Page 1 This manual has been prepared to assist you in the operation, safe use, and care of your outboard. All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating.
Page 2 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not...
Page 3 • Provides timely service for all Mercury Marine customers. • Offers extended service hours and mobile service, when appropriate. • Uses, displays, and stocks adequate inventory of genuine Mercury Precision Parts. • Offers a clean, neat shop with well organized tools and service literature.
Page 4 Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle ☒ Outboard engine ☒ Petrol ☒ 2 stroke Identification of Engines Covered by This Declaration of Conformity Unique engine EC Module H Name of engine family identification number: certificate starting serial number number...
Page 5 Name / function: Mark D. Schwabero, President, Mercury Outboard Date and place of issue:July 24, 2008 Fond du Lac, Wisconsin, USA...
Page 7: Table Of Contents
WARRANTY INFORMATION Warranty Registration..............1 Transfer of Warranty..............2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada......... 2 Outboard Limited Warranty............3 3 Year Limited Warranty Against Corrosion........ 7 Warranty Coverage and Exclusions.......... 11 U.S. EPA Emissions Limited Warranty........13 Emission Control System Components........
Page 8 Avoiding Fuel Flow Restriction..........48 Low Permeation Fuel Hose Requirement ......... 48 EPA Pressurized Portable Fuel Tank Requirements....48 Fuel Demand Valve (FDV) Requirement........49 Mercury Marine's Pressurized Portable Fuel Tank....49 Filling Fuel Tank................ 51 Oil Recommendation..............51 Filling Remote Oil Tank............. 51 Filling Engine Mounted Oil Reservoir Tank.......
Page 9 Features and Controls Panel Mount Control Features and Operation......53 Single Handle Console Control Features and Operation... 56 Slim Binnacle Control Features and Operation......61 Dual Handle Console Control Features and Operation..... 65 Dual Handle Console Control with CAN Trackpad Features and Operation...................
Page 10 Maintenance Outboard Care................. 108 EPA Emissions Regulations............ 108 Inspection and Maintenance Schedule........109 Flushing the Cooling System........... 111 Top Cowl Removal and Installation......... 112 Cleaning Care for Top Cowl............ 112 Alternator Belt Inspection............113 Fuel System................113 Steering Link Rod Fasteners........... 116 Fuse Replacement..............
Page 11 Engine Runs Erratically............140 Performance Loss..............140 Battery Will Not Hold Charge........... 140 Owner Service Assistance Local Repair Service..............142 Service Away from Home............142 Parts and Accessories Inquiries..........142 Service Assistance..............142 Mercury Marine Service Offices..........143 Maintenance Log Maintenance Log..............145...
Page 13: Warranty Information
You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.
Page 14: Transfer Of Warranty
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and...
Page 15: Outboard Limited Warranty
Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
Page 16 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
Page 17 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
Page 18 No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and...
Page 19: Year Limited Warranty Against Corrosion
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Year Limited Warranty Against Corrosion WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser...
Page 20 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
Page 21 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
Page 22 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
Page 23: Warranty Coverage And Exclusions
WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
Page 24 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants, or fluids changed as a matter of normal...
Page 25: U.s. Epa Emissions Limited Warranty
U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at...
Page 26: California Emissions Limited Warranty
California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System...
Page 27 Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
Page 28 Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Marine's sole and...
Page 29 California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.
Page 30: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement
Also included may be hoses, belts, connectors, and other emission‑related assemblies. Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.
Page 31: Emission Certification Star Label
WARRANTY INFORMATION As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists.
Page 32 WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust 42538 emission standards.
Page 33: General Information
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.
Page 34: Boat Horsepower Capacity
For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.
Page 35: Outboard Remote Control Models
GENERAL INFORMATION Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start in gear protection is provided by the control system. This prevents the engine from starting when the shift is actuated in any position other than neutral.
Page 36 GENERAL INFORMATION IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub.
Page 37 RPM range when under normal full throttle operation. PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats.
Page 38: Remote Steering Notice
GENERAL INFORMATION 3 BLADE VS. 4 BLADE Available in many sizes of both aluminum and stainless, 3 and 4‑blade propellers have unique performance characteristics. In general, 3‑blade propellers offer good all around performance and higher top speed than 4‑blade propellers. However, 4‑blade propellers are usually faster to plane and more efficient at cruising speeds, but lack the top end speed of a 3‑blade propeller.
