Mercury 135 Verado Manual
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Mercury 135 Verado Manual

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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
This outboard motor's serial number plate contains in the
lower corner left hand corner either the CE mark alone or the
CE mark accompanied by a notified body number. This
outboard motor manufactured by Mercury Marine, Fond du
Lac, WI, USA or Marine Power Europe Inc. Park Industriel, de
Petit‑Rechain, Belgium complies with the requirements of the
following directives by meeting the associated standards, as
amended:
If the CE mark is accompanied by a notified body number, the
following Recreational Craft Directive applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4) ISO 11547
Fuel tanks (A.5.2.2)
General steering system
Exhaust emission requirements (B.
2)
Owner's manual (B.4)
Noise emission levels (C.1)
nearest
dealer
2003/44/EC amending 94/25/EC
ISO 10240
ISO 8665
ISO 13591; ISO 8469
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
i
can
be
found
on

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  • 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 Vehicles, boats and internal combustion engine driven devices ‑ SAE J551 (CISPR 12) radio disturbance characteristics EN 61000‑6‑2; EN 61000‑4‑2; EN Electrostatic discharge testing 61000‑4‑3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe.
  • Page 3 Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA...

  • 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, Confederation of Independent States, Middle‑East and Africa....................3 3 Year Limited Warranty Against Corrosion........6 Warranty Coverage And Exclusions..........10 General Information Boater's Responsibilities............13...
  • Page 6 TABLE OF CONTENTS Transporting Trailering Boat/Outboard............30 Fuel and Oil Fuel Recommendations.............31 Filling Fuel Tank................33 Engine Oil Recommendations...........33 Checking and Adding Engine Oil..........34 Features and Controls Panel Mount Control Features and Operation......37 Single Handle Console Control Features and Operation... 40 Slim Binnacle Control Features and Operation......45 Dual Handle Console Control Features and Operation.....50 Dual Handle Console Control with CAN Trackpad Features and Operation...................55...
  • Page 7 TABLE OF CONTENTS Maintenance Outboard Care................95 EPA Emissions................95 Inspection And Maintenance Schedule........96 Flushing the Cooling System.............98 Top Cowl Removal and Installation...........99 Cleaning Care for Top and Bottom Cowls.........99 Cleaning Care for the Powerhead (Saltwater Use)....100 Battery Inspection ..............100 DTS Battery Specifications............
  • Page 8 Engine Starts But Will Not Shift Into Gear.......133 Engine Runs Erratically............134 Performance Loss..............134 Battery Will Not Hold Charge...........134 Owner Service Assistance Local Repair Service..............136 Service Away From Home............136 Parts And Accessories Inquiries..........136 Service Assistance..............136 Mercury Marine Service Offices..........137 viii...

  • Page 9: Warranty Information

    1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 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, Confederation Of Independent States, Middle-East And Africa

    Outside the United States, Canada, Europe, Confederation of Independent States, Middle‑East and Africa ‑ check with your local distributor. WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below.
  • Page 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: 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 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 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 18: 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 19 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 20 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 21: 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 22: Boat Horsepower Capacity

    Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start‑in‑gear protection is provided by the remote control system.

  • Page 23: 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 24 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 25: 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 26: 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 27: 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 28: 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 29: Exhaust Emissions

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Exhaust Emissions...
  • Page 30 GENERAL INFORMATION WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide. GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

  • Page 31: 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 32 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 33: 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 34 GENERAL INFORMATION Models 135/150/175/200 Stroke 82 mm (3.23 in.) Recommended Spark Plug NGK ILFR6G‑E Spark Plug Gap 0.8 mm (0.0315 in.) Spark Plug Hex Size 16 mm Gear Ratio 2.08:1 Recommended Gasoline Refer to Fuel & Oil Recommended Oil Refer to Fuel & Oil Right Hand Rotation Gearcase 970 ml (32.8 fl.

  • Page 35: Component Identification

    GENERAL INFORMATION Component Identification 14811 Engine flush Anti‑ventilation plate Auxiliary tilt switch Gearcase Top cowl Cooling water intake holes Bottom cowl Transom brackets Engine oil drain Tilt lock level...

  • Page 36: Installation

    INSTALLATION Installing Outboard WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. Do not accelerate above idle speed in water that may contain underwater obstacles if the outboard is not attached to the transom correctly.

  • Page 37: Propeller Selection

    INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information ‑ Specifications).

