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Mercury Jet OptiMax 110 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.
eng
WARNING
!
i

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  • 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 Emission Control System Components........13 General Information Boater's Responsibilities............
  • Page 8 Fuel and Oil Fuel Recommendations............. 36 Oil Recommendation..............38 Fuel Additives................38 Fuel Requirements..............38 Avoiding Fuel Flow Restriction..........38 Low Permeation Fuel Hose Requirement ......... 38 Filling Remote Oil Tank............. 39 Filling Engine‑Mounted Oil Reservoir Tank....... 39 Filling Fuel Tank................ 40 Features and Controls Remote Control Features............
  • Page 9 Maintenance Outboard Care................59 EPA Emissions Regulations............59 Inspection and Maintenance Schedule........60 Flushing the Cooling System............. 62 Top Cowl Removal and Installation........... 63 Cleaning Care for Top Cowl............64 Flywheel Cover Removal and Installation........64 Fuel System................65 Steering Link Rod Fasteners............. 66 Fuse Replacement..............
  • Page 10 Engine Runs Erratically............. 83 Performance Loss..............83 Engine Overspeed (Excessive RPM)........83 Battery Will Not Hold Charge............. 84 OWNER SERVICE ASSISTANCE Local Repair Service..............85 Service Away from Home............85 Parts and Accessories Inquiries..........85 Service Assistance..............85 Mercury Marine Service Offices..........86...
  • Page 11 OUTBOARD INSTALLATION Important Information..............88 Avoiding Fuel Flow Restriction..........88 Electric Fuel Pump..............89 Boat Horsepower Capacity............89 Start in Gear Protection............. 89 Selecting Accessories for Your Outboard........90 Fuel Tanks................. 90 Low Permeation Fuel Hose Requirement ......... 90 Installation Specifications............91 Lifting the Outboard..............

  • 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: Emission Control System Components

    WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product.
  • Page 26 WARRANTY INFORMATION a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensitive valves and switches d. Electronic controls The emission‑related warranty does not cover components whose failure would not increase an engine's emissions on any regulated pollutant.

  • Page 27: 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 28: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

  • Page 29: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death.

  • Page 30: Lanyard Stop Switch

    GENERAL INFORMATION 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 31 GENERAL INFORMATION The lanyard is a cord usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 32 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 33: Stopping The Boat In An Emergency

    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 34: Protecting People In The Water

    GENERAL INFORMATION WARNING Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death. Use caution when performing the emergency stopping procedure, and be sure to practice in a safe area.

  • Page 35: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running.
  • Page 36 GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 37: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat reenters the water.

  • Page 38: Impact With Underwater Hazards

    GENERAL INFORMATION Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 39: 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 40 GENERAL INFORMATION STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing).

  • Page 41: Selecting Accessories For Your Outboard

    Operating the boat with no forward hatches open (station wagon effect) Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. IMPORTANT: Check with your dealer before installing accessories.

  • Page 42: Safe Boating Suggestions

    GENERAL INFORMATION 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. Safe Boating Suggestions...
  • Page 43 GENERAL INFORMATION Prepare other boat operators. Instruct at least one other person on board in the basics of starting and operating the jet drive, and boat handling, in case the driver becomes disabled or falls overboard. Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat.

  • Page 44: Recording Serial Number

    GENERAL INFORMATION Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when the boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is...
  • Page 45 GENERAL INFORMATION Models 110 Jet Piston displacement 2508 cc (153 in³) Cylinder bore 88.4 mm (3.500 in.) Piston stroke 67.3 mm (2.650 in.) Recommended spark NGK IZFR5G plug Spark plug gap 0.8 mm (0.030 in.) Recommended Refer to Fuel and Oil gasoline Recommended oil Refer to Fuel and Oil...

  • Page 46: Component Identification

    GENERAL INFORMATION Component Identification 33528 Top cowl Bottom cowl Water pump indicator hole Driveshaft housing Water outlet nozzle Reverse gate Water intake housing Jet drive housing Transom brackets Auxiliary tilt switch...

  • Page 47: 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 48: 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 49 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 50: Oil Recommendation

    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 51: Filling Remote Oil Tank

    FUEL AND OIL • Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑ marine fuel hose. Filling Remote Oil Tank Remove filler cap and fill with the specified oil.

