Mercury 150 Manual
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Mercury 150 Manual

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See also: Service Manual , 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 nearest dealer can be found on www.marinepower.com where country maps and
full contact information are displayed.
Is
your
engine
properly
www.marinepower.com. If necessary, please contact your local dealer.

Declaration of Conformity

If the outboard motor's serial number plate contains the CE mark in the lower left-hand corner,
the following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power
Europe Inc. Park Industriel, de Petit-Rechain, Belgium complies with the requirements of the
following directives and standards, as amended:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
General steering system
Safety of Machinery Directive
Principles of safety integration (1.1.2)
Noise (1.5.8)
Vibration
Electromagnetic Compatibility Directive
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine
driven devices - radio disturbance characteristics
Electrostatic discharge testing
This declaration is issued under the sole responsibility of Mercury Marine and Marine Power
Europe.
registered
for
warranty
EN 292-1; EN 292-2; EN 1050
ICOMIA 39/94
ICOMIA 38/94
EN 61000-6-3
EN 61000-6-1
SAE J551 (CISPR 12)
EN 61000-6-2; EN 61000-4-2; EN 61000-4-3
i
purpose?
Please
94/25/EC
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
ABYC P-17
98/37/EC
89/336/EC
check
on

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  • Page 1: Declaration Of Conformity

    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 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 3: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer Of Warranty..........................1 Warranty Registration United States And Canada................. 1 Warranty Registration Outside The United States And Canada............. 1 Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States ................................2 Outboard Limited Warranty (Middle-East, and Africa)................3 3 Year Limited Warranty Against Corrosion...................
  • Page 4 TABLE OF CONTENTS Operation Pre-Starting Check List......................... 29 Operating In Freezing Temperatures....................29 Operating In Salt Water Or Polluted Water................... 29 Operating at High Elevations........................ 29 Setting Trim Angle While Running Engine at Idle Speed..............29 Engine Break-in Procedure........................30 Starting The Engine..........................
  • Page 5 TABLE OF CONTENTS Parts And Accessories Inquiries......................51 Service Assistance..........................51 Mercury Marine Service Offices......................51 Outboard Installation Important Information..........................53 Avoiding Fuel Flow Restriction......................53 Electric Fuel Pump..........................53 Boat Horsepower Capacity........................53 Start in Gear Protection........................54 Selecting Accessories For Your Outboard.................... 54 Fuel Tanks............................

  • Page 7: Warranty Information

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

  • Page 8: Outboard Limited Warranty United States, Canada, Europe And Confederation Of Independent States

    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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 9: Outboard Limited Warranty (Middle-East, And Africa)

    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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 10: Year Limited Warranty Against Corrosion

    WHAT MERCURY WILL DO: Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re–manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.
  • Page 11 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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 12: Warranty Coverage And Exclusions

    All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.
  • Page 13 WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 13. Water entering engine through the fuel intake, air intake or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high or trimmed too far out.

  • Page 14: 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 15: High-Speed And High-Performance Boat Operation

    When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer.
  • Page 16 RPM is within the recommended range, select a replacement or upgrade propeller with the same pitch as the current propeller. • Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200 • Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200 •...

  • Page 17: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine.
  • Page 18 GENERAL INFORMATION The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.

  • Page 19: Protecting People In The Water

    GENERAL INFORMATION Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 20: Wave And Wake Jumping

    GENERAL INFORMATION WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over. Stay back from the front end of the deck and remain seated while the boat is in motion. 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.

  • Page 21: Impact With Underwater Hazards

    GENERAL INFORMATION Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom.
  • Page 22 GENERAL INFORMATION WARNING Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death. GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 21622 Example of desired air flow through the boat POOR VENTILATION...

  • Page 23: Selecting Accessories For Your Outboard

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

  • Page 24: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. rial Numb XXXXXXXX XXXX RP M 23884 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) Specifications Models Horsepower...

  • Page 25: Component Identification

    GENERAL INFORMATION Component Identification 3403 Top cowl Auxiliary tilt switch Bottom cowl Transom brackets Water pump indicator hole Gearcase Driveshaft housing Cooling water intake holes Anti-ventilation plate...

  • Page 26: 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 27: 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 28: Fuel Requirements For Engine Break-In

    FUEL AND OIL IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3.

  • Page 29: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill fuel tanks outdoors away from heat, sparks, and open flames. Remove portable fuel tanks from boat to refill them.