  • Page 38: Trailering Boat/Outboard

    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 39: 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 40 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 41: Filling Fuel Tank

    As an optional choice, Mercury or Quicksilver NMMA FC‑W certified synthetic 25W‑40 multi‑viscosity 4‑Stroke Outboard Oil may be used. If the recommended Mercury or Quicksilver NMMA FC‑W certified oils are not available, a major brand of NMMA FC‑W certified 4‑stroke outboard oil of similar...

  • Page 42: Checking And Adding Engine Oil

    FUEL AND 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 oils or oils that contain solid additives are not recommended.
  • Page 43 FUEL AND OIL IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil level is correct as long as it appears in the operating range (cross hatched region). 14784 Oil level operating range 6.
  • Page 44 FUEL AND OIL IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.

  • Page 45: Features And Controls

    FEATURES AND CONTROLS Panel Mount Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
  • Page 46 FEATURES AND CONTROLS 3. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5152 4. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position.
  • Page 47 FEATURES AND CONTROLS 5. Stop/start button ‑ Allows the boat operator to start or stop the engine without using the ignition key. The ignition key must be in the "ON" position to start the engine. 3414 6. Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.

  • Page 48: Single Handle Console Control Features And Operation

    FEATURES AND CONTROLS 8. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to tension desired. 5171 Detent tension Control handle tension...
  • Page 49 FEATURES AND CONTROLS 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5185 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed).
  • Page 50 FEATURES AND CONTROLS 6. Select button ‑ Selects the System View on‑screen options and confirm data entries. Holding the select button for two seconds will pause the slide show if selected in Favorites. Holding the select button for three seconds will activate the reset data function (except when in the slide show function).
  • Page 51 FEATURES AND CONTROLS 9. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.
  • Page 52 FEATURES AND CONTROLS NOTE: The active light on the remote control will be illuminated at the helm that is in control of the engine. The helm transfer function allows the boat operator to select which helm is in control of engine operation. Pressing the throttle only/ station select button two times allows engine control to be transferred to a new helm.

  • Page 53: Slim Binnacle Control Features And Operation

    FEATURES AND CONTROLS Synchronizing Helms Prior To Helm Transfer Pressing the throttle only/station select button one time allows the boat operator 10 seconds to match up the control handle setting at the new station with the handle setting that is at the old (to be inactive) station.
  • Page 54 FEATURES AND CONTROLS 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 12874 Trim switch 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed).
  • Page 55 FEATURES AND CONTROLS 4. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to the desired tension.
  • Page 56 FEATURES AND CONTROLS 8. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.
  • Page 57 FEATURES AND CONTROLS NOTE: The active light on the remote control will be illuminated at the helm that is in control of the engine. The helm transfer function allows the boat operator to select which helm is in control of engine operation. Pressing the throttle only/ station select button two times allows engine control to be transferred to a new helm.

  • Page 58: Dual Handle Console Control Features And Operation

    FEATURES AND CONTROLS Dual Handle Console Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
  • Page 59 FEATURES AND CONTROLS 4. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to the desired tension. 28556 Detent tension Control handle friction...
  • Page 60 FEATURES AND CONTROLS 8. Neutral LEDs ‑ The neutral LEDs illuminate when engines are in neutral gear position. The lights will flash when in throttle only mode. NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the control handle. 9.
  • Page 61 FEATURES AND CONTROLS Engine auto synchronization will automatically engage when engine speed is over 900 RPM for two seconds and remote control handles are positioned within 10% of each other. The "SYNC" light will turn on when the engines are synchronized. Auto synchronization will stay engaged up to 95% throttle opening.
  • Page 62 FEATURES AND CONTROLS 1. Place active remote control lever to idle position. 2. Proceed to the inactive helm and position remote control lever to the idle position. 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine.

  • Page 63: Dual Handle Console Control With Can Trackpad Features And Operation

    FEATURES AND CONTROLS Dual Handle Console Control with CAN Trackpad Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed.
  • Page 64 FEATURES AND CONTROLS 4. Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering. To activate, move the control handles into forward detent and press the button.
  • Page 65 FEATURES AND CONTROLS 9. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22133 Neutral LEDS Throttle only Troll button 1 lever button Transfer button Sync button Dock button 10.
  • Page 66 FEATURES AND CONTROLS 11. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
  • Page 67 FEATURES AND CONTROLS To disengage the auto synchronization feature, press the "SYNC" button. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22590 HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear.

