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Force 120 User Manual

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90-826881990 398- 1 -Printed in U.S.A.
FORCE 75/90/120 MODELS
INSTALLATION MANUAL
NOTICE to INSTALLER
After Completing Installation, These Instruc-
tions Should Be Placed with the Product for
the Owners Future Use.
75/90/120 Model
This installation manual provides outboard installa-
tion procedure, proper setup and necessary adjust-
ments. PLEASE READ CAREFULLY AND THOR-
OUGHLY BEFORE BEGINNING INSTALLATION.
The remote control connected to your outboard
MUST be equipped with a start-in-gear protection de-
vice. This prevents the engine from starting when the
outboard is in gear.
1998 Mercury Marine
The following are registered trademarks of Brunswick Corpora-
tion: Autoblend, Force, Jet-Prop, Mariner, Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine, Quicksilver, Ride-Guide,
Sport-Jet, and Thruster.
Table of Contents
Page
Notice to Installer and Owner 2. . . . . . . . . . . . . . . . .
Selecting Steering Cables and
Remote Control Cables 2. . . . . . . . . . . . . . . . . . . .
Installing Outboard on Transom 2. . . . . . . . . . . . . . .
Determining Recommended
Outboard Mounting Height 2. . . . . . . . . . . . . .
Locating Centerline of Boat Transom 2. . . . . . .
Drilling Outboard Mounting Holes 3. . . . . . . . . .
Lifting Outboard 3. . . . . . . . . . . . . . . . . . . . . . . . .
Securing Outboard to Boat Transom 3. . . . . . . .
Ride Guide Steering Cable/Attaching
Kit Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Ride Guide Steering
Cable To The Outboard 4. . . . . . . . . . . . . . . . .
Steering Link Rod Installation 4. . . . . . . . . . . . . .
Lubrication 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Installation 5. . . . . . . . . . . . . . . . . . .
Shift and Throttle Cable
Installation to the Outboard 6. . . . . . . . . . . . . . . . .
Shift Cable Installation 6. . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation 6. . . . . . . . . . . . . . . . .
Fuel Line Installation 7. . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Line 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Portable Fuel Tank 8. . . . . . . . . . . . . . . . . . . . . . .
Permanent Fuel Tank 8. . . . . . . . . . . . . . . . . . . . .
Required Side Mount Remote Control
or Ignition Key Switch Assembly 8. . . . . . . . . . . . .
Boats Equipped with Side Mount
Remote Control 8. . . . . . . . . . . . . . . . . . . . . . . .
Boats equipped with Panel
or Console Mount Remote Control 8. . . . . . .
Connecting Remote Control or Key Switch Wire
Harness to Engine Wire Harness 8. . . . . . . . . . . .
Battery Connections 9. . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Installation 9. . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim System 10. . . . . . . . . . . . . . . . . . . . . . . . .
General Information 10. . . . . . . . . . . . . . . . . . . . .
Power Trim Operation 10. . . . . . . . . . . . . . . . . . .
Trim “In” Angle Adjustment
(Models With Power Trim) 11. . . . . . . . . . . . . .
Checking Power Trim Fluid Level 11. . . . . . . . .
Tilt Pin Adjustment
(Models Without Power Trim) 11. . . . . . . . . . . . . .
Trim Tab Adjustment 12. . . . . . . . . . . . . . . . . . . . . . . .
Boat Performance 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Test Instructions 13. . . . . . . . . . . . . . . . . . . . . . . .
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Force 120 Specifications

General IconGeneral
Engine Type2-Stroke
Horsepower120 hp
Ignition SystemCDI
Recommended Fuel87 Octane
Starting SystemElectric
SteeringRemote
Alternator Output16 Amp
Fuel Induction SystemCarburetor
Recommended OilTC-W3
Shaft Length20 in.
Displacement1.6 L
Weight178 kg
Dry Weight178 kg

Summary

Notice to Installer and Owner

Safety Alert Definitions

Defines DANGER, WARNING, and CAUTION alerts used in the manual.

Horsepower Limitations

Advises against exceeding the boat's maximum horsepower rating.

Steering and Remote Control Cable Selection

Guidance on selecting correct length steering and remote control cables.

Installing Outboard on Transom

Outboard Mounting Height Recommendation

Recommends mounting height for optimal performance, aligning anti-ventilation plate.

Transom Centerline Location

Instructions for locating and marking the vertical centerline of the boat transom.

Drilling Outboard Mounting Holes

Pre-Drilling Mounting Hole Considerations

Emphasizes reading mounting height recommendations before drilling.

Mounting Hole Placement Warning

Warns against placing upper bolts too close to the transom top or through shims.

