Mercury 135 Verado FourStroke Operation And Maintenance Manual
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Mercury 135 Verado FourStroke Operation And Maintenance Manual

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Summary of Contents for Mercury 135 Verado FourStroke

  • Page 1 Operation Maintenance Manual...

  • Page 3: Read This Manual Thoroughly

    Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Name / function: John Pfeifer, President, Mercury Marine...
  • Page 4 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 Manual included with the product. The Warranty Manual contains a description of what is...
  • Page 5 Identification Records Please record the following applicable information: Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Boat Model Length Exhaust Gas Emissions Certification Number (Europe Only)

  • Page 7: Table Of Contents

    Low Permeation Fuel Hose Requirement ............21 EPA Pressurized Portable Fuel Tank Requirements........21 Fuel Demand Valve (FDV) Requirement............22 Mercury Marine's Pressurized Portable Fuel Tank........... 22 Filling Fuel Tank....................23 Engine Oil Recommendations................24 Checking and Adding Engine Oil..............24...
  • Page 8 Features and Controls Panel Mount Control Features and Operation..........27 Slim Binnacle Control Features and Operation..........29 Dual‑Handle Console Control Features and Operation........35 Shadow Mode Control with CAN Trackpad Features and Operation....43 Warning System....................46 Power Trim and Tilt................... 48 Operation Important Daily Inspection Before Each Use ...........
  • Page 9 Maintenance Cleaning Care Recommendations..............60 EPA Emissions Regulations................62 Inspection and Maintenance Schedule............. 63 Flushing the Cooling System................64 Top Cowl Removal and Installation..............65 Battery Inspection .................... 65 Verado Engine Battery Specifications.............. 66 Air Filter......................67 Fuel System...................... 71 Corrosion Control Anode..................
  • Page 10 Parts and Accessories Inquiries............... 98 Service Assistance................... 98 Ordering Literature..................100 Installation Information Mercury Marine Validated Engine Mounting Hardware........102 Accessories Mounted to the Transom Clamp Bracket........102 Fastening the Outboard to the Transom............106 Installing Outboard..................111 Propeller Selection..................112 Maintenance Log Maintenance Log....................

  • Page 11: 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 12: High-Speed And High-Performance Boat Operation

    Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start‑in‑gear protection is provided by the remote control system.
  • Page 13 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 14 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 15: 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 16 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 17: 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 18 GENERAL INFORMATION 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 that could be struck by the outboard or the boat bottom. The most significant action you can take to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 19: Exhaust Emissions

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Exhaust Emissions...
  • Page 20 GENERAL INFORMATION Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing).

  • Page 21: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 22 (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 23 GENERAL INFORMATION • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the...

  • Page 24: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard, as shown. XXXXXXXXX XXXXXXXX XXXX 62548 Model designation Serial number Certified Europe Insignia (as applicable) 135/150/175/200 Verado FourStroke Specifications Models Horsepower Kilowatts...
  • Page 25 GENERAL INFORMATION Models Recommended Refer to Fuel and Oil gasoline Recommended oil Refer to Fuel and Oil Right‑hand rotation gearcase lubricant 970 mL (32.8 fl oz) capacity Left‑hand rotation gearcase lubricant 900 mL (30.4 fl oz) capacity Engine oil capacity with oil filter 6.0 liter (6.3 US qt) replacement...

  • Page 26: Component Identification

    GENERAL INFORMATION Component Identification 14811 Engine flush Auxiliary tilt switch Top cowl Bottom cowl Engine oil drain Anti‑ventilation plate Gearcase Cooling water intake holes Transom brackets Tilt lock level...

  • Page 27: Propeller Selection

    When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer.
  • Page 28 PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats. Stainless steel is over five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies.

  • Page 29: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations.

  • Page 30: Fuel And Oil

    USA is alcohol (ethanol, methanol, or butanol). GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 31: Fuel Additives

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

  • Page 32: Fuel Demand Valve (Fdv) Requirement

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

  • Page 33: Filling Fuel Tank

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

  • Page 34: Engine Oil Recommendations

    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.
  • Page 35 FUEL AND OIL 5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region). IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region).
  • Page 36 FUEL AND OIL 7. Push the dipstick back in all the way. 8. Install the oil fill cap hand tight. 9. Install the top cowl.

  • Page 37: Features And Controls

    FEATURES AND CONTROLS Panel Mount Control Features and Operation 1. Operation of the shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear.
  • Page 38 FEATURES AND CONTROLS 4. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.

