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Mercury 2.5 FourStroke Operation, Maintenance & Installation Manual

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Summary of Contents for Mercury 2.5 FourStroke

  • 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...

  • 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..................26 Operating in Freezing Temperatures..............26 Operating in Saltwater or Polluted Water............26 Engine Break‑in Procedure................27 Starting the Engine................... 27 Gear Shifting..................... 30 Reversing Boat....................31 Stopping the Engine..................31 Maintenance Outboard Care....................32 EPA Emission Regulations................32 Inspection and Maintenance Schedule ............
  • Page 9 Maintenance Log Maintenance Log....................50...
  • Page 10 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: 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.

  • 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.

  • 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.

  • 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 Engine oil capacity 300 ml (10 fl oz) Recommended spark plug NGK DCPR6E Spark plug gap 0.9 mm (0.035 in.) Gearcase lubricant capacity 180 ml (6.0 fl oz) Gear ratio 2.15:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Emission control system...

  • Page 23: Installation

    INSTALLATION Installing the Outboard BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of the boat. The anti‑ventilation plate should be 25–50 mm (1–2 in.) below the bottom of the boat. Anti‑ventilation plate 19053 INSTALLING THE OUTBOARD ON THE TRANSOM 1. Place the outboard on the centerline of the transom. 27005 2.

  • Page 24: Transporting

    TRANSPORTING Carrying, Storing, and Transporting the Outboard When Removed from Boat With the outboard still in the water, close the fuel valve and run the engine until it stops. This will empty the fuel from the carburetor. 52330 Transport mode Vent position Fuel valve position Vent screw...

  • Page 25: Trailering The Boat

    TRANSPORTING Carry, transport, or store the outboard only in the upright position, or with the tiller handle (port) side facing up. These positions will prevent oil from draining out of the crankcase. A decal on the port side of the engine indicates which side should be up.
  • Page 26 TRANSPORTING Set the gear shift into forward gear. This prevents the propeller from spinning freely. 19049...

  • Page 27: 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 28: Special Features Of The Fuel Tank

    IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble;...

  • Page 29: Filling The Fuel Tank

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

  • Page 30: Checking Engine Oil

    FUEL AND OIL IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 31 FUEL AND OIL NOTE: If oil level is at the lower mark, add 100 ml (3 oz.) of oil. 52334 Oil level inspection window Upper oil level Lower oil level 3. Install the oil fill cap, and tighten securely. 19139 Oil fill cap...

  • Page 32: Features And Controls

    FEATURES AND CONTROLS Features and Controls Fuel shut off valve ‑ Turn the valve to the closed (OFF) position to prevent fuel flow to the engine. Turn the valve to the open (ON) position when starting the engine. 52331 Choke knob ‑ Pull completely out when starting a cold engine. Push halfway in as the engine is warming up.
  • Page 33 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 34: Tilting Outboard

    FEATURES AND CONTROLS Engine stop switch/lanyard stop switch ‑ Push in or pull lanyard to stop the engine. The engine will not start unless the lanyard is engaged with the stop switch. Engine stop switch/lanyard stop switch Lanyard 19104 Starter rope ‑ Pulling the starter rope cranks the engine over for starting. 19105 Tilting Outboard TILTING TO FULL UP POSITION...

  • Page 35: Setting The Operating Angle Of The Outboard

    FEATURES AND CONTROLS 3. Push in the tilt support pin. Lower the outboard to rest on the tilt support pin. Tilt support pin 19051 LOWERING TO RUN POSITION Lift the outboard and pull out the tilt support pin. Lower the outboard. Setting the Operating Angle of the Outboard The vertical operating angle of the outboard is adjusted by changing the position of the tilt pin in the adjustment holes provided.

  • Page 36: 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 37: Engine Break-In Procedure

    OPERATION Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 1. For the first hour of operation, run the engine at varied throttle settings up to 2000 RPM or at approximately half throttle.
  • Page 38 OPERATION 2. Shift the outboard to the neutral (N) position. 19170 3. Make sure the cooling water intake is submerged. 19056 4. Open the manual vent screw on the fuel tank. 47370 5. Move the fuel shut off valve to the open (ON) position. 52331...
  • Page 39 OPERATION 6. 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 switch Lanyard 19104 7. If the engine is cold, set the throttle grip to the "START" position. If the engine is warm, set the throttle grip to the "RE‑START"...

  • Page 40: Gear Shifting

    OPERATION 9. Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow the rope to return slowly. Repeat until the engine starts. 19172 10. Check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 41: Reversing Boat

    OPERATION Always shift the outboard into gear with a quick motion. 19103 Reversing Boat 1. Move the throttle grip to the slow position. 2. To reverse direction, turn the outboard 180°. The tiller handle can be swung back for ease of operation. 3.

  • Page 42: Maintenance

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

  • Page 43: Inspection And Maintenance Schedule

    FEL : HC+NOx= HP : LOW-PERM/HIGH-PERM : MAXIMUM POWER : TIMING : IDLE SPEED (IN GEAR) : MERCURY MARINE 43058 Piston displacement Maximum emission output for the engine family Percent of fuel line permeation Timing specification US EPA engine family name Horsepower rating Engine power ‑...

  • Page 44: Flushing The Cooling System

    This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. NOTE: Do not run the engine while flushing the cooling system.

  • Page 45: Top Cowl Removal And Installation

    MAINTENANCE 2. Attach the hose coupling to the engine. 3. Attach a water hose to the hose coupling. Turn on the water gently and flush the cooling system for 3 to 5 minutes. 4. Turn the water off. Remove the hose coupling and install the plug and gasket.

  • Page 46: Corrosion Control Anode

    MAINTENANCE 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 19043 INSTALLATION 1. Engage the front hook and position the cowl over the engine. 2. Lock the rear cowl latch. Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase.

  • Page 47: 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 48 MAINTENANCE 4. Pull the propeller straight off the shaft. Retain the drive pin. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Drive pin 19022 5. Insert the drive pin into the propeller shaft. Drive pin 19023 6.

  • Page 49: Spark Plug Inspection And Replacement

    MAINTENANCE 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 50: Lubrication Points

    MAINTENANCE Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Extreme Grease. Tube Ref Description Where Used Part No. Steering friction knob threads, swivel 2-4-C with PTFE bracket bushing, tilt support pin, transom 92-802859A 1...

  • Page 51: Changing Engine Oil

    MAINTENANCE • Swivel bracket ‑ remove four bolts and rear cover and lubricate the inner nylon bushing. Rear cover 19240 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 300 ml (10 fl oz). OIL CHANGING PROCEDURE 1. Place the outboard in an upright (not tilted) position. 2.

  • Page 52: Gearcase Lubrication

    MAINTENANCE Remove the oil fill cap and refill with 300 ml (10 fl oz) of oil. Install the oil fill cap. Idle engine for five minutes and check for leaks. Stop engine and check oil level. Add oil if necessary. Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.

  • Page 53: Submerged Outboard

    MAINTENANCE 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. Vent plug and new sealing washer Vent hole Fill/drain plug and new sealing washer 19080 Tube Ref Description Where Used Part No.

  • Page 54: 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 55: Gearcase

    STORAGE Gearcase • Drain and refill the gearcase lubricant. Refer to Gearcase Lubrication. Positioning Outboard for 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.

  • Page 56: 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 57 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 58: 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 59 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 60 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:

3.5 fourstroke

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