Mercury 40/50 Series Manual
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Mercury 40/50 Series Manual

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Thank You
for your purchase of one of the finest outboards available. You
have made a sound investment in boating pleasure. Your
outboard has been manufactured by Mercury Marine, a world
leader in marine technology and outboard manufacturing
since 1939. These years of experience have been committed
to the goal of producing the finest quality products. This led to
Mercury Marine's reputation for strict quality control,
excellence, durability, lasting performance and being the best
at providing after the sale support.
Please read this manual carefully before operating your
outboard. 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.
Again, thank you for your confidence in Mercury Marine.
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States 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. This
certification is contingent on certain adjustments being set to
factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, wherever
practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission
control devices and systems may be performed by any
marine engine repair establishment or individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth defects
or other reproductive harm.
WARNING
!
i

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Summary of Contents for Mercury 40/50 Series

  • 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 ICOMIA 38/94 Engine type: Outboard Fuel type: Gasoline Combustion cycle: 2‑Stroke This declaration is issued under the sole responsibility of Mercury Marine and Brunswick Marine in EMEA Inc. Name and function: Mark D. Schwabero President, Mercury Marine, Fond du Lac, WI USA...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer of Warranty..............1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan................1 Warranty Registration United States and Canada.......2 Outboard Limited Warranty............3 3 Year Limited Warranty Against Corrosion........6 Warranty Coverage and Exclusions..........9 GENERAL INFORMATION Boater's Responsibilities............12 Before Operating Your Outboard..........12...
  • Page 6 TABLE OF CONTENTS INSTALLATION Boat Horsepower Capacity............41 Installing Outboard..............41 Installing the Remote Control Box..........46 Installation of the Remote Control Cables (Box Side)....46 Installation of the Remote Control Box on your Boat....46 Connecting the Remote Control Cable to the Engine....47 Connecting Electrical Harnesses..........51 Attaching the Steering Link Rod..........55 Battery Installation ..............56...
  • Page 7 TABLE OF CONTENTS FEATURES & CONTROLS Remote Control Features............74 Tilting Outboard.................74 Shallow Water Operation............75 Trim Adjustment.................76 Steering Friction Adjustment............80 Throttle Grip Turning Friction Adjustment........81 Trim Tab Adjustment..............81 OPERATION Pre‑Starting Check List..............84 Operating in Freezing Temperatures.........84 Operating in Saltwater or Polluted Water........84 Operating at High Elevations.............85 Engine Break‑in Procedure............
  • Page 8 TABLE OF CONTENTS MAINTENANCE Outboard Care................. 106 EPA Regulations..............106 EPA Emissions................ 107 Inspection and Maintenance Schedule........107 Flushing the Cooling System........... 109 Top Cowl Removal and Installation......... 110 Battery Inspection ..............111 Fuel System................111 Fuse Replacement ‑ Electric Start Remote Control Models..114 Corrosion Control Anode............
  • Page 9 TABLE OF CONTENTS ASSOCIATED PARTS Associated Parts..............131 Propeller Selection..............132 NOTE:..................133 ACCESSORIES Optional Accessories...............134 OWNER SERVICE ASSISTANCE Local Repair Service..............138 Service Away from Home............138 Parts and Accessories Inquiries..........138 Service Assistance..............138 Mercury Marine Service Offices..........139 WIRING DIAGRAMS Wiring Diagrams..............141 Wire Color Code Abbreviations..........142...

  • Page 11: Warranty Information

    Product Protection or authorized dealer to receive a Request for 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.

  • Page 12: Warranty Registration United States And Canada

    1. 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 13: Outboard Limited Warranty

    Outboard Limited Warranty Outside the United States and Canada ‑ Check with your local distributor. WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet products to be free of defects in material and workmanship during the period described below.
  • Page 14 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 15 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 the limited warranty, and if made,...

  • Page 16: Year Limited Warranty Against Corrosion

    HAVE OTHER LEGAL 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 Inboard or Sterndrive Engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
  • Page 17 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 18 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 19: Warranty Coverage And Exclusions

    WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.
  • Page 20 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 21 WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 13. Water entering engine through the fuel intake, air intake, or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high, or trimmed too far out.