  • Page 68: Shadow Mode Control Features And Operation

    FEATURES AND CONTROLS NOTE: There is a 10 second time frame to complete a helm transfer. If the helm transfer is not completed, the action will be cancelled and a double beep will sound. Pressing the "TRANSFER" button again will re‑initiate a helm transfer. NEUTRAL TROLL SYNC...
  • Page 69 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Port engine throttle and shift = controlled by port control handle Starboard engine throttle and shift = controlled by starboard control handle Running Running Running Center engine throttle = average of port and starboard engines Center engine shift =...
  • Page 70 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Starboard engine throttle and shift = Running controlled by starboard control handle Center engine throttle and shift = Off (ignition key Off (ignition key Running neutral/idle unless switch turned on) switch turned on) both control handles are in the same gear...
  • Page 71 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner and outer engines throttle and shift = controlled by port control handle Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by...
  • Page 72 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner engine throttle Off (ignition and shift = key switch Running Running Running controlled by turned off) starboard control handle Starboard inner engine Off (ignition key throttle and...
  • Page 73 FEATURES AND CONTROLS Turning off the starboard outer engine while underway will cause the starboard inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then re‑engaging.
  • Page 74 FEATURES AND CONTROLS TRIM SWITCH AND KEY PAD FEATURES 1. Trim switch (if equipped) ‑ Operates the trim for all engines. An accessory trim switch panel is required for trimming engines individually. 13853 2. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear.
  • Page 75 FEATURES AND CONTROLS 5. Neutral LEDs ‑ The neutral LEDs illuminate when engines are in neutral gear position. The lights will flash when in throttle only mode. NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the control handle. 6.
  • Page 76 FEATURES AND CONTROLS Engine auto synchronization will automatically engage when engine speed is over 900 RPM for two seconds and remote control handles are positioned within 10% of each other. The "SYNC" light will turn on when the engines are synchronized. Auto synchronization will stay engaged up to 95% throttle opening.

  • Page 77: Shadow Mode Control With Can Trackpad Features And Operation

    FEATURES AND CONTROLS 1. Place active remote control lever to idle position. 2. Proceed to the inactive helm and position remote control lever to the idle position. 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine.
  • Page 78 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Port engine throttle and shift = controlled by port control handle Starboard engine throttle and shift = controlled by starboard control handle Running Running Running Center engine throttle = average of port and starboard engines Center engine shift =...
  • Page 79 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Starboard engine throttle and shift = Running controlled by starboard control handle Center engine throttle and shift = Off (ignition key Off (ignition key Running neutral/idle unless switch turned on) switch turned on) both control handles are in the same gear...
  • Page 80 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner and outer engines throttle and shift = controlled by port control handle Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by...
  • Page 81 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner engine throttle Off (ignition and shift = key switch Running Running Running controlled by turned off) starboard control handle Starboard inner engine Off (ignition key throttle and...
  • Page 82 FEATURES AND CONTROLS Turning off the starboard outer engine while underway will cause the starboard inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then re‑engaging.
  • Page 83 FEATURES AND CONTROLS TRIM SWITCH AND KEY PAD FEATURES 1. Trim switch (if equipped) ‑ Operates the trim for all engines. An accessory trim switch panel is required for trimming engines individually. 22943 2. Neutral lights ‑ The neutral lights illuminate when the engine is in neutral gear position.
  • Page 84 FEATURES AND CONTROLS 5. Dock button ‑ Pressing the "DOCK" button initiates docking mode. Docking mode reduces throttle capacity approximately 50% of normal throttle. To turn off docking mode, shift the engine into neutral and press the "DOCK" button. 6. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear.
  • Page 85 FEATURES AND CONTROLS 8. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22945 Neutral LEDS Throttle only Troll button 1 lever button Transfer button Sync button Dock button 9.
  • Page 86 FEATURES AND CONTROLS 10. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
  • Page 87 FEATURES AND CONTROLS To disengage the auto synchronization feature, press the "SYNC" button. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22590 HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear.

  • Page 88: Warning System

    FEATURES AND CONTROLS NOTE: There is a 10 second time frame to complete a helm transfer. If the helm transfer is not completed, the action will be cancelled and a double beep will sound. Pressing the "TRANSFER" button again will re‑initiate a helm transfer. NEUTRAL TROLL SYNC...
  • Page 89 FEATURES AND CONTROLS 2. Intermittent short beeps for six seconds: Indicates a non‑critical engine condition. This condition does not require immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s power may be limited by the Engine Guardian System (see Engine Guardian System following) to protect the engine.

