Table of Contents
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Table of Contents
Related Manuals for Mercury 2.5 TwoStroke
Summary of Contents for Mercury 2.5 TwoStroke
- Page 1 Operation Maintenance Installation Manual...
- Page 3 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, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves...
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Page 7: Table Of Contents
General Information Boater's Responsibilities..................1 Before Operating Your Outboard................ 1 Boat Horsepower Capacity................. 1 Lanyard Stop Switch................... 2 Protecting People in the Water................5 Exhaust Emissions..................... 5 Selecting Accessories for Your Outboard............7 Safe Boating Recommendations................ 7 Recording Serial Number................. 10 Model Year Production Code................ - Page 8 Operation Prestarting Check List..................23 Operating in Freezing Temperatures..............23 Operating in Saltwater or Polluted Water............23 Engine Break‑in Procedure................24 Starting The Engine..................24 Gear Shifting ‑ Models with Gear Shift............. 27 Stopping The Engine ..................28 Emergency Starting..................28 Maintenance Outboard Care....................
- Page 9 Owner Service Assistance Service Assistance................... 45 Ordering Literature.................... 47 Maintenance Log Maintenance Log....................49...
- Page 10 viii...
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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: Lanyard Stop Switch
GENERAL INFORMATION 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 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.
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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 WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide.
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Page 17: Selecting Accessories For Your Outboard
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories. - Page 18 GENERAL INFORMATION • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S.
- Page 19 (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.
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Page 20: Recording Serial Number
GENERAL INFORMATION • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is... -
Page 21: Model Year Production Code
GENERAL INFORMATION Model Year Production Code The serial number decal lists the year of manufacture as an alpha code. This code can be deciphered into a corresponding number utilizing the following table. XXXXXXXXX XXXXXXXX XXXX 62972 Serial number decal alpha code Model Year Manufactured Code Alpha Production Code Corresponding Number... - Page 22 GENERAL INFORMATION Models Gear Ratio 2.18:1 1.85:1 Recommended Gasoline Refer to Fuel and Oil Recommended Oil Refer to Fuel and Oil...
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Page 23: Installation
INSTALLATION Installing Outboard BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat. The anti‑ventilation plate should be 25–50 mm (1–2 in.) below the bottom of the boat. Anti‑ventilation plate 28376 INSTALLING OUTBOARD ON TRANSOM 1. Place outboard on centerline of transom. 27005 2. -
Page 24: Transporting
TRANSPORTING Carrying Outboard The outboard has a carrying handle located in front. 28379 Transporting Outboard When Removed From Boat 1. With the outboard still in the water, close the fuel shut‑off valve and run engine until it stops. The running engine will consume remaining fuel in the carburetor. -
Page 25: Trailering Boat
TRANSPORTING Trailering Boat IMPORTANT: The tilt lock mechanism is not intended to support the outboard in the tilted up position when trailering. Use of the tilt lock mechanism could allow the outboard to bounce and drop down causing damage to the outboard. The boat should be trailered with the outboard tilted down (normal operating position). -
Page 26: 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 27: Oil Recommendation
Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. -
Page 28: 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 fuel tanks outdoors away from heat, sparks, and open flames. -
Page 29: Features And Controls
FEATURES AND CONTROLS Features and Controls Throttle lever ‑ Move to start position for starting. Move lever up to increase engine speed and down to reduce engine speed. Choke lever ‑ Move up to the closed position for starting a cold engine. Move halfway down as engine warms up. -
Page 30: Tilting Outboard
FEATURES AND CONTROLS WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment, maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released. -
Page 31: Setting The Operating Angle Of Your Outboard
FEATURES AND CONTROLS 3. Take hold of the top cowl grip and raise outboard to the full up position. 28386 4. Push in the tilt support pin. Lower the outboard to rest on the tilt support pin. 28387 LOWERING TO RUN POSITION 1. - Page 32 FEATURES AND CONTROLS The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed. This allows the boat to be driven parallel to the water. 28388 Arrange passengers and load in the boat so the weight is distributed evenly.
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Page 33: Operation
Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on... -
Page 34: 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. ENGINE BREAK-IN FUEL MIXTURE Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel. BREAK-IN PROCEDURE Vary the throttle setting during the first hour of operation. - Page 35 OPERATION 3. Open the fuel shut‑off valve. 28396 4. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch. NOTE: The engine will not start unless the lanyard is engaged with the stop switch. STOP 28397 5.