  • Page 22: 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. Be sure at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 23: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 24: Remote Steering Notice

    GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 37882 Remote Steering Notice WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.

  • Page 25: 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 26 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 27: 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 28: 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 29: 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 30: 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.

  • Page 31: Exhaust Emissions

    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. Exhaust Emissions...
  • Page 32 GENERAL INFORMATION WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide. GOOD VENTILATION Ventilate passenger area, open side curtains or forward hatches to remove fumes.

  • Page 33: 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...

  • Page 34: Safe Boating Suggestions

    GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible.

  • Page 35: Recording Serial Number

    GENERAL INFORMATION Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when operating the boat above idle speed.

  • Page 36: 40/50 Specifications (Include English Units)

    Trim system Manual, 6 position Engine oil Mercury or Quicksilver oil or recommended oil (TC‑W3) Mercury or Quicksilver gear oil or API GL5, SAE #80 to Gear oil #90, approximately 500 mL Fuel tank capacity 25 L (6.6 US gal) Approximately 2.0 L...
  • Page 37 Power trim position Mercury or Quicksilver motor oil or recommended oil Engine oil (TC‑W3) Mercury or Quicksilver gear oil or API GL5, SAE #80 to Gear oil #90, approximately 500 mL Fuel tank capacity 25 L (6.6 US gal) Engine oil capacity Approximately 2.0 L (0.53 US gal)
  • Page 38 Manual, 6 position position Mercury or Quicksilver motor oil or recommended oil Engine oil (TC‑W3) Mercury or Quicksilver gear oil or API GL5, SAE #80 to #90, Gear oil approximately 700 mL Fuel tank capacity 25 L (6.6 US gal) Engine oil Approximately 2.0 L...
  • Page 39 GENERAL INFORMATION COMPONENT IDENTIFICATION 40MH/W50MH 38270 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip -Clamp screw Trim position pin...
  • Page 40 GENERAL INFORMATION Transom bracket Anode Oil drain plug (upper) Water intake Oil drain plug (lower) Stop switch Choke knob...
  • Page 41 GENERAL INFORMATION 40EH/50EH 38271 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip -Clamp screw Trim position pin Transom bracket Anode...
  • Page 42 GENERAL INFORMATION Oil drain plug (upper) Water intake Oil drain plug (lower) Stop switch Choke knob Battery cables Start button...
  • Page 43 GENERAL INFORMATION 40EHO/50EHO 38272 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip -Clamp screw Trim position pin Transom bracket Anode...
  • Page 44 GENERAL INFORMATION Oil drain plug (upper) Water intake Oil drain plug (lower) Stop switch Choke knob Battery cables Low oil light Start button...
  • Page 45 GENERAL INFORMATION 40EHPTO/50EHPTO 38273 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Tilt stopper Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip -Clamp screw Trim position pin Transom bracket...
  • Page 46 GENERAL INFORMATION Oil drain plug (upper) Water intake Oil drain plug (lower) Stop switch Choke knob Power trim and tilt Battery cables Low oil light Start button Anode...
  • Page 47 GENERAL INFORMATION 40EO/50EO 38274 Tilt handle Top cowl Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Clamp screw Trim position pin Transom bracket -Anode Oil drain plug (upper) Water intake Oil drain plug (lower)
  • Page 48 GENERAL INFORMATION Choke knob Battery cables Oil fill door Fuel connector...
  • Page 49 GENERAL INFORMATION 40EPTO/50EPTO 38275 Tilt handle Top cowl Cowl latch Water pump indicaor hole Tilt stopper Water plug Anti‑ventilation plate Trim tab Propeller Clamp screw Trim position pin Transom bracket -Oil drain plug (upper) Water intake Oil drain plug (lower) Choke knob...
  • Page 50 GENERAL INFORMATION Power trim and tilt Battery cables Oil fill door Power trim and tilt switch Fuel connector Anode...

