TECHNICAL UPDATES

2007

• 5/24/2007 18-21752 Engine Couplers

2006

• 7/13/2006 18-5107-1 Ignition Module
• 7/13/2006 18-5885 Power Pack
• 7/13/2006 18-8056 / 18-8092 OMC Fuel Connector Advisory
• 7/13/2006 18-5115 & 18-5116 Ignition Sensor Kit

2005

• 8/08/2005 18-1953-1 Exhaust Manifold Installation Advisory
• 5/25/2005 18-2190E Shift Cable Assembly Advisory
• 5/25/2005 For any 18-2190E kits
• 5/25/2005 Safety Recall: Champion# MC60 - Marine Carburetor I
• 5/25/2005 Repair Procedure: Champion# MC60 - Marine Carburetor
• 5/25/2005 Safety Recall: Champion# MC60 - Marine Carburetor II
• 3/24/2005 Application Update For 18-7288
• 3/07/2005 18-5913 - Starter Bolts
• 3/07/2005 Revised Oil Return Policy

2004

• 8/26/2004 Sierra #183150 Bravo Water Pump Kit & #18-2166 Prop Shaft
• 5/21/2004 2004 Quarterly Service Bulletin

BULLETIN # 5-24-07

18-21752 Engine Couplers
MODELS AFFECTED: V6 Applications ONLY

An application concern regarding part # 18-21752 engine coupler has been identified. This bulletin is for informational purposes only and is not a product recall for currently installed, in-service parts. In 1999 GM made a small change to the end of the crankshaft on their V6 engines. This action required a change to the width and depth of the groove on the engine coupler. Installation of the current coupler configuration on a 1999 and newer V6 would not in most cases cause any problems. In a few cases however, an engine “whine” that changes with the engine RPM has occurred after approximately 10-15 hours of operating time. Inspection of the affected couplers has found the cause of the “whine” to be from metal to metal contact if the paint coating on the coupler’s groove wears through to bare metal.

At this time, part # 18-21752 should only be used on V6 and V8 (5.0 and 5.7) applications 1998 and prior. Sierra is having the current in-house supply of couplers corrected to fit applications after 1999. After the modification, the couplers will be re-introduced to the field as part # 18-21752-1.

In an effort to maintain the highest standards of quality control and customer service, we are taking the current action:

Distributors: Please remove part # 18-21752 from shelves and contact Sierra’s Technical Service Dept. at 217-324-9400 to obtain a Return Goods Authorization #.

Dealers: Please remove part # 18-21752 from shelves and contact your local Distributor for credit.

In-Service Parts: No action is to be taken unless specific complaint from customer.

If you have further questions concerning this bulletin contact Sierra Technical Service Dept. at 217-324-9400.

BULLETIN # 7-13-06

18-5107-1 Ignition Module

It has come to our attention that the 18-5107-1 ignition module may have been manufactured incorrectly causing no timing advancement. The alleged defective module will be stamped “Made in Canada” and should be returned. 18-5107-1 ignition modules stamped with “Assembled in Hong Kong” (see illustration below) function properly and do not need to be returned.

If you have any questions or need to obtain a Return Goods Authorization number, please contact Sierra’s Technical Service Dept. at 217-324-9400.

BULLETIN # 7-13-06

18-5885 Power Pack

It has come to our attention that the 6-pin amphenol connector on the 18-5885 power pack may have been manufactured at an incorrect angle. The alignment shoulder should flatten out, creating a 90-degree angle, as illustrated in the top picture. If the connector does not flatten out, an "intermittent" or "no connection" problem may occur. The bottom illustration explains where a horizontal cut can be made to create the correct angle for proper connection.

If you have any further questions or would like to obtain a Return Goods Authorization number, please contact Sierra’s Technical Service Dept. at 217-324-9400.

BULLETIN # 7-13-06

18-8056 / 18-8092 OMC Fuel Connector Advisory

The 18-8056 / 18-8092-fuel connectors with manufacturer's date code prior to 06/03/06 will not couple to the OMC 3-gallon (OMC Part No. #175984) or the OMC 6-gallon portable fuel tank (OMC Part No. #175981).

These two fuel connectors are also included on the 18-8058, 18-8081, 18-8009, 18-8014, 18-8059 & 18-8066 fuel line assemblies.

The two illustrations below provide the proper fix for the above-mentioned connectors. The picture on the left shows the area of the connector that must be removed.

There may also be an obstruction causing the connector to not fit properly on most Johnson/Evinrude outboards manufactured after 2000. This is caused due to an excessive shoulder near the retaining pin. The illustration at the bottom left shows the area that needs removed to ensure a proper fit. This extra material is easily removed with a diagonal cutter or all-purpose scissors.

