Mercury 2.5 Service Manual
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Mercury 2.5 Service Manual

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See also: Operation & Maintenance Manual , Operation, Maintenance and Installation Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak
efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key
to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty
coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
If the outboard motor's serial number plate contains the CE mark in the lower left-hand corner, the
following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe
Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive:
EMC Directive:
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA
98/37/EC,
89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
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Summary of Contents for Mercury 2.5

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.

  • Page 2: Table Of Contents

    Warranty Registration Outside The United States And Canada................1 Mercury Marine Two Years Limited Warranty (Europe)..................2 Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa).... 3 3 Year Limited Warranty Against Corrosion......................5 Warranty Coverage And Exclusions........................6 General Information Boater's Responsibilities............................
  • Page 3 Positioning Outboard For Storage........................38 Troubleshooting Engine Will Not Start............................39 Engine Runs Erratically............................39 Performance Loss..............................39 Owner Service Assistance Local Repair Service............................40 Service Away From Home............................ 40 Parts And Accessories Inquiries........................... 40 Service Assistance............................... 40 Mercury Marine Service Offices........................... 40...

  • Page 5: Warranty Information

    Warranty Registration United States And Canada 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 6: Mercury Marine Two Years Limited Warranty (Europe)

    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. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 7: Mercury Marine One Year Limited Warranty (Confederation Of Independent States, Middle-East, Africa)

    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 if made, shall not be enforceable against Mercury Marine.
  • Page 8 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. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    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. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 10: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
  • Page 11 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 12: 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 13: Lanyard Stop Switch

    GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY ob00306 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.

  • Page 14: Protecting People In The Water

    GENERAL INFORMATION We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected). WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.
  • Page 15 GENERAL INFORMATION WARNING Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death. GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. ob00316 Example of desired air flow through the boat.

  • Page 16: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.

  • Page 17: Specifications

    GENERAL INFORMATION rial Numb OTXXXXXX 20XX XXXX ob01047 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation Specifications Models Horsepower Kilowatts Full Throttle RPM Range 4000-5000 4500-5500 Idle Speed in Forward Gear 900-1000 RPM Number of Cylinders Piston Displacement 74.6 cc (4.6 cu.

  • Page 18: Installation

    INSTALLATION Installing Outboard BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat. The anti-ventilation plate should be 25 - 50 mm (1 - 2 in.) below the bottom of the boat. ob01048 Anti-ventilation plate INSTALLING OUTBOARD ON TRANSOM Place outboard on center line of transom.

  • Page 19: Transporting

    TRANSPORTING Carrying Outboard The outboard has a carrying handle located in front. ob01051 Transporting Outboard When Removed From Boat CAUTION Transport and store the outboard only as shown. Otherwise, engine damage or property damage could result from leaking oil. With the outboard still in the water, close the fuel shut-off valve and run engine until it stops. This will drain fuel from the carburetor.
  • Page 20 TRANSPORTING Side shift models - Set the gear shift into forward gear. This prevents the propeller from spinning freely. ob01053...

  • Page 21: Fuel And Oil

    IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. 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.

  • Page 22: Filling Fuel Tank

    FUEL AND OIL GASOLINE/OIL MIXING RATIO CHART GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal.) gas 11.5 liters (3 gal.) gas 23 liters (6 gal.) gas 25:1 (4%) 148 ml (5 fl. oz.) oil 473 ml (16 fl. oz.) oil 946 ml (32 fl.

  • Page 23: Features And Controls

    FEATURES AND CONTROLS Features & Controls Throttle lever - Move to start position for starting. Move lever up to increase engine speed and down to reduce engine speed. Choke lever - Move up to the closed position for starting a cold engine. Move halfway down as engine warms up. Move down to the open position after engine is warmed up.

