing Obtain Locally
3. Take two of the lower unit through bolts and place them inside the cable retainer. The through bolts will help position the
cable retainer on top of the acrylic adhesive and prevent the plastic edges from melting together. Place the cable retainer
with the through bolts on top of the acrylic adhesive. Press down against the installed cable retainer/through bolts. Hold for
ten seconds. Once the acrylic adhesive has cooled, remove the through bolts from the cable retainer. Allow to cure a
minimum of five minutes.
a - Cable retainer
b - Through bolts
a b
44133
4. Align the nose cone and bearing housing to the magnet housing. Ensure that the sonar cable hole of the bearing housing is
positioned as shown. The through bolt holes must be positioned, as shown, to assemble the lower unit securely.

Lower Unit
IMPORTANT: Tuck some of the sonar cable back into the nose cone to allow slack for future service.
c f c d
a b
56389
a- Magnet housing
b- Column collar
c- Bearing housing
d- Nose cone
e- Through bolt holes
f- Sonar cable
5. Route the sonar cable through the cable retainer. Ensure that the nose cone and bearing housing are flush against the
magnet housing and that the sonar cable is pulled taut. Insert the sonar cable through the column.
a - Sonar cable
b b - Column
c - Cable retainer
a
56390
6. Install the retaining ring into the magnet housing. Secure the sonar cable with the tab on the retaining ring as shown.
d a- Retaining ring
b- Cable retainer
c- Tab on retaining ring
d- Lower unit power wires
b
a c
55821
7. Insert the lower unit power wires through the column. Refer to Lower Unit Assembly for remaining lower unit assembly
instructions.
Commutator Cap Subassembly

Brush Board Assembly Removal
IMPORTANT: If the wiring harness that runs through the column requires replacement, remove the retainer ring (if present)
holding the wiring harness and pull the wires out through the lower unit.
1. Remove the commutator cap from the lower unit. Refer to Lower Unit Disassembly.

Lower Unit
2. Remove the two screws from the brush board assembly. Remove the cable tie.
3. Unsolder the negative (–) and positive (+) shunt wire solder connections to remove the motor leads from the brush board.
a a- Cable tie
b- Negative (–) motor lead
e b c- Brush board screw
d- Negative (–) shunt wire solder connection
e- Positive (+) shunt wire solder connection
c c
55791
4. If the brush board is damaged, replace the brush board.
Brush Board Assembly Installation

1. Solder the positive (+) and negative (–) motor leads to the brush board terminals. Solder the shunt wires to the brush board
terminals.
2. Route the positive (+) and negative (–) motor leads as shown. Secure the negative motor lead to the brush board with a
cable tie as shown.
3. Install the brush springs onto the brushes. Install the brushes and springs into the brush holders
4. Secure the brush board assembly to the commutator cap housing with the brush board assembly screws. Tighten the
screws to the specified torque.
a a- Cable tie
b- Negative (–) motor lead
e b c- Brush board screw
d- Negative (–) shunt wire solder connection
e- Positive (+) shunt wire solder connection
c c
55791

Brush board assembly screw 3.9 35 –
5. Route the motor leads to the top of the commutator cap (away from the skeg) and secure them together with electrical tape
where they exit the commutator cap. Do not leave any slack in the wires.
Lower Unit Assembly

Armature and Brush Board Assembly
1. If the wiring harness was removed from the column, insert the wiring harness up through the column before installing the
armature.

Lower Unit
2. Insert the armature into the magnet housing.
b a - Armature
b - Magnet housing
55817
3. Retain the brushes in their housings with two brush spring compression tools.
55819

4. While retaining the brushes in their housings, slide the armature shaft into the center hole of the brush board assembly.
IMPORTANT: The brushes must be retained in their housings to avoid damage to the brushes and armature shaft.
c a- Lower unit housing assembly

a b b- Armature shaft
d c- Brush spring compression tool
d- Brush tab
e- Brush housing
e
41690
Assemble Commutator Cap to Lower Unit Housing

1. Replace the seals and washers on the through bolts.
a b a - Washer
b - Seal
42709

Lower Unit
2. Before assembly, ensure that the nose cone is positioned correctly and the skeg is parallel to the column. For sonar
models, refer to Sonar Nose Cone Subassembly.
a - Through bolt holes
43592
3. Install the through bolts. Tighten the through bolts alternately to the specified torque.
a - Through bolts
55785

Lower unit through bolts 5.1 45 –
Propeller Replacement
! WARNING
Removing the Propeller

1. Disconnect the power cables from the battery.
2. While holding the propeller blade with one gloved hand, use a 9/16 in. wrench or a ratchet and a 9/16 in. socket to remove
the propeller nut. Remove the propeller nut and washer (or anode, for saltwater models).
IMPORTANT: Remove the propeller nut with a wrench or a ratchet and socket. Using another tool may damage the
propeller nut or shaft. If the propeller cannot be removed easily, use a rubber mallet to lightly tap the back side of the
opposite blade. If the propeller cannot be removed, have the propeller removed by an authorized dealer.