  • Page 52: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

  • Page 53: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle ‑...

  • Page 54: Warning System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch. 27755 Horn inside remote control Horn connected to ignition key switch WARNING HORN SIGNALS When the key switch is turned to the "ON"...
  • Page 55 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling Continuous Engine Guardian System is activated. Power system limit will vary with level of overheat. Shift problem outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
  • Page 56 The horn will turn off when throttle speed is within the allowable limit. Consult your dealer for assistance. 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 57: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt Your 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 58 FEATURES AND CONTROLS When planing, the outboard should be positioned vertical or tilted in toward the boat to provide a scooping angle on the water intake grate. Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause impeller slippage and cavitation burns on the impeller blades.
  • Page 59 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 The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.

  • Page 60: 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 61: 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 62: How The Jet Drive Operates

    OPERATION When boating through shallow water areas, choose a course of travel that avoids sharp rocks and other underwater obstacles that could damage the boat. Running the boat through these areas on full plane may be helpful as the boat will be riding higher in the water.

  • Page 63: Stopping The Boat In An Emergency

    OPERATION When the jet drive is in neutral, the impeller continues to rotate. However, the reverse gate is positioned so that some of the forward thrust is diverted to create reverse thrust. This approximate balancing of forward and reverse thrust will minimize any boat movement.

  • Page 64: Steering The Boat

    OPERATION In an emergency, putting the jet outboard into reverse and applying reverse throttle can rapidly slow down the boat and reduce stopping distance. However, such a maneuver may cause occupants in the boat to be thrown forward or possibly out of the boat.

  • Page 65: Mooring The Boat

    OPERATION Mooring the Boat Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water. Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting.

  • Page 66: Starting The Engine

    OPERATION The engine break‑in procedure for an OptiMax outboard is important to ensure proper performance and maximum life from the engine. The following break‑in procedure allows the internal engine parts to wear‑in evenly. Incorrect engine break‑in can shorten the engine life. The engine automatically receives extra oil during the first hours of operation.
  • Page 67 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. 1. Ensure that the driveshaft bearing on the jet drive is lubricated.
  • Page 68 OPERATION 4. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to neutral ("N") position. 26838 6. For the initial start of a new engine, or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: a.

  • Page 69: Gear Shifting

    OPERATION 8. Turn the ignition key to "START" position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to "OFF" position, wait one second and try again. 19804 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting.

  • Page 70: Stopping The Engine

    OPERATION After shifting outboard into gear, advance the lever further to increase speed. 27237 Stopping the Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843...

  • Page 71: 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 72: 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 73 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 74: Flushing The Cooling System

    MAINTENANCE • Lubricate splines on the driveshaft. • Check tightness of bolts, nuts, and other fasteners. • Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). • Check cowl seals to make sure seals are intact and not damaged.

  • Page 75: Top Cowl Removal And Installation

    MAINTENANCE 2. Attach a water hose to the fitting. Turn on the water and flush for 3–5 minutes. 28430 Top Cowl Removal and Installation REMOVAL 1. Pull out the front cowl latch. 27816 2. Lift up the rear cowl latch. Remove the top cowl. 27817 INSTALLATION 1.

  • Page 76: Cleaning Care For Top Cowl

    MAINTENANCE Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Follow the cleaning and waxing procedure. CLEANING AND WAXING PROCEDURE 1. Before washing, rinse the top cowl with clean water to remove the dirt and dust that may scratch the surface.

  • Page 77: Fuel System

    MAINTENANCE IMPORTANT: Make sure the flywheel cover is pushed down on the air intake tube for the air compressor. 29395 Front flange Air intake tube Vent hose Fuel System WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.

  • Page 78: Steering Link Rod Fasteners

    MAINTENANCE WATER SEPARATING FUEL FILTER NOTE: The warning system will turn on when water in the fuel filter reaches the full level. See Features & Controls ‑ Warning System The water separating fuel filter removes moisture and also debris from the fuel. If the filter becomes filled with water, the water can be removed.
  • Page 79 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 80: Fuse Replacement

    MAINTENANCE Fuse Replacement IMPORTANT: Always carry spare 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 81: Battery Information

    MAINTENANCE IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 4.

  • Page 82: Spark Plug Inspection And Replacement

    MAINTENANCE Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. NOTICE - DTS & OptiMax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and OptiMax engines must use a marine starting...

