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Mercury 50 4-Stroke Manual

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See also: Operation & Maintenance 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
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.
Declaration of Conformity
Manufacturer:
Authorized Representative:
Recreational Craft Directive:
Applicable Requirement
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engines starting (A.5.1.4)
General steering system (A.5.4.1)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Module used for exhaust emission assessment: Module H;
Certification No. RCD‑H‑2
Module used for noise emission assessment: Module H;
Certification No. RCD‑H‑2
nearest
dealer
Mercury Marine
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939 USA,
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-2800 Verviers - Belgium,
2003/44/EC amending 94/25/EC
i
can
be
found
Standards Applied
EN ISO 10240:2004
EN ISO 8665:1995
EN ISO 11547:1995
ABYC P‑17; EN ISO
10592:1995
EN ISO 8178‑1:1996
EN ISO 8665:1995
EN ISO 14509:2000
on

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Summary of Contents for Mercury 50 4-Stroke

  • 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 Det Norske Veritas AS Veritasveien 1 1322 Hovik Norway Notified Body Number: 0575 Combustion cycle: 4 Engine type: Fuel type: Brands: Outboard Gasoline stroke Mercury, Mariner Module H Starting Engine Manufacturer Noise and Horsepower Serial Family Location Exhaust Number Certificate...
  • Page 3 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 May 1, 2006 European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 5: 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 6 TABLE OF CONTENTS Transporting Portable Fuel Tanks..........33 FUEL & OIL Fuel Recommendations.............35 Filling Fuel Tank................37 Engine Oil Recommendations...........37 Checking and Adding Engine Oil..........38 FEATURES & CONTROLS Remote Control Features............40 Warning System................41 Power Trim and Tilt..............43 Throttle Grip Friction Adjustment ‑ Tiller Handle Models...47 Steering Friction Adjustment............
  • Page 7 TABLE OF CONTENTS Top Cowl Removal and Installation...........67 Exterior Care................67 Battery Inspection ..............67 Fuel System................68 Steering Link Rod Fasteners.............69 Corrosion Control Anode............71 Propeller Replacement ‑ 87.3 mm (3 ‑ 7/16 in.) Diameter Gearcase ....................72 Propeller Replacement ‑ 108 mm (4 ‑ 1/4 in.) Diameter Gearcase ....................75 Spark Plug Inspection And Replacement........79 Fuse Replacement..............
  • Page 8 OWNER SERVICE ASSISTANCE Local Repair Service..............98 Service Away From Home............98 Parts And Accessories Inquiries..........98 Service Assistance..............98 Mercury Marine Service Offices..........99 OUTBOARD INSTALLATION Installation Information............. 101 Fuel Hose Connection ‑ Remote Control Models....111 Electrical Connections and Control Cable Installation.....112 Propeller Installation..............120 Trim Tab Adjustment...............125...

  • Page 9: 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 10: 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 11: 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 12 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 13 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 14: 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 15 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 16 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 17: 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 18 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 19 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 20 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 21: 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 22 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 23 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 24: 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 on board 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 25: 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 26: 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 27: 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 28 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 29: 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 30: 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 31: 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 32: 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 33: Safety Instructions For Hand Tilled Outboards

    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 34: 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 35 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 36: 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 37 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 38: 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 39 GENERAL INFORMATION Models Stroke 75 mm (2.953 in.) Valve Clearance (Cold) Intake Valve 0.15‑0.25mm (0.006‑0.010 in.) Exhaust Valve 0.25‑0.35mm (0.010‑0.014 in.) Recommended Spark Plug Champion RA8HC Spark Plug Gap 1.0mm (0.040 in.) Gear Ratio 83mm (3‑1/4 in.) 1.83:1 Diameter Gearcase 108mm (4‑1/4 in.) 2.31:1 or 2.33:1 Diameter Gearcase...

  • Page 40: Component Identification

    GENERAL INFORMATION Component Identification 28524 Auxiliary tilt switch Water pump indicator hole Tilt support knob Bottom cowl Transom brackets Top cowl Oil drain plug -Shift handle Primary cooling water intake Engine stop switch Gearcase Throttle friction adjustment knob Trim tab Lanyard stop switch Anti‑ventilation plate Steering friction...

  • Page 41: 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 42 TRANSPORTING MANUAL VENTING TYPE FUEL TANK 1. Close fuel tank air vent when transporting tank. This will prevent escape of fuel or vapors from tank. 26793 AUTO-VENTING TYPE FUEL TANK 1. Disconnect the remote fuel line from tank. This will close the air vent and prevent escape of fuel or vapors from tank.

  • Page 43: Fuel & 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 44 FUEL & 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 45: Filling Fuel Tank

    Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions. Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 4‑Stroke Outboard Oil for general, all‑temperature use. If SAE 10W‑30 oil is preferred, use Mercury or Quicksilver NMMA FC‑W certified 10W‑30 4‑Stroke Outboard...

