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 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA on December 16, 2005. European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...
Page 3: Table Of Contents
TABLE OF CONTENTS Warranty Information Transfer of Warranty..............1 Warranty Registration United States and Canada.......1 Warranty Registration Outside the United States and Canada. . .2 FourStroke Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States......3 FourStroke Outboard Limited Warranty (Middle‑East, and Africa) .....................6 3 Year Limited Warranty Against Corrosion........9 Warranty Coverage and Exclusions..........13...
Page 4 TABLE OF CONTENTS Fuel and Oil Fuel Recommendations.............35 Filling Fuel Tank................37 Engine Oil Recommendations...........38 Checking Engine Oil..............38 Features and Controls Tiller Handle Features...............41 Remote Control Features............45 General Features...............45 Manual Tilt Features and Operation..........48 Power Tilt Features and Operation..........52 Warning System Features and Operation.........57 Trim Tab Adjustment..............59 Operation Pre‑Starting Check List..............60...
Page 5 TABLE OF CONTENTS Maintenance Outboard Care................74 EPA Emissions................74 Inspection and Maintenance Schedule........75 Flushing the Cooling System.............77 Top Cowl Removal and Installation...........79 Battery Inspection ..............79 Exterior Care................79 Fuel System................80 Steering Link Rod Fasteners.............81 Corrosion Control Anode ............82 Propeller Replacement .............84 Fuse Replacement ‑ Electric Start Models ....... 86 Spark Plug Inspection and Replacement........
Page 6 Battery Will Not Hold Charge...........104 Owner Service Assistance Local Repair Service..............105 Service Away from Home............105 Parts and Accessories Inquiries..........105 Service Assistance..............105 Mercury Marine Service Offices..........106 Engine Installation Boat Horsepower Capacity............108 Start in Gear Protection............108 Selecting Accessories for Your Outboard........108 Lifting the Outboard..............109 Installing Outboard..............109...
Page 7: Warranty Information
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...
Page 8: Warranty Registration Outside The United States And Canada
2. To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail.
Page 9: Fourstroke Outboard Limited Warranty United States, Canada, Europe And Confederation Of Independent States
Independent States Outside the United States, Canada, Europe and Confederation of Independent States ‑ check with local distributor. WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
Page 10 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 pre–delivery inspection process is completed and documented.
Page 11 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 12: Fourstroke Outboard Limited Warranty (Middle-East, And 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 13 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 pre–delivery inspection process is completed and documented.
Page 14 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 15: Year Limited Warranty Against Corrosion
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 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 pre‑delivery 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 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 19: 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 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 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 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. 26779 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.
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 Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller.
Page 28: Passenger Safety Message - Pontoon Boats And Deck Boats
GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.
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 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.
Page 32: Exhaust Emissions
GENERAL INFORMATION Models with Clamp Screws: Some outboards come with transom bracket clamp screws. The use of clamp bracket screws alone, is insufficient to properly and safely secure the outboard to the transom. Proper installation of the outboard includes bolting the engine to the boat through the transom.
Page 33 GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 34: Selecting Accessories For Your Outboard
The misuse of approved accessories or the use of non‑approved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
Page 35 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) The Red Cross and 4) your state boating law enforcement agency.
Page 36: 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 their 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 37 GENERAL INFORMATION Models Stroke 60 mm (2.36 in.) Recommended Spark NGK DCPR6E Plug Spark Plug Gap 0.8 ‑ 0.9 mm (0.031 ‑ 0.035 in.) Gear Ratio 2.15:1 Recommended Gasoline Refer to Fuel and Oil Recommended Oil Refer to Fuel and Oil Gearcase Lubricant 370 ml (12.5 fl.
Page 38: Transporting
TRANSPORTING Carrying, Storing, and Transporting Your Outboard when Removed from Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run engine until it stops.
Page 39: Transporting Portable Fuel Tanks
TRANSPORTING 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. Transport the fuel tank in a well ventilated area away from open flame or sparks. MANUAL VENTING TYPE FUEL TANK Close fuel tank air vent when transporting tank.