Lower Unit
NOTE: If the propeller pin is bent, replace the propeller pin.
53442 57326
Installing the Propeller

1. Rotate the motor shaft to insert the propeller pin horizontally.
a - Propeller pin
a
44664
2. Install the propeller onto the motor shaft by engaging the propeller onto the propeller pin.
57326
3. Install the washer (or anode, for saltwater models) onto the propeller shaft, then install the propeller nut. Use a wrench or a
socket and ratchet to tighten the propeller nut until it is snug, then tighten the nut another 1/4 turn.
IMPORTANT: Do not overtighten the propeller nut, or damage to the propeller or propeller pin may occur.
53442

Foot Pedal

Section 3D - Foot Pedal
Table of Contents
3
Foot Pedal Disassembly—Digital Models..........................3D-2 Adjusting the Steering Cable Tension............................... 3D-9
Foot Pedal Assembly—Digital Models...............................3D-5
90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 3D-1

Foot Pedal

6 Dielectric Grease Battery and motor power wire terminals 92-823506 1
Foot Pedal Disassembly—Digital Models

1. Use a screwdriver or small punch to press the cable barrels out of the foot pedal tread.
NOTE: It may be necessary to loosen the cable tension prior to removing the cable barrels. Refer to Adjusting the
Steering Cable Tension.
a - Cable barrel on heel end of

the foot pedal tread
b - Cable barrel on toe end of
the foot pedal tread
a b
58274
2. Remove the four screws securing the speed control module bracket to the foot pedal.
a - Screws (4)
a
a
58275
3. Remove the three screws securing the battery cables and motor power wires to the speed control module.
Page 3D-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Foot Pedal
4. Disconnect the bullet connector and disconnect the 4‑wire connector from the speed control module.
a - Screws (3)
a b - Bullet connector
c - 4‑wire connector
b
58276
5. Remove the three screws securing the speed control module to the bracket.
a - Screws (3)
a
59316
6. Remove the screws securing the wire guard, wire clamp, wire guard clamp, and strain relief clips.
a a- Screws
a c
b- Strain relief clips
b c- Wire clamp
a d- Wire guard
e- Wire guard clamp
d
e a
58278
7. Remove the rivet nut from the axle pin. Press the axle pin out of the pulley. Retain the pulley after removing the axle pin.
a - Rivet nut
a b - Axle pin
b
58294

Foot Pedal
8. Gently pull on the wire guard to remove the wire guard, wiring, and cable tensioner assembly from the foot pedal.
58281
9. Use a screwdriver to gently bend the retainer clip tab away from the axle pin.
a - Retainer clip tab
58296
10. Use a screwdriver to gently pry the axle pin from the foot pedal. Retain the pulley after removing the axle pin.
a - Axle pin
58298
11. Remove the two wires from the terminals on the momentary switch.
12. Remove the two nuts and bolts securing the momentary switch to the foot pedal.
13. Remove the momentary switch.
a - Wire terminals (2)

b - Bolts (2)
c - Nuts (2)
a
c
a
b 58299
14. Press in on the locking tabs and remove the speed control knob.

Foot Pedal
15. Loosen the hex nut and remove the speed control switch.
b c a- Speed control knob

b- Locking tabs (4)
d c- Hex nut
d- Speed control switch
58300
16. Carefully drive the hinge pin out with a hammer and brass drift to remove the foot pedal tread, if required.
NOTE: Drive the knurled end of the hinge pin out first to ease removal of the hinge pin.
a - Hinge pin
56652
Foot Pedal Assembly—Digital Models

1. Carefully drive the hinge pin into the foot pedal with a hammer and brass drift (if removed for service).
NOTE: Install the hinge pin with the knurled end on the opposite side of where it was removed to provide maximum
retention.
a - Hinge pin
56652
2. Install the speed control switch into the foot pedal tread. Tighten the hex nut to secure the switch.
3. Press the speed control knob onto the speed control switch until the four locking tabs engage.

