Mercury 150 Operation, Maintenance And Installation Manual
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Mercury 150 Operation, Maintenance And Installation Manual

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  • Page 1 Operation Maintenance Installation 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 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...

  • Page 7: Table Of Contents

    Low Permeation Fuel Hose Requirement ............23 Quick‑Disconnect Fuel Hose Fitting..............23 EPA Pressurized Portable Fuel Tank Requirements........24 Fuel Demand Valve (FDV) Requirement............24 Mercury Marine's Pressurized Portable Fuel Tank........... 25 Filling Fuel Tank....................26 Engine Oil Recommendations................26 Checking and Adding Engine Oil..............27...
  • Page 8 Stopping the Engine..................42 Maintenance Cleaning Care Recommendations..............43 EPA Emissions Regulations................45 Inspection and Maintenance Schedule............. 46 Maintenance Schedule Decal (150 FourStroke)..........48 Flushing the Cooling System................49 Top Cowl Removal and Installation..............50 Battery Inspection .................... 51 Fuel System...................... 51 Corrosion Control Anode..................
  • Page 9 Battery Will Not Hold Charge................73 Owner Service Assistance Service Assistance................... 74 Ordering Literature.................... 76 Outboard Installation Mercury Marine Validated Engine Mounting Hardware........78 Accessories Mounted to the Transom Clamp Bracket........78 Important Information..................82 Boat Horsepower Capacity................82 Start in Gear Protection..................83 Fuel System......................
  • Page 10 Maintenance Log Maintenance Log.................... 112 viii...

  • 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

    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 13 • Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200 • Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200...

  • Page 14: Outboard Remote Control Models

    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 15: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice Models with steering link rod ‑ The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 16 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 17 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 18: 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 19 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 20: 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 21 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 22: 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 23 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 24: 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 25 (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 26 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 27: 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 62550 Model designation Serial number Certified Europe Insignia (as applicable) Specifications 150 Horsepower Kilowatts Full throttle RPM range 5000–5800 In neutral gear cold 650–800 RPM warm‑up Idle speed in neutral...

  • Page 28: Specifications 150 Seapro

    RPM to compensate for a low battery charge condition. The increased idle RPM will charge the battery at a higher rate. Activating the troll control (optional accessory) will override this low battery charge condition feature. Specifications 150 SeaPro Horsepower Kilowatts Full throttle RPM range 4800–5300...
  • Page 29 GENERAL INFORMATION Gear ratio 1.92:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Right‑hand rotation Gearcase lubricant 830 mL (28.1 fl oz) capacity Left‑hand rotation Engine oil capacity with oil filter replacement 6.0 liters (6.3 US qt) 1000 marine cranking amps (MCA), 800 cold Battery rating...

  • Page 30: Component Identification

    GENERAL INFORMATION Component Identification 47824 Top cowl Engine flush Bottom cowl Auxiliary tilt switch Transom brackets Cooling water intake holes Gearcase Anti‑ventilation plate Driveshaft housing Engine oil drain Water pump indicator hole...

  • Page 31: 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 32: 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 33: 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 34: Epa Pressurized Portable Fuel Tank Requirements

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

  • Page 35: 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 36: Filling Fuel Tank

    As an optional choice, Mercury or Quicksilver SAE 25W‑40 Mineral Marine 4‑Stroke Engine Oil or SAE 25W‑40 Synthetic Blend Marine 4‑Stroke engine oil may be used. If the recommended Mercury or Quicksilver NMMA FC‑W certified oils are not available, a major outboard manufacturer's brand of NMMA FC‑W certified 4‑Stroke outboard oil of similar...

  • Page 37: Checking And Adding Engine Oil

    FUEL AND OIL IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives are not recommended.
  • Page 38 FUEL AND OIL IMPORTANT: Do not try to fill the oil level to the top bar. Oil level is correct as long as it appears in the operating range (between the top bar and bottom bar). 47403 Oil level operating range Top bar Bottom bar Upper 1/3 level...
  • Page 39 FUEL AND OIL 8. Install the oil fill cap hand‑tight. 9. Install the top cowl.