Page 40 TRANSPORTING 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. 32176 IMPORTANT: Do not rely on the power tilt system or the tilt support lever to maintain proper ground clearance for trailering.
Page 41: 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 42 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 43: 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 44: Engine Oil Recommendations
FUEL AND OIL Engine Oil Recommendations We recommend the use of Mercury or Quicksilver SAE 10W‑30 multi‑viscosity 4‑Stroke Outboard Oil for general, all‑temperature use. If SAE 25W‑40 multi‑viscosity oil is preferred, use Mercury MerCruiser 4‑cycle engine oil or Quicksilver sterndrive & inboard 4‑cycle engine oil.
Page 45 FUEL AND OIL 1. Tilt outboard to vertical operating position. 2. Remove the top cowl. Refer to Maintenance - Cowl Removal and Installation. 3. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way. 4.
Page 46 Outboard engines can typically handle large amounts of oil dilution without causing durability problems. However, to ensure extended life of the outboard engine, Mercury recommends that the oil and filter be changed regularly following the oil change interval and using the recommended oil quality. It is further...
Page 47: Features And Controls
FEATURES AND CONTROLS Tiller Handle Features • Tiller handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage. 28535 • Tiller lock release lever ‑ Push lever to move tiller handle from one position to another. 3274 Tiller lock release lever...
Page 48 FEATURES AND CONTROLS • Tiller handle lock cap ‑ Remove and retain the lock cap on the top of the tiller handle to lock in the up position. Push the tiller lock release lever to release the handle from the locked up position.
Page 49 FEATURES AND CONTROLS • Power tilt switch ‑ Push to tilt engine up/down. 4639 • Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction or turn knob counterclockwise to loosen friction. 28542 Loosen friction (counterclockwise) Tighten friction (clockwise)
Page 50 FEATURES AND CONTROLS • Throttle grip ‑ Controls engine speed and shifting. The outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). 31971 • Choke/fast idle ‑ Pull out when starting a cold engine. •...
Page 51: Remote Control Features
FEATURES AND CONTROLS Remote Control Features 26800 Control handle ‑ forward, neutral, reverse Neutral release lever Power tilt switch (if equipped) ‑ Refer to Features and Controls ‑ Power Tilt Features and Operation Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch Lanyard ‑...
Page 52 FEATURES AND CONTROLS WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment, maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released.
Page 53 FEATURES AND CONTROLS • Fuel connector protector cap ‑ Place over the fuel connector when the fuel hose is disconnected. 32122 Fuel connector protector cap • Cooling water intakes ‑ The outboard has two water intakes for cooling the engine, the primary water intake and the secondary water intake.
Page 54: Manual Tilt Features And Operation
FEATURES AND CONTROLS Manual Tilt Features and Operation • Tilt lever ‑ Allows the outboard to be locked into the shallow water drive position or the full up position. Refer to Basic Tilting Operation. • Tilt pin ‑ Set the vertical operating angle on the outboard. Refer to Setting the Operation Angle of the Outboard.
Page 55 FEATURES AND CONTROLS TILTING OUTBOARD TO FULL UP POSITION 1. Stop the engine. 2. Shift the outboard to forward gear position. 3. Position the tilt lever to the tilt position. 4. Take hold of the top cowl grip and tilt the outboard all the way up until it locks in place.
Page 56 FEATURES AND CONTROLS 5. To release the outboard out of shallow water drive, position the tilt lever to the release position, slightly lift up the outboard, and gently lower it down. 32151 SETTING THE OPERATION ANGLE OF THE OUTBOARD The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the six adjustment holes provided.
Page 57 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 32152 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.
Page 58: Power Tilt Features And Operation
FEATURES AND CONTROLS • Lift the bow out of the water • Generally increase top speed • Increase clearance over submerged objects or a shallow bottom • Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller) •...
Page 59 FEATURES AND CONTROLS 1. Engage the tilt support lever by rotating the lever down. 2. Lower the outboard to rest on the tilt support lever. 3. Disengage the tilt support lever by slightly tilting up the outboard and releasing the tilt support bracket. Lower the outboard.
