Mercury 2.5 Operation And Installation Manual
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Mercury 2.5 Operation And Installation Manual

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  • Page 1 Outboard Operation Maintenance Warranty Installation Manual...
  • Page 3 CISPR 12; EN 55012:2002/ characteristics A1:2005 EN 61000‑6‑2; EN Electrostatic discharge testing 61000‑4‑2; EN 61000‑4‑3 Engine type: Outboard Fuel type: Gasoline Combustion cycle: 2‑Stroke This declaration is issued under the sole responsibility of Mercury Marine and Brunswick Marine in EMEA Inc.
  • Page 4 Please review this information. The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, and to change specifications, designs, methods, or procedures without notice and without incurring obligation.
  • Page 5 Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.

  • Page 7: Table Of Contents

    Warranty Information Transfer of Warranty................... 1 Warranty Registration—Outside the United States and Canada......1 3 Year Limited Warranty Against Corrosion............2 Warranty Coverage and Exclusions..............4 Warranty Policy—Australia and New Zealand............ 6 Global Warranty Charts Outboard and Jets............10 General Information Boater's Responsibilities...................
  • Page 8 Features and Controls Features & Controls..................28 Tilting Outboard....................29 Setting The Operating Angle Of Your Outboard ..........30 Operation Prestarting Check List..................32 Operating in Freezing Temperatures..............32 Operating in Saltwater or Polluted Water............32 Engine Break‑in Procedure................33 Starting The Engine..................
  • Page 9 Troubleshooting Engine Will Not Start..................54 Engine Runs Erratically..................54 Performance Loss..................... 54 Owner Service Assistance Service Assistance................... 55 Ordering Literature.................... 57 Maintenance Log Maintenance Log....................59...
  • Page 10 viii...

  • Page 11: Warranty Information

    P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 907 6663 Upon processing the transfer of warranty, Mercury Marine will record the new owner's information. There is no charge for this service. OUTSIDE THE UNITED STATES AND CANADA For products purchased outside the United States and Canada, contact the distributor in your country or the Marine Power Service Center closest to you.

  • Page 12: Year Limited Warranty Against Corrosion

    IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your Mercury Marine distributor or Mercury Marine authorized dealer fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.
  • Page 13 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 predelivery inspection process is completed and documented.

  • Page 14: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
  • Page 15 9. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 10. 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 16: Warranty Policy-Australia And New Zealand

    What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.
  • Page 17 Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty 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 predelivery inspection process is completed and documented.
  • Page 18 The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au.
  • Page 19 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. For additional information regarding events and circumstances covered by this...

  • Page 20: Global Warranty Charts Outboard And Jets

    You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.
  • Page 21 WARRANTY INFORMATION ASIA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 1 year 3 years Contact the Marine FourStroke 1 year 3 years Power Service Center OptiMax 1 year 3 years closest to you Verado 1 year...
  • Page 22 WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Contact the Marine Verado 400R 2 years 3 years Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 23 WARRANTY INFORMATION SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 years 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years closest to you Verado...

  • Page 24: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard.

  • Page 25: Lanyard Stop Switch

    GENERAL INFORMATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S.
  • Page 26 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.

  • Page 27: Protecting People In The Water

    GENERAL INFORMATION 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 28 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 29: 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 30 GENERAL INFORMATION Make sure everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the back of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat;...

  • Page 31: 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 XXXX 28375 Serial number Model year Model designation Year manufactured Certified Europe Insignia (as applicable) Specifications Models Horsepower...

  • Page 32: Installation

    INSTALLATION Installing Outboard BOAT TRANSOM HEIGHT REQUIREMENT 1. Measure the transom height of your boat. The anti‑ventilation plate should be 25 ‑ 50 mm (1 ‑ 2 in.) below the bottom of the boat. Anti‑ventilation plate 28376 INSTALLING OUTBOARD ON TRANSOM 1.

  • Page 33: Transporting

    TRANSPORTING Carrying Outboard The outboard has a carrying handle located in front. 28379 Transporting Outboard When Removed From Boat 1. With the outboard still in the water, close the fuel shut‑off valve and run engine until it stops. The running engine will consume remaining fuel in the carburetor.

  • Page 34: Trailering Boat

    TRANSPORTING Trailering Boat IMPORTANT: The tilt lock mechanism is not intended to support the outboard in the tilted up position when trailering. Use of the tilt lock mechanism could allow the outboard to bounce and drop down causing damage to the outboard. The boat should be trailered with the outboard tilted down (normal operating position).

  • Page 35: 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 36: Oil Recommendation

    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 37: Filling Fuel Tank

    FUEL AND OIL GASOLINE/OIL MIXING RATIO CHART Gas/Oil 3.8 liters 11.5 liters (3 gal.) 23 liters (6 gal.) gas Ratio (1 gal.)gas 473 ml (16 fl. oz.) 89 ml (3 fl. oz.) oil 237 ml (8 fl. oz.) oil 50:1 (2%) MIXING PROCEDURE Pour the full amount of oil along with approximately one gallon of gasoline into an approved container.

  • Page 38: Features And Controls

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

  • Page 39: Tilting Outboard

    FEATURES AND CONTROLS WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment, maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released.