  • Page 40: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 58240 Trim/tilt switch –...
  • Page 41 FEATURES AND CONTROLS It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present. For visual display of the specific engine functions and additional engine data, refer to SmartCraft Product information, following.

  • Page 42: Power Trim And Tilt

    FEATURES AND CONTROLS SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.
  • Page 43 FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control.
  • Page 44 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 47705 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.

  • Page 45: Propeller Steering Torque-Trim Tab Adjustment

    FEATURES AND CONTROLS NOTICE Operating the engine with the outboard in the tilt range can damage the engine or the transom. If operating the engine in the tilt range, such as in shallow water, do not exceed 2000 RPM. 1. Reduce the engine speed below 2000 RPM. 2.

  • Page 46: 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 47: 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 48: 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 49: 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 two hours of operation, run the engine at varied throttle settings up to 4500 RPM or at three‑quarter throttle, and at full throttle for approximately one minute every ten minutes.
  • Page 50 OPERATION 3. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 4. Set the lanyard stop switch to the RUN position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to neutral (N) position. 58237 6.
  • Page 51 OPERATION 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 position for approximately five seconds. Turn the key to the START position and release it, the engine will crank for a maximum of eight seconds.

  • Page 52: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift the outboard into or out of gear unless the engine speed is at idle. Shifting at higher than engine idle speed could cause damage to the gearcase. • Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed.

  • Page 53: Maintenance

    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 54 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 55: 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 56: 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 BEFORE EACH USE • Check engine oil level. Refer to Fuel and Oil ‑ Checking and Adding Engine Oil.
  • Page 57 MAINTENANCE • Check low‑pressure fuel filter for contaminants. Replace filter if required. Refer to Fuel System. • Remove the propeller and lubricate the propeller shaft. Refer to Propeller Replacement. • Inspect the condition of propeller bore sleeve when the propeller is removed.

  • Page 58: Maintenance Schedule Decal (150 Fourstroke)

    Replace the spark plugs. BEFORE PERIODS OF STORAGE • Refer to Storage section. Maintenance Schedule Decal (150 FourStroke) The following table shows the icons and a general description of the maintenance schedule decal located on the engine. 58260 Replace the water pump impeller more often if overheating occurs or reduced water pressure is noted.

  • Page 59: Flushing The Cooling System

    MAINTENANCE Icon Definition Icon Definition Replace Inspect 58250 58249 Engine oil and filter Gearcase lubricant 58251 58252 Spark plugs Thermostat 58253 58254 Low pressure fuel filter Anodes 58256 58255 Accessory drive belt Water pump impeller 58257 58258 Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water.

  • Page 60: Top Cowl Removal And Installation

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

  • Page 61: Battery Inspection

    MAINTENANCE 2. Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply pressure to the back of the cowl to lock it in place. Ensure the cowl is securely fastened by trying to pull up on the back of the cowl.
  • Page 62 MAINTENANCE 3. Inspect any completed service work for sign of fuel leakage. 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.

  • Page 63: Corrosion Control Anode

    MAINTENANCE 6. Remove the fuel filter from the lift handle. 47441 Fuel hose release tab Low‑pressure fuel filter Hose holder Installation 1. Place the lift handle onto the fuel filter. Install the new fuel filter so the arrow points towards the engine. 2.

  • Page 64: Propeller Bore Sleeve Inspection-If Equipped

    MAINTENANCE Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 47569 Propeller Bore Sleeve Inspection—If Equipped The propeller bore sleeve is an important integral component of the gear housing and should be inspected when the propeller is removed.

  • Page 65: Propeller Replacement

    MAINTENANCE Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
  • Page 66 MAINTENANCE 5. Coat the propeller shaft with Extreme Grease or 2‑4‑C with PTFE. 47623 Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in saltwater, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed.
  • Page 67 MAINTENANCE 3. Secure the locknut by bending the tabs up against the locknuts. 45232 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer Locknut Raised pins Tabs bent against the locknut Description lb‑in. lb‑ft Propeller nut – 55.3 FLO-TORQ IV PROPELLERS 1.

