2002+ Mercury 240 Jet Drive EFI Outboard OEM Service & Repair Manual

1 A SPECIFICATIONS 90-884822 DECEMBER 2001 Page 1A-1 IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Master Specifications 1A-2 . . . . . . . . . . . . . . . . . . . . Torque Chart 1A-5 . . . . . . . . . . . . . . . . . . . . . . . . . Standard Hardware 1A-6 . . . . . . . . . . . . . . . . . . . Metric Hardware 1A-6 . . . . . . . . . . . . . . . . . . . . . Mercury/Quicksilver Lubricants and Sealants 1A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS Page 1A-2 90-884822 DECEMBER 2001 Master Specifications Model 240 EFI Jet Drive HORSEPOWER (KW) Model 240 Full Throttle RPM Idle RPM (In Gear) RPM Limiter 240 (178.9) 5500 - 6000 1000 - 1100 6700 JET DRIVE WEIGHT Powerhead Pump Unit 231 (105.0 kg) 110 (49 kg) CYLINDER BLOCK Type Displacement V-6 Cylinder, Two Cycle 153 cu. in. (2508 cc) 60° Vee STROKE Length (All Models) 2.65 in. (67.3 mm) CYLINDER BORE Diameter (Std) Diameter 0.015 in. Oversize Taper/Out of Round/Wear Maximum Bore Type 3.501 in. (88.925 mm) 3.516 in. (89.306 mm) 0.003 in. (0.076 mm) Cast Iron CRANKSHAFT Maximum Runout 0.006 in. (0.152 mm) PISTON Piston Type Diameter Standard Diameter 0.015 in. Oversize Aluminum 3.494 in. ± .001 in. (88.748 mm ± 0.025 mm) 3.509 in. ± 0.001 in. (89.129 mm ± 0.025 mm) PISTON DIAMETER Dimension “A” at Right Angle (90°) to Piston Pin .500 12.7mm 3.494 in. ± .001 in. (88.748 mm ± .025 mm) Using a micrometer, measure dimension “A” at location shown. Dimension “A” should be 3.494 in. ± .001 for a STAN- DARD size piston (new) Dimension “A” will be 0.001 – 0.0015 less if coating is worn off piston (used) REEDS Reed Type Reed Stand 0pen (Max.) Single Stage Plastic 5 Petal No Reed Stops

SPECIFICATIONS 90-884822 DECEMBER 2001 Page 1A-3 Model 240 EFI Jet Drive FUEL INJECTION Idle RPM – All Models Wide Open Throttle (WOT) RPM Float Adjustment (Vapor Separator) Float Level Injectors – All Models (Quantity) – Injectors are Crank Angle Driven by ECM – #1 Cylinder – #2 Cylinder – #3 Cylinder – #4 Cylinder – #5 Cylinder – #6 Cylinder Line Pressure @ Injectors Injector Resistance Electric Fuel Pump Resistance Electric Fuel Pump Amperage Draw 1000 ± 1100 5500 – 6000 Preset @ Factory 6 RED + BRN Leads RED + WHT Leads RED + ORG Leads RED + YEL Leads RED + LT BLUE Leads RED + PUR Leads 41 psi – 45 psi (283 kPa – 310 kPa) 12.3 ohms ± 0.5 ohms 0.7 ± 0.3 ohms 4 amperes ± 0.5 amperes FUEL SYSTEM Fuel Recommended Gasoline Recommended Oil Gasoline/Oil Ratio – @ Idle – @ WOT Gasoline w/Oil Injection Unleaded 87 Octane Minimum TC-W3 Premium Plus 2 Cycle Outboard Oil 125:1 40:1

SPECIFICATIONS Page 1A-4 90-884822 DECEMBER 2001 Model 240 EFI Jet Drive STARTING SYSTEM Electric Start – All Models Solenoid Driven Bendix Starter Draw (Under Load) Starter Draw (No Load) Minimum Brush Length Battery Rating 175 Amperes 60 Amperes 0.25 in. (65.4 mm) 670 (Minimum) Marine Cranking Amps 520 (Minimum) Cold Cranking Amps IGNITION SYSTEM Type Spark Plug Type Spark Plug Gap Maximum Timing Idle Timing Throttle Position Sensor @ Idle @ WOT Crank Position Sensor Air Gap Firing Order Digital Inductive NGK BPZ8HS-10 0.040 in. (1.0 mm) Not Adjustable; Controlled by ECM Not Adjustable; Controlled by ECM 0.19 – 1.0 VDC 3.45 – 4.63 VDC 0.025 in. – 0.040 in. (0.635 mm – 1.01 mm) 1-2-3-4-5-6 CHARGING SYSTEM Alternator Output (Regulated) Brush Length Voltage Output Regulator Current Draw 42 - 48 Amperes @ 2000 RPM @ Battery* 52 - 60 Amperes @ 2000 RPM @ Alternator Std Exposed Length: 0.413 in. (10.5 mm) Min. Exposed Length: 0.059 in. (1.5 mm) 13.5 to 15.1 Volts 0.15 mA (Ign. Switch Off) 30.0 mA (Ign. Switch On) *Amperage listed is when battery is in a discharged state. If battery is fully charged, amperage readings will be less.