  • Page 40: Setting The Operating Angle Of Your Outboard

    FEATURES AND CONTROLS 3. Take hold of the top cowl grip and raise outboard to the full up position. 28386 4. Push in the tilt support pin. Lower the outboard to rest on the tilt support pin. 28387 LOWERING TO RUN POSITION 1.
  • Page 41 FEATURES AND CONTROLS The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed. This allows the boat to be driven parallel to the water. 28388 Arrange passengers and load in the boat so the weight is distributed evenly.

  • Page 42: 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...

  • Page 43: Engine Break-In Procedure

    OPERATION Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. ENGINE BREAK-IN FUEL MIXTURE Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel. BREAK-IN PROCEDURE Vary the throttle setting during the first hour of operation.
  • Page 44 OPERATION 3. Open the fuel shut‑off valve. 28396 4. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch. NOTE: The engine will not start unless the lanyard is engaged with the stop switch. STOP 28397 5.
  • Page 45 OPERATION 6. Move the throttle lever to the start position. Throttle lever Choke lever STOP 28398 7. Models with gear shift ‑ Move gear shift lever to neutral position. 28385 WARNING Sudden acceleration can serious injury or death. This outboard is a direct‑drive model, meaning the lower unit is in gear at all times.

  • Page 46: Gear Shifting - Models With Gear Shift

    OPERATION NOTE: Starting flooded engine ‑ Move the choke lever down to the open position. Wait 30 seconds, keep the throttle lever at the start position, then continue to crank engine for starting. 9. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 47: Stopping The Engine

    OPERATION Stopping The Engine Reduce engine speed and push in the stop switch or pull the lanyard. STOP 28401 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope.
  • Page 48 OPERATION 4. Reconnect the black lead using a bolt from the rewind starter. Bolt Black lead 28403 5. Place the starter rope knot into the starter cup notch and wind the rope clockwise around the cup. 6. Pull the starter rope to start the engine. WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.

  • Page 49: Maintenance

    Genuine Lubricants. EPA Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards.

  • Page 50: Epa Emissions

    MAINTENANCE EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines. Refer to Owner's Manual for required maintenance.

  • Page 51: Top Cowl Removal And Installation

    MAINTENANCE AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. • Wash off all salt deposits with fresh water if operating in salt water. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST •...

  • Page 52: Exterior Care

    MAINTENANCE INSTALLATION 1. Position top cowl over engine. Place the rear of the cowl on first, then the front. 2. Engage cowl latches to fasten cowl. 28686 Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes.
  • Page 53 MAINTENANCE 2. Move gear shift lever into neutral. 28385 3. Straighten and remove cotter pin. 28704 4. Pull the propeller off the shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 28706 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the...

  • Page 54: Corrosion Control Anode

    MAINTENANCE 5. Apply 2‑4‑C with PTFE to the propeller shaft. 28707 Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 6. If removed, insert drive pin into propeller shaft. 7. Slide propeller onto shaft and verify the slot in propeller engages with the drive pin.

  • Page 55: Spark Plug Inspection And Replacement

    MAINTENANCE The anode requires periodic inspection especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. 28709 Spark Plug Inspection And Replacement WARNING...

  • Page 56: Engine Idle Speed Adjustment

    MAINTENANCE 3. Remove the spark plug to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 28438 4. Set spark plug gap to specifications. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 5.

  • Page 57: Lubrication Points

    MAINTENANCE 3. Adjust the idle speed screw to obtain the recommended engine idle speed. See General Information ‑ Specifications. 28712 Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Copilot threads, swivel bracket, tilt 2-4-C with PTFE support pin, transom clamp screw 92-802859A 1...
  • Page 58 MAINTENANCE • Swivel bracket ‑ Remove four (4) bolts and rear cover and lubricate the inner nylon bushings. 28714 • Tilt support pin. 28387 • Transom clamp screw threads. 28715 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller.

  • Page 59: Gearcase Lubrication

    MAINTENANCE 2. Lubricate the following with lightweight oil. • Tilt pivot. 28717 • Throttle linkage ‑ Lubricate pivot point. 28718 Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
  • Page 60 MAINTENANCE 3. Remove vent plug and fill/drain plug and drain lubricant. Vent plug Fill/drain plug 28719 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 135 ml (4.5 fl. oz.). CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2.

  • Page 61: Submerged Outboard

    MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 62: Storage

    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 Description Where Used Part No.

  • Page 63: Gearcase

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

  • Page 64: Troubleshooting

    TROUBLESHOOTING Engine Will Not Start POSSIBLE CAUSES • Incorrect starting procedure. Refer to Operation section. • Old or contaminated gasoline. • Engine flooded. Refer to Operation section. • Fuel is not reaching the engine. a. Fuel tank is empty. b. Fuel tank vent not open or restricted. c.

  • Page 65: Owner Service Assistance

    STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.
  • Page 66 RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.

  • Page 67: Ordering Literature

    Ordering Literature Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:...
  • Page 68 (USA only) P.O. Box 1939 Fond du Lac, WI 54936-1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package. Mercury Marine Submit the following...

  • Page 69: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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