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 ............22 EPA Pressurized Portable Fuel Tank Requirements........22 Fuel Demand Valve (FDV) Requirement............22 Mercury Marine's Pressurized Portable Fuel Tank........... 23 Filling Remote Oil Tank..................24 Filling Engine‑Mounted Oil Reservoir Tank............24 Filling Fuel Tank....................25...
  • Page 8 Features and Controls Remote Control Features................. 26 Warning System....................26 Power Trim and Tilt................... 29 Operation Important Information..................33 Prestarting Check List..................34 Operating in Freezing Temperatures..............34 Operating in Saltwater or Polluted Water............34 Operating at High Elevations................35 Setting Trim Angle While Running Engine at Idle Speed.........
  • Page 9 Battery Will Not Hold Charge................65 Owner Service Assistance Service Assistance................... 66 Ordering Literature.................... 68 Outboard Installation Mercury Marine Validated Engine Mounting Hardware........70 Accessories Mounted to the Transom Clamp Bracket........70 Boat Horsepower Capacity................74 Start in Gear Protection..................74 Fuel System...................... 75 Installation Specifications.................
  • Page 10 Maintenance Log Maintenance Log.................... 104 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 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: 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 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 GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 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: Recording Serial Number

    GENERAL INFORMATION Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.

  • Page 27: Specifications

    *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

  • Page 28: Component Identification

    GENERAL INFORMATION Component Identification Top cowl Auxiliary tilt switch Transom brackets Gearcase Cooling water intake holes Trim tab Anti‑ventilation plate Driveshaft housing Water pump indicator hole Bottom cowl 29461...

  • 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: Oil Recommendation

    Outboard Oil Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended for your engine. If Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium Plus 2‑Cycle Oil. Severe engine damage may result from use of an inferior oil.

  • Page 32: Avoiding Fuel Flow Restriction

    FUEL AND OIL Avoiding Fuel Flow Restriction IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.

  • Page 33: Mercury Marine's Pressurized Portable Fuel Tank

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

  • Page 34: Filling Remote Oil Tank

    FUEL AND OIL DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening.

  • Page 35: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill the fuel tanks outdoors away from heat, sparks, and open flames.

  • Page 36: 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. 26800 Control handle –...
  • Page 37 FEATURES AND CONTROLS 1. Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian system may engage and protect the engine by limiting power. You should return to port immediately and contact your servicing dealer. 2.
  • Page 38 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 39: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.
  • Page 40 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 41 FEATURES AND CONTROLS TILTING OPERATION To tilt the outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. 1.
  • Page 42 FEATURES AND CONTROLS 3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range. AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system.

  • Page 43: Operation

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

  • Page 44: Prestarting Check List

    IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3.

  • Page 45: Operating At High Elevations

    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 46: Starting The Engine

    OPERATION Break‑in Procedure • Avoid using a hydraulic jack plate to raise the engine during the break‑in cycle. Next Three Hours: Change the engine speed every 10 minutes. Starting the Engine Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑in Procedure in the Operation section.
  • Page 47 OPERATION 4. Set the lanyard stop switch to the RUN position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift the outboard to the neutral (N) position. 26838 6. For the 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: a.

  • Page 48: Gear Shifting

    OPERATION 8. Turn the ignition key to START position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to OFF position, wait one second and try again. 19804 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting.

  • Page 49: Stopping The Engine

    OPERATION • After shifting the outboard into gear, advance the lever further to increase speed. Stopping the Engine Reduce the engine speed and shift the outboard to neutral position. Turn the ignition key to "OFF" position. 26843...

  • Page 50: 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 51 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 52: 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 53: 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 54: Flushing The Cooling System

    MAINTENANCE • Check the remote control cable adjustment, if equipped—dealer item • Replace the high‑pressure fuel filter, if equipped—dealer item • Replace the accessory drive belt, if equipped—dealer item • Check the power trim fluid level, if equipped—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...

  • Page 55: Flywheel Cover Removal And Installation

    MAINTENANCE INSTALLATION 1. Engage the front hook and push cowl back over the cowl seal. 2. Push cowl down and move the rear latch lever down to lock. Flywheel Cover Removal and Installation REMOVAL 1. Remove the flywheel cover by lifting off. 2.
  • Page 56 MAINTENANCE Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well‑ventilated area.

  • Page 57: 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 a special washer head bolt ("a" ‑ Part Number 10‑849838) and self‑locking nylon insert locknuts ("c" and "d" ‑ Part Number 11‑826709113).