  • Page 51: Boat Horsepower Capacity

    INSTALLATION Boat Horsepower Capacity WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating. Do not overpower or overload your boat.
  • Page 52 INSTALLATION NOTE: Consult your authorized dealer to receive the proper instructions or ask your dealer to mount the motor as necessary. IMPORTANT: Most boats are rated and certified in terms of their maximum horsepower limit, and this is shown on the boat's certification plate.
  • Page 53 INSTALLATION 3. Transom height: Clearance between the anti‑ventilation plate of the motor and the bottom of the boat must be 10–30 mm (0.4–1.2 in.). If the height difference exceeds 30 mm (1.2 in.), engine power performance is likely to be reduced as a result of increased water resistance to the gearcase assembly.
  • Page 54 INSTALLATION Attaching the transom bracket: After positioning the transom bracket, tighten the clamp screws. Drill four holes in the boat transom, matching the holes in the transom bracket. Secure the engine with the supplied bolts (M12 x 105 mm), washers, and nuts. Use the larger diameter washers inside of the transom board and the smaller diameter washers outside of the transom bracket.
  • Page 55 INSTALLATION Power trim and tilt model: EHPTO, EPTO 327(12.87) 163.5(6.44) 163.5(6.44) (6.81) 51(2) 18(0.7) 69(2.72) 18(0.7) 87(3.43) 18(0.7) 105(4.13) 316(12.44) 158(6.22) 158(6.22) (1.18) 251(9.87) 125.5 125.5 254(10) (4.24) (4.24) 310(12.2) (0.51) 38306 Washer (smaller diameter) Bolt (M12 x 105 mm) Top of transom Washer (larger diameter) NOTE: We recommend the bolt head of the upper bolts face inward...

  • Page 56: Installing The Remote Control Box

    INSTALLATION Installing the Remote Control Box 1. Position the remote control box in a place that will not interfere with the handling of the controls, levers, and switches. Confirm that there are no obstacles in the passage of the remote control cables.

  • Page 57: Connecting The Remote Control Cable To The Engine

    INSTALLATION Connecting the Remote Control Cable to the Engine 1. Detach the top cowl by rotating the cowl latch. 38308...
  • Page 58 INSTALLATION 2. Detach the bracket and set cable harness B and remote control cables. Having secured the remote control cables to the bracket, attach them to the bottom cowl. 38309 Grommet Shift cable Key switch harness Battery cables Throttle cable Screw Bracket Shift cable...
  • Page 59 INSTALLATION 3. Detach the throttle and shift cable joints by removing the cotter pins. Throttle cable joint Cotter pin Washer Shift cable joint Washer Cotter pin 38310 4. Thread at least 15 mm (0.59 in.) of the remote control cables through the terminal eyes.
  • Page 60 INSTALLATION • Double‑check that the remote control cables, the throttle cable, and the shift cable have been connected correctly. Move the remote control lever Forward (F) until the first engaging point (approximately 32°). The cable which is moved first when the lever is turned, is a shift cable. Check that the shift lever is in Neutral (N) and the neutral warm‑up lever is fully closed when the remote control cables have been connected.

  • Page 61: Connecting Electrical Harnesses

    INSTALLATION 7. Adjust the cable joint until the hole meets with the throttle arm pin. After adjustment, lock a cable joint with a nut and secure with a cotter pin. Cotter pin Cable joint Throttle cable 38314 Connecting Electrical Harnesses 1.
  • Page 62 INSTALLATION INSTALLING THE METERS 1. Install the meters securely in the dashboard where they can be easily read and are not exposed to water splashes. The recommended dashboard thickness is 2–11 mm (0.08–0.4 in.). For dashboards thicker than 11 mm (0.4 in.), the fitting plate should be cut accordingly.
  • Page 63 INSTALLATION 4. Cut holes with 85 mm (3.346 in.) diameter for the tachometer and 52.5 mm (2.067 in.) for the trim gauge. Tachometer Trim gauge 5. Connection of leads: • Tachometer: EO, EPTO • Trim gauge: EPTO • Trim sender: EPTO...
  • Page 64 INSTALLATION Meter wiring diagram 38319 Meter lamp switch (optional) Trim gauge Tachometer Analog gauge harness Key switch harness Trim sender NOTE: The parts of * mark is to be wired when a meter lamp switch (optional) is connected.

