Mercury 25 TwoStroke Operation, Maintenance And Installation Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. 2.5 TwoStroke
  6. Operation, maintenance and installation manual

Mercury 25 TwoStroke Operation, Maintenance And Installation Manual

Hide thumbs Also See for 25 TwoStroke:
Table of Contents

Advertisement

Quick Links

See also: Operation, Maintenance and Installation Manual
Operation
Maintenance
and
Installation
Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 25 TwoStroke and is the answer not in the manual?

Questions and answers

Related Manuals for Mercury 25 TwoStroke

Summary of Contents for Mercury 25 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, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...
  • Page 7 General Information Boater's Responsibilities..................1 Before Operating Your Outboard................ 1 Boat Horsepower Capacity................. 1 High‑Speed and High‑Performance Boat Operation.......... 2 Outboard Remote Control Models..............2 Remote Steering Notice..................3 Lanyard Stop Switch................... 4 Protecting People in the Water................6 Passenger Safety Message ‑ Pontoon Boats and Deck Boats......7 Wave and Wake Jumping...................
  • Page 8 Operation Prestarting Check List..................36 Operating in Freezing Temperatures..............36 Operating in Saltwater or Polluted Water............36 Operating at High Elevations................37 Engine Break‑in Procedure................37 Starting the Engine................... 38 Warm‑Up......................44 Gear Shifting..................... 44 Stopping the Engine..................47 Emergency Starting..................48 Maintenance Cleaning Care Recommendations..............
  • Page 9 Engine Runs Erratically..................67 Performance Loss..................... 68 Battery Will Not Hold Charge................68 Engine Installation Mercury Marine Validated Engine Mounting Hardware........69 Installing Outboard.................... 69 Installing the Remote Control Device .............. 72 Attaching the Steering Link Rod............... 82 Battery Installation ................... 83 Propeller Selection....................
  • Page 10 viii...

  • Page 11: Boater's Responsibilities

    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

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 13: Remote Steering Notice

    GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 37882 Remote Steering Notice WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch.
  • Page 15 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.

  • Page 16: Protecting People In The Water

    GENERAL INFORMATION KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

  • Page 17: Passenger Safety Message ‑ Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 18: Wave And Wake Jumping

    GENERAL INFORMATION Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 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 19: Impact With Underwater Hazards

    GENERAL INFORMATION Impact with Underwater Hazards Your outboard may be equipped with a hydraulic trim and tilt system that also contains a shock absorbing feature. This feature helps the outboard withstand damage in the case of impact with an underwater object at low to moderate speeds.
  • Page 20 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.

  • Page 21: Exhaust Emissions

    GENERAL INFORMATION This product must be secured to the transom with the required mounting hardware. If the outboard strikes an underwater object, the required mounting hardware prevents the outboard from propelling off the transom. A decal on the swivel bracket reminds the installer of the potential hazard. WARNING Avoid serious injury or death.
  • Page 22 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 23: 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 24 (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 25: Recording Serial Number

    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 26: Model Year Production Code

    GENERAL INFORMATION Serial number: Model year: Model designation: Year manufactured: Certified Europe Insignia (as applicable): 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.

  • Page 27: Specifications

    GENERAL INFORMATION 25/30 Specifications Model 30EH 600 mm (23.6 Overall length 884 mm (34.8 in.) in.) Overall width 430 mm (16.9 in.) 355 mm (14 in.) Overall height S: 1124 mm (44.3 in.) ‑ L: 1251 mm (49.3 in.) Transom height S: 435 mm (17.1 in.) ‑...