  • Page 39: Slim Binnacle Control Features And Operation

    FEATURES AND CONTROLS 7. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water.
  • Page 40 FEATURES AND CONTROLS 2. Trim Switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM.
  • Page 41 FEATURES AND CONTROLS Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. STOP/ START DOCK TRANSFER THROTTLE - ONLY 52365 Slim binnacle ERC Item Control Function Trim control Raises and lowers the engine for best efficiency, or (handle) for conditions such as shallow water, trailering, etc.
  • Page 42 FEATURES AND CONTROLS HELM TRANSFER Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to another helm.
  • Page 43 FEATURES AND CONTROLS 1. At the helm you are requesting be made active and with the ERC levers in neutral, press the transfer button one time. After the transfer button is pressed, the transfer button light turns on and one beep will sound confirming the impending transfer.
  • Page 44 FEATURES AND CONTROLS 3. Place either ERC lever into gear. The warning horn will beep each time the lever is moved in and out of gear while in throttle only, but will remain in neutral. 4. The RPM of the engines can be increased. NOTE: Pressing the "Throttle‑Only"...

  • Page 45: Dual-Handle Console Control Features And Operation

    FEATURES AND CONTROLS Dual‑Handle Console Control Features and Operation DUAL-HANDLE ELECTRONIC REMOTE CONTROL (ERC)— OPERATION AND ADJUSTMENT Operation The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear.
  • Page 46 FEATURES AND CONTROLS To adjust handle tension: 1. Remove the side cover plugs of the handle that needs adjustment. 2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension. 3. Adjust to the tension desired. Detent tension adjustment screw Handle tension...
  • Page 47 FEATURES AND CONTROLS SPECIAL DIGITAL THROTTLE AND SHIFT (DTS) FEATURES The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously. 55232 Dual engine ERC Item Control Function Trim control Raises and lowers the engines for best efficiency, or (handle)
  • Page 48 FEATURES AND CONTROLS Item Control Function Enables the throttle and shift functions of both engines 1 LEVER to be controlled by the port lever. Turns off or on the auto‑synchronization feature. Refer SYNC to Sync. NOTE: Not all functions may be active. Dock Dock mode reduces throttle capacity to approximately 50% of normal throttle demand, allowing finer control of engine power in close quarter situations.
  • Page 49 FEATURES AND CONTROLS 2. Press the THROTTLE ONLY button. The button light will turn on and the neutral lights will blink. 3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in throttle only, but will remain in neutral.
  • Page 50 FEATURES AND CONTROLS Sync Sync is an automatic engine synchronization feature that is always on unless it is turned off. Sync monitors the position of both ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM.
  • Page 51 FEATURES AND CONTROLS Transfer (Boats equipped with dual helms) The TRANSFER button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer. 51858 TRANSFER button HELM TRANSFER...
  • Page 52 FEATURES AND CONTROLS NOTICE The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects nearby resulting in damage. Keep an adequate look out while performing the helm transfer. To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items or when near other vessels.

  • Page 53: Shadow Mode Control With Can Trackpad Features And Operation

    FEATURES AND CONTROLS Shadow Mode Control with CAN Trackpad Features and Operation TRIPLE ENGINE THROTTLE AND SHIFT OPERATION Movement of the handles on the remote control allows the boat operator to control the engine throttle speed and gear shift positions of all three engines. The throttle and shift function is dependant on what engines are running.
  • Page 54 FEATURES AND CONTROLS Turning off one of the outer engines while underway will cause the center engine to go into forced neutral/idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral position and then engaging.
  • Page 55 FEATURES AND CONTROLS Port Starboard Port Outer Starboard Inner Inner Control Handle Function Engine Outer Engine Engine Engine Off (ignition Port inner engine throttle key switch Running Running Running and shift = controlled by turned on) port control handle Starboard inner engine Off (ignition throttle and shift = Running...

  • Page 56: Warning System

    FEATURES AND CONTROLS Turning off one of the inner engines while underway will have no effect on the operation of the outer engines. If a failure should occur while underway which causes the starboard outer engine into forced neutral/idle condition, the inner starboard engine will also be forced to neutral/idle.
  • Page 57 2. Engage the throttle. If the engine does not respond, repeat step one. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.

  • Page 58: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt The 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. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard further away from the boat transom is called trimming out or up.
  • Page 59 FEATURES AND CONTROLS WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully.
  • Page 60 FEATURES AND CONTROLS TRIM WITHOUT KEY Trim without key is a method of allowing trim operation after the ignition key switch is turned off. The command module and PCM remain powered and are able to process trim requests for up to 15 minutes after the key switch is turned off.
  • Page 61 FEATURES AND CONTROLS MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve three turns counterclockwise.

  • Page 62: Operation

    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.

