Mercury 4-STROKE Installation Operation Maintenance Warranty Manual
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Mercury 4-STROKE Installation Operation Maintenance Warranty Manual

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  • Page 1 Outboard Installation Operation Maintenance Warranty Manual...
  • Page 3 Declaration of Conformity – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Tohatsu Marine Corporation (TMC) Mercury Marine Joint Venture Address: Shimodaira 4495‑9 Town: Post Code: 399‑4101 Country: Japan Komagane‑City, Nagano...
  • Page 4 Identification of Engines Covered by This Declaration of Conformity EC Type–examination Name of engine model or Starting serial certificate or type–approval engine family number certificate number 8, 9.9 hp 0R098000 RCD‑H‑2 Rev 4 9.9 hp Command Thrust 0R285784 RCD‑H‑2 Rev 4 10 hp Norway 0R285784 RCD‑H‑2 Rev 4...

  • Page 5: Epa Emissions Regulations

    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 information. The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, and to change specifications, designs, methods, or procedures without notice and without incurring obligation.

  • Page 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 Fuel Recommendations..................44 Low Permeation Fuel Hose Requirement ............45 EPA Pressurized Portable Fuel Tank Requirements........45 Fuel Demand Valve (FDV) Requirement............45 Mercury Marine's Pressurized Portable Fuel Tank........... 46 Filling Fuel Tank....................47 Engine Oil Recommendations................47 Checking Engine Oil..................48 Features and Controls Tiller Handle Features..................
  • Page 9 Maintenance Outboard Care....................77 EPA Emission Regulations................77 Inspection and Maintenance Schedule............. 78 Flushing the Cooling System................80 Top Cowl Removal And Installation..............82 Battery Inspection .................... 82 Exterior Care..................... 82 Fuel System...................... 83 Steering Link Rod Fasteners................83 Corrosion Control Anode ................. 85 Propeller Replacement ..................
  • Page 10 Owner Service Assistance Service Assistance..................102 Ordering Literature..................104 Installation Boat Horsepower Capacity................106 Start in Gear Protection.................. 106 Selecting Accessories for Your Outboard............106 Low Permeation Fuel Hose Requirement ............107 Installing Outboard..................107 Remote Control Installation................110 Steering Link Rod Fasteners................110 Remote Wire Harness Connection..............

  • 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 (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 34 GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 35 GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 36: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 37 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.

  • Page 38: Wave And Wake Jumping

    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.

  • Page 39: 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 40: 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.
  • Page 41 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.

  • Page 42: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 43 GENERAL INFORMATION • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S.
  • 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

    GENERAL INFORMATION • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is...
  • Page 46 GENERAL INFORMATION 9.9 Command Thrust/ Models ProKicker Gear ratio 2.08:1 2.42:1 Recommended Refer to Fuel and Oil gasoline Recommended oil Refer to Fuel and Oil Engine oil capacity 800 ml (27.0 fl oz) Gearcase lubricant 320 ml (10.8 fl oz) 370 ml (12.5 fl oz) capacity Battery rating (electric...

  • Page 47: Component Identification - Standard Models

    GENERAL INFORMATION Component Identification ‑ Standard Models STARBOARD SIDE VIEW Cowl latch Throttle only button Throttle friction adjustment knob Water pump indicator hole Oil drain plug Transom angle preset knob Engine flush plug Gear lubricant level plug Water inlet Gear lubricant fill/drain plug Trim tab 38541...
  • Page 48 GENERAL INFORMATION FRONT VIEW 57671 Choke/fast idle knob Oil pressure light Fuel line connector Start switch (electric tiller handle) Lanyard safety switch Copilot tension adjustment...
  • Page 49 GENERAL INFORMATION PORT VIEW 38571 Tiller lock release lever Start switch (electric tiller handle model) Steering friction adjustment lever (tiller model only) Tilt lock knob...

  • Page 50: Component Identification - Command Thrust/Prokicker Models

    GENERAL INFORMATION Component Identification ‑ Command Thrust/ProKicker Models 38533 Transom bracket Tilt support lever Gear lubricant level plug Primary water inlet Gear lubricant fill/drain plug Secondary water inlet Anti‑ventilation plate Engine flush plug Water pump indicator hole Cowl latch Oil drain screw Power tilt Kicker strap Throttle only button...

  • Page 51: Transporting

    TRANSPORTING Carrying, Storing, and Transporting Your Outboard when Removed from Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run engine until it stops.

  • Page 52: Trailering Boat/Outboard - Models With Power Tilt

    TRANSPORTING 4. Never carry, store, or transport the outboard in the two positions shown. Engine damage could result from oil draining out of the crankcase. Tiller handle up Front side up 39058 Trailering Boat/Outboard ‑ Models with Power Tilt 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.
  • Page 53 TRANSPORTING Shift the outboard to forward gear. This prevents the propeller from spinning freely.