Page 39: Lanyard Stop Switch
GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch.
Page 40 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.
Page 41 GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.
Page 42: Protecting People In The Water
GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Page 43: Passenger Safety Message - Pontoon Boats And Deck Boats
GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.
Page 44: Wave And Wake Jumping
GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.
Page 45: Impact With Underwater Hazards
GENERAL INFORMATION WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.
Page 46 WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
Page 47: Exhaust Emissions
GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories.
Page 48 GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 49: Selecting Accessories For Your Outboard
The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
Page 50 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) the U.S. Coast Guard Auxiliary, 2) the Power Squadron, 3) the Red Cross, and 4) your state boating law enforcement agency.
Page 51: Recording Serial Number
GENERAL INFORMATION Watch fallen skiers. When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to assist the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.
Page 52 GENERAL INFORMATION Models Kilowatts Full throttle RPM range 5000–5750 Idle speed in forward gear 575 ± 25 RPM Number of cylinders Piston displacement 3048 cc (186 in³) Cylinder bore 92.1 mm (3.626 in.) Piston stroke 76.2 mm (3.000 in.) Recommended spark plug NGK IZFR5G Spark plug gap 0.8 mm (0.031 in.)
Page 53: Component Identification
GENERAL INFORMATION Component Identification Top cowl Bottom cowl Water pump indicator hole Driveshaft housing Anti‑ventilation plate Anode plate Auxiliary tilt switch Transom brackets Gearcase Cooling water intake holes 29423...
Page 54: Installing Outboard
INSTALLATION Installing Outboard WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware.
Page 55: Propeller Selection
INSTALLATION MAXIMUM OUTBOARD MOUNTING HEIGHT The mounting height of the outboard must not exceed 635 mm (25 in.) for EL models, 762 mm (30 in.) for EXL models, and 889 mm (35 in.) for EXXL models. Mounting the outboard higher may cause damage to the gearcase components.
Page 56 INSTALLATION Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.
Page 57: Transporting
TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.
Page 58: Fuel And Oil
FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum.
Page 59 FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).
Page 60: Fuel Additives
FUEL AND OIL Fuel Additives To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickleen Engine Treatment additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container.
Page 61: Fuel Demand Valve (Fdv) Requirement
46273 Vent/water drain holes Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.
Page 62 FUEL AND OIL • When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening. • The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal.
Page 63: Filling Fuel Tank
Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Recommended Oil Engine Oil Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended for your engine. If Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium Plus 2‑Cycle Oil.
Page 64: Filling Engine Mounted Oil Reservoir Tank
FUEL AND OIL IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air leak will prevent oil flow to the engine. 2723 Filling Engine Mounted Oil Reservoir Tank NOTE: Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated.
Page 65: Features And Controls
FEATURES AND CONTROLS Panel Mount Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
Page 66 FEATURES AND CONTROLS 3. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5152 4. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear.
Page 67 FEATURES AND CONTROLS 5. Stop/start button ‑ Allows the boat operator to start or stop the engine without using the ignition key. The ignition key must be in the "ON" position to start the engine. 3414 6. Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.
Page 68: Single Handle Console Control Features And Operation
FEATURES AND CONTROLS 8. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to tension desired.
Page 69 FEATURES AND CONTROLS 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5185 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed).
Page 70 FEATURES AND CONTROLS 6. Select button ‑ Selects the System View on‑screen options and confirm data entries. Holding the select button for two seconds will pause the slide show if selected in Favorites. Holding the select button for three seconds will activate the reset data function (except when in the slide show function).
Page 71 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.
Page 72 FEATURES AND CONTROLS 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STATION SELECT STAT ION SELECT 22753 Active light Throttle only/station select button 4.
Page 73: Slim Binnacle Control Features And Operation
FEATURES AND CONTROLS Slim Binnacle Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
Page 74 FEATURES AND CONTROLS 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the remote control handle in rough water.
Page 75 FEATURES AND CONTROLS 8. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.
Page 76 FEATURES AND CONTROLS The helm transfer function allows the boat operator to select which helm is in control of engine operation. Pressing the throttle only/station select button two times allows engine control to be transferred to a new helm. When a helm transfer is initiated, the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm.