  • Page 63: Operating In Freezing Temperatures

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

  • Page 64: Setting Trim Angle While Running Engine At Idle Speed

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

  • Page 65: Starting The Engine

    OPERATION Starting the Engine Before starting, read the Pre‑Starting Check List, special operating instructions, Engine Break‑in Procedure, and Gear Shifting in the Operation section and the remote control features and operation in the Features and Controls section. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
  • Page 66 OPERATION 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to neutral (N) position. 3413 3417 NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON"...

  • Page 67: Gear Shifting

    OPERATION 7. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole. 15301 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.
  • Page 68 OPERATION • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). 3427 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position.

  • Page 69: Stopping The Engine

    OPERATION • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). 3417 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Advance the control lever to further increase speed. Stopping the Engine IMPORTANT: Turning key to the "START"...

  • Page 70: Cleaning Care Recommendations

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package.
  • Page 71 Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 72: Epa Emissions Regulations

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

  • Page 73: Inspection And Maintenance Schedule

    MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Inspection and Maintenance Schedule DAILY CHECKS • Check the engine oil level • Check the lanyard stop switch •...

  • Page 74: Flushing The Cooling System

    MAINTENANCE • Check the remote control cable adjustment, if applicable—dealer item • Replace the high‑pressure fuel filter—dealer item • Replace the accessory drive belt—dealer item • Check the power trim fluid level—dealer item • Inspect the engine motor mounts—dealer item Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water.

  • Page 75: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation REMOVAL Unlock the top cowl by pulling out on the rear cowl latch. Lift the top cowl off the engine. 29767 INSTALLATION Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply downward pressure to the back of the cowl to lock it in place.

  • Page 76: Verado Engine Battery Specifications

    IMPORTANT: Verado engines require a 12‑volt absorbed glass mat (AGM) marine starting battery that meets the minimum ratings. For best performance, Mercury Marine does not recommend using the more common flooded (wet cell) or gel cell type lead acid batteries for starting Verado engines.

  • Page 77: Air Filter

    MAINTENANCE WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.
  • Page 78 MAINTENANCE 2. Remove the bolts securing the flywheel cover to the rear mounting posts. 15247 Flywheel cover bolt and washer (2) FSM vent hose Crankcase ventilation hose 3. Lift the flywheel cover off the front mounting post and the intake resonator.
  • Page 79 MAINTENANCE 6. Remove the air filter from the lower flywheel cover assembly. Flywheel cover subassembly Air filter 14145 AIR FILTER INSTALLATION 1. Install the air filter onto the flywheel cover subassembly. Flywheel cover subassembly Air filter 14145...
  • Page 80 MAINTENANCE 2. Install the upper half of the flywheel cover subassembly to the lower flywheel cover subassembly. Ensure the upper flywheel cover latch opening is properly secured to the lower flywheel cover. Upper flywheel cover latch opening Lower flywheel cover latch 14314 3.

  • Page 81: Fuel System

    MAINTENANCE 6. Secure the flywheel cover to the rear mounting posts with two bolts with washers. Tighten bolts to the specified torque. 15247 Flywheel cover bolt and washer (2) FSM vent hose Crankcase ventilation hose Description lb‑in. lb‑ft Flywheel cover bolt 88.5 –...
  • Page 82 MAINTENANCE FUEL LINE INSPECTION Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line must be replaced. WATER SEPARATING FUEL FILTER NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
  • Page 83 MAINTENANCE 3. Place a rag or towel around the valve, release pressure by pushing core of valve end in. 13282 4. Unscrew the filter in a counterclockwise direction to remove. 14762 Filter Draining 1. Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter holder.

  • Page 84: Corrosion Control Anode

    MAINTENANCE 2. Tip the filter holder to drain any fluid into an approved container. 13468 Filter Installation 1. Position filter holder onto bracket and secure filter holder in place. 2. Lubricate the sealing ring on the filter with oil. 3. Install the filter and tighten securely by hand. IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition key to the "RUN"...

  • Page 85: Propeller Replacement

    MAINTENANCE Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. Two anodes are located on each side of the gearcase.
  • Page 86 4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. 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 87: Spark Plug Inspection And Replacement

    MAINTENANCE 9. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection and Replacement NOTE: To gain access to the bottom spark plug, remove the rear cover and rear cowl lock. COWL LOCK AND REAR COVER REMOVAL 1.
  • Page 88 MAINTENANCE 4. Remove the six screws securing the cowl lock and remove the lock. Retain the two hex nuts that are used to fasten the top two screws. 29739 Rear cover Pry point (arrow) Cowl lock SPARK PLUG REMOVAL AND INSPECTION 1.
  • Page 89 MAINTENANCE 3. Remove the spark plugs to inspect. 20753 4. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode. IMPORTANT: The color of the plug may not accurately reflect its condition.
  • Page 90 MAINTENANCE a. All of the spark plugs should have the gap checked and corrected as necessary before installation. b. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap. c.