  • Page 65: Attaching The Steering Link Rod

    INSTALLATION Attaching the Steering Link Rod 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.

  • Page 66: Battery Installation

    INSTALLATION NOTE: Apply grease in the required places (refer to the illustration below). Apply grease inside the tilt tube. Grease (apply grease inside the tilt tube) Apply grease on tip of steering cable Seal ring Grease Lock nut Washer Collar 38320 Bolt Steering link rod...

  • Page 67: Propeller Selection

    INSTALLATION • Battery cables must be arranged and protected from damage during steering. • With poor cable connections, the starter will fail to start. • Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. •...
  • Page 68 INSTALLATION Alternative propellers are available for specific boating requirements. See your outboard dealer. AVAILABLE PROPELLERS Refer to Associated Parts - Propeller Selection for the propeller selection. Model Maximum engine 5000–5700 RPM 5150–5850 RPM operating RPM range If changing conditions cause the RPM to drop below the recommended range, such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a propeller change or cleaning may be required...

  • Page 69: Transporting

    TRANSPORTING Removing the Motor 1. Stop the engine. 2. Disconnect the fuel connector, the remote control cable, the battery cables, mounting bolts and nuts, etc. from the motor. 3. Remove the motor from the hull and completely drain the water from the outboard. Be sure to keep the engine higher than the propeller whenever you carry the motor.

  • Page 70: Trailering Boat/Outboard

    TRANSPORTING IMPORTANT: Beware of explosion danger. Spilled and vapored gasoline may easily catch fire and explode. Be sure to fully discharge gasoline from the carburetors when transporting the engine. Wipe off spilled gasoline with a rag. When carrying or putting the engine up for storage, make sure the side with the electric pump or the power trim and tilt is down, otherwise air will enter the pump system for the power trim and tilt operation.

  • Page 71: Mooring With The Engine Tilted Up

    TRANSPORTING Shift the outboard to the forward gear. This prevents the propeller from spinning freely. 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 72 TRANSPORTING IMPORTANT: When tilting up or down, be sure your finger, or hand, is not placed in‑between the swivel bracket and transom bracket. Be sure to tilt down the outboard slowly. 3. Tilt the engine up entirely. The outboard will lock in the raised position.
  • Page 73 TRANSPORTING EHPTO, EPTO 1. Disconnect the fuel connector from the engine. 38345 2. Operate the power trim and tilt switch on the remote control lever and tilt the engine up. 38378 Down (DN)
  • Page 74 TRANSPORTING 3. The engine can also be tilted up using the switch provided under the bottom cowl. 38379 Power trim and tilt switch 4. Lock the tilt with the tilt stopper after the engine has been tilted 38381 Tilt stopper...

  • Page 75: Storing The Motor

    TRANSPORTING 5. Manual tilting: If the engine cannot be trimmed up electrically, turn the manual valve a few turns counterclockwise. This will allow manual tilting of the engine. 38382 Storing the Motor Keep the motor in a vertical position when you store it. NOTE: If you store the motor in a horizontal position, lay the motor as shown in the figure.

  • Page 76: Transporting Portable Fuel Tanks

    TRANSPORTING 2. Pay attention to the tilting direction so as not to be injured by the transom bracket. Reverse lock lever Lock Transom bracket Tilting direction Rope 39894 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank.
  • Page 77 TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidentally pushed‑in, allowing fuel or vapor to escape. Connector stem Tether cap 26794...

  • Page 78: 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 79 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 80: Oil Recommendation

    For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. Severe engine damage may result from use of an inferior oil.
  • Page 81 FUEL AND OIL IMPORTANT: During engine break‑in, engine oil must be added to the gasoline in addition to the oil, which is automatically supplied from the oil tank. Mixing ratio (during break-in on oil injected models) Gasoline Engine Oil During break‑in After break‑in Automatic: Fill up engine oil tank regularly Pour oil into the fuel tank.
  • Page 82 FUEL AND OIL 2. Turn off the ignition switch, and fill up the oil tank with recommended engine oil. 3. Start the engine, and shift into gear carefully. 4. Confirm that the indicator lamp goes out and the buzzer does not sound.
  • Page 83 FUEL AND OIL Loosen the air vent screw on the oil pump to purge the air, and tighten it when all air, as seen through the oil line to the oil pump has been purged. Air vent screw To check valve Oil line Oil line From oil filter...