  • Page 68: Spark Plug Inspection And Replacement

    MAINTENANCE 3. Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter. 45248 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer Locknut Tabs bent into grooves Description lb‑in. lb‑ft Propeller nut –...
  • Page 69 MAINTENANCE 2. Remove the spark plugs to inspect. 47662 3. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode. IMPORTANT: The color of the plug may not accurately reflect its condition.

  • Page 70: Fuse Replacement

    MAINTENANCE a. All of the spark plugs should have the gap checked and corrected as necessary before installation. b. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap. c.
  • Page 71 MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 47408 Cover Spare fuse holders Fuse holder Fuse 4 ‑...

  • Page 72: Alternator Drive Belt Inspection

    MAINTENANCE Alternator Drive Belt Inspection 1. Remove the three screws that fastens the flywheel cover to the engine. Lift the flywheel cover off the engine. Flywheel cover Screws (3) 47585 2. Inspect the alternator drive belt. Alternator drive belt 47588 3.
  • Page 73 MAINTENANCE 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. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
  • Page 74 MAINTENANCE • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 47651 Fitting Steering cable end WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

  • Page 75: Checking Power Trim Fluid

    47646 2. Remove the fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
  • Page 76 MAINTENANCE 3. Use a 16 mm (5/8 in.) wrench and loosen the oil drain valve so that it can be turned by hand. Be careful not to open the valve too far allowing oil to drain. 4. Attach a 12 mm (7/16 in.) I.D. drain hose to the oil drain valve. Position the opposite end of the hose into an appropriate container.
  • Page 77 MAINTENANCE 5. Clean the oil filter mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. Loosen Oil filter Oil trough Drain hose 47562 OIL FILLING...

  • Page 78: Gearcase Lubrication

    Right‑hand rotation 830 ml (28.1 fl oz) Left‑hand rotation 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. 2. Remove the vent plug/sealing washer.
  • Page 79 MAINTENANCE 3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole. 22693 Vent hole Fill hole IMPORTANT: Replace the sealing washers if damaged. 4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube.

  • Page 80: 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 81: Protecting Internal Engine Components

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

  • Page 82: Troubleshooting

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

  • Page 83: Performance Loss

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

  • Page 84: 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 85 OWNER SERVICE ASSISTANCE RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.

  • Page 86: Ordering Literature

    Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 87 OWNER SERVICE ASSISTANCE Mercury Marine Submit the following Attn: Publications Department order form with payment W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Copy this form and print or type–This is your shipping label) Name...

  • Page 88: Outboard Installation

    51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the same fasteners that secure the outboard to the transom or jack plate.
  • Page 89 OUTBOARD INSTALLATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
  • Page 90 OUTBOARD INSTALLATION • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners...
  • Page 91 OUTBOARD INSTALLATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition.

  • Page 92: Important Information

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

  • Page 93: Start In Gear Protection

    OUTBOARD INSTALLATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S.
  • Page 94 OUTBOARD INSTALLATION EPA PRESSURIZED PORTABLE FUEL TANK REQUIREMENTS The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following: •...
  • Page 95 OUTBOARD INSTALLATION Priming the FSM with a Fuel Pressure Gauge The use of a purge tool for priming the FSM is the preferred method, but is not always practical. The objective is to purge the air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port.
  • Page 96 OUTBOARD INSTALLATION 4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel. 58370 Fuel pressure gauge purge valve Schrader valve Purge hose to appropriate container 5. Open the fuel pressure gauge purge valve and turn the ignition key on. The fuel pumps will run for approximately three to five seconds.
  • Page 97 OUTBOARD INSTALLATION Priming the FSM (Ran out of Fuel Condition) The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is void of fuel volume, it can be primed without the use of a purge tool.

  • Page 98: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.2 cm (33 in.) Dual engine 149.9 cm (59 in.) Lifting Outboard 1. Remove the top cowl. 2.