Page 77: Dual Handle Console Control Features And Operation
FEATURES AND CONTROLS Dual Handle Console Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
Page 78 FEATURES AND CONTROLS 4. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to the desired tension.
Page 79 FEATURES AND CONTROLS 8. Neutral LEDs ‑ The neutral LEDs illuminate when engines are in neutral gear position. The lights will flash when in throttle only mode. NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the control handle.
Page 80 FEATURES AND CONTROLS Engine auto synchronization will automatically engage when engine speed is over 900 RPM for two seconds and remote control handles are positioned within 10% of each other. The "SYNC" light will turn on when the engines are synchronized. Auto synchronization will stay engaged up to 95% throttle opening.
Page 81 FEATURES AND CONTROLS NOTE: There is a 10 second time frame to complete a helm transfer. If the helm transfer is not completed, the action will be cancelled and a double beep will sound. Pressing the throttle only/station select button again will reinitiate a helm transfer. 1.
Page 82: Dual Handle Console Control With Can Trackpad Features And Operation
FEATURES AND CONTROLS Dual Handle Console Control with CAN Trackpad Features and Operation DUAL-HANDLE CONSOLE CONTROL WITH CAN TRACKPAD: FEATURES AND OPERATION 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear.
Page 83 FEATURES AND CONTROLS 4. Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering. To activate, move the control handles into forward detent and press the button.
Page 84 FEATURES AND CONTROLS 9. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22133 Neutral LEDS Troll button Transfer button Dock button Throttle only 1 lever button Sync button 10.
Page 85 FEATURES AND CONTROLS 11. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
Page 86 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.
Page 87: Shadow Mode Control Features And Operation
FEATURES AND CONTROLS Synchronizing Helms Prior to Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash.
Page 88 FEATURES AND CONTROLS Center Starboard Port Engine Control Handle Function Engine Engine Port engine throttle and shift = controlled by port control handle Running Running Starboard engine throttle and shift = controlled by starboard control handle Port engine throttle and shift = Running controlled by port control handle Starboard engine throttle and shift...
Page 89 FEATURES AND CONTROLS Port Starboard Starboard Port Outer Control Handle Inner Inner Outer Engine Function Engine Engine Engine Port inner and outer engines throttle and shift = controlled by port control handle Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by starboard control handle...
Page 90 FEATURES AND CONTROLS Port Starboard Starboard Port Outer Control Handle Inner Inner Outer Engine Function Engine Engine Engine Port outer engine throttle and shift = controlled by port control handle Running Running Starboard outer engine throttle and shift = controlled by starboard control handle Port inner engine throttle and shift =...
Page 91 FEATURES AND CONTROLS If a failure should occur while underway which causes the starboard outer engines into forced neutral/idle condition, the inner starboard engine will also be forced to neutral/idle. Operation to the inner engine can be restored by moving the starboard control handle back into neutral and then reengaging.
Page 92 FEATURES AND CONTROLS 2. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.
Page 93 FEATURES AND CONTROLS 7. Sync LED ‑ The "SYNC" LED illuminates when the RPM of the engines are being synchronized by the DTS system. Neutral LEDS Select button Arrow trackpad Sync LED NEUTRAL Throttle only/station SELECT select button SYNC ACTIVE THROTTLE Active LED ONLY...
Page 94 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.
Page 95: Shadow Mode Control With Can Trackpad Features And Operation
FEATURES AND CONTROLS 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STATION SELECT STAT ION SELECT 22753 Active light Throttle only/station select button 4.
Page 96 FEATURES AND CONTROLS Center Starboard Port Engine Control Handle Function Engine Engine Port engine throttle and shift = controlled by port control handle Starboard engine throttle and shift = controlled by starboard control handle Running Running Running Center engine throttle = average of port and starboard engines Center engine shift = neutral unless both engines are in the...
Page 97 FEATURES AND CONTROLS If a failure should occur while underway which causes one of the outer engines into forced neutral/idle condition, the center engine will also be forced to neutral/idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral and then reengaging.
Page 98 FEATURES AND CONTROLS Port Starboard Starboard Port Outer Control Handle Inner Inner Outer Engine Function Engine Engine Engine Port inner engine Off (ignition throttle and shift = key switch Running Running Running controlled by starboard turned off) control handle Starboard inner engine Off (ignition throttle and shift = Running...