  • Page 46: Checking And Adding Engine Oil

    FUEL & OIL IMPORTANT: The use of non detergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 47 FUEL & OIL 3. Pull the dipstick back out again and observe the oil level. If the oil level is low, remove the oil filler cap and fill to (but not over) the upper oil level with the recommended oil. IMPORTANT: Inspect oil for signs of contamination.

  • Page 48: Features & Controls

    FEATURES & 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 49: Warning System

    FEATURES & CONTROLS Warning System WARNING HORN SIGNALS The outboard warning system incorporates a warning horn inside the boat. Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. Tiller handle models will have the warning horn located in the ignition key panel.
  • Page 50 Moving the throttle lever back to the idle position will reset the system. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption and engine operating hours.

  • Page 51: Power Trim And Tilt

    FEATURES & 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 52 FEATURES & CONTROLS The most significant control hazard is a pull or torque that is felt on the steering wheel or tiller handle. This steering torque results from the outboard trimmed so that the propeller shaft is not parallel to the water surface.
  • Page 53 FEATURES & CONTROLS • 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) • In excess can cause boat porpoising (bouncing) or propeller ventilation •...
  • Page 54 FEATURES & CONTROLS 1. 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. 26809 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

  • Page 55: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES & CONTROLS 1. Reduce engine speed below 2000 RPM. 2. Tilt outboard up, keeping the water intake holes submerged at all times. 3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range.
  • Page 56 FEATURES & CONTROLS NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened. 26811 Tighten friction Locknut Loosen friction REMOTE STEERING MODELS WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control.

  • Page 57: Trim Tab Adjustment

    FEATURES & CONTROLS Steering Friction Adjustment ‑ Adjust this screw to achieve the desired steering friction (drag) on the steering wheel. Turn screw clockwise to tighten friction or turn counterclockwise to loosen friction. 28519 Loosen friction Tighten friction Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction.
  • Page 58 FEATURES & CONTROLS If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right.

  • Page 59: 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 60: Pre-Starting Instructions

    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 61: Starting The Engine - Remote Control Models

    OPERATION 1. For the first hour of operation, run the engine at varied throttle settings up to 3500 RPM or at approximately half throttle. 2. For the second hour of operation, run the engine at varied throttle settings up to 4500 RPM or at three‑quarter throttle, and during this period of time, run it at full throttle for approximately one minute every ten minutes.
  • Page 62 OPERATION 3. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 4. Shift outboard to neutral ("N") position. 26838 5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. 26840 Fully closed position Maximum fast idle speed position...

  • Page 63: Starting The Engine - Tiller Handle Models

    OPERATION 7. Turn ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON" position, wait 30 seconds and try again. 19804 8. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.
  • Page 64 OPERATION 1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 2. Connect the remote fuel line to the outboard. Make sure the connector is snapped into place. 28526 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up.
  • Page 65 OPERATION 5. Shift outboard to neutral ("N") position. 28522 6. Set the throttle grip to start position. 7. Starting a flooded engine ‑ Set the throttle grip to half‑way position. 0%100 0%100 START START START 19799 Start position Half‑way position 8.

  • Page 66: Gear Shifting

    OPERATION 9. Check for a steady stream of water flowing out of the water pump indicator hole. 28521 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.

  • Page 67: Stopping The Engine

    OPERATION • Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle. 26779 • Tiller handle models ‑ Reduce the engine speed to idle before shifting. 26842 • Always shift the outboard into gear with a quick motion. •...

  • Page 68: Emergency Starting

    OPERATION 2. Tiller Handle Models ‑ Reduce engine speed and shift outboard to neutral position. Push in the engine stop button or turn ignition key to "OFF" position. 26776 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow procedure.
  • Page 69 OPERATION WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. 3. Electric start models ‑ Turn the ignition key to "ON" position. 26846 WARNING High voltage is present any time the key is turned on, especially...
  • Page 70 OPERATION 5. Pull the starter rope to start the engine. 26848...

  • Page 71: 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 72: 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 73 MAINTENANCE • Inspect thermostat visually for corrosion and broken spring. Make sure thermostat closes completely at room temperature. • Check engine fuel filter for contaminants. See Fuel System. • Check engine timing setup. • Check corrosion control anodes. Check more frequently when used in salt water.

  • Page 74: Flushing The Cooling System

    MAINTENANCE Flushing the Cooling System 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. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.

  • Page 75: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation REMOVAL 1. Pull out the rear lock lever and remove the top cowl. 28439 INSTALLATION 1. Lower the top cowl over the engine. 2. Bring the front of the cowl down first and engage the front hook.

  • Page 76: Fuel System

    MAINTENANCE IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4.