  • Page 99: Shipping Bracket Removal

    OUTBOARD INSTALLATION Flywheel Puller/Lifting Ring 91‑895343T02 Removes flywheel from engine. Used for lifting powerhead/engine. 14869 Shipping Bracket Removal 1. Remove the two top screws and loosen the two bottom screws. 2. Slide the shipping bracket off the bottom screws. 3. Tighten the bottom screws to the specified torque. 47720 Shipping bracket Top screws...

  • Page 100: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate O‑ring seal and entire cable end. 3724 Tube Ref Description Where Used Part No. 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1 2. Insert steering cable into tilt tube. 3.
  • Page 101 OUTBOARD INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

  • Page 102: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height...

  • Page 103: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions This line may be preferred to determine outboard mounting height dimension, if maximum speed is the only objective This line may be preferred to determine outboard mounting height dimension for dual outboard installation Outboard mounting height (height of outboard mounting brackets from...
  • Page 104 OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 105: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 8M0071543 Outboard mounting bolt ½‑20 x 5.00 in. long (3.25 in. thread) 826711‑17 Nylon insert locknut ½‑20 28421 Flat washer 1.50 in.
  • Page 106 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 107 OUTBOARD INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 108 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 109 OUTBOARD INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 110: Electrical, Fuel Hose, And Control Cables

    OUTBOARD INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Electrical, Fuel Hose, and Control Cables RIGGING GROMMET Installation IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, that are routed between the rigging grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.
  • Page 111 OUTBOARD INSTALLATION 1. Route the hoses, wiring, and cables through the rigging adapter and correct opening in the rigging grommet as shown. 47374 Screw (2) Rigging adapter Rigging grommet Speedometer tube opening Remote 14 pin boat harness opening Battery cable opening Accessory harness opening Shift cable opening Fuel hose opening...
  • Page 112 OUTBOARD INSTALLATION NOTICE Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring harnesses. Cable tie 47753 Description lb‑in. lb‑ft Screws for attaching the rigging –...
  • Page 113 OUTBOARD INSTALLATION SMARTCRAFT HARNESS AND VESSEL HARNESS CONNECTION If the boat is equipped with a SmartCraft and/or vessel (accessory) harness, route the wiring harness through the rigging grommet and connect it to the connector on the engine. Vessel (accessory) harness connector SmartCraft harness connector 47723...
  • Page 114 OUTBOARD INSTALLATION Maximum Length American Wire Gauge (AWG) Meter (Feet) 24.4 m (80 ft) Single Outboard Red sleeve ‑ positive Black sleeve ‑ negative (–) Cranking battery 15496...
  • Page 115 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ positive (+) Black sleeve ‑ negative (–) Ground cable Cranking battery FUEL HOSE CONNECTION Fasten the remote fuel hose to fitting with a hose clamp.
  • Page 116 OUTBOARD INSTALLATION Fuel Hose Size Minimum fuel hose inside diameter (ID) is 9.5 mm (3/8 in.) with separate fuel hose/fuel tank pickup for each engine. Hose clamp Remote fuel hose 47751 SHIFT CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control.
  • Page 117 OUTBOARD INSTALLATION 3. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to the neutral position.
  • Page 118 OUTBOARD INSTALLATION 8. Secure the shift cable to the anchor pin with the bow tie clip retainer. 47743 Shift cable end guide Bow tie clip retainer Center mark Cable barrel Barrel cup...
  • Page 119 OUTBOARD INSTALLATION 9. Lock the barrel in place with the cable latch. 47744 Cable latch 10. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b.
  • Page 120 OUTBOARD INSTALLATION 1. Shift remote control into the neutral (N) position. 58237 2. Fit the throttle cable through the rigging grommet. 47739 3. Install the throttle cable to the throttle arm with the bow tie clip retainer. 4. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
  • Page 121 OUTBOARD INSTALLATION 5. Place the barrel cup onto the barrel. Place the cable barrel and barrel cup into the barrel retainer. 47747 Bow tie retainer Throttle cable end guide Cable barrel Barrel cup 6. Lock the cable in place with the cable latch. Cable latch 47748...
  • Page 122 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:

150 seapro fourstroke

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