Fiberglass Drilling Tip

Suggests using masking tape to prevent fiberglass chipping when drilling.

Transom Drilling Fixture Usage

Instructions for using the drilling fixture and guide holes.

Lifting Outboard

Outboard Lifting Safety Warning

Warns about secure lifting ring threading and hoist capacity before lifting.

Securing Outboard to Boat Transom

Steering Cable Integration During Mounting

Ensures steering cable is installed in tilt tube before securing outboard.

Water-Tight Mounting Sealant

Requires marine sealer on bolt shanks for a water-tight installation.

Transom Bolt Tightening Method

Advises against using an impact driver for tightening mounting bolts.

Critical Transom Securing Warning

Ride Guide Steering Cable/ Attaching Kit Installation

Steering Cable Kit Application Note

Specifies instructions are for single cable installations.

Steering Cable Length Reference

Directs users to the accessory guide for correct steering cable length.

Steering Cable Length Importance

Highlights issues with too-short or too-long cables (kinks, stress).

Installing Ride Guide Steering Cable To The Outboard

Lubrication for Steering Cable Installation

Advises lubricating the cable end and tilt tube with marine lubricant.

Pre-Lubricated Steering Cable Note

Notes that the Ride Guide cable is factory lubricated.

Steering Link Rod Installation

Steering Link Rod Fastener Specification

Specifies using a special washer head bolt and self-locking nuts.

Steering Link Rod Disengagement Hazard

Warns of severe injury or death if the link rod disengages.

Steering Link Rod to Cable Assembly

Details assembling the link rod to the steering cable with specific hardware.

Steering Link Rod to Engine Assembly

Remote Control Installation

Remote Control Cable Length Reference

Directs users to the accessory guide for correct remote control cable length.

Remote Control Cable Length Importance

Highlights issues with too-short or too-long cables (kinks, stress).

Remote Control Installation Sequence

Advises installing cables to remote control and mounting it before connecting to engine.

Post-Installation Steering Check Warning

Steering System Lubrication Schedule

Shift and Throttle Cable Installation to the Outboard

Shift Cable Installation Priority

States that the shift cable should be installed before the throttle cable.

Shift Cable Installation

Shift Cable: Neutral Position Setup

Ensures the remote control handle is in neutral before starting.

Shift Cable: Engine Neutral Setup

Manually shifts the engine's shift actuator to the neutral position.

Shift Cable: Measuring and Adjusting Barrel

Describes measuring distance and adjusting the cable barrel for proper fit.

Shift Cable: Securing to Mounting Stud

Details fastening the shift cable to the mounting stud with washer and locknut.

Shift Cable Adjustment Checks

Provides steps to verify correct shift cable engagement in forward, neutral, and reverse.

Throttle Cable Installation

Throttle Cable: Installation Priority

Instructs to attach the shift cable before attaching the throttle cable.

Throttle Cable: Neutral Position Setup

Ensures the remote control handle is in neutral before starting.

Throttle Cable: Engine Idle Setup

Positions the engine's throttle lever against the idle stop.

Throttle Cable: Measuring and Adjusting Barrel

Describes measuring distance and adjusting the cable barrel for preload.

Throttle Cable: Barrel Adjustment for Preload

Adjusts the cable barrel to achieve the specified distance for preload.

Throttle Cable: Securing to Mounting Stud

Details fastening the throttle cable to the mounting stud with washer and locknut.

Throttle Cable Adjustment Checks

Provides steps to verify the throttle cable returns to idle correctly.

Throttle Cable Preload Note

Bottom Cowl Grommet Installation

Fuel Line Installation

Fuel Line Specification

Specifies minimum inside diameter for fuel lines.

Fuel Line: Fuel Pump Connection

Installs the fuel line onto the fuel pump and secures it.

Fuel Line: Bottom Cowl Grommet Connection

Connects the fuel line connector through the bottom cowl grommet.

Portable Fuel Tank Installation

Permanent Fuel Tank Installation Standards

Required Side Mount Remote Control or Ignition Key Switch Assembly

Side Mount Remote Control Requirement

Requires a Quicksilver Commander 2000 series with a warning horn.

Panel/Console Mount Remote Control Requirement

Requires a Quicksilver Ignition Key/Choke Assembly with a warning horn.

Connecting Remote Control or Key Switch Wire Harness to Engine Wire Harness

Harness Routing to Outboard

Instructions for routing wiring harnesses along the boat to the outboard.

Harness Connection Through Cowl

Guides routing the harness through the cowl and connecting connectors.

Power Trim Wire Harness Connection

Details connecting power trim wires between remote and engine harnesses.

