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Mercury 75 Pro XS FourStroke Operation Maintenance Installation Warranty Manual

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Summary of Contents for Mercury 75 Pro XS FourStroke

  • Page 1 Outboard Operation Maintenance Warranty Installation Manual...
  • Page 3 Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC Name of engine manufacturer: Mercury Marine Address: W6250 Pioneer Road, P.O. Box 1939 Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA Name of authorized representative: Brunswick Marine in EMEA Inc.
  • Page 4 Identification of Engines Covered by This Declaration of Conformity Unique engine EC Module H Name of engine family identification number: certificate number starting serial number Verado 6 cylinder 200, 225, 0P401000 or RCD‑H‑2 Rev 4 250, 275, 300, 350, 400R hp 1B227000 Verado 4 cylinder 135, 150, 0P401000 or...
  • Page 5 Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States 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.
  • Page 6 Please review this important 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, to change specifications, designs, methods, or procedures without notice and without incurring obligation.

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration United States and Canada..........1 Transfer of Warranty United States and Canada..........1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada.................. 2 3 Year Limited Warranty Against Corrosion............2 Warranty Coverage and Exclusions..............5 U.S.
  • Page 8 Low Permeation Fuel Hose Requirement ............43 EPA Pressurized Portable Fuel Tank Requirements........43 Fuel Demand Valve (FDV) Requirement............44 Mercury Marine's Pressurized Portable Fuel Tank........... 44 Filling Fuel Tank....................45 Engine Oil Recommendations................46 Checking and Adding Engine Oil..............46 Features and Controls Remote Control Features.................
  • Page 9 Maintenance Outboard Care....................62 EPA Emissions Regulations................62 Inspection and Maintenance Schedule............. 63 Maintenance Schedule Decal (75–115)............66 Flushing the Cooling System................67 Top Cowl Removal and Installation..............68 Cleaning Care for Top and Bottom Cowls............69 Flywheel Cover Removal and Installation............70 Cleaning Care for the Powerhead (Saltwater Use)...........
  • Page 10 Owner Service Assistance Service Assistance................... 92 Ordering Literature.................... 94 Outboard Installation Mercury Marine Validated Engine Mounting Hardware........96 Accessories Mounted to the Transom Clamp Bracket........96 Important Information..................100 Boat Horsepower Capacity................100 Start in Gear Protection.................. 101 Selecting Accessories for Your Outboard............101 Fuel System....................

  • Page 11: Warranty Information

    Federal Safety Act be required. You may change your registered 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 12: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.
  • 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 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: 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 16: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use warranty, whichever occurs first, to the retail customer, that the engine is designed, built,...

  • Page 17: California Emissions Limited Warranty

    The regulations apply to all outboard engines sold to retail consumers in California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the...
  • Page 18 Mercury 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 dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
  • Page 19 California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 20: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

  • Page 21: Warranty Policy-Australia And New Zealand

    90% lower emissions than One Star ‑ Low Emission engines. Warranty Policy—Australia and New Zealand MERCURY/MARINER OUTBOARD LIMITED WARRANTY–AUSTRALIA AND NEW ZEALAND POLICY This limited warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia...
  • Page 22 WARRANTY INFORMATION 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 23 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 24 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 25 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...

  • Page 26: Global Warranty Charts Outboard And Jets

    WARRANTY INFORMATION Global Warranty Charts Outboard and Jets UNITED STATES WARRANTY CHARTS–OUTBOARD AND JET Standard Limited Standard Limited Product Corrosion Warranty Warranty FourStroke (2.5–350 hp including Verado, Pro FourStroke and Jet 3 years 3 years outboards) OptiMax (75–250 hp including Pro 3 years 3 years XS and Jet outboards)
  • Page 27 WARRANTY INFORMATION Racing Product Standard Limited Standard Limited (Recreation use only) Warranty Corrosion Warranty OptiMax (250 XS) 2 years 3 years OptiMax (225 Sport XS) 2 years 3 years OptiMax (300 XS) 2 years 3 years Verado (400R) 2 years 3 years Outside of Canada For product purchased outside of Canada, contact the distributor in your...
  • Page 28 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 29 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 30 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 31: 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 32: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 33: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.