If you have any further questions or would like to obtain a Return Good Authorization number, please contact Sierra's Technical Service Dept. at 217-324-9400.

BULLETIN # 7-13-06

18-5115 & 18-5116 Ignition Sensor Kit

The "SCR" leads on both the 18-5115 and 18-5116 may have been damaged during the manufacturing process (see illustration below) resulting in a sensor that will not function or will fail shortly after installation. If ignition sensor has been installed and is performing properly, there is no need to replace. Please do not attempt to correct this in the field, as this could cause further damage.

An upgraded sensor has been developed to correct this potential problem, please reorder part number 18-5116-1 for both the 18-5115 & 18-5116. At this time, we are requesting that you contact Sierra’s Technical Service Dept. at 217-324-9400 to obtain a Return Goods Authorization number to return any of the alleged defective ignition sensors that are currently in your inventory.

If you have any further questions please contact Sierra’s Technical Service Dept. at 217-324-9400.

BULLETIN # 8-08-05

18-1953-1 Exhaust Manifold Installation Advisory

In our continuing effort to ensure the Marine market is provided with quality products and information, Sierra is issuing the following "Installation Advisory":

It has come to our attention that the installation of our 18-1953-1 manifold on late model "Vortec" style heads has interference issues when installing/removing the spark plugs. "Vortec" cylinder heads can be identified by the valve covers utilizing long center mount valve cover bolts.

We are sorry for any inconvenience this may have caused. If you have any questions regarding the 18-1953-1, feel free to contact Sierra's Technical Service Dept. at 217-324-9400.

BULLETIN # 5-25-05

18-2190E SHIFT CABLE ASSEMBLY ADVISORY

In our continuing effort to ensure the Marine market is provided with quality products and information, Sierra brings you the following "Quality Advisory":
We have found the following issues concerning proper installation of the 18-2190E Cable Assembly.
In some instances, the 18-2162E shift slide may not pass over the brass end piece. To test, please take the 18-2162E shift slide from its package and attempt to slide it over the brass end of the extreme cable. If there is interference and it stops short of passing over the brass end piece, contact your selling Distributor or Sierra at the number listed at the end of this bulletin.

It has also been found that the sheared end of the inner core, on the 18-2190E, may not have been ground back to a slight taper at the factory. If inner core is pushed through sheathing in this condition, a part of the inner coating can be peeled away and lost. Please inspect the tip of the cable for a sharp 90-degree edge. If necessary take a fine to medium grit metal file to the edge at a 45-degree angle to remove burr before installing.

If you have any further questions please contact Sierra’s Technical Service Dept. at 217-324-9400.

BULLETIN #5-25-05

It has come to our attention that the transom guide bushing was included in some 18-2190E kits sent out. Due to the thicker sheathing on the extreme cable series, this bushing is not required for protection as with the standard cable. Please dispose of the bushing in any
18-2190E kits you might receive; also remember to extract any existing bushing that may already be installed in the transom housing before installing the new series cable.

We apologize for any inconvenience this may have caused you. If you have any questions, or need a Warranty Replacement regarding the 18-2190E (or a component of it) do not hesitate to contact Doug Hale, Warranty/Technical Service Representative, or Sierra's Technical Service Dept. for a replacement to be sent out to you.
That number is 217-324-9400

BULLETIN # 5-25-05

SAFETY RECALL: Champion # MC60 - Marine Carburetor

In our continuing effort to provide quality products and information to the Marine Market, Sierra is notifying all customers that Champion Parts, Inc. is voluntarily issuing the following Recall of MC60 carburetors in cooperation with the U.S. Coast Guard.

Product affected: Champion Parts, Inc. is voluntarily recalling about 850 carburetors sold through Sierra International Inc. part # 18-7611.

Claim Procedure: Follow procedures as listed on attached Champion Parts, Inc. SERVICE BULLETIN

which identifies the following Topic Categories:

* PRODUCT
* PROBLEM
* WHERE THIS WAS USED
* WHAT TO DO
* WHERE TO LOOK
* IN FIELD SERVICE REPAIR

For all claims, please contact Champion Technical
Service Department toll-free at 800-850-0846
(Monday-Friday 7:00am-5:00pm CST )
for Carburetors affected by this recall.

BULLETIN # 5-25-05

Repair Procedure:
Champion# MC60 - Marine Carburetor

A qualified service technician can make the following field repair.