Page 60 FEATURES AND CONTROLS WARNING Avoid injury or death from loss of steering control. ProKicker centering straps prevent the outboard from turning when tilted up. If using a steering tie bar to a second outboard, disconnect the steering tie bar to allow steering of the second outboard before operating the boat.
Page 61 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. 31967 TILT-IN STOP ADJUSTMENT NOTE: The outboard should be positioned against the tilt‑in stop pins during operation.
Page 62 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 32191 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.
Page 63: Warning System Features And Operation
FEATURES AND CONTROLS • Lift the bow out of the water • Generally increase top speed • Increase clearance over submerged objects or a shallow bottom • Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller) •...
Page 64 FEATURES AND CONTROLS ENGINE OVERHEAT Check for a steady stream flowing out of the water pump indicator hole. If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check cooling water intake holes for obstruction.
Page 65: Trim Tab Adjustment
FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause the boat to pull in one direction. Steering torque results from the outboard not being tilted so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.
Page 66: 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 67: Operating Outboard As An Auxiliary Engine
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 68: Engine Break-In Procedure
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. 3. Make sure the cooling water intake is submerged. 26837 Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can...
Page 69 OPERATION 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after the engine has warmed up.
Page 70 OPERATION NOTE: For initial start of a new engine or first start after a prolonged storage, the primer lines may have air in them. In this case, depress the fuel primer ten times rapidly. 31978 Choke/fast idle knob Fuel primer IMPORTANT: Avoid engine flooding ‑...
Page 71 OPERATION 7. Electric starting models ‑ Push the starter button and crank the engine. Release button when the engine starts. Do not operate the starter motor continuously for longer than ten seconds at a time. If the engine fails to start, wait 30 seconds and try again.
Page 72: Starting The Engine - Remote Control Models
OPERATION 9. Check for the low oil pressure warning light to turn off. The low oil pressure warning light will turn on for ten seconds after the outboard starts as a normal system test. If the light should stay on, refer to Features and Controls ‑ Warning System. 32208 10.
Page 73 OPERATION 1. Open the fuel tank vent screw in the filler cap on manual venting type tanks. 19748 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm.
Page 74 OPERATION IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle while engine is not running. This will inject fuel into the engine and may cause a hard starting flooded condition. 26838 IMPORTANT: Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery. Damage to the charging system may result.
Page 75 OPERATION NOTE: If the engine fails to start after five attempts, pump the throttle twice by moving the throttle‑only feature to the full open position two times. Return the throttle‑only feature back so that the throttle is only opened slightly and re‑try starting the engine. 33289 NOTE: Starting flooded engine ‑...
Page 76: Gear Shifting
OPERATION 9. Check for a steady stream of water flowing out of the water pump indicator hole. 31982 IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction.
Page 77: Stopping The Engine
OPERATION • Remote control models ‑ Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). When shifting, always stop at neutral position and allow the engine speed to return to idle. 31971 27237 •...
Page 78: Emergency Starting
OPERATION 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to the neutral position. Push in the engine stop button. 26776 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow this procedure. WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope.
Page 79 OPERATION 4. Remote control models ‑ Ensure the key switch is in the "ON" position. WARNING High voltage is present when starting or operating the engine. Do not touch any ignition component, wiring, or spark plug lead when starting or operating the engine. WARNING The exposed moving flywheel can cause serious injury.
Page 80: Maintenance
Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA Emissions EMISSION CERTIFICATION LABEL...
Page 81: Inspection And Maintenance Schedule
MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. 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.
Page 82 MAINTENANCE • Replace spark plugs at first 100 hours or first year. After that, inspect spark plugs every 100 hours or once yearly. Replace spark plugs as needed. See Spark Plug Inspection and Replacement. • Inspect thermostat visually for corrosion and broken spring. Make sure thermostat closes completely at room temperature.
Page 83: 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 84 MAINTENANCE Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water.