  • Page 24: Tilting Outboard

    FEATURES AND CONTROLS ob01056 Tighten friction Loosen friction Side handle gear shift (if equipped) - controls gear shift. ob01057 Tilting Outboard TILTING TO FULL UP POSITION Stop the engine. Take hold of the top cowl grip and raise outboard to the full up position. ob01058 Push in the tilt support pin.

  • Page 25: Setting The Operating Angle Of Your Outboard

    FEATURES AND CONTROLS LOWERING TO RUN POSITION Lift outboard and pull out the tilt support pin. Lower the outboard. ob01059 Setting The Operating Angle Of Your Outboard The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the adjustment holes provided.

  • Page 26: Pre-Starting Check List

    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 27 OPERATION CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged. ob01061 Open fuel tank vent.
  • Page 28 OPERATION STOP ob01064 If engine is cold, move choke lever to closed (up) position. Move halfway down as engine warms up. Move down to the open position after engine is warmed up. Move the throttle lever to the start position. STOP ob01065 Throttle lever...

  • Page 29: Gear Shifting - Models With Gear Shift

    OPERATION WARNING Direct Drive Models (non-gear shift) - Outboard is in gear at all times. Do not start the engine with the throttle lever past the start position. Always remain seated when attempting to start the engine. Sudden acceleration could cause loss of balance by occupants resulting in serious injury or death. Always remain seated when attempting to start the engine.

  • Page 30: Emergency Starting

    OPERATION STOP ob01068 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. WARNING When using the emergency starter rope to start engine, the start at idle speed protection is inoperative. Make sure to have the engine speed set at slow, and the outboard gear shift positioned in neutral to prevent outboard from starting in gear.
  • Page 31 OPERATION ob01070 Bolt Black lead Place the starter rope knot into the starter cup notch and wind the rope clockwise around the cup. Pull the starter rope to start the engine. WARNING To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine.

  • Page 32: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 33: Inspection And Maintenance Schedule

    MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Inspection And Maintenance Schedule BEFORE EACH USE • Visually inspect the fuel system for deterioration or leaks. •...

  • Page 34: Exterior Care

    Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. 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. NOTE: Do not run the engine while flushing the cooling system.
  • Page 35 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.

  • Page 36: Corrosion Control Anode

    MAINTENANCE ob01220 Cotter pin Drive pin Propeller Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. The anode requires periodic inspection especially in salt water which will accelerate the erosion.

  • Page 37: Engine Idle Speed Adjustment

    MAINTENANCE Remove the spark plug boot. Twist the rubber boots slightly and pull off. ob00375 Remove the spark plug to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. ob01092 Set spark plug gap to specifications. ob00424 Spark Plug Spark plug gap...

  • Page 38: Lubrication Points

    MAINTENANCE ob01223 Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. • Co-Pilot - Lubricate threads. ob01224 • Swivel Bracket - Remove four (4) bolts and rear cover and lubricate the inner nylon bushings.

  • Page 39: Gearcase Lubrication

    • Throttle linkage - Lubricate pivot point. ob01228 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. • Propeller Shaft - Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft.
  • Page 40 MAINTENANCE Examine the drained gearcase lubricant for metal particles. A small amount of 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. DRAINING GEARCASE Place outboard in a vertical operating position.

  • Page 41: Submerged Outboard

    MAINTENANCE ob01230 Vent plug Fill/drain plug Vent hole IMPORTANT: Replace sealing washers if damaged. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. 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 42: Storage

    • With engine running at fast idle, stop the fuel flow by closing the fuel shut-off valve. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel.

  • Page 43: Troubleshooting

    TROUBLESHOOTING Engine Will Not Start POSSIBLE CAUSES • Incorrect starting procedure. Refer to Operation section. • Old or contaminated gasoline. • Engine flooded. Refer to Operation section. • Fuel is not reaching the engine. Fuel tank is empty. Fuel tank vent not open or restricted. Fuel shut-off valve closed Fuel tank filter obstructed.

  • Page 44: Owner Service Assistance

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 45 Telephone (954) 744-3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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