  • Page 77: Steering Link Rod Fasteners

    MAINTENANCE REMOVAL 1. Read the preceeding fuel system servicing information and warning. 2. Pull out the filter assembly from mount. Hold onto the cover to prevent it from turning and remove the sight bowl. Empty contents into an approved container. 3.
  • Page 78 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 serious injury or death due to occupants being thrown within or out of the boat.

  • Page 79: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion.

  • Page 80: Propeller Replacement - 87.3 Mm (3 - 7/16 In.) Diameter Gearcase

    MAINTENANCE Propeller Replacement ‑ 87.3 mm (3 ‑ 7/16 in.) Diameter Gearcase WARNING Rotating the propeller shaft may cause the engine to crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always turn the ignition key or lanyard stop switch to the "OFF"...
  • Page 81 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 26901 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref No.
  • Page 82 MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install the forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft. 26903 Propeller nut Propeller Propeller nut retainer Forward thrust hub 8. Flo‑Torq II drive hub propellers ‑ Install the forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft.

  • Page 83: Propeller Replacement - 108 Mm (4 - 1/4 In.) Diameter Gearcase

    MAINTENANCE 10. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer. Secure the propeller nut by bending the tabs up and against the flats on the propeller nut. 26906 Pins Tabs 11. Reinstall the spark plug leads. Propeller Replacement ‑...
  • Page 84 MAINTENANCE 2. Remove the spark plug leads to prevent the engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900 4. Place a block of wood between gearcase and propeller to keep the propeller from turning. Remove the propeller nut. 5.
  • Page 85 MAINTENANCE 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref No. Description Where Used Part No. Anti-Corrosion 92-802867Q Propeller shaft Grease 2-4-C with Teflon Propeller shaft 92-802859A1 IMPORTANT: To prevent the propeller hub from corroding and...
  • Page 86 MAINTENANCE 8. Flo‑Torq II drive hub propellers ‑ Install the forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft. 26941 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Thrust hub Forward thrust hub NOTE: We recommend the installation of a Flo‑Torq III drive hub propeller for stainless steel applications.

  • Page 87: Spark Plug Inspection And Replacement

    MAINTENANCE 11. Secure the propeller nut by bending three of the tabs into the thrust hub grooves. 26945 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.

  • Page 88: Fuse Replacement

    MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 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.

  • Page 89: Timing Belt Inspection

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 28900 Spare fuse slot Diagnostic circuit 4‑pin connector SmartCraft data bus circuit ‑...

  • Page 90: Lubrication Points

    MAINTENANCE e. Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No. Anti-Corrosion...
  • Page 91 MAINTENANCE • Swivel Bracket ‑ Lubricate through fitting. 28466 Tilt support lever Swivel bracket • Tilt Tube ‑ Lubricate through fitting. 28461 • Co‑pilot shaft (tiller handle models) ‑ Lubricate through fitting. Move the steering friction lever back and forth while lubricating.
  • Page 92 MAINTENANCE • WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. Steering Cable Grease Fitting (If equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube.

  • Page 93: Checking Power Trim Fluid

    2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 94 MAINTENANCE 2. Turn the the outboard so the drain hole is facing downward. Remove the drain plug and drain the engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. 28531 Drain plug Drain hole CHANGING OIL FILTER 1.

  • Page 95: Gearcase Lubrication - For 87.3 Mm(3-7/16 In.) Diameter Gearcase

    MAINTENANCE 2. Idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. 28418 Oil fill cap Gearcase Lubrication ‑ For 87.3 mm (3‑7/16 in.) Diameter Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
  • Page 96 MAINTENANCE 3. Remove vent plug and fill/drain plug and drain lubricant. 26973 Vent plug Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity approximately 340 ml (11.5 fl. oz.). CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2.

  • Page 97: Gearcase Lubrication - For 108 Mm(4 - 1/4 In.) Diameter Gearcase

    MAINTENANCE 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. 26975 Vent hole Fill/drain plug Vent plug Gearcase Lubrication ‑ For 108 mm (4 ‑ 1/4 in.) Diameter Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
  • Page 98 MAINTENANCE 3. Remove vent plugs and fill/drain plug and drain lubricant. 26977 Vent plugs Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 fl. oz.). CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place outboard in a vertical operating position. 2.

  • Page 99: Submerged Outboard

    MAINTENANCE 6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. 27001 Front vent plug Rear vent plug Front vent hole Fill/drain plug and sealing washer Rear vent hole 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 100: 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 101: 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 102 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 103: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Blown 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 104: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Guardian System activated. Refer to Features & Controls - Warning System. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a.
  • Page 105 TROUBLESHOOTING • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator.

  • Page 106: 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 107: 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 108 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 109: Outboard 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 110 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 111 OUTBOARD INSTALLATION LIFTING OUTBOARD Use the lifting eye on the engine. 28510...