Foot Pedal
NOTE: The speed control knob has a molded flat on the shaft to ensure proper alignment.
b c a- Speed control knob

b- Locking tabs (4)
d c- Hex nut
d- Speed control switch
58300
4. Install the momentary switch into the foot pedal tread as shown. Secure the switch with two bolts and two nuts.
5. Connect the momentary switch wiring as shown. The red (+) wire is connected to the terminal labeled "norm open" and the
black (–) wire is connected to the "common" terminal.
a - Wire terminals (2)

b - Bolts (2)
c - Nuts (2)
a
c
a
b 58299
6. Insert the tensioning bracket partially into the foot pedal base, as shown. Route the steering cables through the pulley slots
in the foot pedal base.
NOTE: The cables must be routed through the foot pedal base before installing the pulleys. There is not adequate space to
route the cables after the pulleys are installed.
a - Tensioning bracket (partially inserted)

b - Steering cable (toe end of pedal)
c - Steering cable (heel end of pedal)
c b 58322

Foot Pedal
7. Insert the pulley into the slot on the heel end of the pedal with the cable resting in the pulley groove.
a a - Cable
b - Pulley
c - Slot
b
c
58324
8. Insert a new axle pin through the foot pedal base and the hole in the pulley until it is fully seated. Secure the axle pin with a
new rivet nut.
NOTE: To ease installation, hold the pulley from below while aligning the axle pin with the hole in the pulley.
NOTE: MotorGuide does not recommend reusing the axle pin and rivet nut.
a - Rivet nut
a b - Axle pin
b
58294
9. Install the pulley into the pulley housing at the toe end of the foot pedal base from below. Ensure that the cable is resting in
the pulley groove.
10. Insert the axle pin through the foot pedal base and the hole in the pulley.
NOTE: To ease installation, hold the pulley from below while aligning the axle pin with the hole in the pulley.
Retainer clip removed for visual clarity

c a - Cable (resting in the pulley groove)
b - Pulley housing
c - Axle pin
b
a
58325
11. Use a screwdriver to gently bend the retainer clip tab to secure the axle pin.
a - Retainer clip tab
56842

Foot Pedal
12. Install the tensioning bracket, wiring, wire guard, strain relief clips, wire clamp, and wire guard clamp onto the foot pedal.
a a- Screws
a c
b- Strain relief clips
b c- Wire clamp
a d- Wire guard
e- Wire guard clamp
d
e a
58278
13. Insert the steering cables into the cable barrels as shown.
b a - Steering cable
b - Cable barrel
a 56845
14. Install the cable barrels into the recessed hole in the foot pedal tread.
NOTE: Align the molded notches in the cable barrel and the recessed hole to fully seat the cable barrels.
a - Cable barrel
b - Recessed hole
a
56846
15. Install the speed control module to the bracket with three screws.
a - Screws (3)
a
59316

Foot Pedal
16. Connect the wiring to the speed control module as shown. Apply Dielectric Grease to the battery and motor power wire
terminals.
a a - Screw securing the black (–) battery wire terminal

b - Screw securing the red/black (+) battery wire
terminal and red (+) motor wire terminal
b c - Screw securing the black (–) motor wire terminal
e d - 4‑wire connector
e - Bullet connector (for directional indicator light in top
housing)
c
58318

6 Dielectric Grease Battery and motor power wire terminals 92-823506 1
17. Place the speed control module bracket assembly onto the foot pedal base. Carefully align the on/off/pedal switch through
the hole in the foot pedal base.
18. Secure the speed control module bracket assembly to the foot pedal base with four screws.
IMPORTANT: Ensure that no wiring is pinched between the bracket and foot pedal base.
a - Screws (4)
a
a
58275
19. Adjust the steering cable tension. Refer to Adjusting the Steering Cable Tension.
Adjusting the Steering Cable Tension

! WARNING
Neglecting to inspect, maintain, or repair your trolling motor can result in product damage or serious injury or death. Do not
perform maintenance or service on your trolling motor if you are not familiar with the correct service and safety procedures.
The cable tension on the X3 trolling motor is preset at the factory. With time and use, the cables may stretch slightly, requiring
occasional adjustment. The following procedure explains how to adjust the steering cable tension.
Use care while adjusting the steering cable tension. Excessive cable tension will cause premature wear to the cables and
pulleys, while excessively loose tension may cause the cables to jump off of the pulleys, resulting in a loss of steering control.
1. Remove the foot pedal from the boat deck if it has been secured with screws.