  • Page 28: Components

    GENERAL INFORMATION Components 25 26 37417...
  • Page 29 GENERAL INFORMATION MH models Tilt handle Upper cowl Water pump indicator hole Water plug Reverse lock lever Driveshaft housing Anti‑ventilation plate Trim tab Secondary water intake 10 - Propeller 11 - Starter rope handle 12 - Shift lever 13 - Throttle grip 14 - Clamp screw...
  • Page 30 GENERAL INFORMATION 37461...
  • Page 31 GENERAL INFORMATION EH models Tilt handle Upper cowl Water pump indicator hole Water plug Reverse lock lever Driveshaft housing Anti‑ventilation plate Trim tab Secondary water intake 10 - Propeller 11 - Starter rope handle 12 - Shift lever 13 - Throttle grip 14 - Clamp screw...
  • Page 32 GENERAL INFORMATION 37463...
  • Page 33 GENERAL INFORMATION E models Tilt handle Upper cowl Water pump indicator hole Water plug Reverse lock lever Driveshaft housing Anti‑ventilation plate Trim tab Secondary water intake 10 - Propeller 11 - Starter rope handle 12 - Shift lever 13 - Clamp screw 14 - Clamp bracket...

  • Page 34: Trailering Boat/Outboard

    TRANSPORTING Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. IMPORTANT: The tilt lock and shallow water drive feature (tiller handle models) on the outboard are not intended to support the outboard in the tilted position when trailering.

  • Page 35: Transporting Portable Fuel Tanks

    TRANSPORTING 4. Rest the motor on the ground with the clamp screw handles facing upward. 37884 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank. Transport the fuel tank in a well ventilated area away from open flame or sparks.
  • Page 36 TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidentally pushed‑in, allowing fuel or vapor to escape. Connector stem Tether cap 26794...

  • Page 37: Fuel Requirements

    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 38: 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 39: 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 40: Remote Control Features

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with the Mercury Precision or Quicksilver remote control shown. If not, consult your dealer for a description of the functions and operations of the remote control. 37982 Remote control handle ‑ Forward (F), Neutral (N), Reverse (R)

  • Page 41: Shallow Water Operation

    FEATURES AND CONTROLS TILT UP Turn the reverse lock lever to release side and tilt up the engine; the engine is set automatically. Reverse lock lever 37535 TILT DOWN Turn the reverse lock lever to lock side, lift up the engine slightly, and put it down.

  • Page 42: Trim Adjustment

    FEATURES AND CONTROLS SHALLOW WATER RUNNING POSITION Turn the reverse lock lever to release side and tilt up the engine to set the engine to shallow water running position. Reverse lock lever 37535 TILT DOWN FROM SHALLOW WATER RUNNING POSITION Turn the reverse lock lever to lock side, lift up the engine slightly, and put it down.

  • Page 43: Steering Friction Adjustment

    FEATURES AND CONTROLS • Trim up: If the bow falls into the water level when cruising, trim the trim position pin up. 37883 Correct trim Trim down Trim up Trim position pin Move pin to raise bow up Move pin to lower bow down Steering Friction Adjustment Steering friction can be adjusted according to your preference with the steering co‑pilot.

  • Page 44: Trim Tab Adjustment

    FEATURES AND CONTROLS • Turn counterclockwise for less friction. Steering co‑pilot 37516 Trim Tab Adjustment Propeller steering torque will cause the boat to pull in one direction. Steering torque results from the outboard not being tilted so the propeller shaft is parallel to the water surface.

  • Page 45: Features And Controls

    FEATURES AND CONTROLS • If the boat steers toward the right, set the trim tab in the direction of C. 37494 Trim tab Steers toward the left, set the trim tab in the direction of B Steers toward the right, set the trim tab in the direction of C Turning left Turning right...

  • Page 46: Prestarting Check List

    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 47: Operating At High Elevations

    OPERATION Operating at High Elevations IMPORTANT: To prevent serious damage to the engine caused by a lean fuel mixture, do not operate your outboard (if the jets were changed for high elevation) at a lower elevation unless the jets are changed again to correspond to the new elevation.