  • Page 84: Features & Controls

    FEATURES & CONTROLS Remote Control Features Your boat may be equipped with the remote control shown. If not, consult your dealer for a description of the functions and operations of the remote control. 39924 Remote control box Remote control handle Power trim and tilt switch Neutral warm‑up lever Ignition key switch...

  • Page 85: Shallow Water Operation

    FEATURES & CONTROLS Shallow Water Operation The outboard is equipped with a shallow water tilt feature that allows you to tilt the outboard to a higher tilt angle to prevent hitting bottom. IMPORTANT: Before tilting the outboard into the shallow water drive position, reduce engine speed to idle and shift engine into neutral gear.

  • Page 86: Trim Adjustment

    FEATURES & CONTROLS 2. Tilt the engine up approximately 45° and lower it. The engine will now be set to the shallow water setting. 38367 3. Releasing the shallow water setting: a. Turn the reverse lock lever upward to set them in the lock position.
  • Page 87 FEATURES & CONTROLS MH, EH, EHO, EO The trim angle is adjusted by setting the trim position pin in the correct trim position. Arrange passengers and load in the boat so the weight is distributed evenly. • Correct trim: The trim angle is optimum when the boat is parallel to the water surface while running.
  • Page 88 FEATURES & CONTROLS • Trim up: If the trim angle is low, the bow will dip into the water, the speed will decrease, and water may enter the boat. In this case, the trim angle should be increased by setting the trim position pin in a higher hole.
  • Page 89 FEATURES & CONTROLS How to use the trim gauge: When the trim angle is set as desired, take a reading off the trim gauge, and record it for future reference. Trim angle adjustable range 74° 8° 28° 38375 • Correct trim: The trim angle is optimum when the boat is parallel to the water surface while running.

  • Page 90: Steering Friction Adjustment

    FEATURES & CONTROLS • Trim up: If the trim angle is low, the bow will dip into the water and the speed will decrease. Water may also enter the boat. In this case, the trim angle should be increased by pressing the switch on the remote control lever to UP.

  • Page 91: Throttle Grip Turning Friction Adjustment

    FEATURES & CONTROLS EHPTO, EPTO Tight Loose Copilot 38387 Throttle Grip Turning Friction Adjustment Turn the screw clockwise to tighten friction and turn the screw counterclockwise to loosen friction. Loosen friction Tighten friction 38388 Trim Tab Adjustment Propeller steering torque will cause the boat to pull in one direction. This steering torque is a normal result from the outboard not trimmed with the propeller shaft parallel to the water surface.
  • Page 92 FEATURES & CONTROLS • After the adjustment, securely tighten the trim tab bolt. NOTE: Inspect the tightness of the bolt and the trim tab at regular intervals. Due to corrosion, the trim tab will wear down over time. IMPORTANT: The trim tab also acts as an anode to prevent galvanic corrosion.
  • Page 93 FEATURES & CONTROLS REMOTE CONTROL LEVER FRICTION EO, EPTO (Throttle friction adjustment screw) To adjust the load of the remote control lever, turn the throttle friction adjustment screw on the front of the remote control box. Turn clockwise to increase the friction and counter‑clockwise to decrease it.