  • Page 34: Propeller Selection

    GENERAL INFORMATION The outboard must be secured to the transom with the four 12.7 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of holes and two bolts through the lower set of holes. 27746 Propeller Selection For best all around performance from your outboard/boat combination, select a...

  • Page 35: 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 36 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 37: Protecting People In The Water

    GENERAL INFORMATION KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

  • Page 38: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 39: Wave And Wake Jumping

    GENERAL INFORMATION Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.

  • Page 40: 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. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 41: 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 42 GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 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 43: 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. Read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 44 (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 45: Recording Serial Number

    It is important to record this number for future reference. The serial number is located on the outboard, as shown. Model Number XXXXXXX Serial Number XXXXXXX XXXXXX Mercury Marine Brunswick Corp. Fond du Lac, WI 54935 Assembled in the USA from US and foreign components 54204...

  • Page 46: Specifications 75-115

    GENERAL INFORMATION Specifications 75–115 NOTE: 80 and 100 HP are international models. Models Horsepower Kilowatts 55.9 59.6 66.2 73.6 85.7 Full throttle 4500–5500 5000–6000 RPM range Idle speed in neutral gear (engine at 700 RPM operating temperature) Troll control RPM range 550–1000 (accessory) Number of...

  • Page 47: Specifications 115 Pro Xs

    GENERAL INFORMATION Models Recommended Refer to Fuel and Oil gasoline Recommended Refer to Fuel and Oil Engine oil capacity with oil 5.2 liter (5.5 US qt) filter replacement 1000 marine cranking amps (MCA), 800 cold cranking Battery rating amps (CCA), or 65 amp hour (Ah) Emission control Electronic engine control (EC) system...
  • Page 48 GENERAL INFORMATION Models 115 Pro XS Recommended NGK ZFR5F spark plug Spark plug gap 0.8 mm (0.032 in.) Spark plug hex 16 mm size Valve clearance (cold) Intake valve 0.050–0.102 mm (0.002–0.004 in.) Exhaust valve 0.128–0.179 mm (0.005–0.007 in.) Standard 2.07:1 Gear ratio Command Thrust 2.38:1 Standard 800 ml (27.1 fl oz)

  • Page 49: Component Identification

    GENERAL INFORMATION Component Identification 54205 Top cowl Engine flush Auxiliary tilt switch Tilt bracket knob Anode Cooling water intake holes Gearcase Engine oil drain Water pump indicator hole Manual release for trim system...

  • Page 50: 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.

  • Page 51: Fuel And Oil

    Damages caused from the use of improper fuel is not covered under the limited warranty. 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 52: Fuel Additives

    Fuel Additives To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container.

  • Page 53: Low Permeation Fuel Hose Requirement

    FUEL AND OIL IMPORTANT: The fuel line quick disconnect fuel hose fitting is not equipped with a check valve. Fuel will be present at the connection and may drain from the hose when disconnected. Ensure there is a suitable container ready when disconnecting the fuel line from the engine.

  • Page 54: Fuel Demand Valve (Fdv) Requirement

    Vent/water drain holes 46273 Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 55: Filling Fuel Tank

    FUEL AND OIL REMOVING THE FUEL CAP Fuel cap Manual vent screw Tab lock 46290 IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening. 1. Open the manual vent screw on top of the fuel cap. 2.

  • Page 56: Engine Oil Recommendations

    IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), low quality oils, or oils that contain solid additives are not recommended.
  • Page 57 FUEL AND OIL 4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way. 5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region).
  • Page 58 FUEL AND OIL 6. If the oil level is below the operating range (cross hatched region), remove the oil filler cap and add approximately 500 ml (16 oz) of the specified outboard motor oil. Allow a few minutes for the added oil to drain to the oil sump and check the level on the dipstick.

  • Page 59: 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. 58240 Trim/tilt switch –...
  • Page 60 FEATURES AND CONTROLS It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present. For visual display of the specific engine functions and additional engine data, refer to SmartCraft Product information, following.

  • Page 61: 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 62 FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control.
  • Page 63 FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down. Lower the outboard. Tilt support lever Knob 54169 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
  • Page 64 FEATURES AND CONTROLS AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system. Auxiliary tilt switch 54178 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 65: Operation

    OPERATION Important Information IMPORTANT DAILY INSPECTION BEFORE EACH USE Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

  • Page 66: Operating In Freezing Temperatures

    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 67: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION EXAMPLE: An engine running at an elevation of 8,000 feet will have over a 30% power loss while a loss of engine power on a hot and humid day could be as much as 14%. These losses apply to normally aspirated and supercharged engines.