WHERE THIS WAS USED: Champion Carburetor# MC60 is a replacement part fitting: 1987-95 MerCruiser 200 5.0L SN# 0B525982 - 0F600999 engines
1996-97 MerCruiser 5.7L SN# 0F601000 - 0K999999 engines
1996-97 MerCruiser Ski 5.7L SN# 0F775200 - 0K999999 engines

WHAT TO DO:
With the engine off and the battery disconnected.
Remove the flame arrestor. Disconnect the fuel and fume lines.
Disconnect the accelerator linkage.
Remove the carburetor from the engine.
Invert carburetor and drain fuel from carburetor. ALL fuel must be drained from carburetor.
Locate the square notch on the carburetor. (See picture below).
Hole must be drilled from the well, below surface of notch, into the
Use a drill with 5/32" or 11/64" drill bit and drill a connecting hole in the carburetors' bore/throat.
It is only necessary to drill the hole through the well wall (1/8" thick).
Remove burrs from edge of hole using a small file.
Use air gun or small brush to remove metal shavings from carburetor, until clean.
Reinstall carburetor. Connect the fuel line and fume lines. Connect the accelerator linkage. Reinstall the flame arrestor. Connect the battery, turn engine over to fill fuel bowl.
Inspect for carburetor and fuel line for leaks. Repair all leaks before starting engine.

Call Champion Technical Service Department for repair assistance details and to acknowledge that the repairs have been made.

For more information, contact Champion Technical Service Dept. toll-free at: 800-850-0846
(Monday-Friday 7:00a.m.-5:00p.m. CST)

BULLETIN # 5-25-05

Safety Recall:
Champion# MC60 - Marine Carburetor

In our continuing effort to provide quality products and information to the Marine market, Champion Parts, Inc. is voluntarily issuing the following Recall of approximately 1,170 MC60 carburetors in cooperation with the U.S. Coast Guard.

PRODUCT: Champion Parts, Inc. is voluntarily recalling about 1,170 carburetors, sold as CPI Marine Part# MC60 (Sierra Part# 18-7611).

PROBLEM: The problem may exist that the carburetor may have a fuel/fume pipe that is not drilled through to the bore/throat. A fuel/fume line on a marine designed mechanical fuel pump provides a safe fuel exit to the carburetor in the unlikely event of a rupture of the fuel pump's double diaphragm.
If the recall condition exists and the fuel pump's double diaphragm were to experience a catastrophic rupture, excess fuel could spill into the engine compartment and a fire could result and could cause serious personal injury and/or death.

Champion Parts, Inc. is not aware of any injuries or incidents involving these carburetors.

WHERE THIS WAS USED: Champion Carburetor# MC60 is a replacement part fitting:1987-95 MerCruiser 200 5.0L SN# 0B525982 - 0F600999 engines
1996-97 MerCruiser 5.7L SN# 0F601000 - 0K999999 engines
1996-97 MerCruiser Ski 5.7L SN# 0F775200 - 0K999999 engines

WHAT TO DO: Only MC60 carburetors are involved in this recall. Consumers possessing the recalled carburetor are to stop using it immediately, and bring it to a service center to perform an inspection of the carburetor to determine if the recall condition exists.

WHERE TO LOOK: To determine if your carburetor is part of this recall, look for part number MC60 on the product label. If your carburetor has a fuel/fume line attached to the carburetor, it will be necessary to perform the following inspection. With the engine off and the battery disconnected, remove the flame arrestor and inspect the
carburetor. Carburetors with a square notch must have a hole drilled through to the bore/throat for the fuel/fume line (see picture at right).
If your MC60 Carburetor is part of the recall (without the hole drilled through) contact the service center or retailer where purchased for repair or free replacement.
Call Champion Technical Service Department for warranty details.

For more information, contact Champion Technical Service Dept. toll-free at: 800-850-0846
(Monday-Friday 7:00a.m.-5:00p.m. CST)

BULLETIN # 3-24-05

Application Update For 18-7288

In our continuing effort to ensure the Marine market is provided with quality products and information, Sierra is issuing the following "Quality Advisory":

We have found that the application information provided in the 2005 Marine Parts Catalog is incorrect for the 18-7288. The fuel pump should only be used for GM V-8 454 (7.4L).

Do NOT attempt to use this Fuel Pump on a GM V-8 305 or 350.

The error can be found within the application chart on page 74 and within the picture on page 530. The application chart on page 530, however, is correct. Please adjust your records accordingly.

We are sorry for any inconvenience this may have caused.
If you have any questions regarding the 18-7288
please contact Sierra's Technical Service Department
at 217-324-9781.

BULLETIN # 3-07-05

18-5885 Power Pack

In our continuing effort to ensure the Marine market is provided with quality products and information, Sierra is issuing the following "Quality Advisory":

We have found that some 18-5913 starters were supplied with defective bolts. Please reference picture below of the suspect bolts. If the starter has already been installed & torqued, firmly grasp rear of starter to ensure starter is properly secured.