  • Page 94: 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 95: Operating At High Elevations

    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 96: Starting The Engine

    OPERATION The use of poor quality fuel will shorten the life of a motor and cause trouble, including starting failure. It is recommended to use a high quality gasoline and genuine or recommended engine oil. (Refer to Fuel and Oil section.) Starting the Engine IMPORTANT: Never fill up portable fuel tanks on board to avoid fire or explosion resulting from spilled gasoline.
  • Page 97 OPERATION 3. Squeeze the primer bulb until firm. To fuel tank To engine Fuel flow direction 37714 IMPORTANT: To prevent the engine from flooding, do not squeeze the primer bulb after the engine has warmed up. 4. Install the lanyard cord. 38346 Lanyard cord Lanyard switch...
  • Page 98 OPERATION NOTE: Be sure the shift is at Neutral (N) when starting the engine. This model is provided with start in gear protection. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
  • Page 99 OPERATION NOTE: Operation of the choke knob is not required if the engine is warm. 4. Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow the rope to return slowly. Pull slowly Pull rapidly 37523...
  • Page 100 OPERATION 1. Set the shift lever to Neutral (N). 38347 NOTE: If the engine starts in gear, do not use the engine. Contact your dealer. 2. Turn the throttle grip so the indicator line meet the "START" mark. 38348 3. Pull the choke knob out. 38349 NOTE: Operation of the choke knob is not required if the engine is warm.
  • Page 101 OPERATION 4. Turn the key switch to ON. Continue turning the key switch clockwise to start the motor. Start 38350 5. Release the key switch as soon as the engine starts. The key will return to the ON position automatically. 6.
  • Page 102 OPERATION • Never operate the starter motor once the engine has started. • If the starter motor won't turn over, ensure that the battery terminal connections are tight and the battery is fully charged. STARTING (REMOTE CONTROL MODEL) IMPORTANT: Before starting, read the Pre‑Starting Check List, special operating instructions, and Engine Break‑in Procedure in the Operation section.
  • Page 103 OPERATION 3. Turn the key switch to the ON position and push ON for choke operation. The key does not need to be pushed if the engine is warm. Push to choke 37466 NOTE: The neutral warm‑up lever is inoperative unless the remote control lever is set to Neutral (N).

  • Page 104: Gear Shifting

    OPERATION 5. When the engine starts, release the key and allow it to return to ON. Push to choke 37466 IMPORTANT: Please follow the instructions below: • Extended operation of the starter motor will run the battery down. Operate the starter motor for a maximum of five seconds.
  • Page 105 OPERATION IMPORTANT: It may be dangerous to attempt shifting at high RPM. Be sure to slow engine RPM down to idle RPM before shifting. MH, EH, EHO, EHPTO Tiller handle models: Turn the throttle grip to the "SLOW" position and move the shift lever to Forward (F) or Reverse (R) position swiftly when the engine speed drops to its lowest level.
  • Page 106 OPERATION IMPORTANT: Never shift the outboard into gear unless the engine speed is at idle. Do not shift the outboard into reverse when the engine is not running. It may damage the shift linkage and possibly the gear mechanism. EO, EPTO 1.
  • Page 107 OPERATION 2. If the shift/throttle handle is moved pass the gear detent position, the throttle will begin to open. 37531 Full throttle position Idle position Throttle range Shift range (32°) Neutral (N) Forward (F) Reverse (R) Newtral warm‑up lever NOTE: Please follow the instructions below: 1.

  • Page 108: Emergency Starting

    OPERATION 2. Before moving the shift lever to Reverse (R), ensure the reverse lock is engaged in the "UP" position. 39890 EO, EPTO NOTE: The remote control lever becomes inoperative unless the neutal warm‑up lever is in the fully closed position. IMPORTANT: Never shift the outboard into gear unless the engine speed is at idle.
  • Page 109 OPERATION 2. MH, EH, EHO, EHPTO: Remove the top cowl. Take off the starter assembly/flywheel cover. 39941 3. EO, EPTO: Remove the top cowl. Take off the flywheel cover. 38355 4. Pull the choke knob. 38349 5. MH, EH, EHO, EHPTO: Turn the throttle grip so the indicator line meets the "START"...
  • Page 110 OPERATION 6. EO, EPTO: Lift up the newtral warm‑up lever 1/3 to 1/2 of its stroke. 38356 7. EO, EPTO: Turn the key switch to ON. Key switch 37881 8. EH, EHO, EHPTO: Turn the key switch to ON. 38359...
  • Page 111 OPERATION 9. Wind the starter rope around the flywheel a few turns clockwise. Give it a sharp tug to start the engine. Use a socket wrench to get a firm grip on the end of the rope. 38361 10. Remote control models: Ensure the key switch is in the "ON" position.
  • Page 112 OPERATION In‑gear Neutral 750 RPM 900 RPM Do not exceed the full‑throttle engine speed Full throttle engine speed 5000–5700 RPM 5150–5850 RPM OVERHEAT ALARM AND SENSOR (OPTIONAL ON SOME MODELS) EH, EHO, EHPTO, EO, EPTO • The overheat alarm will sound if the engine temperature exceeds the preset level.