Foot Pedal
2. Adjust the cable tension by turning the cable tension screw clockwise to increase tension, and counterclockwise to
decrease tension. Adjust the cable tension screw to the specified torque value.

Cable tension screw 1.7 15 –
Bottom of foot pedal

a - Cable tension screw
54574

Mounts

Section 3E - Mounts
Table of Contents
3
Deck Mount........................................................................3E-2 Front Locking Pin Replacement.......................................3E-11
Clutch Spring Removal............................................... 3E-2 Rear Locking Pin Replacement....................................... 3E-12
Top Channel Removal................................................ 3E-5 Rope Replacement.......................................................... 3E-13
Bow Arm Replacement............................................... 3E-8
Decket Replacement................................................ 3E-10
Tying A Bowline Knot ......................................................3E-15
Tying a Stevedore Knot................................................... 3E-16
E
Deck Channel Replacement..................................... 3E-10
90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 3E-1

Mounts

Contact areas of the lower pivot pin
95 2-4-C with PTFE 92-802859A 1
Contact areas of the upper pivot
Deck Mount
Clutch Spring Removal
! WARNING
Failure to relieve tension on the mount spring before service may result in personal injury or product failure. Always relieve
the spring tension before servicing the product.
1. With the mount in the deployed position, remove the clutch knobs and washers.
a b b a - Clutch knob
a
b - Washers (hidden)
c - Shoulder bolts (hidden)
c
c
58890
2. Insert a pry bar into the head assembly.

NOTE: The mount assembly must be secured to a boat deck or sturdy work surface before applying pressure to the pry
bar.
! WARNING
Uncontrolled release of the clutch springs can cause serious injury. Relieve the spring tension slowly.
3. Apply pressure to the pry bar to stretch the clutch spring assembly to remove tension on the shoulder bolts. Remove the
shoulder bolts.
b a- Pry bar
a
b- Shoulder bolts
c
c- Clutch springs
d- Head assembly
58893
d
4. Remove the pry bar from the head assembly.
! WARNING
Avoid personal injury by applying pressure to the top channel when releasing the lockslide pins. Failure to apply pressure on
top of the top channel when pulling the rope to release the lockslide pins may cause the top channel to spring upward.
Page 3E-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Mounts
5. Pull the lockslide release rope and raise the bow arm assembly. Allow the bow arm to rest on the mount.
6. Pull the top channel away from the clutch channel and remove the clutch insert.
a a- Top channel
b- Bow arm
c- Clutch insert
d- Clutch channel
d
58895
7. Push the lock pin through the clutch channel side rails and clutch springs.
a b c
b a - Clutch channel
b - Lock pin
c - Clutch springs
58899
8. Pivot the top channel onto the boat deck or work surface.
9. Remove one retaining ring from the end of the long lock pin. Push the long lock pin through the top channel side rails and
the clutch springs.
10. Remove the clutch springs.
a b c a- Clutch springs
d
b- Retaining ring
c- Long lock pin
d- Top channel
58901

Mounts
Clutch Spring Installation

1. To install new clutch springs, insert the long lock pin through the top channel rail and the two clutch springs. Ensure that
the clutch spring hooks are in the lock pin grooves. Install the previously removed retaining ring onto the long lock pin.
a b c a- Clutch springs
d
b- Retaining ring
c- Long lock pin
d- Top channel
58901
2. Install the short lock pin through the clutch channel and new springs.
a b c
b a - Clutch channel
b - Lock pin
c - Clutch springs
58899
3. Install the clutch insert over the clutch channel to secure the short lock pin in the clutch channel.
a a- Top channel
b- Bow arm
c- Clutch insert
d- Clutch channel
d
58895
4. Pivot the top channel down over the clutch channel.

5. Insert a pry bar into the head assembly.
! CAUTION
Avoid serious injury from uncontrolled release of the spring. Always wear eye protection and use caution when servicing the
spring should it uncoil.