Page 85: Top Cowl Removal And Installation
MAINTENANCE Top Cowl Removal and Installation REMOVAL 1. Release the rear latch. 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 31925 INSTALLATION 1. Engage the front hook and position the cowl over the engine. 2.
Page 86: Fuel System
MAINTENANCE Fuel System WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.
Page 87: Steering Link Rod Fasteners
MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine.
Page 88: Corrosion Control Anode
MAINTENANCE Assemble steering link rod to engine with bolt, locknut, spacer, and flat washers. Torque the locknut to specifications. 31917 Bolt (12‑71970) Flat washer Spacer Nylon insert locknut (11‑16147‑‑3) Steering bracket Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off 1/4 turn) Description lb.
Page 89 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. POWER TILT MODELS One anode is the trim tab and another anode is installed on the swivel bracket.
Page 90: Propeller Replacement
MAINTENANCE Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 91 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 31927 Tube Ref No.
Page 92: Fuse Replacement - Electric Start Models
MAINTENANCE 7. Install the front thrust hub onto the shaft so that the larger diameter end is facing the propeller. 8. Install the propeller, rear thrust washer, and propeller nut onto the shaft. 9. Place a block of wood between the gearcase and the propeller to prevent rotation and tighten the propeller nut to the specified torque.
Page 93 MAINTENANCE The voltage regulator circuit and the electric starting circuit are protected from overload by a 20 amp fuse. If the fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. 32119 Voltage regulator circuit ‑...
Page 94: 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 95: Timing Belt Inspection
MAINTENANCE 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight and then tighten 1/4 turn, or torque to specifications. Description lb. in. lb. ft. Spark plug Timing Belt Inspection Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found.
Page 96 MAINTENANCE 4. After the initial oil has been drained, temporarily reinstall the drain plug. Disengage the tilt lock and lower the outboard. Wait a minute to allow the remaining oil that was trapped in the engine to return to the drain. Return outboard to the full tilt position and drain the remaining oil.
Page 97 MAINTENANCE 2. Electric start models ‑ To gain clearance to the oil filter, remove the starter solenoid along with its rubber isolation mount from the metal plate that holds it. 31995 Electric start model Starter solenoid Oil filter 3. Place a rag or towel below the oil filter to absorb any spilled oil.
Page 98: Lubrication Points
3. Idle engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No.
Page 99 MAINTENANCE Tube Ref No. Description Where Used Part No. Swivel bracket, transom clamp screws, tilt tube, 92-802859A 2-4-C with Teflon throttle/shift cables, steering cable grease fitting • Swivel bracket ‑ Lubricate through fitting. 31934 • Transom clamp screws ‑ Lubricate threads. •...
Page 100 2. Lubricate the following with lightweight oil. • Steering link rod pivot points ‑ Lubricate points. 31938 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon.
Page 101: Gearcase Lubrication
MAINTENANCE Tube Ref No. Description Where Used Part No. Anti-Corrosion 92-802867Q Propeller shaft Grease 92-802859A 2-4-C with Teflon Propeller shaft • 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 102 Vent plug Fill/drain plug GEARCASE LUBRICANT CAPACITY Approximately 370 ml (12.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position.
Page 103: Checking Power Tilt Fluid
MAINTENANCE 5. Remove the lubricant tube and reinstall the cleaned fill/drain plug and new sealing washer. 31933 Vent plug and new sealing washer Vent hole Fill/drain plug and new sealing washer Checking Power Tilt Fluid 1. Tilt outboard to the full up position and engage the tilt support lever.
Page 104: Submerged Outboard
MAINTENANCE 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Mercury or Quicksilver Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
Page 105: 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 106: 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 Ref No. Description Where Used Part No.
Page 107: Positioning Outboard For Storage
STORAGE Positioning Outboard for Storage NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position. •...
Page 108 STORAGE • Remove the battery from the boat and check water level. Recharge if necessary. • Store the battery in a cool, dry place. • Periodically check the water level and recharge the battery during storage.
Page 109: Troubleshooting
TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • 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 110: Performance Loss
TROUBLESHOOTING • 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. Stuck anti‑siphon valve located on permanently built in type fuel tanks.