Page 99 FEATURES AND CONTROLS Turning off the port outer engine while underway will cause the port inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the port outer engine ignition key to the on position and moving the port control handle back into neutral position and then reengaging.
Page 100 FEATURES AND CONTROLS 2. Neutral lights ‑ The neutral lights illuminate when the engine is in neutral gear position. The lights will flash when the engine is in throttle only mode. NOTE: Gear position is determined by the position of the shift actuator on the engine, not the position of the control handle.
Page 101 FEATURES AND CONTROLS 7. 1 lever button ‑ Pressing the "1 LEVER" button initiates single lever mode. Single lever mode enables the throttle and shift functions of both engines to be controlled by the port control handle. To turn off single lever mode, shift the engine into neutral and press the "1 LEVER"...
Page 102 FEATURES AND CONTROLS 10. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
Page 103 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.
Page 104: Warning System
FEATURES AND CONTROLS Synchronizing Helms Prior to Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash.
Page 105 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling Continuous Engine Guardian System is activated. system Power limit will vary with level of overheat. problem Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
Page 106 Moving the throttle lever back to the idle position will reset the system. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption, and engine operating hours.
Page 107: Power Trim And Tilt
FEATURES AND CONTROLS Power Trim and Tilt The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.
Page 108 FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and...
Page 109 FEATURES AND CONTROLS • In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired.
Page 110 FEATURES AND CONTROLS TILTING TO FULL UP POSITION Tilt At Helm NOTE: The trim/tilt switch will remain active for 15 minutes after the ignition key switch has been turned off. 1. If the ignition key switch has been turned off for over 15 minutes, turn it to the "ON"...
Page 111 FEATURES AND CONTROLS Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 22362 AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system.
Page 112: Operation
OPERATION Pre‑Starting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.
Page 113: Operating In Saltwater Or Polluted Water
Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.
Page 114: Engine Break-In Procedure
OPERATION Engine Break‑In Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. GASOLINE/OIL BREAK-IN MIXTURE NOTE: Do not use premixed gas and oil during break‑in. Use straight gasoline during engine break‑in and after engine break‑in.
Page 115: Starting The Engine
OPERATION 2. For the next three hours of operation, change engine speed every ten minutes. Starting the Engine Before starting, read the pre‑starting check list, special operating instructions, engine break‑in procedure and Gear Shifting in the Operation section, and the remote control features and operation in the Features and Controls section.
Page 116 OPERATION 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. 27348 NOTE: The engine will not start unless the lanyard is set to the "RUN"...
Page 117 OPERATION b. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. c. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. Turn the ignition key switch to the "ON"...
Page 118: Gear Shifting
OPERATION Gear Shifting DTS PANEL MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R).
Page 119: Stopping The Engine
OPERATION DTS CONSOLE MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R).
Page 120: Outboard Care
We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.
Page 121: Inspection And Maintenance Schedule
MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...
Page 122 MAINTENANCE • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retorque the outboard mounting fasteners to 75 Nm (55 lb‑ft). • Check steering system for binding or loose components. •...
Page 123: Flushing The Cooling System
MAINTENANCE • Lubricate splines on the driveshaft and shift shaft. • Check tightness of bolts, nuts, and other fasteners. • Check cowl seals to make sure seals are intact and not damaged. • Check internal cowl sound reduction foam (if equipped) to make sure foam is intact and not damaged.
Page 124: Top Cowl Removal And Installation
MAINTENANCE 2. Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. 29445 Top Cowl Removal and Installation REMOVAL 1. Release the front and side cowl latches. 2. Lift the top cowl from the outboard. 29447 INSTALLATION 1.
Page 125: Alternator Belt Inspection
MAINTENANCE 4. Wax the surface using a non‑abrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. Alternator Belt Inspection 1. Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found.
Page 126 MAINTENANCE Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle.
Page 127 MAINTENANCE Installation 1. Lubricate the O‑ring seals with oil. 3388 Filter O‑ring seals 2. Install the fuel filter and tighten securely. IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm, forcing fuel into the filter.