Mounts
6. Apply pressure to the pry bar to stretch the clutch spring assembly while installing the shoulder bolts through the clutch
insert, clutch channel, and top channel.
b a- Pry bar
a
b- Shoulder bolts
c
c- Clutch springs
d- Head assembly
58893
d
7. Install a stainless steel washer and knob on each shoulder bolt and tighten the knobs securely.
a b b a - Clutch knob
a
b - Washers (hidden)
c - Shoulder bolts (hidden)
c
c
58890
Top Channel Removal

1. Remove the clutch springs. Refer to Clutch Spring Removal.
2. Remove the nylon locknut, plastic washers, and rubber insulator from the shoulder bolts on each side of the top channel.
3. Remove the shoulder bolt from each side of the deck channel and remove the top channel.
a- Shoulder bolt (one per side)

a b- Top channel
b c- Rubber insulator (one per side)
d- Nylon locknut
e- Plastic washers (two per side)
c
e
d 58990
Top Channel Installation

1. Align the top channel with the deck channel as shown.

Mounts
2. Install the shoulder bolts, plastic washers, rubber insulators, and nylon locknuts onto each side of the deck channel.
Tighten the locknuts securely.

a b- Top channel
d- Nylon locknut
c
e
d 58990
3. Install the clutch springs. Refer to Clutch Spring Installation.
Head Assembly Removal

1. Remove the clutch springs. Refer to Clutch Spring Removal.
2. Remove the E‑clip from the pivot shaft.
3. Remove the upper pivot pin, washers, spacers, and rope bushing.
a c b a- Rope bushing
b- Spacers (2)
c- Washers (one per side)
d- E‑clip (one per side)
e- Upper pivot pin
e
58993
4. Remove the set screw securing the lower pivot pin.
5. Remove the lower pivot pin and spacer.
a- Spacer
b- Set screw
c- Lower pivot pin
d- Head assembly
d
a
c 58995
6. Move the latch release rope aside and remove the head assembly from the bow arm.

Mounts
Head Assembly Installation

1. Lubricate the contact areas of the lower pivot pin with 2‑4‑C with PTFE.

95 2-4-C with PTFE Contact areas of the lower pivot pin 92-802859A 1
2. Route the rope handle under the spacer, then upwards behind the new head assembly.
3. Install the lower pivot pin and spacer through the head assembly and bow arm. Secure the lower pivot pin with the set
screw.
a- Spacer
b- Set screw
c- Lower pivot pin
d- Head assembly
d
a
c 58995
4. Lubricate the contact areas of the upper pivot pin with 2‑4‑C with PTFE.

95 2-4-C with PTFE Contact areas of the upper pivot 92-802859A 1
5. Install the upper pivot pin, washers, spacers, and rope bushing as shown.
6. Install the E‑clip onto the upper pivot pin.
a c b a- Rope bushing
b- Spacers (2)
c- Washers (one per side)
d- E‑clip (one per side)
e- Upper pivot pin
e
58993
7. Install the clutch springs. Refer to Clutch Spring Installation.

Mounts
Bow Arm Replacement

1. Pull the lockslide release rope and raise the bow arm to a 45° angle. Place a block of wood between the bow arm and the
deck channel.
a- Lockslide release rope

b- Bow arm
c- Deck channel
a d- Block of wood
b
d 43997
c
2. Remove the set screw securing the lower pivot pin.
3. Remove the lower pivot pin and spacer.
a- Spacer
b- Set screw
c- Lower pivot pin
d d- Head assembly
b
c 59397
4. Support the bow arm with a wood block as shown.

5. Remove the locking pins. Refer to Front Locking Pin Replacement and Rear Locking Pin Replacement.
b a - Rear locking pin

b - Front locking pin
a
59404

Mounts
6. Remove the rear bow arm pin, flanged bushings, washer, and retaining ring. Remove the bow arm.
a a- Bow arm
b- Retaining ring
c- Flanged bushings (both sides)
d- Washer (hidden)
e- Rear bow arm pin
b
c
e
d
59334
7. Transfer the lockslide assembly to the new bow arm if it is not damaged, or install a new lockslide assembly. Refer to
Lockslide Replacement.
8. Transfer the rope to the new lockslide assembly if it is not damaged, or install a new rope. Refer to Rope Replacement.
9. Transfer the front and rear locking pins to the new bow arm if they are not damaged, or install new locking pins. Refer to
Front Locking Pin Replacement and Rear Locking Pin Replacement.
10. Install the rear flanged bushings, plastic washer, bow arm pin, and retaining ring.
IMPORTANT: Ensure that the lockslide spring is secured to the rear bow arm pin and resting in the pivot pin groove.
11. Install the lower pivot pin, spacer, and set screw.
Lockslide Replacement
1. Remove the front and rear locking pins from the bow arm. Refer to Front Locking Pin Replacement and Rear Locking
Pin Replacement.
2. Remove the bow arm from the mount. Refer to Bow Arm Replacement.
3. Pull the lockslide assembly out of the bow arm.
a b a - Lockslide assembly
b - Bow arm
59410
4. Insert the new lockslide assembly into the bow arm, oriented as shown.
5. Install the bow arm onto the mount. Refer to Bow Arm Replacement.
IMPORTANT: Ensure that the lockslide spring is secured to the rear bow arm pin and resting in the pivot pin groove.
a b c a - Lockslide assembly
b - Lockslide spring
c - Bow arm
59411
6. Install the rope and latch release handle onto the new lockslide mechanism. Refer to Rope Replacement.