  • Page 54: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump octane rating of 87 (R+M)/2 minimum.

  • Page 55: Low Permeation Fuel Hose Requirement

    IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided.

  • Page 56: Mercury Marine's Pressurized Portable Fuel Tank

    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 57: Filling Fuel Tank

    Mercury or Quicksilver NMMA FC‑W certified SAE 10W‑30 4‑Stroke Marine Engine Oil is recommended for general, all‑temperature use. If NMMA certified synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil. If the recommended Mercury or Quicksilver NMMA FC‑W certified outboard oils are not available, a major...

  • Page 58: Checking Engine Oil

    FUEL AND 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 or oils that contain solid additives are not recommended.
  • Page 59 FUEL AND OIL 4. Install the oil filler cap and tighten securely. Dipstick Oil filler cap 4914...

  • Page 60: Features And Controls

    FEATURES AND CONTROLS Tiller Handle Features IMPORTANT: Avoid engine flooding ‑ Do not rotate the throttle grip while engine is not running. Doing so will inject fuel into the engine and cause a possible hard starting flooded condition. • A decal on the tiller handle is a quick reference guide for starting a cold or hot engine.
  • Page 61 FEATURES AND CONTROLS • Tiller lock release lever ‑ Push the lever to move tiller handle from one position to another. Tiller lock release lever 3274 • Tiller handle lock cap ‑ Remove the lock cap on top of the tiller handle to lock in the up position.
  • Page 62 FEATURES AND CONTROLS • Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch. 19791 • Engine stop switch ‑ Push in to stop the engine. 57673 • Power tilt switch ‑ Push to tilt engine up/down. 4639 •...
  • Page 63 FEATURES AND CONTROLS • Throttle only button ‑ Pressing the button in while the outboard is in neutral disables the gear shift control of the tiller handle. 28550 • Throttle grip ‑ Controls the engine speed and shifting. 57674 Reverse gear throttle Forward gear throttle •...
  • Page 64 FEATURES AND CONTROLS • Low oil pressure warning light ‑ Warns the operator the engine has low oil pressure. When the low oil pressure light is on or is blinking, the engine will run rough and will not exceed 3000 RPM. 57676 •...
  • Page 65 FEATURES AND CONTROLS • Tilt lock knob ‑ Locks the engine in the full tilt position. 28564 • Trim position knob ‑ Presets the trim position. 28551 • Kicker strap (power tilt models) ‑ Prevents the engine from turning while tilted up.

  • Page 66: Remote Control Features

    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 Ignition key switch—OFF, ON, START...

  • Page 67: Warning System

    FEATURES AND CONTROLS GEAR SHIFTING IMPORTANT: Observe the following: • Never shift the drive into gear unless the engine speed is at idle. • Do not shift the drive into reverse when the engine is not running. • Your power package has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R).

  • Page 68: Power Tilt (If Equipped)

    FEATURES AND CONTROLS Power Tilt (if equipped) This outboard has a tilt control called power tilt. This enables the operator to easily adjust the position of the outboard by pressing the tilt switch. With the engine turned off, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up to permit shallow water operation.
  • Page 69 FEATURES AND CONTROLS TILTING OPERATION To tilt the outboard, shut off the engine and press the tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. Tiller handle models have a kicker strap located on each side of the outboard, preventing the outboard from turning when tilted up.

  • Page 70: Setting The Transom Angle Of Your Outboard

    FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and lifting the knob. Lower the outboard. Tilt support lever Knob 4650 Setting The Transom Angle Of Your Outboard The vertical transom angle of your outboard is adjusted by changing the position of the preset tilt knob in one of the three adjustment holes provided.
  • Page 71 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 28533 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.

  • Page 72: Adjusting Transom Angle

    FEATURES AND CONTROLS Adjusting Transom Angle 1. Stop the engine. Shift the outboard into forward. Raise the engine to one of the tilt release positions. Change the preset knob position and lower the outboard to the preset transom angle position. 2.

  • Page 73: Tilting Outboard

    FEATURES AND CONTROLS 2. To release the shallow water drive, stop the engine and tilt the outboard up to one of the tilt release position. Gently lower the outboard to the preset transom angle. 28592 Shallow water drive positions Tilt release positions Water Intake Tilting Outboard 1.

  • Page 74: Trim Tab Adjustment

    FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 75: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on...

  • Page 76: Operating Outboard As An Auxiliary Engine

    OPERATION Operating Outboard as an Auxiliary Engine If the outboard is used as an auxiliary engine, stop the engine and tilt the outboard out of the water when using the main power source. IMPORTANT: The outboard must be restrained from bouncing while operating the boat using the main power source.

