Found the Buelletin on Overcurrent Problem. https://www.crowleymarine.com/sb/2/14300

https://cimg5.ibsrv.net/gimg/www.off...0bac47d2b6.jpg
https://cimg7.ibsrv.net/gimg/www.off...d46b4785fd.jpg
https://cimg8.ibsrv.net/gimg/www.off...dded115ab9.jpg
https://cimg9.ibsrv.net/gimg/www.off...1674cd7090.jpg

Fuse/Harness kit for this Overcurrent Recall:

https://www.crowleymarine.com/mercur...cfm?mdl=LRPM2O

Fuse link
 

Those IAC fuse harnesses are from MDC correct? The link I posted was the Improper Overcurrent Protection on the starter solenoid going to the main harness and alternator sense wires...the recall from Mercury that BUP pointed out in this thread as being related to the IAC issues. They might be separate but nonetheless, I was able to find the instructions so wanted to post it. I plan on buying the IAC fuse harnesses from MDC and then doing the Mercury recall update on the starter solenoid adding the additional fuses there as well.

I found 2 more critical recalls/updates for the 600sci/700sci. The electric fuel pumps need to be replaced as they leak and the boost bypass valve needs to be reprogrammed because it can limit boost and or no boost, thus hurting performance. This is the website to search on your engine serial number to find recalls and also it has very nice diagrams of all the parts for these engines! It's a great resource. https://www.crowleymarine.com/mercury-outboard/13131.cfm?mdl=LRPM2O&q=0M958889

I made those It doesnt take much

old BUP knows his stuff as I been telling everyone up here about the SB.

Its called IMPROPER OVER PROTECTION for a reason and needs to be done for many reasons

Also the one amp fuse is not the design to use as that was basically an after thought and basically a bandaide . .That is not per Merc recs and is not protecting other over current issues and areas. . One can call Merc and or including myself for the reasons for not using the 1 amp fuse.. I do not want to type all this out..

follow what I have been telling everyone.up here will fix that issue along with proper maintenance. .There is many keys to follow so one does not have PCM failures.

Eddie yes the HP 525 and the 600 Sci and 700 Sci for the ones that do not have the over current protection I know because I have repaired the PCMs internally of the failure.

The 496 is the worse as thats because the boat owner does not include the correct maintenance for protecting the IAC inwhich can lead to a bad PCM / ECM for a jist.

also the 4.3 and 5.0 and 5.7 and the 6.2 using ECM 555 the same - the boat owner improper or Zero maintenance for IAC longevity Anyways the jist..

Also the 600 and 700 --- ign coil driver(s) internally can BE KNOCKED OUT in the PCM from ign coil failure.

Totally NOT recommended period. half the battle is proper maintenance and the other issue is over current protection needed,

I have the OEM kits to Make right as how Merc engineered it after the fact.

The 496 is not included in this for over current protection.. The issues are boaters buying aftermarket IACs inwhich most do not perform the correct PWM per Merc PCM and ECM 555. The next issue is total lack of proper maintenance. Voltage issues add to the mix as well for all. .

Update. I ended up sourcing all the factory ends, had 1 amp fuse pigtails made, etc enough to make up to 50 of these IAC isolators. After talking to BUP I did the Mercury over current protection kit install and replaced both of my IAC with a MERC part # instead of the cross referenced Windstar part #. I did the IAC every year anyways in the past, just going to use the factory part from here on out. If anyone wants a deal on this box of ends, plugs, wiring, etc send me a PM. Also have a couple of new in box Motorcraft IAC.

I didnt make any out of all the parts I ordered. I wouldnt sell you pigtails unless I tested them in a complete state. If your looking for finished pigtails, Marine Design Corp (MDC) makes them. http://www.marinedesigncorp.com/

old BUP knows his stuff as I been telling everyone up here about the SB.

Its called IMPROPER OVER PROTECTION for a reason and needs to be done for many reasons

Also the one amp fuse is not the design to use as that was basically an after thought and basically a bandaide . .That is not per Merc recs and is not protecting other over current issues areas. . One can call Merc and or including myself for the reasons for not using the 1 amp fuse.. I do not want to type all this out..

follow what I have been telling everyone.up here will fix that issue along with proper maintenance. .There is many keys to follow so one does not have PCM failures.