  • Page 58: Fuse Replacement

    MAINTENANCE Assemble steering link rod to engine with special washer head bolt and self‑locking nylon insert locknut. First torque bolt, then torque locknut to specifications. Fuse Replacement IMPORTANT: Always carry spare 5 and 20 AMP fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring.

  • Page 59: Battery Inspection

    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. The gearcase has two corrosion control anodes, one on each side.
  • Page 60 MAINTENANCE 1. Shift the outboard to neutral (N) position. 26838 IMPORTANT: Refer to Spark Plug Inspection and Replacement for removing spark plug leads. 2. Remove the spark plug leads to prevent the engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900 4.
  • Page 61 MAINTENANCE 5. Pull the propeller off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref Description...

  • Page 62: Spark Plug Inspection And Replacement

    MAINTENANCE 9. Secure the propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.
  • Page 63 MAINTENANCE IMPORTANT: The color of the plug may not accurately reflect its condition. To accurately diagnose a faulty plug, inspect the precious metal on the plug's electrode. If no precious metal is visible, replace the plug. 9381 Precious metal 3. Set the spark plug gap. Refer to Specifications. 27848 a.

  • Page 64: Compressor Air Intake Filter

    MAINTENANCE Description lb‑in. lb‑ft Spark plug – Compressor Air Intake Filter The filter should be changed every 100 hours of operation, or once a season. IMPORTANT: Never run the engine without the air filter. REMOVAL 1. Remove the flywheel cover from the engine. 2.

  • Page 65: Lubrication Points

    MAINTENANCE • Signs of wear on edges or outer surfaces of belt. 29398 Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. 2-4-C with PTFE Trim rod ball ends 92-802859A 1 • Trim rod ball ends ‑ Turn the ball ends to work the lubricant into the ball sockets.
  • Page 66 MAINTENANCE • 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. 26902 3. Lubricate the following with 2‑4‑C with PTFE. Tube Ref Description Where Used...
  • Page 67 MAINTENANCE • Tilt tube ‑ Lubricate through the fitting. 27874 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 68: Checking Power Trim Fluid

    27877 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 69 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 665 ml (22.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position. 2. Remove the vent plug.

  • Page 70: Submerged Outboard

    MAINTENANCE 5. Remove the lubricant tube and install cleaned fill/drain plug and sealing washer. 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 71: Storage Preparation

    • 8 cc (0.27 oz) or two teaspoons of Mercury Precision Quickleen lubricant. • 8 cc (0.27 oz) or two teaspoons of Mercury Precision Fuel Stabilizer. 5. Pour this mixture in a new water separating fuel filter. Install the fuel filter.

  • Page 72: Protecting Internal Engine Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref Description Where Used Part No.

  • Page 73: Battery Storage

    STORAGE NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.

  • Page 74: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20‑amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure.

  • Page 75: Performance Loss

    TROUBLESHOOTING d. Fuel line is kinked or pinched. e. Injector plugged. • Threaded connection of an air hose is loose. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged propeller or improper propeller size. •...

  • Page 76: 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 77 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 78: 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 79 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 80: 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 81 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 82 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 83 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 84: Boat Horsepower Capacity

    OUTBOARD INSTALLATION 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 Boat Horsepower Capacity WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death.

  • Page 85: Fuel System

    OUTBOARD INSTALLATION The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting in gear. Fuel System AVOIDING FUEL FLOW RESTRICTION IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow.
  • Page 86 OUTBOARD INSTALLATION The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve. Fuel demand valve ‑ installed in the fuel hose between the fuel tank and primer bulb Manual release Vent/water drain holes...

  • Page 87: 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 84.8 cm (33‑3/8 in.) Dual engine 151.8 cm (59‑3/4 in.) Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death.

  • Page 88: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine for removal/installation.

  • Page 89: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 3. Tighten the nut to the specified torque. 3727 Description lb‑in. lb‑ft 47.5 – Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 90 OUTBOARD INSTALLATION WARNING Worn, loose, or seized steering components can lead to loss of boat control. Inspect all steering attachment components for wear, lubricate all attachment hardware, and check all fasteners for proper tightness in accordance with the inspection and maintenance schedule. 2767 Special washer head bolt (P/N 10‑849838) Nylon insert locknut (P/N 11‑826709113) ‑...

