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Declaration of Conformity 30/40/50/60 4‑Stroke – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Mercury Marine Technology Suzhou Co., Ltd. Address: No 200 Suhong Middle Road, Suzhou Industrial Park Town: Suzhou...
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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 30, 40 hp 3 cylinder 1C010000 RCD‑H‑2 Rev 4 40, 50, 60 hp 4 cylinder 1C010000 RCD‑H‑2 Rev 4 60 hp Formula Race 4...
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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. This certification is contingent on certain adjustments being set to factory standards.
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Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine. The terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not...
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Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment to service. Earning a Mercury Premier Service rating means a dealer: • Achieves a high 12‑month service Customer Satisfaction Index (CSI) score for warranty service.
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........ 3 Warranty Coverage and Exclusions..........6 U.S.
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Features and Controls Remote Control Features............56 Warning System................ 57 Power Trim and Tilt..............59 Throttle Grip Friction Adjustment ‑ Tiller Handle Models... 63 Steering Friction Adjustment ‑ Tiller Handle Models....63 Replaceable Jet Drive Shear Key..........64 Operation Important Daily Inspection Before Each Use ......65 Prestarting Check List..............
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Maintenance Outboard Care................83 EPA Emissions Regulations............83 Inspection and Maintenance Schedule........84 Flushing the Cooling System............. 86 Top Cowl Removal and Installation........... 88 Exterior Care................88 Battery Inspection ..............89 Fuel System................89 Steering Link Rod Fasteners............. 91 Corrosion Control Anode............92 Spark Plug Inspection and Replacement........
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Parts and Accessories Inquiries..........110 Service Assistance..............110 Ordering Literature..............113 Outboard Installation Mercury Marine Validated Engine Mounting Hardware... 115 Installation Information............. 116 Determining the Mounting Height of the Outboard ....118 Checking Boat Transom Construction........121 Fastening the Outboard............122 Steering Cable ‑...
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.
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. Plan coverage is not transferable from one product to another product or for noneligible applications.
WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
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Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
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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.
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...
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8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants, or fluids changed as a matter of normal...
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, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at...
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 components listed in the Emission Control System...
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Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
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Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Marine's sole and...
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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.
Also included may be hoses, belts, connectors, and other emission‑related assemblies. Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.
WARRANTY INFORMATION 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. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists.
What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. 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.
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WARRANTY INFORMATION Guarantees Under Australian Consumer Law Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
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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.
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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.
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WARRANTY INFORMATION What is Not Covered This limited warranty does not cover routine maintenance items, tune‑ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation...
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WARRANTY INFORMATION No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For...
There is no charge for this service. 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...
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WARRANTY INFORMATION Outside the United States For product purchased outside the Unites States, contact the distributor in your country, or the authorized Marine Power Service Center closest to you. CANADA WARRANTY CHARTS–OUTBOARD AND JET Standard Limited Standard Limited Product Corrosion Warranty Warranty 2‑Stroke carbureted (50 ‑...
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WARRANTY INFORMATION AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS– OUTBOARD AND JET Standard Standard Limited Products Limited Light Commercial Corrosion Warranty Warranty Contact the Marine All outboard 3 years 3 years Power Service Center closest to you Outside of Australia and New Zealand For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the Marine Power Service Center closest to you.
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WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Verado 350 SCi 1 year 3 years None Outside of Asia For product purchased outside of the Asian region, contact the distributor in your country, or the Marine Power Service Center closest to you.
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WARRANTY INFORMATION MIDDLE-EAST AND AFRICA (EXCLUDING SOUTH AFRICA) WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 1 year 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years...
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WARRANTY INFORMATION Racing Product Standard Limited Standard Limited Corrosion (Recreational only) Warranty Warranty Verado 350 SCi 2 years 3 years Outside South Africa For products purchased outside of the South Africa region, contact the distributor in your country, or the Marine Power Service Center closest to you.
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. Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
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.
GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 26838 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.
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.
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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.
GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.
GENERAL INFORMATION WARNING Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death. Use caution when performing the emergency stopping procedure, and be sure to practice in a safe area.
GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running.
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GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
GENERAL INFORMATION 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.