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. ob00329...
  • Page 31 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following. Warning Horn Function Sound...

  • Page 32: 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, battery voltage, fuel consumption and engine operating hours.
  • Page 33 FEATURES AND CONTROLS Consider the following lists carefully. Trimming In or Down Can: • Lower the bow. • Result in quicker planing off, especially with a heavy load or a stern heavy boat. • Generally improve the ride in choppy water. •...

  • Page 34: Auxiliary Tilt Switch

    FEATURES AND CONTROLS NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard.

  • Page 35: Operation

    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 36: Engine Break-In Procedure

    OPERATION Engine Break-in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. GASOLINE/OIL BREAK-IN MIXTURE Do not use pre-mixed gas and oil during break-in. Oil from the oil injection system will supply adequate lubrication during engine break-in.

  • Page 37: Gear Shifting

    OPERATION Squeeze the fuel line primer bulb several times until it feels firm. 19779 Set the lanyard stop switch to "RUN" position. Refer to General Information - Lanyard Stop Switch. 19791 Shift outboard to neutral "N" position. ob00351 NOTE: It is not necessary to use the neutral fast idle speed feature on the remote control to increase engine speed for starting and warm up.

  • Page 38: Stopping The Engine

    OPERATION • Your outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R). • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Always shift outboard into gear with a quick motion. •...

  • Page 39: 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. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 40: Inspection And Maintenance Schedule

    MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that the lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •...

  • Page 41: Top Cowl Removal And Installation

    MAINTENANCE Remove the plug from fitting in the bottom cowl. ob01084 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. ob01085 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. ob01086 Lift up the rear cowl latch.

  • Page 42: Fuel System

    MAINTENANCE Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions.

  • Page 43: Fuse Replacement

    MAINTENANCE WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00676 Special washer head bolt (10-849838) Nylon insert locknut (11-826709113) Flat washer (2) Nylon insert locknut (11-826709113)

  • Page 44: Corrosion Control Anode

    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. 3395 Good fuse Accessories - 20 AMP fuse Blown fuse Ignition coil circuit - 20 AMP fuse SmartCraft data bus circuit - 5 AMP...

  • Page 45: Propeller Replacement

    MAINTENANCE Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. Make sure the battery is equipped with a non-conductive shield to prevent accidental shorting of battery terminals.
  • Page 46 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.

  • Page 47: Spark Plug Inspection And Replacement

    MAINTENANCE 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. ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications.

  • Page 48: Lubrication Points

    1/4 turn or torque to specifications. Description lb. in. lb. ft. Spark plug Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants Special Lubricant 101. Tube Ref No. Description Where Used Part No. Special Lubricant 101...
  • Page 49 Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 50 MAINTENANCE • Tilt Support Lever - Lubricate through fitting. ob00683 Swivel bracket Tilt support lever • Tilt Tube - Lubricate through fitting ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant.

  • Page 51: Checking Power Trim Fluid

    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 52: Submerged Outboard

    Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug.

  • Page 53: 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 54: Gearcase

    STORAGE • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No. Corrosion Guard External metal surfaces 92-802878Q55 Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase Lubrication).

  • Page 55: Troubleshooting

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

  • Page 56: Battery Will Not Hold Charge

    TROUBLESHOOTING • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •...

  • Page 57: Owner Service Assistance

    Should you have a question, concern, or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
  • Page 58 Telephone (954) 744-3500 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

  • Page 59: Outboard Installation

    Mercury or Quicksilver Premium 2-Cycle TC-W3 Outboard Oil IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3.

  • Page 60: Start In Gear Protection

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

  • Page 61: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine center line for dual engine - 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33-3/8 in.) Dual engine 151.8 cm (59-3/4 in.) Lifting the Outboard WARNING Avoid possible serious injury or death. Before lifting the outboard, verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight.

  • Page 62: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION Lifting Eye 91-90455--1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine for removal/ installation. 2756 Steering Cable - Starboard Side Routed Cable Lubricate O-ring seal and entire cable end. 3724 Tube Ref No.

  • Page 63: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION Torque nut to specification. 3727 Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10-849838) and self-locking nylon insert locknuts (P/N 11-826709113).
  • Page 64 OUTBOARD INSTALLATION WARNING Avoid equipment damage, serious injury or death. Visually inspect all steering attachment components for wear, lubricate all attachment hardware, and check for proper torque tightness in accordance with the inspection and maintenance schedule. or79 Special washer head bolt (P/N Flat washer (2) 10-849838) Nylon Locknut - used on cable coupler...