  • Page 91: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 24305 The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions...
  • Page 92 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 93: 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 94 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 95 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 96 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 97 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 98: Electrical, Hoses, 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, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove the screws and open the front clamp assembly. Screw (2) Front clamp 7644...
  • Page 99 OUTBOARD INSTALLATION REMOTE WIRING HARNESS Route the remote 14‑pin boat harness through the front clamp. Connect the remote harness to the 14‑pin connector on the engine harness. 11033 14‑pin connector Remote 14‑pin boat harness BATTERY INFORMATION (ALL BATTERIES INCLUDING DTS) 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...

  • Page 100: Battery Cable Connections

    OUTBOARD INSTALLATION A decal advising against using deep cycle batteries and wing nuts should be placed on or near the battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut is supplied per battery for wing nut replacement. Metric hex nuts are not supplied.
  • Page 101 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 AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel hose size ‑...
  • Page 102 OUTBOARD INSTALLATION 2. Connect the remote oil hoses to the engine hose connections. Fasten hose connections with cable ties. Hose clamp Cable tie Oil hose without blue stripe Oil hose with blue stripe Remote fuel hose 3767 SPEEDOMETER AND WATER PRESSURE TUBING CONNECTIONS NOTE: This applies to models without SmartCraft gauges.

  • Page 103: Shift And Throttle Cable

    OUTBOARD INSTALLATION Make the water pressure gauge hose connection to this tubing as follows: 7728 Speedometer water pickup tube Water pressure tube Coupler Plug Barb hose fitting Speedometer hose Water pressure tube Shift and Throttle Cable COUNTERROTATION OUTBOARDS Counterrotating (left‑hand) gearcases can be identified by a "L" stamped into the end of the propeller shaft.
  • Page 104 OUTBOARD INSTALLATION On counterrotation outboards, the shift linkage moves in the opposite direction compared to a standard rotation outboard. Reverse Gear Forward Gear 7724 Standard Rotation Forward Gear Reverse Gear 7726 Counterrotation INSTALLING THE SHIFT CABLE IMPORTANT: The shift cable is the first cable to move when the remote control handle is moved out of neutral, so install/connect it to the engine first.
  • Page 105 OUTBOARD INSTALLATION c. Place a mark on the shift cable against the cable end guide. 4355 Forward position mark 2. Mark the reverse position as follows: a. Move the remote control handle into reverse and advance the handle to the full speed position. Ensure that the throttle control lever is touching the throttle control lever stop screw.
  • Page 106 OUTBOARD INSTALLATION 6. Slide the shift cable retainer forward until resistance is felt, then slide the cable anchor toward the rear until resistance is felt. 7. Center the anchor pin between these resistance points. 4363 Anchor pin Shift cable retainer Adjusting the Shift Cable To adjust the shift cable: 1.
  • Page 107 OUTBOARD INSTALLATION 3. Secure the shift cable with the shift cable retainer. 4364 Cable barrel Shift cable retainer 4. Check the shift cable adjustments as follows: a. Shift the remote control to forward while turning the propeller shaft. If the propeller shaft does not lock in gear, adjust the cable barrel closer to the cable end guide.
  • Page 108 OUTBOARD INSTALLATION 2. Attach the throttle cable to the throttle lever. Secure with washer and locknut. Washer and locknut Throttle cable Throttle lever 7738 3. Adjust the throttle cable barrel so that the installed throttle cable will hold the idle stop screw against the stop. 4366 Throttle cable barrel Idle stop screw...

  • Page 109: Front Clamp Reassembly

    OUTBOARD INSTALLATION IMPORTANT: The idle stop screw must be touching the stop. 7740 Idle stop screw Idle stop 5. Lock the barrel holder in place with the cable latch. Front Clamp Reassembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.

  • Page 110: Oil Injection Set-Up

    OUTBOARD INSTALLATION 2. Fasten the clamp together with two screws. Screw (2) Front clamp 7644 Oil Injection Set‑Up FILLING THE OIL TANKS 1. Remove the fill cap from the remote oil tank and fill the tank with the recommended oil. Install the fill cap and tighten securely. Fill cap 2683 IMPORTANT: Do not remove the vent cap from the engine‑mounted oil...
  • Page 111 OUTBOARD INSTALLATION 3. If the oil level is less than 118 ml (4 oz), loosen the vent cap. Use a squirt can and fill the tank with at least 118 ml (4 oz) of the recommended oil. Tighten the vent cap. Engine‑mounted oil reservoir tank Vent cap 7745...
  • Page 112 OUTBOARD INSTALLATION 2. Position the fuel primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel hose primer bulb until it feels firm. 27348 3. Turn the ignition key switch to the "ON" position. 26846 4.

  • Page 113: Trim In Pin

    OUTBOARD INSTALLATION Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 114 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...

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