GENERAL INFORMATION MODELS WITH CLAMP SCREWS: Some outboards come with transom bracket clamp screws. The use of clamp bracket screws alone, is insufficient to properly and safely secure the outboard to the transom. Proper installation of the outboard includes bolting the engine to the boat through the transom.
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GENERAL INFORMATION WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide.
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GENERAL INFORMATION 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. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide.
The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
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GENERAL INFORMATION Manual bilge pump and extra drain plugs Drinking water Radio Paddle or oar Spare propeller, thrust hubs, and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment, batteries, bulbs, and fuses Compass and map or chart of the area Personal flotation device (one per person onboard) Watch for signs of weather change and avoid foul weather and rough‑sea boating.
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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.
GENERAL INFORMATION • When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.
*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.
GENERAL INFORMATION Component Identification Auxiliary tilt switch Tilt support knob Transom brackets Jet drive housing Water intake housing Reverse gate Water outlet nozzle Driveshaft housing Water pump indicator hole Bottom cowl 28684 Top cowl...
TRANSPORTING Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailering.
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TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidentally pushed‑in, allowing fuel or vapor to escape. Connector stem Tether cap 26794...
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.
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).
FUEL AND OIL • 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. • Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑...
FUEL AND OIL 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.
FUEL AND OIL 2. Turn the fuel cap until it contacts the tab lock. 3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure. 4. Press down on the tab lock again and remove the cap. DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1.
25W‑40 4‑Stroke Outboard Oil. IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives are not recommended.
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FUEL AND OIL 1. Turn the engine off. Have the outboard in a level operating position. Remove the top cowl. 2. Flip the handle up and pull out the dipstick. Wipe it with a clean rag or towel and push it back in all the way. 3.
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. 26800 Control handle –...
FEATURES AND CONTROLS Warning System WARNING HORN SIGNALS The outboard warning system incorporates a warning horn inside the boat. Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. Tiller handle models will have the warning horn located in the ignition key panel.
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Moving the throttle lever back to the idle position will reset the system. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.
FEATURES AND CONTROLS The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems. Power Trim and Tilt Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch.
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FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.
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FEATURES AND CONTROLS WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
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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 28931 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
FEATURES AND CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. Auxiliary tilt switch 28534 Throttle Grip Friction Adjustment ‑ Tiller Handle Models Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed.
FEATURES AND CONTROLS NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened. Tighten friction Loosen friction Locknut 26811 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 is released.
OPERATION 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.
Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. NOTE: Do not spray on corrosion control anodes as this will...
OPERATION Operating in Shallow Water The life of the impeller and water intake can be greatly increased by avoiding the intake of sand and gravel. The intake suction will act like a dredge when the water intake comes close to the bottom.
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OPERATION The driveshaft driven impeller draws water up through the water intake and then directs it at a high pressure through the water outlet nozzle to create forward thrust. To obtain reverse, the reverse gate moves over the outlet nozzle to direct the water in the opposite direction.
OPERATION WARNING Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running.
OPERATION WARNING Steering the vessel in a tight turn can result in loss of boat control. In some cases, the boat can spin out or roll over, causing serious injury or death. Avoid steering beyond the capabilities of the vessel, especially at high speeds. WARNING A loss or reduction in water jet thrust will directly affect boat directional control, and may result in property damage,...
OPERATION Water Intake Blockage WARNING A rotating impeller could cause injury if contact is made with hands, clothing, or tools. To avoid injury, keep hands and clothing away from the inlet or outlet of the jetdrive, regardless of whether the boat is in the water. Secure tools and loose items to avoid being struck by projectiles as a result of contact with the rotating impeller, and to prevent damage to the impeller.
OPERATION If this does not dislodge the impeller, it will be necessary to remove the six screws and water intake housing. Pre‑Starting Instructions 1. Check the engine oil level. 28525 2. Ensure that the driveshaft bearing on the jet drive is lubricated.
OPERATION 3. For the next eight hours of operation, avoid continuous operation at full throttle for more than five minutes at a time. Starting the Engine ‑ Remote Control Models Before starting, read the pre‑starting check list, special operating instructions, and engine break‑in procedure in the Operation section.
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OPERATION 3. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 4. Shift outboard to neutral ("N") position. 26838 5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. 26840 Fully closed position Maximum fast idle speed position...
OPERATION 7. Turn ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON" position, wait 30 seconds and try again. 19804 8. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.