  • Page 48: Starting The Engine

    OPERATION Starting the Engine PREPARATIONS 1. Install the fuel connector to the engine side connector. 37522 2. Loosen the air vent screw on the tank cap. For tanks with a fuel tank auto air vent (optional): There is no need to loosen the air vent screw. An air vent opens automatically when the connector is attached to the tank.
  • Page 49 OPERATION NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 4. Tiller handle models: Set the shift lever to neutral position. NOTE: Be sure that the shift is at Neutral (N) when starting the engine.
  • Page 50 OPERATION 8. Turn the key to the on position, and push it for choke operation. No need to push the key when the engine is warm. Push for choke operation 37466 9. Place the control lever at Neutral (N), and move the throttle only lever to the open position.
  • Page 51 OPERATION SET THE LANYARD STOP SWITCH TO RUN POSITION Be sure to connect the lanyard stop switch to your body. The engine will shut down if the stop lanyard is disconnected. Tiller handle models Lanyard stop switch Stop switch lock Hook 37465 Remote control models...
  • Page 52 OPERATION STARTING THE ENGINE 1. Pull the rewind starter slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow the rope to return slowly. Slowly Rapidly 37523 IMPORTANT: Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑in Procedures in the Operation section.
  • Page 53 OPERATION NOTE: When restarting a warm engine, do not push the key; merely turn it to the start position. Start 37717 5. When the engine starts, release the key, and it will return automatically to the run position. 6. If the engine fails to start in 10 seconds, wait 30 seconds and try again. If the engine begins to stall, reprime (push key in) until the engine is running.

  • Page 54: Warm‑Up

    OPERATION Warm‑Up Run the engine at a low speed for about three minutes for warm‑up operation before cruising, permitting the oil to circulate throughout the engine, otherwise the life of the engine will be shortened greatly. During warm‑up operation, confirm that cooling water is discharged from its water pump indicator hole. IMPORTANT: If cooling water is not discharged, and operation continues, it may cause overheating, resulting in engine damage.
  • Page 55 OPERATION • Tiller handle models—reduce the engine speed to idle before shifting into another gear. • Always shift the outboard into gear with a quick motion. • After shifting the outboard into gear, advance the remote control handle or rotate the throttle grip (tiller handle) to increase the engine speed. Tiller handle models: Turn the throttle grip to the slow position and move the shift lever to Forward (F) position swiftly when the engine speed drops to its lowest level.
  • Page 56 OPERATION NOTE: Forward running is not possible unless the throttle only lever is at the lower position. 37531 Fully opened position Fully closed position Throttle range Shift range Neutral (N) Forward (F) Reverse (R) Throttle only lever REVERSE Tiller handle models: Move the shift lever to the Reverse (R) position swiftly when the engine speed drops to its lowest level.

  • Page 57: Stopping The Engine

    OPERATION Remote control models: Shift the outboard only when the engine is at idle speed. To change Forward (F) to Reverse (R), first idle the engine and shift into Neutral (N). With the engine still running, slowly engage and gradually increase the reverse speed.

  • Page 58: Emergency Starting

    OPERATION 4. Remote control models: Place the remote control lever at Neutral (N) and idle the engine. 37882 5. Turn the key to the off position, or pull the lanyard stop switch. Hook Lanyard stop switch 37716 IMPORTANT: Follow the instructions below. •...
  • Page 59 OPERATION 2. Remove the starter rope. 3. Wind a pull rope around the flywheel. 4. Use a 10 mm socket wrench as a pull grip, as shown below. 37880 5. Remote control models: Ensure the key switch is in the on position. NOTE: Confirm that the shift lever is in Neutral (N).

  • Page 60: Cleaning Care Recommendations

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package.

  • Page 61: Inspection And Maintenance Schedule

    4. Wax the surface using a nonabrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. 5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1). Inspection and Maintenance Schedule DAILY CHECKS •...

  • Page 62: 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. IMPORTANT: The engine must be run during flushing in order to open the...
  • Page 63 MAINTENANCE 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 64: Top Cowl Removal And Installation

    MAINTENANCE 4. Adjust the water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 27260 5. Check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 65: Battery Inspection

    MAINTENANCE 2. Push cowl down and move the rear latch lever up to lock. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1.

  • Page 66: Fuse Replacement ‑ Electric Start Remote Control Models

    MAINTENANCE 1. Unscrew four screws, remove the housing, then clean the fuel filter. 37711 Filter: Unscrew the fuel pickup elbow and then clean it Fuel pickup elbow 2. Remove the fuel filter bowl, then clean the fuel filter at the engine. Carburetor Fuel filter bowl 37710...