  • Page 113: Stopping The Engine

    OPERATION NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. IMPORTANT: If a steady flow of water is coming out of the water pump indicator hole and the engine continues to overheat, consult your dealer.
  • Page 114 OPERATION 2. Turn the main switch to "OFF," press the stop switch or pull the lanyard. The engine will then stop. 38369 Lanyard /stop switch EO, EPTO 1. Move the remote control lever to Neutral (N) and let the engine idle for two or three minutes to allow it to cool down.
  • Page 115 OPERATION 2. Turn the key switch counterclockwise to the "OFF" position or pull the lanyard. The engine will then stop. The engine can also be stopped by pressing on the lanyard switch. Stop switch lock plate 39943 NOTE: Please follow the instructions below: •...

  • Page 116: Outboard Care

    We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA 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 117: Epa Emissions

    MAINTENANCE EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines. Refer to Owner's Manual for required maintenance.
  • Page 118 Inspection. • Remote control models ‑ Check control cable adjustments. • Remove engine deposits with Mercury Precision or Quicksilver Power Tune Engine Cleaner. • Check tightness of bolts, nuts, and other fasteners. 1. These items should be serviced by an authorized dealer.

  • Page 119: Flushing The Cooling System

    This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver Accessory (or equivalent) flushing attachment. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.

  • Page 120: Top Cowl Removal And Installation

    MAINTENANCE 3. Be sure to secure the water strainer and sub‑water strainer on the gearcase beforehand. 40/50 Flushing attachment (optional) Wash plug Oil plug Tape (for flushing with screw in attachment) 38389 4. With the shift lever in Neutral (N), run the engine at a low speed so that water flushes out the cooling system to remove seawater and mud.

  • Page 121: Battery Inspection

    MAINTENANCE 2. Lift rear of cowl and disengage front hook. 26851 INSTALLATION 1. Engage the front hook and push cowl back over the cowl seal. 2. Push cowl down and move the rear latch lever up to lock. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability.
  • Page 122 NOTE: Do not fully unscrew the oil plug with the engine tilted down. Pressurized oil in the oil tank may spurt out. 3. Recommended oil: Add Mercury or Quicksilver Power Trim and Steering Fluid. If not available, use automotive automatic...
  • Page 123 MAINTENANCE 4. Air purging from the power trim and tilt unit: Entrapped air in the power trim and tilt unit will cause poor tilting movement. With the engine mounted on the boat, set the manual release valve to the manual side, and tilt the engine manually up/down 5–6 times while checking the oil level.

  • Page 124: Fuse Replacement - Electric Start Remote Control Models

    MAINTENANCE 2. Clean the fuel filter on the engine after removing the fuel filter cases. Oil filter Fuel filter 38393 3. Oil filter and oil tank: Check the oil tank and/or filter for entrapped water and dust. a. Disconnect all hoses between the oil tank and oil pump. b.

  • Page 125: Propeller Replacement

    MAINTENANCE The anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode, as this will reduce effectiveness of the anode. Anode (trim tab) 37879 Important:...
  • Page 126 MAINTENANCE 2. Tiller handle model: Move shift lever to Neutral (N) position. 38347 3. Remove the spark plug leads to prevent the engine from starting. 26899 4. Place a block of wood between the gearcase and propeller to hold the propeller. 27296...
  • Page 127 6. Pull propeller straight off the propeller shaft. If the propeller is seized to the propeller shaft and cannot be removed, have the propeller removed by an authorized dealer. 7. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube...
  • Page 128 MAINTENANCE Tube Description Where Used Part No. Ref No. 2-4-C with Propeller shaft 92-802859A 1 Teflon 27344 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.
  • Page 129 MAINTENANCE INSTALLING PROPELLER 1. Install the propeller thrust holder, propeller, washer, nut, stopper, and cotter pin onto the propeller shaft. 38390 Cotter pin Washer Stopper Propeller Propeller thrust holder 2. Place the propeller nut retainer over the pins. Place a block of wood between the gearcase and propeller.