  • Page 68: Engine Break-In Procedure

    OPERATION NOTICE Operating the engine with the outboard in the tilt range can damage the engine or the transom. If operating the engine in the tilt range, such as in shallow water, do not exceed 2000 RPM. 1. Reduce the engine speed below 2000 RPM. 2.
  • Page 69 OPERATION 2. Ensure the cooling water intake is submerged. 47412 3. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 4. Set the lanyard stop switch to the RUN position. Refer to General Information ‑...
  • Page 70 OPERATION 6. Ignition key starting ‑ Turn ignition key to the 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 the START position again until engine starts.

  • Page 71: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift the outboard into gear unless the engine speed is at idle. • Do not shift the outboard into reverse when the engine is not running. • Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R).

  • Page 72: Outboard Care

    Genuine Lubricants. EPA Emissions 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 set to factory standards.

  • Page 73: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...
  • Page 74 MAINTENANCE • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, tighten the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard transom brackets.
  • Page 75 MAINTENANCE Description lb‑in. lb‑ft Outboard mounting locknuts and – bolts ‑ standard boat transom Outboard mounting locknuts and bolts ‑ metal lift plates and setback – brackets • Check corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anode. •...

  • Page 76: Maintenance Schedule Decal (75-115)

    MAINTENANCE Maintenance Schedule Decal (75–115) 58248 75–115 59342 115 Pro XS The following table shows the icons and a general description of the maintenance schedule decal that is located on the engine.

  • Page 77: Flushing The Cooling System

    MAINTENANCE Icon Definition Icon Definition Replace Inspect 58249 58250 Engine oil and filter Gearcase lubricant 58251 58252 Spark plugs Thermostat 58253 58254 Low pressure fuel filter Anodes 58256 58255 Water pump impeller 58258 Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water.

  • Page 78: Top Cowl Removal And Installation

    MAINTENANCE 3. Remove the cover from the flush connector and thread a water hose into the flush connector. 47592 4. Turn on the water tap (½ maximum) and let the water flush through the cooling system for about 15 minutes. 5.

  • Page 79: Cleaning Care For Top And Bottom Cowls

    3. Dry thoroughly with a soft clean cloth. 4. Wax the surface using a nonabrasive 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).

  • Page 80: Flywheel Cover Removal And Installation

    Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 81: Battery Inspection

    MAINTENANCE Tube Ref Description Where Used Part No. External metal surfaces of the powerhead Corrosion Guard 92-802878 55 and powerhead components. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery.
  • Page 82 MAINTENANCE The engine is equipped with two fuel filters, a low‑pressure filter and a high‑pressure filter. The low‑pressure filter can be serviced as a general maintenance item, however, the high‑pressure filter should only be serviced by an authorized dealer. 53767 Low pressure fuel filter LOW-PRESSURE FUEL FILTER Removal...

  • Page 83: Corrosion Control Anode

    MAINTENANCE 3. Push in on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter. Fuel hose release tab Low‑pressure fuel filter 20815 Installation 1. Install the new fuel filter so the arrow points toward the engine. 2.

  • Page 84: Propeller Replacement

    MAINTENANCE Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 47569 Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
  • Page 85 MAINTENANCE 3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. 26901 4. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.
  • Page 86 MAINTENANCE 2. Place the locknut retainer over the raised pins on the drive sleeve adapter and tighten the locknut to the specified torque. 3. Secure the locknut by bending the tabs up against the locknuts. 45232 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer...

  • Page 87: Spark Plug Inspection And Replacement

    MAINTENANCE 3. Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter. 45248 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer Locknut Tabs bent into grooves Description lb‑in. lb‑ft Propeller nut –...
  • Page 88 MAINTENANCE 2. Remove the spark plugs to inspect. 53782 3. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode. IMPORTANT: The color of the plug may not accurately reflect its condition.

  • Page 89: Fuse Replacement

    MAINTENANCE a. All of the spark plugs should have the gap checked and corrected as necessary before installation. b. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap. c.