Page 128: Steering Link Rod Fasteners
MAINTENANCE 3. Retighten the drain screw and reattach the hose. 24686 Drain hose Side fitting Drain screw IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt ("a"...
Page 129 MAINTENANCE WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.
Page 130: Fuse Replacement
MAINTENANCE Fuse Replacement IMPORTANT: Always carry spare 2, 5 and 20 amp fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.
Page 131: Dts Wiring System
MAINTENANCE DTS Wiring System WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system.
Page 132: Battery Inspection
MAINTENANCE The gearcase has three anodes. Two anodes are located on each side of the gearcase, and a third is an anode plate installed underneath the anti‑ventilation plate. If a trim tab should be installed, this anode plate will be removed. Another anode is installed on the bottom of the transom bracket assembly.
Page 133: Battery Information
MAINTENANCE Battery Information WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.
Page 134: Propeller Replacement
MAINTENANCE Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 135 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.
Page 136 MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c Propeller nut Propeller nut retainer Rear thrust hub Continuity washer Propeller 26908 Forward thrust hub...
Page 137: Spark Plug Inspection And Replacement
MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.
Page 138: Compressor Air Intake Filter
MAINTENANCE 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten 1/4 turn or torque to specifications. Description lb‑in. lb‑ft Spark plug Compressor Air Intake Filter The filter should be changed every 100 hours of operation, or once a season.
Page 139 MAINTENANCE 2. Remove the hose cable tie and and pull the air filter off the hose. 28732 Air filter Nylon washer Rubber washer Clamp Filter housing Cable tie...
Page 140: Lubrication Points
Reinstall the hose and secure with a cable tie. 3. Secure the filter housing with the clamp. Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Description Where Used Part No.
Page 141 MAINTENANCE • Trim rod ball ends ‑ Turn the ball ends to work the lubricant into the ball sockets. 28458 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Description Where Used Part No.
Page 142 MAINTENANCE Tube Description Where Used Part No. Ref No. Alternator belt tensioner pivot 2-4-C with shaft, swivel bracket, tilt 92-802859A 1 PTFE support lever, tilt tube, steering cable • Alternator belt tensioner pivot shaft ‑ Lubricate through fitting. 2884 • Swivel bracket ‑ Lubricate through fitting. •...
Page 143 MAINTENANCE • Tilt tube ‑ Lubricate through fitting. 27874 WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. • Steering cable ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube.
Page 144: Checking Power Trim Fluid
2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricant Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
Page 145: Gearcase Lubrication
3. Place drain pan below outboard. 4. Remove vent plug and fill/drain plug and drain lubricant. 22692 Vent plug Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 970 ml (32.8 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant.
Page 146: Submerged Outboard
MAINTENANCE CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove vent plug/sealing washer. 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. 22693 Vent hole Fill hole...
Page 147: Storage Preparation
Adding fuel stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will help clean and lubricate the fuel injectors.
Page 148 8. Retighten the drain screw and reattach the hose. 9. Premix the following in a container: a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant. b. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer.
Page 149: Protecting Internal Engine Components
STORAGE 10. Remove the fuel filter. See Maintenance ‑ Fuel System for procedure. 11. Pour this mixture into the fuel filter opening. Reinstall the fuel filter. 12. Prime the fuel system. See Operation ‑ Starting The Engine. 13. Place the outboard in water or use the flush hose or flushing device or for circulating cooling water.
Page 150: Gearcase
STORAGE • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Description Where Used Part No. Ref No. Corrosion External metal surfaces...
Page 151: Troubleshooting
TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 5 amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. •...
Page 152: Engine Starts But Will Not Shift Into Gear
TROUBLESHOOTING • Spark plugs fouled or defective. Refer to Maintenance section. Engine Starts But Will Not Shift Into Gear • Shift actuator failure. "Gear Shift Diff" error message shown on System View. Refer to Maintenance section. Engine Runs Erratically POSSIBLE CAUSES •...
Page 153 TROUBLESHOOTING • Low electrolyte level in battery. • Worn out or inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator. • Open circuit in the alternator output wire (fused link).
Page 154: Owner Service Assistance
If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.
Page 155: Mercury Marine Service Offices
• The name and address of your dealership • Nature of problem 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 ‑ (920) 929‑5040...
Page 156 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944...
Page 157: Maintenance Log
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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