  • Page 90: Power Trim And Tilt

    FEATURES AND CONTROLS 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 91 FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.
  • Page 92 FEATURES AND CONTROLS WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 93 FEATURES AND CONTROLS The trim without key period may be ended at any time by moving the control handle to Wide Open Throttle Reverse (WOTR) with the key off. To end the 15 minute period for the center engine in a shadow mode application, ensure all ignition key switches are in the "OFF"...
  • Page 94 FEATURES AND CONTROLS MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.
  • Page 95 FEATURES AND CONTROLS 2. Tilt outboard up. Make sure all the water intake holes stay 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 96: 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 97: Setting Trim Angle While Running Engine At Idle Speed

    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 98: Starting The Engine

    OPERATION Starting The Engine Before starting, read the Pre‑Starting Check List, Special Operating Instructions, Engine Break‑in Procedure and Gear Shifting in the Operation Section and the remote control features and operation in the Features and Controls Section. NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat.
  • Page 99 OPERATION 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to neutral (N) position. 3413 3417 NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON"...

  • Page 100: Gear Shifting

    OPERATION 6. Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking. Turn the key to "START" position again until engine starts.
  • Page 101 OPERATION • The outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R). 3427 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position.

  • Page 102: Stopping The Engine

    OPERATION • The outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R). 3417 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Advance the control lever to further increase speed. Stopping The Engine IMPORTANT: Turning key to the "START"...

  • Page 103: 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 104: 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 105 MAINTENANCE • Check engine water separating fuel filter for contaminants. Clean and/or replace filter. See Fuel System. • Check corrosion control anodes. Check more frequently when used in salt water. See Corrosion Control Anodes. • Drain and replace gearcase lubricant. See Gearcase Lubrication.

  • Page 106: Flushing The Cooling System

    MAINTENANCE • Replace high pressure in‑line fuel filter. • Replace spark plugs at first 300 hours or three years. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and Replacement. •...

  • Page 107: Top Cowl Removal And Installation

    MAINTENANCE 6. Reinstall the cover on the flush connector. Place the flush connector back into the bottom cowl. Top Cowl Removal and Installation REMOVAL Unlock the top cowl by pulling out on the rear cowl latch. Lift the top cowl off the engine. 29767 INSTALLATION Bring the front of the cowl down first and engage the front hook.

  • Page 108: Cleaning Care For The Powerhead (Saltwater Use)

    4. Wax the surface using a non‑abrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. 5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1). Cleaning Care for the Powerhead (Saltwater Use) If the outboard is operated in saltwater, remove the top cowl and flywheel cover.

  • Page 109: Dts Battery Specifications

    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 110: Air Filter

    MAINTENANCE WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.
  • Page 111 MAINTENANCE AIR FILTER REMOVAL 1. Remove the FSM vent hose and the engine ventilation hose from the flywheel cover. 2. Remove the bolts securing the flywheel cover to the rear mounting posts. 15247 Flywheel cover bolts Engine ventilation hose FSM vent hose 3.
  • Page 112 MAINTENANCE 6. Remove the air filter from the lower flywheel cover assembly. 14145 Flywheel cover Air filter sub‑assembly AIR FILTER INSTALLATION 1. Install the air filter onto the flywheel cover sub‑assembly. 14145 Flywheel cover Air filter sub‑assembly...
  • Page 113 MAINTENANCE 2. Install the upper half of the flywheel cover sub‑assembly to the lower flywheel cover sub‑assembly. Ensure the upper flywheel cover latch opening is properly secured to the lower flywheel cover. 14314 Upper flywheel cover Lower flywheel cover latch opening latch 3.

  • Page 114: Fuel System

    MAINTENANCE 6. Secure the flywheel cover to the rear mounting posts with two bolts with washers. Tighten bolts to the specified torque. 15247 Flywheel cover bolts Engine ventilation hose FSM vent hose Description lb. in. lb. ft. Flywheel cover bolt 88.5 Fuel System WARNING...
  • Page 115 MAINTENANCE FUEL LINE INSPECTION Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line must be replaced. WATER SEPARATING FUEL FILTER NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
  • Page 116 MAINTENANCE 3. Place rag or towel around valve, release pressure by pushing core of valve end in. 13282 4. Unscrew the filter in a counterclockwise direction to remove. 14762 Filter Draining 1. Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter holder.
  • Page 117 MAINTENANCE 2. Tip the filter holder to drain any fluid into an approved container. 13468 Filter Installation 1. Position filter holder onto bracket and secure filter holder in place. 2. Lubricate the sealing ring on the filter with oil. 3. Install the filter and tighten securely by hand. IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition key to the "RUN"...