  • Page 90: Lubrication Points

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 53784 Cover Spare fuse holders Fuse 3 ‑ HELM 15 amp ‑ 14 pin remote control harness/cowl trim switch Fuse 4 ‑...
  • Page 91 MAINTENANCE Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
  • Page 92 MAINTENANCE WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. • Tilt lever grease fitting and the swivel pin grease fitting. Tilt lever grease fitting Swivel pin grease fitting 54186...

  • Page 93: Checking Power Trim Fluid

    54169 2. Remove the 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 and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
  • Page 94 MAINTENANCE 2. Tilt the outboard to a vertical position. 3. Use a 16 mm (5/8 in.) wrench and loosen the oil drain valve so that it can be turned by hand. Be careful not to open the valve too far allowing oil to drain.
  • Page 95 MAINTENANCE 5. Clean the oil filter mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. Loosen Oil filter Oil trough Drain hose 53792 OIL FILLING...

  • Page 96: Gearcase Lubrication

    Right‑hand rotation 810 ml (27.4 fl oz) Command Thrust Left‑hand rotation 790 ml (26.7 fl oz) GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position.
  • Page 97 MAINTENANCE 2. Remove the vent plug/sealing washer. 3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole. 22693 Vent hole Fill hole IMPORTANT: Replace the sealing washers if damaged. 4.

  • Page 98: Storage

    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 Description Where Used Part No.

  • Page 99: Protecting Internal Engine Components

    STORAGE Protecting Internal Engine Components IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacement for correct procedure for removing spark plugs. • Change the engine oil and filter. • Remove the spark plugs. • Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole.

  • Page 100: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 15 amp fuse. Check 14 pin remote control harness/cowl trim switch/main power relay fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. •...

  • Page 101: Performance Loss

    TROUBLESHOOTING • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Throttle not opening fully. • Damaged propeller or improper propeller size. • Incorrect engine timing, adjustment, or setup. •...

  • Page 102: 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 103 OWNER SERVICE ASSISTANCE 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 104: 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: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 105 OWNER SERVICE ASSISTANCE Mercury Marine Submit the following Attn: Publications Department order form with payment W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Copy this form and print or type–This is your shipping label) Name...

  • Page 106: Outboard Installation

    51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the same fasteners that secure the outboard to the transom or jack plate.
  • Page 107 OUTBOARD INSTALLATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
  • Page 108 OUTBOARD INSTALLATION • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners...
  • Page 109 OUTBOARD INSTALLATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition.

  • Page 110: Important Information

    Rigging boats, which includes proper engine installation has become more complex over the years. As a result, Mercury Marine recommends that engines be installed only by Mercury authorized dealers. If you intend to disregard this recommendation, and install the engine yourself, please make sure to read and comply with these instructions.

  • Page 111: 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 112 OUTBOARD INSTALLATION LOW PERMEATION FUEL HOSE REQUIREMENT Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.
  • Page 113 OUTBOARD INSTALLATION FUEL SUPPLY MODULE PRIMING PROCEDURE The fuel supply module (FSM) is not vented to the ambient air. The air trapped in the FSM, fuel lines, and fuel rail, will be slightly compressed during the initial ignition key on with a dry or drained fuel system. Additional key on events under these conditions, will not compress the air further to finish the priming of the FSM.
  • Page 114 OUTBOARD INSTALLATION 4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel. 58336 Fuel pressure gauge purge valve Schrader valve Purge hose to appropriate container 5. Open the fuel pressure gauge purge valve and turn the ignition key on. The fuel pumps will run for approximately three to five seconds.
  • Page 115 OUTBOARD INSTALLATION 8. Turn the ignition key on. When the fuel pumps stop running, start the engine. The engine may not start on the first attempt. The engine will run rough at idle for up to two minutes while the residual air is purged from the fuel system.

  • Page 116: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine centerline for dual engine ‑ 66.0 cm (26 in.) minimum Minimum Transom Opening Single engine 84.2 cm (33 in.) Dual engine 149.9 cm (59 in.)

  • Page 117: 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.) 47710 The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions...

  • Page 118: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions.

  • Page 119: Lifting Outboard

    OUTBOARD INSTALLATION Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Lifting Outboard 1. Remove the top cowl. 2. Install the lifting base to the flywheel using three bolts. Tighten the bolts securely.