Please review date codes between Nov. 25th, 2004 and Jan. 25th, 2005 to determine if you have installed, or currently have the questionable material in stock. If defective material is found contact Sierra's Technical Service Dept. at 217-324-9781.

If defective material is found contact Sierra's Technical Service Dept. at 217-324-9781.

BULLETIN # 3-07-05

Revised Oil Return Policy

In an effort to maximize efficiencies we are introducing a new oil return policy. Effective immediately, in order for Sierra to process a credit request due to "leaking" oil products, a digital picture must be provided along with proper documentation.

The digital picture should meet the following criteria for a credit to be issued:

. Picture shows what the product looked like when delivered.
. Picture shows a faulty package, bottle or drum, where individual container is leaking.
. Item should be photographed in such a way so that the leaking area is visible.

* NOTE: In the event that the outer carton shows damage, it is imperative that a digital picture be provided. If the freight terms were prepaid, then the consignee must provide Sierra with a bill of lading that has been signed for damaged and include copies of the digital pictures, then Sierra will file a freight claim. If the freight terms are collect then the consignee should sign the bill of lading damaged, take digital pictures and file a claim with the carrier.

In the case where genuine leaking has occurred, a credit will also be issued to re-package those items that have been damaged as a result of the leakage.

This new procedure should facilitate claims and expedite solutions for both parties.

If you have any questions, please do not hesitate to call Technical Service at 217-324-9781.

Thank you for your support of Sierra products.

BULLETIN # 8-26-04

In our continuing efforts to ensure that the market is provided with quality products and information, Sierra is issuing the following "Service Bulletin". This bulletin is designed to keep our customers apprised of issues affecting the Sierra product line.

As always, if you have any questions please contact out technical service department at 217-324-9428 for more detailed information.

18-3150 Bravo Water Pump Kit

We have discovered that some kits were sent out with an incorrect torque specification sheet. The incorrect statement reads as follows. Pump housing mounting bolts must be torqued to a value of 8 - 10 in. lbs. (not to exceed 10 in. lbs.). This statement should actually read... Pump housing mounting bolts must be torqued to a value of 96- 120in. lbs. All other information on the specification sheet is correct.

Leaking may occur if the Bravo water pump housing is installed at the 8- 10 in. lb.

18-2166 Prop Shaft

Our research indicates that the splines machined over the cross pin passage may still have a burr on them. This area was apparently overlooked during the de-burring process of machining. Interference may be experienced during assembly of the clutch dog over the splines of the 18-2166 prop shaft. Please return all defectives to Sierra for credit or replacement.

Impellers

Sierra has received information from the field that our 18-3056 impeller has a "tight" fit condition or will not fit over the driveshaft. We have determined the following part numbers with the date codes below are affected:

* 18-3056 date code 041606
* 18-3214 date code 041606
* 18-3570 date code 041706

If you have product which you feel is defective in regards to this bulletin please contact technical services for
replacement instructions.

BULLETIN #5-21-04

In our continuing efforts to ensure that the market is provided with quality products and information, Sierra is issuing the following "Quarterly Service Bulletin". This bulletin is designed to keep our customers apprised of issues effecting the Sierra product line.

As always, if you have any questions please contact out technical service department at 217-324-9428 for more detailed information.

18-2186 OMC Drive Shaft

Sierra has received one 18-2186 from the field that was incorrectly machined where the pinion gear mates to the shaft. All in-house shafts have been checked with all defective units being destroyed.

In the unlikely event that you have an 18-2186 drive shaft with date code 032608 on the package, please return to Sierra for credit and/ or replacement.

18-2363, 18-2364, 18-2365 Mercruiser Gear Housing Service Kits

During assembly, some kits were packaged missing the 18-1161 bearing. If you have any of these units on your shelf, please contact technical services to have the correct number of bearings sent to complete these kits or to make arrangements to replace your existing stock with correctly packaged kits.

18-2765 OMC U-joint Bellows

Several Sierra users have complained that the mounting rim of the Sierra bellows is thicker than the OE, making it slightly more difficult to install. To facilitate ease of assembly, we have modified the molding tool to provide a thinner lip. This is a running change and required no action on your behalf.

18-5801 Mercruiser Solenoid

We have modified the internal working of this solenoid, resulting in an inner winding which now surpasses the functionality of the OE unit. Implemented months ago, this improved solenoid has now filtered to all distributing locations. If you have stock which you feel is suspect, contact technical services for replacement instructions.