  • Page 83: Compressor Air Intake Filter

    MAINTENANCE 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.80 mm (0.030 in.) 4.

  • Page 84: Steering Pull Adjustment

    MAINTENANCE 2. Snap out the retainer and remove filter. Retainer Filter 29397 INSTALLATION 1. Install filter into cover. 2. Secure filter into cover with retainer. Steering Pull Adjustment The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1.5 mm (1/16 in.) toward the starboard side of the outboard.

  • Page 85: Worn/Dull Impeller

    MAINTENANCE Worn/Dull Impeller The intake of gravel through the pump can round off and wear the leading edges of the impeller. Some conditions that could be experienced from a worn/dull impeller are as follows: • Noticeable performance loss, especially on acceleration •...

  • Page 86: Alternator Belt Inspection

    MAINTENANCE As the blades wear, shims located in the stack outside of the impeller can be transferred behind the impeller. This will move the impeller further down into the tapered liner to reduce the clearance. Shims Clearance between impeller edge and liner 29080 Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller...

  • Page 87: Lubrication Points

    MAINTENANCE Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision 2‑4‑C with PTFE. Tube Description Where Used Part No. Ref No. 2-4-C with Driveshaft bearing 92-802859A 1 PTFE IMPORTANT: It is important not to use a general all‑purpose grease for this bearing.
  • Page 88 Lubricant 101 • Trim rod ball ends ‑ Turn the ball ends to work the lubricant into the ball sockets. 28458 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Special Lubricant 101. Tube Description Where Used Part No.
  • Page 89 MAINTENANCE • Tilt support lever ‑ Lubricate through fitting. Swivel bracket Tilt support lever 27873 • 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.

  • Page 90: Submerged Outboard

    MAINTENANCE • Steering link rod pivot points ‑ Lubricate pivot points. 27876 Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 91: Storage

    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 92: Protecting Internal Engine Components

    STORAGE 4. Premix the following in a container: • 8 cc (0.27 oz) or two teaspoons of Mercury Precision Quickleen lubricant. • 8 cc (0.27 oz) or two teaspoons of Mercury Precision Fuel Stabilizer. 5. Pour this mixture in a new water separating fuel filter.

  • Page 93: Jet Drive

    STORAGE Tube Description Where Used Part No. Ref No. Corrosion External metal surfaces 92-802878 55 Guard Jet Drive • Pump extra grease into the jet drive bearing to purge out moisture. Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of the outboard.

  • Page 94: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 95: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c.

  • Page 96: Battery Will Not Hold Charge

    TROUBLESHOOTING Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. • Worn out or inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator. •...

  • Page 97: 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 98: 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 99 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 100: Outboard Installation

    IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3. The use of an inferior 2‑Cycle outboard oil can reduce engine durability.

  • Page 101: Electric Fuel Pump

    OUTBOARD INSTALLATION Electric Fuel Pump The fuel pressure must not exceed 28 kPa (4 psi). If necessary, install a pressure regulator. 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.

  • Page 102: Selecting Accessories For Your Outboard

    Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.

  • Page 103: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 33489 Minimum transom opening Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33‑3/8 in.) Dual engine 151.8 cm (59‑3/4 in.) Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death.

  • Page 104: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. Lifting eye 28495 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead...

  • Page 105: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 2. Insert steering cable into tilt tube. 3725 3. Torque nut to specification. 3727 Description lb‑in. lb‑ft 47.5 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 (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 106 OUTBOARD INSTALLATION 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 107: Determining The Mounting Height Of The Outboard

    OUTBOARD INSTALLATION 2. Assemble the steering link rod to the engine with the special washer head bolt "a" and self‑locking nylon insert locknut "b." 3. Torque the head bolt, then the locknut to specifications. Description lb‑in. lb‑ft Cable coupler nylon insert locknut Tighten locknut until it seats, then "d"...
  • Page 108 OUTBOARD INSTALLATION BOATS WITH A "V" BOTTOM HULL 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line on the transom up from the "V" bottom the same length as the width of the water intake housing.