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OPERATION 1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 2. Connect the remote fuel line to the outboard. Make sure the connector is snapped into place. 28526 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up.
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OPERATION 5. Shift outboard to neutral ("N") position. 28522 6. Set the throttle grip to start position. 7. Starting a flooded engine ‑ Set the throttle grip to half‑way position. 0%100 0%100 START START START 19799 Start position Half‑way position 8.
OPERATION 9. Check for a steady stream of water flowing out of the water pump indicator hole. 28521 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.
OPERATION • Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle. 26779 • Tiller handle models ‑ Reduce the engine speed to idle before shifting. 26842 • Always shift the outboard into gear with a quick motion. •...
OPERATION 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to neutral position. Push in the engine stop button or turn the ignition key to "OFF" position. 26776 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow procedure.
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OPERATION WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. 3. Electric start models ‑ Turn the ignition key to "ON" position. 26846 WARNING High voltage is present any time the key is turned on,...
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OPERATION 5. Pull the starter rope to start the engine. 26848...
We recommend using original Mercury Precision or Quicksilver replacement parts and 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.
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):...
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MAINTENANCE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retighten the outboard mounting fasteners.
MAINTENANCE • Check corrosion control anodes. Check more frequently when used in saltwater. See Corrosion Control Anodes. • Lubricate splines on the driveshaft. • Check power trim fluid. See Checking Power Trim Fluid. • Inspect battery. See Battery Inspection. • Check control cable adjustments.
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MAINTENANCE IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages. 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.
MAINTENANCE Top Cowl Removal and Installation REMOVAL 1. Pull out the rear lock lever and remove the top cowl. 28439 INSTALLATION 1. Lower the top cowl over the engine. 2. Bring the front of the cowl down first and engage the front hook.
MAINTENANCE 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. 1. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3.
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MAINTENANCE ENGINE FUEL FILTER Check the fuel filter for water accumulation or sediment. If water is in the fuel, remove the sight bowl and drain the water. If the filter appears to be contaminated, remove and replace. REMOVAL 1. Read the preceding fuel system servicing information and warning.
MAINTENANCE Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("e" ‑ Part Number 10‑856680) and self‑locking nylon insert locknuts ("b" and "d" ‑ Part Number 11‑826709113). These locknuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
MAINTENANCE Description lb‑in. lb‑ft Tighten until it seats, then back off 1/4 Nylon insert locknut "d" turn Special washer head bolt Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn.
MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.
MAINTENANCE 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten 1/4 turn or torque to specifications. Description lb‑in. lb‑ft Spark plug Steering Pull Adjustment The steering on some boats will have the tendency to pull towards starboard.
MAINTENANCE Check the impeller blades occasionally for damage. Use a flat file to sharpen the leading edges. Sharpen to a 0.8 mm (1/32 in.) radius by removing material from bottom side only. Leading edge Top side lifting angle 29079 Impeller Clearance Adjustment The impeller should be adjusted so there is approximately 0.8 mm (0.03 in.) clearance between the impeller edge and liner.
MAINTENANCE Fuse Replacement IMPORTANT: Always carry spare 20 amp fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.
Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision 2‑4‑C with PTFE. Tube Description Where Used Part No.
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Some discoloration of the grease is normal during the break‑in period on a new set of seals. 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE. Tube...
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MAINTENANCE • Swivel bracket ‑ Lubricate through fitting. Tilt support lever Swivel bracket 28466 • Tilt tube ‑ Lubricate through fitting. 28461 • Co‑pilot shaft (tiller handle models) ‑ Lubricate through fitting. Move the steering friction lever back and forth while lubricating.
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MAINTENANCE WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube.
2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
Synthetic Blend 25W‑40 4‑Stroke Outboard Oil 3.0 Liter Engine oil (3 U.S. Quarts) Mercury Precision Parts or Quicksilver 10W‑30 4‑Stroke Outboard Oil OIL CHANGING PROCEDURE 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward.
MAINTENANCE 4. Screw the new filter on until the gasket contacts the base, then tighten 3/4 to 1 turn. 28417 OIL FILLING 1. Remove the oil fill cap and add oil to the proper operating level. 2. Idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick.
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).
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 Description Where Used Part No.
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STORAGE • Periodically check the water level and charge the battery during storage.
TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Blown fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...
TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Guardian System activated. Refer to Features & Controls ‑ Warning System. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a.
TROUBLESHOOTING • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. •...
Mercury products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package.
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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.
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Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring about parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.
+81 72 233 8833 Sakai‑shi, Osaka 590‑0984, Japan Asia, Singapore Telephone +65 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive +65 65467789 Singapore, 508944 Ordering Literature Before ordering literature, have the following information about...
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OWNER SERVICE ASSISTANCE 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 Attn: Publications Department...
OUTBOARD INSTALLATION Mercury Marine Validated Engine Mounting Hardware IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability issues that can lead to safety concerns.
OUTBOARD INSTALLATION Installation Information BOAT HORSEPOWER CAPACITY WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating.
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The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
OUTBOARD INSTALLATION LIFTING OUTBOARD Use the lifting eye on the engine. 28510 Determining the Mounting Height of the Outboard The following outboard mounting height settings will work good for most applications, however, because of different boat/hull designs, the setting should be checked by test running the boat. Refer to Water Testing.
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OUTBOARD INSTALLATION BOATS WITH A "V" BOTTOM HULL 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line on the transom up from the "V" bottom the same length as the width of the water intake housing.
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OUTBOARD INSTALLATION BOATS WITH A FLAT BOTTOM HULL 1. Place (center) the outboard on the boat transom. Set the height of the outboard on the boat transom so that the front edge of the water intake housing is in line with the bottom of the boat as shown.
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.
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...
OUTBOARD INSTALLATION The outboard must be secured to the transom with the four 13 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of mounting holes and two bolts through the lower set of mounting holes. 1/2 in.
OUTBOARD INSTALLATION 2. Insert the steering cable into the tilt tube. 28507 3. Tighten the nut to the specified torque. 29506 Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a"...
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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.
OUTBOARD INSTALLATION Description lb‑in. lb‑ft Nylon insert locknut "b" Tighten until it seats, then back off 1/4 Nylon insert locknut "e" turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn.
OUTBOARD INSTALLATION FUEL HOSE CONNECTION Fasten the remote fuel hose to the fitting with a metal hose clamp or the plastic type hose clamp that is provided with the outboard. Hose clamp Remote fuel hose 28511 Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover.
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OUTBOARD INSTALLATION Route the remote wiring harness through the rubber grommet. Connect the 14 pin connector to the engine harness. Fasten the harness with the retainer. 41029 Remote wiring harness Retainer 14 pin connector THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
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OUTBOARD INSTALLATION 2. Center the roller with the alignment mark on the cam. Adjust the cable barrel so that it fits into the anchor pocket. 26838 3. Fit the throttle cable through the rubber grommet. Rubber grommet Throttle cable 28701 4.
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OUTBOARD INSTALLATION 5. Adjust the cable barrel so the center of the roller is lined up with the alignment mark on the cam when the cable barrel is placed in the barrel receptacle. 28699 Cable barrel Alignment mark Roller Retainer 6.
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OUTBOARD INSTALLATION 8. Install the access cover with two bolts. Tighten the bolts to the specified torque. 28702 Access cover Description lb‑in. lb‑ft Access cover bolt SHIFT CABLE INSTALLATION WARNING If not properly installed, the reverse gate can interfere with water coming off the rudder, suddenly and unexpectedly slowing the boat.
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OUTBOARD INSTALLATION 3. Adjust the shift cable adjustment barrel so that the roller is at the full end of travel (bottom) in the shift cam. 4. Attach the shift cable adjustment barrel to the bracket with a bolt and locknut. Tighten the bolt until it seats against the adjustment barrel, then back‑off the bolt 1/4 turn.
OUTBOARD INSTALLATION Trim‑In Stop Adjustment ‑ Power Trim Models If an adjustment is required to the trim‑in stop, reposition the tilt stop pins in the desired holes. Tighten the tilt stop pins to the specified torque. Tilt stop pins 28538 Description lb‑in.
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OUTBOARD INSTALLATION Test run the boat. If cavitation occurs (air enters the pump), the first thing to try is lowering the outboard mounting height. If cavitation still exists after lowering the outboard, it may be helpful to seek advice from the boat manufacturer. Another option to further reduce cavitation is a rough water plate.
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...