  • Page 77: Engine Break-In Procedure

    OPERATION Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 1. For the first hour of operation, run the engine at varied throttle settings up to 2000 RPM or at approximately half throttle.
  • Page 78 OPERATION 3. Set the lanyard stop switch to RUN position. Refer to General Information—Lanyard Stop Switch. 19791 4. Set the tiller handle gear shift to the neutral start position. 57677 5. Cold engine ‑ • Pull the choke knob out two detent positions for starting a cold engine. The choke is closed in this position.
  • Page 79 OPERATION 6. Manual starting models ‑ Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until the engine starts. After the engine has started, push in the choke knob.

  • Page 80: Starting The Engine - Remote Control Models

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat.
  • Page 81 OPERATION 3. Set the lanyard stop switch to RUN position. Refer to General Information—Lanyard Stop Switch. 19791 4. Ensure the remote control handle is in the neutral position. IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle when the engine is not running.

  • Page 82: Starting A Hot Engine

    OPERATION 6. Turn the ignition key to the START position. If the engine is cold, push the key in to choke the engine while cranking. If the engine fails to start in ten seconds, wait 30 seconds and try again. If the engine begins to stall, push the key in (choke) until the engine is running smoothly.

  • Page 83: Stopping The Engine

    OPERATION • Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). • Tiller handle models ‑ Reduce the engine speed to idle before shifting. 57740 (R) reverse (N) neutral (F) forward • Remote control models ‑...

  • Page 84: Emergency Starting

    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 this procedure.
  • Page 85 OPERATION 4. Remove the three screws holding the flywheel cover on. 28614 Flywheel cover screws (3) Recoil neutral interlock Fuse holder 5. Remove the flywheel cover. 6. Remote Control models ‑ Ensure the key switch is in the "ON" position. WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.
  • Page 86 OPERATION 8. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 28616 9. Pull the starter rope quickly.

  • Page 87: Outboard Care

    Genuine Lubricants. EPA Emission 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 88: Inspection And Maintenance Schedule

    FAMILY : FEL : HC+NOx= HP : LOW-PERM/HIGH-PERM : MAXIMUM POWER : TIMING : IDLE SPEED (IN GEAR) : MERCURY MARINE 43058 Piston displacement Maximum emission output for the engine family Percent of fuel line permeation Timing specification Family number Engine family description Engine power ‑...
  • Page 89 MAINTENANCE AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST •...

  • Page 90: Flushing The Cooling System

    This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.
  • Page 91 MAINTENANCE 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 27259 3. Start the engine and run it at idle speed in neutral shift position. IMPORTANT: Do not run the engine above idle when flushing.

  • Page 92: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal And Installation REMOVAL 1. Pull out the front cowl latch. 4936 2. Lift front of cowl to clear front latch and push toward the rear to clear rear hook. 3. Lift top cowl to remove. INSTALLATION 1.

  • Page 93: Fuel System

    MAINTENANCE Fuel System WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors.
  • Page 94 MAINTENANCE 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 95: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your outboard has a corrosion control anode installed to the gearcase. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. The anode requires periodic inspection especially in saltwater which will accelerate the erosion.
  • Page 96 MAINTENANCE 2. Move the gear shift lever into neutral (N). 26838 57677 3. Straighten and remove the cotter pin. 4. Place a block of wood between the gearcase and propeller to hold the propeller and remove the propeller nut. 5. 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 97: Fuse Replacement - Electric Start Models

    MAINTENANCE Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 7. Install the front thrust washer, propeller, rear thrust washer, and propeller nut onto the shaft. 8. Place a block of wood between the gearcase and propeller to prevent rotation and tighten the propeller nut.

  • Page 98: Spark Plug Inspection And Replacement

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace the fuse with a new fuse with the same rating. Identifying a blown fuse Good fuse Blown fuse 28619 Spark Plug Inspection and Replacement WARNING...

  • Page 99: Timing Belt Inspection

    MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.9 mm (0.035 in.) 4. Before installing spark plug, clean off any dirt on the spark plug seat. Install plug finger‑tight, and then tighten 1/4 turn or torque to specifications.
  • Page 100 MAINTENANCE OIL CHANGING PROCEDURE 1. Lock the outboard in the full tilt up position. 2. Position the outboard so the drain hole is facing downward. 3. Remove the drain plug and drain the engine oil into an appropriate container. IMPORTANT: Do not use a crankcase oil pump when changing the oil or engine damage may occur.

  • Page 101: Lubrication Points

    MAINTENANCE Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref Description Where Used Part No. Swivel bracket, transom clamp screws, Extreme Grease tilt tube, throttle and shift cables, 8M0071842 steering cable grease fitting Swivel bracket, transom clamp screws, 2-4-C with PTFE tilt tube, throttle and shift cables, 92-802859A 1...
  • Page 102 MAINTENANCE • Lubricate the throttle and shift cable moving components, pivot locations, and shift detent. 57719 • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting.