SPECIFICATIONS 90-884822 DECEMBER 2001 Page 1A-5 Torque Chart PUMP UNIT Special Items Torque Inlet Screen Screw (6 mm) 75 lb. in. (8.5 N·m) Ride Plate Screw 75 lb. in. (8.5 N·m) Reverse Gate Stop Screw 120 lb. in. (13.6 N·m) Impeller Shaft Cover Screw 15 lb. ft. (20.3 N m) Steering Lever Screw 15 lb. ft. (20.3 N m) Pinion Shaft Housing Screw 15 lb. ft. (20.3 N m) Inlet Screen Screw (8 mm) 16.5 lb. ft. (22.4 N m) Drive Housing Cover Nuts 35 lb. ft. (47.5 N·m) Nozzle to Stator Bolts 35 lb. ft. (47.5 N·m) Stator Bolts 35 lb. ft. (47.5 N·m) Rudder Pivot Bolt 50 lb. ft. (68 N·m) Reverse Gate Pivot Bolt 80 lb. ft. (108.5 N·m) Impeller Gear Nut 90 lb. ft. (122 N·m) Impeller Nut 150 lb. ft. (203.4 N·m) POWERHEAD Special Items Torque Reed Block Screws 90 lb. in. (10.2 N m) Vapor Separator 140 lb. in. (15.8 N m) Air Handler Assembly 14.5 lb. ft. (19.7 N m) Crank Case Cover Bolts .312-18x1-1/4 (6 ea) 15 lb. ft. (20.3 N m) Crank Case Cover Bolts 3/8-16x3-1/4 (8 ea) 37 lb. ft. (50.2 N m) Expansion Chamber Nuts 20 lb. ft. (27.1 N·m) Connecting Rod Screws *20 lb. ft. (27.1 N·m) Then Turn Additional 90° Spark Plug 20 lb. ft. (27.1 N m) Cylinder Head *30 lb.ft. (40.6 N·m) Then Turn Additional 90° Adaptor Plate to Powerhead 35 lb. ft. (47.5 N·m) Powerhead to Drive Housing Nuts 35 lb. ft. (47.5 N·m) Flywheel Nut 125 lb. ft. (169.5 N·m) *NOTE: Screws should not be reused after removal

SPECIFICATIONS Page 1A-6 90-884822 DECEMBER 2001 Standard Hardware Screw or Nut Size Torque 6 - 32 9 lb. in. (1.0 N·m) 8 - 32 20 lb. in. (2.3 N·m) 10 - 24 30 lb. in. (3.4 N·m) 10 - 32 35 lb. in. (3.9 N·m) 12 - 24 45 lb. in. (5.0 N·m) 1/4 - 20 70 lb. in. (7.8 N·m) 5/16 - 18 160 lb. in. (18.1 N·m) 3/8 - 16 270 lb. in. (30.4 N·m) Metric Hardware Torque Specification A B lb. in. lb. ft. N·m 8 mm M5 36 3 4 10 mm M6 70 6 8 12 mm M8 156 13 18 14 mm M10 312 26 36 17 mm M12 372 31 42 A B

SPECIFICATIONS 90-884822 DECEMBER 2001 Page 1A-7 Mercury/Quicksilver Lubricants and Sealants Description Mercury Part Number Quicksilver Part Number Needle Bearing Assy. Lubricant [8 oz. (226.8 grams)] tube 92-802868A1 N/A Dielectric Grease [8 oz. (226.8 grams)] can 92-823506-1 92-823506-1 Loctite 271 – Thread Locker (10 ml) tube 92-809819 92-809819 Loctite 567 PST Pipe Sealant (50 ml) tube 92-809822 92-809822 Loctite Master Gasket Kit 92-12564-2 92-12564-2 2 Cycle Premium Outboard Oil [1 Gallon (3.7 liter)] 92-802815A1 92-802815Q1 Perfect Seal [16 oz. (0.45 kg)] can 92-34227-1 92-34227-1 Liquid Neoprene [8 oz. (226.8 grams)] can 92-25711-3 92-25711-3 Cyanacrylate Adhesive Obtain Locally Obtain Locally Bellows Adhesive N/A 92-86166Q1 Loctite 680 Retaining Compound (10 ml) tube 92-809833 92-809833 Loctite 222 Thread Locker (10 ml) tube 92-809818 92-809818 3M Permabond #3M08155 Obtain Locally Obtain Locally Loctite 242 Thread Locker (10 ml) tube 92-809821 92-809821 Loctite 609 Obtain Locally Obtain Locally Loctite 405 Obtain Locally Obtain Locally

SPECIFICATIONS Page 1A-8 90-884822 DECEMBER 2001 Description Mercury Part Number Quicksilver Part Number RTV 587 Silicone Sealer [3 oz. (85.05 grams)] 92-809825 92-809825 Loctite 262 Obtain Locally Obtain Locally Premium Gear Lubricant [1 Quart (0.94 liter)] 92-802846A1 92-802846Q1 Loctite 7649 Primer [4.5 oz (127.57 grams)] 92-809824 92-809824 Anti-Corrosion Grease [8 oz. (226.8 grams)] tube 92-802867A1 92-802867Q1 2-4-C with Teflon [8 oz. (226.8 grams)] tube 92-802859A1 92-802859Q1 Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally Hot Glue Obtain Locally Obtain Locally Special Lubricant 101 [8 oz. (226.8 grams)] tube 92-802865A1 92-802865Q1 4 Stroke 10W30 Outboard Oil [1 Quart (0.94 liter)] 92-802833A1 92-802833Q1 4 Cycle 25W40 Engine Oil [1 Quart (0.94 liter)] 92-802837A1 92-802837Q1 Power Trim & Steering Fluid [8 oz. (226.8 grams)] 92-802880A1 92-802880Q1 Engine Coupler Spline Grease [14 oz. (0.39 kg)] cartridge 92-802869A1 92-802869Q1

2002+ Mercury 240 Jet Drive EFI Outboard OEM Service & Repair Manual

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