Not trying to sound bad about my statements here. But alot of boaters are running around with one or many recalls and service bulletins that NEED TO BE DONE and done with the proper parts and proper installs.

Not to discredit anyone nor their parts here but the 1 amp fuse does nothing for the over current protection for the starter side nor does it do anything for the Alternator side of the power that all leads back to the PCM.

I brought the info to the table for years now --- that many boaters have no idea about their set up needing huge updates and many of you need to listen to someone like myslef who does this daily and repairs ECM / PCM s almost daily

This is a huge case in point that boaters actually need to take their boats into oem dealer because they need an update or many updates done and get the correct info of awareness.

I can not tell you how many boaters have not had the update done and its in the 1000s because most of the serial numbers I run still show still an outstanding recall that has NEVER BEEN DONE.

And for the record if you are still listening to me there is 7 Merc racing engines that need to make sure the update are DONE along with many important service bulletins that side with ones engine serial number. AGAIN need to be done correctly with the proper parts for the complete protection.

This have been since 2008 for the update and like I said , 1000s of boaters are running around with a time bomb. Boaters need to rethink about what a huge benefit to have a relationship with an OEM dealer can be .

And for the record I have 60 kits in stock that are the proper kit and for the proper install. Just saying.

last week fix HP 600 sci and the recall was NEVER DONE - Blew the whole track and circuit completely out. The few that repair ECMs / PCMs would have said sorry your PCM is totally junk and NON REPAIRABLE but I keep at it and repaired the whole darn thing good as new actually better than new because of the better better internal components I installed Just saying.

The ECM / PCM 555 have some average components installed at best.. By far the largest group of failures in the whole marine industry not even close is the 555 s.
its 100 - ecm / pcm 555 s fail to 1 Econtrols ecm. https://cimg1.ibsrv.net/gimg/www.off...6924f6298c.jpg

last week fix HP 600 sci and the recall was NEVER DONE - Blew the whole track and circuit completely out. The few that repair ECMs / PCMs would have said sorry your PCM is totally junk and NON REPAIRABLE but I keep at it and repaired the whole darn thing good as new actually better than new because of the better better internal components I installed Just saying.

The ECM / PCM 555 have some average components installed at best.. By far the largest group of failures in the whole marine industry not even close is the 555 s.
its 100 - ecm / pcm 555 s fail to 1 Econtrols ecm. https://cimg1.ibsrv.net/gimg/www.off...6924f6298c.jpg

Boat was running rough one day while in Destin last week. Then alarms started going off with key on and while ign on. IAC code.

Glad I installed those 1A fuses. Fuse was blown, IAC shorted. Put in a new fuse and a new IAC at the dock, and we're boating again. Nice!

Terry

Speaking out loud: Merc has so many damn IAC issues across all their motors, and many use OE Ford or GM IAC’s that have little trouble in vehicles.

What gives ? Belt dust ? Too much IAC opening ?

It is very strange that an IAC will run 200K miles on a car, but will only last a year in a boat. I would like to know the reason as well. I have always carried a spare with me and have used them more than one would think.

I always wondered if it was the higher duty cycle compared to a car?

I really think it is this. Merc should have more idle air thru the blades and little thru iac. Big propped boats with little engine torque at idle will need mire isc action, but......

I wonder if opening the tb blade up a touch to lower the iac percent would make the iac last longer? (Draw less amps). I know BUP (am I allowed to say that? Lol) would say it has to be a certain percent (20 or 30٪ if I remember right) for a warmed up engine at idle.

When I tune my cars I usually set the desired idle rpm about 50rpms lower with the iac disconnected.

Yup, but your tps had to be within spec still as that will move. If not, and If tps is adjustable, and/or you can program your computer to your idle setting spec.

We are on the same exact page.

Merc could/should do better on this issue for sure. Especially since these issues have been going on for so many years now across mist all motor lines.