  • Page 112: Installing Outboard

    OUTBOARD INSTALLATION INSTALLING OUTBOARD Drilling Outboard Mounting Holes 1. Mark four mounting holes on the transom using the transom drill fixture. or69-1 Drill guide holes Transom drilling fixture Transom center line Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes.
  • Page 113 OUTBOARD INSTALLATION 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 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.
  • Page 114 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. 20860 Large transom washer Transom reinforcement plate Description Part Number Large transom washer 67‑896392 Transom reinforcement plate 67‑896305...
  • Page 115 OUTBOARD INSTALLATION NOTE: For a more accurate torque, turn/tighten the mounting locknuts rather than turning the mounting bolts. 28481 1/2 in. diameter bolt (4) Flat washer (4) Locknut (4) Description lb. in. lb. ft. Outboard mounting locknuts and bolts STEERING CABLE - STARBOARD SIDE ROUTED CABLE 1.
  • Page 116 OUTBOARD INSTALLATION 2. Insert the steering cable into the tilt tube. 28507 3. Tighten the nut to the specified torque. 29506 Description lb. in. lb. ft. 47.5 STEERING CABLE SEAL 1. Mark tilt tube 6.4 mm (0.25 in.) from end. Install seal components.
  • Page 117 OUTBOARD INSTALLATION STEERING LINK ROD FASTENERS IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("e" ‑ Part Number 10‑856680) and self‑locking nylon insert locknuts ("b" & "d" ‑ Part Number 11‑826709113). These locknuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 118 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 serious injury or death due to occupants being thrown within or out of the boat.

  • Page 119: Fuel Hose Connection - Remote Control Models

    OUTBOARD INSTALLATION Description lb. in. lb. ft. Nylon insert locknut "b" Tighten until it seats, then back off 1/4 Nylon insert locknut "e" turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn.

  • Page 120: Electrical Connections And Control Cable Installation

    OUTBOARD INSTALLATION Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover. 28505 Access cover Route the remote wiring harness through the rubber grommet.
  • Page 121 OUTBOARD INSTALLATION Connect the 14 pin connector to the engine harness and fasten the harness with the retainer. 28482 Remote wiring harness Retainer 14 pin connector...
  • Page 122 OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard or86 Red sleeve ‑ positive (+) Cranking battery Black sleeve ‑ negative (–)
  • Page 123 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. or87 Red sleeve ‑ positive (+) Ground cable Black sleeve ‑ negative Cranking battery (–) SHIFT CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 124 OUTBOARD INSTALLATION b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark ("b") on the cable next to the cable end guide. c.
  • Page 125 OUTBOARD INSTALLATION 4. Fit the throttle cable through the rubber grommet. 28489 Rubber grommet Shift cable 5. Attach the shift cable to the shift lever with a cotter pin retainer. 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 126 OUTBOARD INSTALLATION 8. Lock in barrel in place with the barrel latch. 28488 Barrel latch 9. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end guide.
  • Page 127 OUTBOARD INSTALLATION 2. Fit the throttle cable through the rubber grommet. 28491 Rubber grommet Throttle cable 3. Attach the throttle cable to the throttle lever with a cotter pin retainer. 4. Adjust cable barrel until the barrel slips onto the mounting stud.

  • Page 128: Propeller Installation

    OUTBOARD INSTALLATION 6. Reinstall the access cover with two bolts. Tighten the bolts to the specified torque. 28500 Access cover Description lb. in. lb. ft. Access cover bolt Propeller Installation PROPELLER INSTALLATION - 108 MM (4-1/4 IN.) DIAMETER GEARCASE WARNING Rotating propellers can cause serious injury or death.
  • Page 129 OUTBOARD INSTALLATION 1. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C Marine Lubricant with Teflon. 26902 Tube Ref No. Description Where Used Part No. Anti-Corrosion 92-802867Q Propeller shaft Grease 2-4-C Marine Propeller shaft 92-802859A1...
  • Page 130 OUTBOARD INSTALLATION 3. Flo‑Torq II Drive Hub Propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft. 26941 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Thrust hub Forward thrust hub NOTE: Stainless Steel Applications ‑...
  • Page 131 1. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C Marine Lubricant with Teflon.
  • Page 132 OUTBOARD INSTALLATION IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.

  • Page 133: Trim Tab Adjustment

    OUTBOARD INSTALLATION Description lb. in. lb. ft. Propeller nut 5. Align flat sides of the propeller nut with tabs on the propeller nut retainer. Secure propeller nut by bending tabs up and against the flats on the propeller nut. 26906 Pins Tabs 6.

  • Page 134: Trim-In Stop Adjustment - Power Trim Models

    OUTBOARD INSTALLATION If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right.

This manual is also suitable for:

40 4-stroke60 4-stroke

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