Page 111: 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 112: Mercury Marine Service Offices
Model and serial number of your outboard • 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 Telephone (920) 929‑5040...
Page 113 OWNER SERVICE ASSISTANCE 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 5467789 Singapore, 508762...
Page 114: Engine Installation
This prevents the engine from starting in gear. 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.
Page 115: Lifting The Outboard
The misuse of approved accessories or the use of non‑approved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
Page 116 ENGINE INSTALLATION BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat. The boat bottom should be aligned or be within 25 mm (1 in.) above the anti‑ventilation plate of the outboard. 27151 Anti‑ventilation plate INSTALLING OUTBOARD ON TRANSOM 1.
Page 117 ENGINE INSTALLATION 3. To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts. Drill two 7.9 mm (5/16 in.) holes through the transom bracket mounting holes. Fasten with two bolts, flat washers, and locknuts.
Page 118: Steering Cable Installation
ENGINE INSTALLATION Steering Cable Installation 1. Lubricate the entire cable end with Mercury or Quicksilver 2‑4‑C with Teflon. 28722 Tube Ref No. Description Where Used Part No. 2-4-C Marine 92-802859A Steering cable end Lubricant with Teflon 2. Insert the steering cable into the tilt tube.
Page 119: Steering Link Rod Fasteners
ENGINE INSTALLATION Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine. Never replace the locknuts (11‑16147‑‑3) with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
Page 120 ENGINE INSTALLATION Assemble steering link rod to engine with bolt, locknut, spacer, and flat washers. Torque the locknut to specifications. 31917 Bolt (12‑71970) Flat washer Spacer Nylon insert locknut (11‑16147‑‑3) Steering bracket Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off 1/4 turn) Description lb.
Page 121: Remote Wiring Harness And Control Cable Installation
ENGINE INSTALLATION Remote Wiring Harness and Control Cable Installation REMOTE WIRE HARNESS CONNECTION 1. Remove the two bolts and remove the access cover. 32048 Access cover 2. Connect the remote harness to the engine harness connector. 3. Route the remote wiring harness through the rubber grommet.
Page 122 ENGINE INSTALLATION 4. Connect the 8 pin connector to the engine harness. If the outboard is equipped with power trim, connect the power trim wire connections. BLUE/WHITE BLUE/WHITE GREEN/WHITE GREEN/WHITE 32064 BROWN/WHITE 8 pin connector Rubber grommet Remote wiring Power trim wire harness connections 1.
Page 123 ENGINE INSTALLATION a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to neutral. Place a mark ("a") on the cable next to the end guide. b. Move the remote control handle from neutral into reverse and advance the handle to full speed position.
Page 124 ENGINE INSTALLATION 4. Attach the shift cable to the shift lever with a washer and cotter pin retainer. 32105 Cotter pin retainer Shift cable Flat washer Shift lever 5. Manually shift the outboard into neutral (propeller will rotate freely). 6. Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle.
Page 125 ENGINE INSTALLATION 7. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. 32068 End guide cable barrel Center mark Rubber grommet 8. Check shift cable adjustments as follows: a. Shift the remote control into forward. The propeller shaft should be locked in gear.
Page 126 ENGINE INSTALLATION 2. Attach the throttle cable end guide to the throttle lever with a washer and cotter pin retainer. 3. Adjust the cable barrel so that the installed throttle cable will hold the lever on the carburetor against the full throttle stop. 4.
Page 127: Battery Installation - Electric Start Models
ENGINE INSTALLATION 5. Reinstall the access cover with two bolts. Tighten the bolts to the specified torque. 32112 Access cover Description lb. in. lb. ft. Access cover bolt Battery Installation ‑ Electric Start Models MOUNTING BATTERY Follow the battery manufacturer's instructions carefully. Mount battery in the boat so it is secured against movement, preferably in a battery box.
Page 128 ENGINE INSTALLATION DISCONNECTING OUTBOARD BATTERY CABLES First, disconnect the black battery cable from the (–) negative terminal and then disconnect the red battery cable from the (+) positive terminal. 27158...

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