Wiring Harness Slack Check

Cable and Harness Grommet Routing

Battery Connections

Battery Connection Polarity Warning

Warns that incorrect battery polarity can damage the charging system.

Battery Cable Connection Procedure

Details connecting positive and negative battery cables to the terminals.

Propeller Selection

Propeller Selection for Performance

Guides selection for optimal RPM in the upper half of the throttle range.

Propeller Adjustment for Conditions

Advises changing propeller for varying conditions like weather or load.

Full-Throttle RPM Verification

Recommends checking full-throttle RPM with engine trimmed for balance.

Propeller Installation

Propeller Installation Safety Warning

Warns about accidental engine starting and potential injury.

Loose Propeller Caution

Warns that a loose propeller can cause damage.

Propeller Security Check

Advises periodically checking the propeller locknut for tightness.

Propeller Hub Corrosion Prevention

Recommends applying anti-corrosion grease to the shaft.

Propeller Installation: Neutral Gear

Sets the remote control to neutral before starting propeller installation.

Propeller Installation: Spark Plug Disconnection

Removes spark plug leads to prevent accidental engine start.

Propeller Installation: Shaft Greasing

Propeller Installation: Component Assembly

Propeller Installation: Torque Specification

Propeller Installation: Nut Securing

Power Trim System

Power Trim System General Information

States the power trim system is pre-filled and pressurized.

Power Trim Operation Overview

Explains how trim affects boat attitude, performance, and steering torque.

Power Trim Steering Torque Hazard

Warns about potential loss of boat control due to steering torque from trimming.

Effects of Trimming In or Down

Lists benefits and potential hazards of trimming the outboard down.

Power Trim Over-Trimming Warning

Warns against turning the boat when on plane if trimmed extremely in or down.

Effects of Trimming Out or Up

Lists benefits and potential hazards of trimming the outboard up.

Trim 'In' Angle Adjustment (Models With Power Trim)

Trim 'In' Angle Adjustment Benefits

Explains how greater trim 'under' capability improves acceleration and planing.

Limiting Trim 'Under' Capability

Details how to limit trim under using a stainless steel tilt pin.

Trim 'In' Angle Adjustment Safety

Warns against turning the boat when on plane if trimmed extremely in or down.

Checking Power Trim Fluid Level

Power Trim Fluid Level Check Procedure

Steps to check the power trim fluid level with the outboard tilted up.

Power Trim Fluid Level Specification

Specifies checking fluid level against the fill hole and fluid types.

Tilt Pin Adjustment (Models Without Power Trim)

Tilt Pin Installation Warning

Warns that operating without the tilt pin can cause serious injury or death.

Tilt Pin Adjustment for Water Alignment

Guides placing the tilt pin to align the outboard perpendicular to the water.

Tilt Pin Adjustment Considerations

Directs user to review lists for guidance on adjusting the tilt pin.

Effects of Tilt Pin in Lower Holes

Effects of Tilt Pin in Upper Holes

Trim Tab Adjustment

Trim Tab for Steering Torque Compensation

Explains how trim tabs can compensate for steering torque.

Trim Tab Adjustment Limitation Note

Notes trim tab effectiveness is limited if outboard is mounted too high.

Trim Tab Adjustment (No Power Trim)

Details trim tab adjustment for boats without power trim.

Trim Tab Adjustment (With Power Trim)

Details trim tab adjustment for boats with power trim.

Boat Performance

Boat Performance Test Instructions

Provides instructions for testing boat performance and engine RPM.

Boat Performance: Steering Grip Importance

Advises a firm grip on steering during acceleration, deceleration, and trimming.

Dual Outboard Trimming Caution

Advises simultaneous and then individual trimming for dual outboards.

Initial Trim Setting for Performance Test

Sets initial trim based on cowl decal being horizontal for acceleration/speed.

Familiarization Ride Before Testing

Recommends a short ride to get familiar with settings before testing.

Wind Conditions for Performance Testing

Suggests testing with or against wind for accuracy; downwind for high winds.

Top Speed WOT Test Procedure

Details conducting a wide-open throttle test to check engine RPM.

Acceleration Test Accuracy Note

Recommends using a stopwatch for accurate acceleration testing.

Acceleration Test Procedure

Describes performing an acceleration test up to 20 MPH.

Propeller 'Break Loose' During Acceleration

Addresses propeller break loose and how to mitigate it by trimming or lowering.

Data Recording for Performance Tests

Recommends recording all test data on a chart.

Propeller Selection for General Purpose

Guides selecting a propeller that allows optimal RPM and performance.

Pitch vs. Acceleration Trade-off Note

Compares higher pitch (top speed) versus lower pitch (acceleration).

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