  • Page 118: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion.
  • Page 119 4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/ Quicksilver products: Tube Ref No. Description Where Used Part No.

  • Page 120: Spark Plug Inspection And Replacement

    MAINTENANCE 7. Flo‑Torq IV Drive Hub Propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft. 14797 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Thrust hub Forward thrust hub 8.
  • Page 121 MAINTENANCE 2. Pull out on the rear corner of the latch to clear the rear cover. Remove the rear cowl latch. 29740 Rear cowl latch 3. Remove the two screws securing the rear cover. Locate the two arrows (pry points) on the rear cover. Use a thin blade screw driver at these pry points and pry out the cover.
  • Page 122 MAINTENANCE SPARK PLUG REMOVAL AND INSPECTION 1. Disconnect the wiring harness connectors from the pencil coils. 2. Remove the mounting bolts that are securing the pencil coils. Pull the pencil coils from the spark plugs using a twisting motion. 3658 Wiring harness connector Pencil coil Bolt...
  • Page 123 MAINTENANCE 5. Saltwater use ‑ Apply a thin coating of Anti‑Seize Compound only on threads of the spark plugs. Tube Ref No. Description Where Used Part No. Anti-Seize Spark plug threads 92-881091K1 Compound SPARK PLUG INSTALLATION 1. Before installing the spark plugs, clean off any dirt on the spark plug seats.

  • Page 124: Fuses

    MAINTENANCE Description lb. in. lb. ft. Rear cover ‑ screws (2) Pivot screw Fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.
  • Page 125 MAINTENANCE Remove the cover from the fuse holder. Remove the suspected blown fuse and look at the silver band inside the fuse. If the band is broken, replace the fuse. Replace the fuse with a new fuse with the same amp rating. 29731 Fuse puller Fuse holder...

  • Page 126: Steering Link Rod Fasteners

    MAINTENANCE 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 ("a" ‑ Part Number 10‑849838) and self‑locking nylon insert locknuts ("c" & "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 127: Dts Wiring System

    Rubber portion swollen by oil. • Belt surfaces roughened. • Signs of wear on edges or outer surfaces of belt. Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 128 MAINTENANCE • Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets. 28458 2. 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.
  • Page 129 • Tilt Support Lever ‑ Lubricate through fitting. 29759 Swivel bracket Tilt support lever • Tilt Tube ‑ Lubricate through fitting. 29757 Tilt tube fitting • Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101.
  • Page 130 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 ‑ Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube.

  • Page 131: Checking Power Trim Fluid

    2. Remove fill cap and check 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 132: Checking Power Steering Fluid

    MAINTENANCE Checking Power Steering Fluid Remove power steering cover and fill cap to check fluid level. The fluid level should be slightly below the bottom of the fill hole. Use SAE 0W‑30 synthetic power steering fluid, if needed. 29315 Power steering cover Fill/full level Fill cap Tube Ref No.
  • Page 133 MAINTENANCE Crankcase Oil Pump 91‑90265A 5 Aids in the removal of engine oil without draining the crankcase. 11591 4. Pump out the engine oil into an appropriate container. DRAIN METHOD 1. Tilt outboard up to the trailer position. 2. Turn the outboard so that the drain hole is facing downward. 3.
  • Page 134 MAINTENANCE 3. Unscrew old filter using oil filter wrench and turning the filter counterclockwise. 14772 Oil Filter Wrench 91‑802653Q02 Assists in removal of oil filter. 5221 4. Clean the oil filter mounting base. 5. Apply film of clean oil to filter gasket. Do not use grease. 6.

  • Page 135: Gearcase Lubrication

    MAINTENANCE OIL FILLING 1. Remove the oil fill cap and add recommended oil to the midpoint of the operating range (midpoint of cross hatched region). Adding approximately 6 liters (6.3 quarts) will bring oil level to midpoint of cross hatched region. 14770 2.
  • Page 136 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity approximately 970 ml (32.8 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove vent plug/sealing washer.
  • Page 137 MAINTENANCE 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. 22693 Vent hole Fill hole IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube.

  • Page 138: 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 139: Protecting External Outboard Components

    Stabilizer Protecting External Outboard Components • 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 140: Battery Storage

    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. Battery Storage •...

  • Page 141: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 5 Amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. •...

  • Page 142: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a.
  • Page 143 TROUBLESHOOTING • Defective rectifier, alternator, or voltage regulator. • Open circuit in the alternator output wire (fused link).

  • Page 144: 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 145: 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 146 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...

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