Mounts
Decket Replacement
1. Remove the four decket screws from the deck channel. Slide the decket off of the deck channel.
a c a - Decket
b - Decket screws
c - Deck channel
b
b
58999
2. To assemble the decket to the deck channel, place the decket on the end of the deck channel. Use a rubber mallet to align
the decket screw holes with the deck channel screw holes.
3. Secure the decket to the deck channel using the four decket screws. Tighten the decket screws to the specified torque.

Decket screws 2.3 20 –
Deck Channel Replacement

1. Pull the lockslide release rope and raise the top channel bow arm to a 45° angle. Support the top channel and bow arm
with wooden blocks.
a - 45° angle
59336
2. Remove the decket. For instructions, refer to Decket Replacement.

3. Remove the rear bow arm pin, flanged bushings, washer, and retaining ring.
a a- Bow arm
b- Retaining ring
c- Flanged bushings (both sides)
d- Washer (hidden)
e- Rear bow arm pin
b
c
e
d
59334

Mounts
4. Remove the shoulder bolts, rubber insulator, plastic washers, and nylon locknuts. Remove the deck channel.

a b- Deck channel
d- Nylon locknut
c
e
d 58990
5. Install the new deck channel.

6. Install the shoulder bolts, nylon washers, and locknuts. Tighten the locknuts securely.
7. Insert the rear bow arm pin. Ensure that the lockslide spring is securely positioned in the middle of the lockslide pin.
Front Locking Pin Replacement

The front locking pin can be easily replaced if the locking pin is damaged. Refer to the following instructions and follow them
completely for a successful repair.
! WARNING
1. Pull the latch release handle and open the mount to a position where it is part way between the stowed and deployed
positions. Support the mount in this position.
2. Pull and hold the latch release handle until the lock is aligned as shown. Hold the latch release handle in this position.
IMPORTANT: Do not release the latch release handle until the new locking pin is installed, or internal damage to the
mount will occur.
a - Locking pin
b - Lock
a
b
58757
3. Once the lock is aligned as shown, press the locking pin in the direction indicated, but do not remove it completely.

Mounts
NOTE: If required, tap the locking pin out with a screwdriver handle or small hammer to disengage the locking pin.
58758
4. Continue to hold the latch release handle once the locking pin is partially removed.
5. Orient the new locking pin so the alignment tab is facing the same direction as the alignment tab of the old locking pin.
6. Press the new locking pin into the opposite side of the mount. Continue to press the new locking pin until it clicks into
position.
NOTE: The new locking pin will press out the old locking pin as it is installed.
a - Alignment tabs
a a
58760
7. Release the latch release handle and move the trolling motor to the stowed or deployed position as desired.
Rear Locking Pin Replacement

The rear locking pin can be easily replaced if the locking pin is damaged. Refer to the following instructions and follow them
completely for a successful repair.
IMPORTANT: The rear locking pin is made from stainless steel for durability. MotorGuide does not recommend interchanging
the stainless steel locking pin with the plastic locking pin used on the front of the mount.
! WARNING
1. Pull the latch release handle and open the mount to a position where it is part way between the stowed and deployed
positions. Support the mount in this position.
2. Pull and hold the latch release handle until the lock is aligned as shown. Hold the latch release handle in this position.