  • Page 91: Fuses

    MAINTENANCE Description lb‑in. lb‑ft Rear cowl latch ‑ top screws with – hex nuts (2) Rear cover ‑ screws (2) – Pivot screw – 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.

  • Page 92: Steering Link Rod Fasteners

    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 ("a" ‑ Part Number 10‑849838) and self‑locking nylon insert locknuts ("c" & "d" ‑ Part Number 11‑826709113).

  • Page 93: Dts Wiring System

    MAINTENANCE Assemble the steering link rod to the engine with special washer head bolt and self‑locking nylon insert locknut. First torque the bolt, then torque the locknut to specifications. DTS Wiring System WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring.
  • Page 94 MAINTENANCE • Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets. 28458 2. 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...
  • Page 95 29759 • Tilt Tube ‑ Lubricate through fitting. Tilt tube fitting 29757 4. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Extreme Grease. 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.

  • Page 96: Checking Power Trim Fluid

    MAINTENANCE • Steering Cable ‑ Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through the fitting. Fitting Cable end 29763 5. Lubricate the following with lightweight oil. • Steering Link Rod Pivot Points ‑ Lubricate pivot points. 29765 Checking Power Trim Fluid 1.

  • Page 97: Checking Power Steering Fluid

    MAINTENANCE 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 Lubricant Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 98: Changing Engine Oil

    MAINTENANCE Remove the power steering cover and fill cap to check the fluid level. The fluid level should be slightly below the bottom of the fill hole. Use Synthetic Power Steering Fluid SAE 0W‑30, if needed. 29315 Power steering cover Fill cap Fill/full level Tube Ref...
  • Page 99 MAINTENANCE Crankcase Oil Pump 91‑90265A 5 Aids in the removal of engine oil without draining the crankcase. 11591 4. Pump out the engine oil into an appropriate container. DRAIN METHOD 1. Tilt outboard up to the trailer position. 2. Turn the outboard so the drain hole is facing downward. 3.
  • Page 100 MAINTENANCE 3. Unscrew old filter using oil filter wrench and turning the filter counterclockwise. 14772 Oil Filter Wrench 91‑802653Q02 Assists in removal of oil filter. 5221 4. Clean the oil filter mounting base. 5. Apply a film of clean oil to filter gasket. Do not use grease. 6.

  • Page 101: Gearcase Lubrication

    MAINTENANCE OIL FILLING 1. Remove the oil fill cap and add recommended oil to the midpoint of the operating range (midpoint of cross hatched region). Adding approximately 6 liter (6.3 US qt) will bring oil level to midpoint of cross hatched region. 14770 2.
  • Page 102 Gearcase lubricant capacity is approximately 970 ml (32.8 fl oz) for right hand rotation gearcases and 900 ml (30.4 fl oz) for left hand rotation gearcases. GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position.
  • Page 103 MAINTENANCE 4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove the lubricant tube and install cleaned fill/drain plug and sealing washer.

  • Page 104: Storage Preparation

    Stabilizer Protecting External Outboard Components • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref Description Where Used Part No.

  • Page 105: Protecting Internal Engine Components

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

  • Page 106: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in RUN position. • Blown 5‑amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Remote control is not shifted to the neutral position. •...

  • Page 107: Performance Loss

    TROUBLESHOOTING a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c. Stuck anti‑siphon valve located on permanently built‑in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel system is not primed. •...

  • Page 108: 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 109 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 110: Ordering Literature

    OWNER SERVICE ASSISTANCE CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English +1 920 929 5040...
  • Page 111 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...

  • Page 112: Installation Information

    51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the same fasteners that secure the outboard to the transom or jack plate.
  • Page 113 INSTALLATION INFORMATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
  • Page 114 INSTALLATION INFORMATION • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners...
  • Page 115 INSTALLATION INFORMATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition.

  • Page 116: Fastening The Outboard To The Transom

    INSTALLATION INFORMATION 3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4. Figure 4 Boat transom or jack plate Transom clamp bracket Wedge/plate 54058 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑...
  • Page 117 INSTALLATION INFORMATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 118 INSTALLATION INFORMATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 119 Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area.
  • Page 120 INSTALLATION INFORMATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 121: Installing Outboard

    INSTALLATION INFORMATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Installing Outboard WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death.

  • Page 122: Propeller Selection

    INSTALLATION INFORMATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information ‑...

  • Page 123: 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:

175 verado fourstroke200 verado fourstroke150 verado fourstroke400r verado fourstroke

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