  • Page 65: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 24305 The solid line is recommended to This line may be preferred to determine determine the outboard mounting outboard mounting height dimension for...
  • Page 66 OUTBOARD INSTALLATION Mark four mounting holes on the transom using the transom drilling fixture. or69-1 Drill guide holes Transom centerline Transom drilling fixture Transom Drilling Fixture 91-98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 Drill four 13.5 mm (17/32 in.) mounting holes.

  • Page 67: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware - Supplied with Outboard Part Number Part Name Description 10-67755-1 Transom bolt 1/2-20 x 4.50 in. long (2.25 in. thread) 11-826711-17 Nylon insert locknut 1/2-20 12-28421 Washer - Inner 0.516 in.
  • Page 68 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 69: Electrical, Hoses, And Control Cables

    OUTBOARD INSTALLATION Electrical, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove screws and open the front clamp assembly. 7644 Screw (2) Front clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp. Connect remote harness to the 14 pin connector on the engine harness.
  • Page 70 OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard or86 Red sleeve - positive (+) Cranking battery Black sleeve - negative (–) 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...
  • Page 71 OUTBOARD INSTALLATION FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel Hose Size - Minimum fuel line inside diameter (I.D.) is 8mm (5/16 in.), with separate fuel line/fuel tank pickup for each engine. Fasten remote fuel hose to fitting with hose clamp. Connect the remote oil hoses to the engine hose connections.

  • Page 72: Shift And Throttle Cable

    OUTBOARD INSTALLATION Make the water pressure gauge hose connection to this tubing as follows: 7728 Speedometer water pick-up tube Barb hose fitting Water pressure tube Speedomer hose Coupler Water pressure tube Plug Shift and Throttle Cable COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gearcases can be identified by a "L" stamped into the end of the propeller shaft.

  • Page 73: Installing The Shift Cable

    OUTBOARD INSTALLATION On counter rotation outboards, the shift linkage moves in the opposite direction compared to a standard rotation outboards. 24498 Standard rotation outboards Forward gear Reverse gear 24497 Counter rotation outboards Forward gear Reverse gear Installing the Shift Cable IMPORTANT: The shift cable is the first cable to move when the remote control handle is moved out of neutral, so install/connect it to the engine first.
  • Page 74 OUTBOARD INSTALLATION Mark the reverse position as follows: a. Move the remote control handle into reverse and advance the handle to the full speed position. Ensure that the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the handle back to the neutral detent position. c.

  • Page 75: Adjusting The Shift Cable

    OUTBOARD INSTALLATION ADJUSTING THE SHIFT CABLE To adjust the shift cable: Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable. 4362 Center mark Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder.

  • Page 76: Throttle Cable Installation

    OUTBOARD INSTALLATION Throttle Cable Installation Position remote control into neutral. ob00351 Attach throttle cable to the throttle lever. Secure with washer and locknut. 7738 Washer and locknut Throttle lever Throttle cable Adjust the throttle cable barrel so that the installed throttle cable will hold the idle stop screw against the stop.

  • Page 77: Front Clamp Reassembly

    OUTBOARD INSTALLATION IMPORTANT: The idle stop screw must be touching the stop. 7740 Idle stop screw Idle stop Lock the barrel holder in place with the cable latch. Front Clamp Reassembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.

  • Page 78: Filling The Fuel System

    OUTBOARD INSTALLATION Fasten clamp together with two screws. 7644 Screw (2) Front clamp Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: Squeeze the fuel line primer bulb until it feels firm.

  • Page 79: Priming The Oil Injection Pump

    OUTBOARD INSTALLATION Remove cap and fill engine oil tank with oil. Reinstall the fill cap. 7745 Engine oil tank Fill cap PRIMING THE OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages.

  • Page 80: Propeller Installation

    OUTBOARD INSTALLATION Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until it feels firm. 19779 Turn the ignition key switch to the "ON" position. ob00364 Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times.

  • Page 81: Trim In Pin

    OUTBOARD INSTALLATION 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. ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque to specifications.
  • Page 82 OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow- down planing condition called plowing. Plowing can cause bow steering or over steering and inefficiently consumes horsepower. or116 Tilt pin (not included with engine) Stainless Steel Tilt Pin 17-49930A 1 Limits the down trim angle of the power trim...

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