  • Page 109: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION BOATS WITH A FLAT BOTTOM HULL 1. Place (center) the outboard on the boat transom. Set the height of the outboard on the boat transom so that the front edge of the water intake housing is in line with the bottom of the boat as shown.
  • Page 110 OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 111: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 10‑8M0033366 Transom bolt 1/2‑20 x 5.00 in. long (3.25 in. thread) 11‑826711‑17 Nylon insert locknut 1/2‑20 12‑28421 Washer ‑...
  • Page 112 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 113 OUTBOARD INSTALLATION NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. 33962 Large transom washer Transom reinforcement plate 1. Apply marine sealer to shanks of bolts, not the threads. 2.

  • Page 114: Electrical, Hoses, And Control Cables

    OUTBOARD INSTALLATION Description lb. in. lb. ft. Outboard mounting locknuts and bolts Electrical, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove screws and open the front clamp assembly. Screw (2) Front clamp 7644...
  • Page 115 OUTBOARD INSTALLATION REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp. Connect remote harness to the 14 pin connector on the engine harness. 11033 14 pin connector Remote 14 pin boat harness 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.
  • Page 116 OUTBOARD INSTALLATION IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements. The decal needs to be placed on or near the battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut is supplied per battery for wing nut replacement.
  • Page 117 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Black sleeve ‑ Negative (–) Ground cable Cranking battery FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel hose size ‑...
  • Page 118 OUTBOARD INSTALLATION 2. Connect the remote oil hoses to the engine hose connections. Fasten hose connections with cable ties. Hose clamp Cable tie Oil hose without blue stripe Oil hose with blue stripe Remote fuel hose 3767 ENGINE WATER PRESSURE TUBE CONNECTION NOTE: This applies to models without SmartCraft gauges.

  • Page 119: Shift And Throttle Cable

    OUTBOARD INSTALLATION Shift and Throttle Cable SHIFT CABLE INSTALLATION WARNING If not properly installed, the reverse gate can interfere with water coming off the rudder, suddenly and unexpectedly slowing the boat. This can cause serious injury or death from occupants being thrown within or out of the boat. Adjust the shift cable to prevent the reverse gate from interfering with water flow off the rudder.
  • Page 120 OUTBOARD INSTALLATION 4. Attach the shift cable adjustment barrel to the bracket with a bolt and locknut. Tighten the bolt until it seats against the adjustment barrel, then back‑off the bolt 1/4 turn. Hold the bolt from turning, and tighten the locknut on the bolt. The adjustment barrel must be free to pivot.
  • Page 121 OUTBOARD INSTALLATION THROTTLE CABLE INSTALLATION 1. Position remote control into neutral. 26838 2. Attach throttle cable to the throttle lever. Secure with washer and locknut. Washer and locknut Throttle cable Throttle lever 7738 3. Adjust the throttle cable barrel so that the installed throttle cable will hold the idle stop screw against the stop.

  • Page 122: Front Clamp Reassembly

    OUTBOARD INSTALLATION a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse. b. Return remote control to neutral. Place a thin piece of paper between idle adjustment screw and idle stop. Adjustment is correct when the paper can be removed without tearing, but has some drag on it.

  • Page 123: Filling The Fuel System

    OUTBOARD INSTALLATION 1. Place the neoprene wrap over the wiring, hoses, and control cables. 3766 2. Fasten clamp together with two screws. Screw (2) Front clamp 7644 Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system.

  • Page 124: Oil Injection Set-Up

    OUTBOARD INSTALLATION 4. Turn the key switch to the "ON" position again for three seconds. 5. Continue this procedure until the fuel line primer bulb stays firm. Oil Injection Set‑Up FILLING THE OIL TANKS 1. Remove the fill cap from the remote oil tank and fill the tank with the recommended oil.
  • Page 125 OUTBOARD INSTALLATION 3. If the oil level is less than 118 ml (4 oz), loosen the vent cap. Use a squirt can and fill the tank with at least 118 ml (4 oz) of the recommended oil. Tighten the vent cap. Engine‑mounted oil reservoir tank Vent cap...
  • Page 126 OUTBOARD INSTALLATION 2. Position the fuel primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel hose primer bulb until it feels firm. 27348 3. Turn the ignition key switch to the "ON" position. 26846 4.

  • Page 127: Trim In Pin

    OUTBOARD INSTALLATION Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 128 OUTBOARD INSTALLATION The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired. A nonstainless steel shipping bolt should not be used in this application other than on a temporary basis.

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