  • Page 120: Shipping Bracket Removal

    OUTBOARD INSTALLATION 5. Lift the outboard and place it on the transom. 53797 Lifting base Lifting eye Flywheel Puller/Lifting Ring 91‑895343T02 Removes flywheel from engine. Used for lifting powerhead/engine. 14869 Shipping Bracket Removal 1. Remove the two top screws and loosen the two bottom screws. 2.

  • Page 121: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 3. Tighten the bottom screws to the specified torque. 47720 Shipping bracket Top screws Bottom screws Description lb‑in. lb‑ft Bottom screws Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate O‑ring seal and entire cable end. 3724 Tube Ref Description Where Used Part No.

  • Page 122: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION 3. Tighten the nut to the specified torque. 47708 Description lb‑in. lb‑ft 47.5 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 67755‑1 Outboard mounting bolt ½‑20 x 4.50 in. long (2.25 in. thread) 826711‑17 Nylon insert locknut ½‑20...
  • Page 123 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 124 OUTBOARD INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 125 Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area.
  • Page 126 OUTBOARD INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 127: Steering Link Rod Fasteners (If Equipped)

    OUTBOARD INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Steering Link Rod Fasteners (if equipped) IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt ("a"...
  • Page 128 OUTBOARD INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

  • Page 129: Electrical, Fuel Hose, And Control Cables

    OUTBOARD INSTALLATION Electrical, Fuel Hose, and Control Cables RIGGING GROMMET Installation IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, that are routed between the rigging grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.
  • Page 130 OUTBOARD INSTALLATION 2. Fasten the rigging grommet and rigging adapter with two M6 x 30 screws and one M6 x 50 screw. Tighten the screws to the specified torque. 3. Secure the wiring, hoses, and cables together with a cable tie. NOTICE Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring harnesses.
  • Page 131 OUTBOARD INSTALLATION REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the rigging grommet. Remove the harness cover and connect the remote harness to the 14 pin connector on the engine harness. Secure the harness with the retainer. Remote 14 pin boat harness Retainer...
  • Page 132 OUTBOARD INSTALLATION 2. Route the SmartCraft and/or vessel harness through the rigging grommet and connect it to the connector. 53857 Vessel (accessory) harness connector SmartCraft harness connector BATTERY CABLE CONNECTIONS This outboard is factory equipped with 3.6 m (12 ft) #4 gauge battery cables. If battery cables longer than the factory supplied cables are required, the wire gauge size must increase.
  • Page 133 OUTBOARD INSTALLATION Maximum Length American Wire Gauge (AWG) Meter (Feet) 12.2 m (40 ft) 15.2 m (50 ft) 19.6 m (64 ft) 24.4 m (80 ft) Single Outboard Red sleeve ‑ positive Black sleeve ‑ negative (–) Cranking battery 15496...
  • Page 134 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ positive (+) Black sleeve ‑ negative (–) Ground cable Cranking battery FUEL HOSE CONNECTION Install and secure the quick disconnect fuel hose fitting with a hose clamp.
  • Page 135 OUTBOARD INSTALLATION Fuel Hose Size Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with separate fuel hose/fuel tank pickup for each engine. 53883 Quick disconnect fuel hose fitting SHIFT CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control.
  • Page 136 OUTBOARD INSTALLATION 2. Center the shift cable anchor pin with the neutral detent alignment mark. 53873 Shift cable anchor pin Neutral detent alignment mark 3. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a.
  • Page 137 OUTBOARD INSTALLATION c. Make a center mark "c," midway between marks "a" and "b." Align the cable end guide against this center mark when installing the cable to the engine. 6098 4. Position the remote control into neutral. 5. Place the barrel cup into the barrel pocket. 6.
  • Page 138 OUTBOARD INSTALLATION c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps a through c. d. Shift remote control back to neutral. The propeller shaft should turn freely without drag.
  • Page 139 OUTBOARD INSTALLATION 5. Lock the cable in place with the cable latch. 53874 Anchor pin latch Cable latch 6. Press on the cable latch to ensure the cable latch locks onto the bracket. 7. Pull up on the throttle cable near the cable latch to confirm the cable latch has locked onto the bracket.

  • Page 140: Trim In Pin

    OUTBOARD INSTALLATION Trim In Pin 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 141: 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...

This manual is also suitable for:

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