  • Page 130: 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 131: Lubrication Points

    Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first. For periodic servicing and maintenance guidelines, please contact your local Mercury dealer. Every 50 hours or 3 Every 100 hours or 6...
  • Page 132 MAINTENANCE Remove the fill/drain plug and examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer.
  • Page 133 MAINTENANCE 4. Place the lubricant tube nozzle into the fill/drain hole and add the lubricant until it appears at the upper oil plug hole. 40/50 Vent plug Fill plug Lubricant tube nozzle 38392 Vent plug Fill plug 39898 5. Install the vent plug. Then remove the lubricant tube nozzle and install the fill plug.

  • Page 134: Submerged Outboard

    17 fl oz Approximation 700 mL 24 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 135: Storage

    STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer).

  • Page 136: Protecting External Outboard Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • 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.

  • Page 137: Gearcase

    STORAGE • Remove the spark plugs and inject a five second spray of storage seal around the inside of the cylinder. • Rotate the flywheel manually several times to distribute the storage seal in the cylinder. Reinstall spark plug. Gearcase •...
  • Page 138 STORAGE Specific Gravity at 20 °C Terminal Voltage (V) Charge Condition 1.210 11.7 1/2 charged 1.250 12.0 3/4 charged 1.280 13.2 Fully charged • Check that the battery is secure and the battery cables are installed properly. • Clean the engine oil filter. •...

  • Page 139: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models ‑ Blown 20 amp fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 140: Performance Loss

    TROUBLESHOOTING • Incorrect setup and adjustments. • Fuel is being restricted to the engine. • Engine fuel filter is obstructed. Refer to Maintenance section. • Fuel tank filter obstructed. • Stuck anti‑siphon valve on built in fuel tank. • Fuel line is kinked or pinched. •...

  • Page 141: Associated Parts

    ASSOCIATED PARTS Associated Parts We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. Name Quantity Dimensions Tool bag Pliers Socket wrench 10 x 13 mm Socket wrench 21 mm Service tools Socket wrench handle Screwdriver (phillips and flat...

  • Page 142: Associated Parts

    ASSOCIATED PARTS Propeller Selection IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.

  • Page 143: Note

    ASSOCIATED PARTS Mark L transom 16.5 17.5 NOTE:...

  • Page 144: Optional Accessories

    ACCESSORIES Optional Accessories 38397...
  • Page 145 ACCESSORIES Tie bar kit B (for twin ‑ engine operation) Twin ‑ control kit (for twin ‑ engine operation) Propeller Grease Gear oil (500 ml) Touch‑up spray...
  • Page 146 ACCESSORIES 38396 Speedometer (50 mph) Speedometer (75 mph) Water pressure gauge...
  • Page 147 ACCESSORIES Water temperature gauge Voltmeter Hour meter (engine operation hour counter) Fuel gauge Tachometer Flushing attachment Drive cleaner...

  • Page 148: Owner Service Assistance

    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 149: 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 150 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 5467789 Singapore, 508762...

  • Page 151: Wiring Diagrams

    WIRING DIAGRAMS Wiring Diagrams 1. Pulser coil assembly 2. Alternator 3. Exciter coil 4. CD unit 5. Ignition coil 6. Rectifier 7. Starter motor 8. Starter solenoid 9. Power trim and tilt 10. Power trim and tilt solenoid switch A 11.

  • Page 152: Wire Color Code Abbreviations

    WIRING DIAGRAMS 32. Power trim and tilt switch 33. Tachometer 34. Trim gauge 35. Gauge harness 36. Oil light 37. Low oil light 38. Speedometer 39. Water pressure gauge 40. Hour meter 41. Voltmeter 42. Water temperature gauge 43. Fuel gauge 44.

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