Mounts
IMPORTANT: Do not release the latch release handle until the new locking pin is installed, or internal damage to the
mount will occur.
a a - Lock
b - Locking pin
59356
3. Once the lock is aligned as shown, press the locking pin out of the bow arm in the direction indicated.
NOTE: If required, tap the locking pin out with a screwdriver handle or small hammer to disengage the locking pin.
59358
4. Continue to hold the latch release handle while removing the locking pin.
5. Orient the new locking pin so the alignment tab is facing the mount head.
6. Press the new locking pin into the opposite side of the mount. Continue to press the new locking pin until it clicks into
position.
a - Alignment tab
59359
7. Release the latch release handle and move the trolling motor to the stowed or deployed position as desired.
Rope Replacement
1. Move the mount to the stowed position and remove the trolling motor from the mount.

Mounts
2. Untie the bowline knot from the latching mechanism.
a - Latching mechanism
a b b - Bowline knot
c
c - Spacer
59214
3. Remove the defective rope. Retain the handle and washer if they are not broken.
4. Route the replacement rope through the rope bushing.
a - Rope bushing
b - Replacement rope
a b
59215
5. Route the replacement rope over the spacer. Tie the replacement rope to the loop on the latching mechanism using a
bowline knot. Refer to Tying a Bowline Knot for knot instructions.
a - Latching mechanism
a b b - Bowline knot
c
c - Spacer
59214
6. Replace the handle, if necessary. Insert the rope through the handle and the washer, then tie a stevedore knot. Refer to
Tying a Stevedore Knot for knot instructions.
a a - Handle
b - Washer
c - Stevedore knot
b
c
56887

Mounts
7. Push the button into the handle.
a - Handle
b - Stevedore knot
c - Button
44110
b
c
Tying A Bowline Knot

1. Make a small loop. Ensure that the free end of the rope is underneath the intersection formed by the loop.
40115
2. Pass the free end of the rope through the loop.
40116
3. Bring the free end of the rope around and behind the standing end.
40117
4. Put the free end of the rope back through the loop and then tighten the hitch. The free end of the rope lies in the middle of
the loop.
40118

Mounts
Tying a Stevedore Knot

1. Make a small loop. Ensure that the free end of the rope is on top of the intersection formed by the loop.
40568
2. Bring the free end of the rope around and behind the standing end twice.
40569
3. Insert the free end through the loop. Pull the loops toward the free end of the rope to tighten the hitch.
40570

X5
Service Manual
© MARCH 2016, Mercury Marine. All Rights Reserved. 90-8M0107213

Service Manual: © MARCH 2016, Mercury Marine. All Rights Reserved. 90-8M0107213

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X5

© MARCH 2016, Mercury Marine. All Rights Reserved. 90-8M0107213

IMPORTANT: Identifies information essential to the successful completion of the task.

Page i © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Copyright and Trademark Information

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page ii

Page iii © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1A-1

Lubricants, Sealants, Adhesives

Inspection and Maintenance Schedule

AFTER EACH USE

EVERY 100 HOURS OF USE OR ANNUALLY

c c b a a- Latch pin hooks

Page 1A-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Tube Ref No. Description Where Used Part No.

Adjusting the Steering Cable Tension

Description Nm lb‑in. lb‑ft

Bottom of foot pedal

X5‑55/X5‑70/X5‑80/X5‑105 MotorGuide Trolling Motor

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1A-3

Page 1A-4 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1B-1

Wiring and Battery Information

Wire Color Code Abbreviations

Recommended Practice and Procedures

Page 1B-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Recommended MotorGuide Accessory Description Part Number

Battery Cutoff Voltage

Establishing a Common Ground

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1B-3

12‑Volt Battery Connection

c - Trolling motor battery

d - Engine starting battery

24‑Volt Battery Connection

Page 1B-4 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

36‑Volt Battery Connection

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1B-5

X5 Wiring Diagram—Cable Steer Models

Page 1B-6 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Head Cover Assembly Wiring

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 1B-7

Page 1B-8 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 2A-1

Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

Page 2A-2 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Symptom Possible Cause Resolution

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 2A-3

Symptom Possible Cause Resolution

1. Place the armature in a growler. Turn on the growler.

Checking the Armature for Ground

DMT 2004 Digital Multimeter 91‑892647A01

Checking for Interference

Page 2A-4 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Mercury Marine Service Offices

United States, Canada

Europe, Middle East, Africa

Mexico, Central America, South America, Caribbean

Asia, Singapore, Japan

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 2A-5

Page 2A-6 © 2016 Mercury Marine 90-8M0107213 eng MARCH 2016

Trolling Motor Disassembly and Assembly

90-8M0107213 eng MARCH 2016 © 2016 Mercury Marine Page 3A-1

Trolling Motor Assembly