- Page 36 OPERATION 6. Move the throttle lever to the start position. Throttle lever Choke lever STOP 28398 7. Models with gear shift ‑ Move gear shift lever to neutral position. 28385 WARNING Sudden acceleration can serious injury or death. This outboard is a direct‑drive model, meaning the lower unit is in gear at all times.
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Page 37: Gear Shifting - Models With Gear Shift
OPERATION NOTE: Starting flooded engine ‑ Move the choke lever down to the open position. Wait 30 seconds, keep the throttle lever at the start position, then continue to crank engine for starting. 9. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole. -
Page 38: Stopping The Engine
OPERATION Stopping The Engine Reduce engine speed and push in the stop switch or pull the lanyard. STOP 28401 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. - Page 39 OPERATION 4. Reconnect the black lead using a bolt from the rewind starter. Bolt Black lead 28403 5. Place the starter rope knot into the starter cup notch and wind the rope clockwise around the cup. 6. Pull the starter rope to start the engine. WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.
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Page 40: 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. Inspection and Maintenance Schedule DAILY CHECKS •... -
Page 41: Top Cowl Removal And Installation
MAINTENANCE • Check the torque of the outboard mounting hardware—dealer item • Check the battery condition and tightness of the battery cable connection, if equipped—dealer item THREE YEARS OR 300 HOURS • Replace the spark plugs • Replace the water pump impeller—dealer item •... -
Page 42: Exterior Care
MAINTENANCE 2. Engage cowl latches to fasten cowl. 28686 Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes. 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 43 MAINTENANCE 2. Move gear shift lever into neutral. 28385 3. Straighten and remove cotter pin. 28704 4. Pull the propeller off the shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 28706 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the...
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Page 44: Corrosion Control Anode
MAINTENANCE 5. Apply 2‑4‑C with PTFE to the propeller shaft. 28707 Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 6. If removed, insert drive pin into propeller shaft. 7. Slide propeller onto shaft and verify the slot in propeller engages with the drive pin. -
Page 45: Spark Plug Inspection And Replacement
MAINTENANCE The 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. 28709 Spark Plug Inspection And Replacement WARNING... -
Page 46: Engine Idle Speed Adjustment
MAINTENANCE 3. Remove the spark plug to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 28438 4. Set spark plug gap to specifications. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 5. -
Page 47: Lubrication Points
MAINTENANCE 3. Adjust the idle speed screw to obtain the recommended engine idle speed. See General Information ‑ Specifications. 28712 Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Copilot threads, swivel bracket, tilt 2-4-C with PTFE support pin, transom clamp screw 92-802859A 1... - Page 48 MAINTENANCE • Swivel bracket ‑ Remove four (4) bolts and rear cover and lubricate the inner nylon bushings. 28714 • Tilt support pin. 28387 • Transom clamp screw threads. 28715 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller.
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Page 49: Gearcase Lubrication
MAINTENANCE 2. Lubricate the following with lightweight oil. • Tilt pivot. 28717 • Throttle linkage ‑ Lubricate pivot point. 28718 Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. - Page 50 MAINTENANCE 3. Remove vent plug and fill/drain plug and drain lubricant. Vent plug Fill/drain plug 28719 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 135 ml (4.5 fl oz). CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2.
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Page 51: Submerged Outboard
MAINTENANCE 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 52: Storage
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 53: Gearcase
With engine running at fast idle, stop the fuel flow by closing the fuel shut‑off valve. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel. •... -
Page 54: Troubleshooting
TROUBLESHOOTING Engine Will Not Start POSSIBLE CAUSES • Incorrect starting procedure. Refer to Operation section. • Old or contaminated gasoline. • Engine flooded. Refer to Operation section. • Fuel is not reaching the engine. a. Fuel tank is empty. b. Fuel tank vent not open or restricted. c. -
Page 55: 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 56 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.
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Page 57: Ordering Literature
Ordering Literature Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:... - Page 58 (USA only) P.O. Box 1939 Fond du Lac, WI 54936-1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package. Mercury Marine Submit the following...
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Page 59: 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...