  • Page 103: Gearcase Lubrication

    MAINTENANCE 3. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller.
  • Page 104 Standard model gearcase: Approximately 320 ml (10.8 fl oz). Command Thrust model gearcase: Approximately 370 ml (12.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position.

  • Page 105: Checking Power Tilt Fluid

    4530 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).

  • Page 106: Submerged Outboard

    MAINTENANCE Tube Ref Description Where Used Part No. Power Trim and Power tilt 92-858074K01 Steering Fluid Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 107: Storage

    STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 108: Protecting Internal Engine Components

    STORAGE • 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. Corrosion Guard External metal surfaces...

  • Page 109: Battery Storage

    STORAGE • Never carry, store, or transport the outboard in the two positions shown. Engine damage could result from oil draining out of the crankcase. Tiller handle up Front side up 39058 Battery Storage • Follow the battery manufacturer's instructions for storage and charging. •...

  • Page 110: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Blown 20 amp 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. •...

  • Page 111: Performance Loss

    TROUBLESHOOTING c. Stuck anti‑siphon valve located on permanently built in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Low oil pressure. Check the oil level. •...

  • Page 112: 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 113 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 114: Ordering Literature

    Ordering Literature Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:...
  • Page 115 (USA only) P.O. Box 1939 Fond du Lac, WI 54936-1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package. Mercury Marine Submit the following...

  • Page 116: Installation

    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...

  • Page 117: Low Permeation Fuel Hose Requirement

    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 118 INSTALLATION This product must be secured to the transom with the required mounting hardware. If the outboard strikes an underwater object, the required mounting hardware prevents the outboard from propelling off the transom. A decal on the swivel bracket reminds the installer of the potential hazard. WARNING Avoid serious injury or death.
  • Page 119 INSTALLATION 3. Nonpower tilt models ‑ To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts. Drill two 7.9 mm (5/16 in.) holes through‑the‑transom bracket mounting holes. Fasten with two bolts, flat washers, and locknuts. Use a marine waterproofing sealer in the holes and around the bolts to make the installation watertight.

  • Page 120: Remote Control Installation

    INSTALLATION Remote Control Installation STEERING CABLE 1. Lubricate the entire cable end with Mercury Precision or Quicksilver 2‑4‑C with PTFE. 28722 Tube Ref Description Where Used Part No. 2-4-C with PTFE Steering cable end 92-802859A 1 2. Insert the steering cable into the tilt tube.
  • Page 121 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 122: Remote Wire Harness Connection

    INSTALLATION Remote Wire Harness Connection 1. Remove the cover and cable receptacle bracket from the bottom cowl. 28003 Cover Cable receptacle bracket 28107 2. Route the remote wiring harness through the rubber grommet.
  • Page 123 INSTALLATION 3. Open up the clamp in the bottom cowl and position the remote wiring harness below the clamp. Connect the 8 pin connector to the engine harness. Push the clamp down and secure the remote wiring harness into the bottom cowl. 28798 Clamp Remote wiring harness...

  • Page 124: Control Cable Installation

    INSTALLATION Description lb‑in. lb‑ft Cable receptacle bracket Control Cable Installation THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control. 1. Position the remote control handle into full forward throttle position. NOTE: The throttle cable is the second cable to move when moving the control box out of neutral.
  • Page 125 INSTALLATION IMPORTANT: Make sure that the throttle cable end guide does not contact the remote wiring harness when the throttle cable is at full throttle position. If necessary, position and clamp the remote wiring harness. 28079 Cotter pin retainer Flat washer Full throttle stop Throttle lever Cable barrel...
  • Page 126 INSTALLATION b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark ("b") on the cable next to the end guide. c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the end guide with this center mark when installing cable to the engine.
  • Page 127 INSTALLATION 6. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. 28096 Flat washer Cotter pin retainer End guide Center mark Rubber grommet Shift cable Cable barrel Barrel receptacle...

  • Page 128: Battery Installation - Electric Start Models

    INSTALLATION 7. Install the access cover with two bolts. Tighten the bolts to the specified torque. 28097 Access cover Description lb‑in. lb‑ft Access cover bolt 8. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear.

  • Page 129: Battery Connections

    Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Tube Ref Description Where Used Part No.
  • Page 130 INSTALLATION 3. Place a block of wood between gearcase and propeller to prevent rotation and tighten propeller nut. Secure propeller nut to the shaft with the cotter pin. Cotter pin Propeller nut Rear thrust washer Propeller Front thrust washer 27094...

  • Page 131: 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:

Fourstroke 8Fourstroke 9.9Fourstroke 9.9 command thrustFourstroke 9.9 prokicker8 fourstroke9.9 fourstroke ... Show all

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