  • Page 67: Propeller 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. Anode (trim tab) 37879 Important:...
  • Page 68 MAINTENANCE 2. Remove the spark plug leads to prevent the engine from starting. 26899 3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. 27296 4. Remove the propeller from the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.
  • Page 69 MAINTENANCE 5. Coat the propeller shaft with Mercury Extreme Grease or 2‑4‑C with PTFE. 27305 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...
  • Page 70 MAINTENANCE 6. Install forward thrust hub, propeller, washer, nut, and cotter pin onto the propeller shaft. 37520 Cotter pin Washer Propeller Forward thrust hub Propeller shaft 7. Place a block of wood between the gearcase and propeller and tighten the propeller nut. 27341 8.

  • Page 71: 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 72: Lubrication Points

    It is important to inspect and maintain your outboard motor regularly. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first. For periodic servicing and maintenance guidelines, please contact your local Mercury dealer. Every 50 hours or 3 Every 100 hours or...
  • Page 73 MAINTENANCE 3. Remove the oil plugs (upper and lower) and drain the gear oil completely. 37849 4. Place the lubricant tube into the fill/drain hole and add the lubricant until it appears at the upper oil plug hole. Upper oil plug hole 37848 5.

  • Page 74: Submerged Outboard

    GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 280 cc (9.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 75: Storage Preparation

    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 76: Protecting Internal Engine Components

    With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel. •...

  • Page 77: Starter Motor Will Not Crank The Engine (Electric Start Models)

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models ‑ Blown 20 amp fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 78: Performance Loss

    TROUBLESHOOTING • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. •...

  • Page 79: Mercury Marine Validated Engine Mounting Hardware

    ENGINE INSTALLATION Mercury Marine Validated Engine Mounting Hardware IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability issues that can lead to safety concerns.
  • Page 80 ENGINE INSTALLATION 1. One outboard: Position the outboard motor at the center of the stern. Refer to General Information ‑ 25/30 Specifications for the transom height. Transom height 37508 2. Two outboards: Position the outboard engines about 580 mm (23 in.) apart.
  • Page 81 ENGINE INSTALLATION NOTE: Select an outboard motor that allows the clearance shown below. Bottom of boat Anti‑ventilation plate 30–50 mm (1.2” 2”) – 37510 4. After positioning the clamp brackets, attach it with the clamp screws then drill two holes in the transom board, matching the holes in the clamp bracket.

  • Page 82: Installing The Remote Control Device

    ENGINE INSTALLATION Installing the Remote Control Device RIGHT-HAND STEERING 1. Position the remote control box in a place that will not obstruct handling of the control levers and switches. Confirm there is no obstacle in the passage of the remote control cables. 37529 2.
  • Page 83 ENGINE INSTALLATION 3. Determining remote control cable length: A guideline for determining the proper length for a remote control cable is dimensions A plus B plus 300 mm (1 foot). Center of transom 37530 NOTE: The minimum bend radius for a remote control cable is typically 203 mm (8 in.).
  • Page 84 ENGINE INSTALLATION 5. Thread the remote control cables through the terminal eyes at a distance of more than 16 mm (0.63 in.). Securely lock the terminal eyes with the locknut. 11 mm 37497 Terminal eyes Locknut 6. Press the neck of the shift remote control cable down into the clamp on the housing of the remote control box.
  • Page 85 ENGINE INSTALLATION 7. Connect the throttle remote control cable to the throttle arm in a manner similar to the shift remote control cable. Throttle cable Shift cable Throttle arm Shift arm 37526 8. Install the back panel. Back panel 37528...
  • Page 86 ENGINE INSTALLATION 9. Install the remote control box with three screws, spacers, and nuts. Screw Remote control box Hull Spacer Washer 37464...
  • Page 87 ENGINE INSTALLATION 10. Connect the remote control cables to the engine and attach the cord assembly as shown below. 37495 Steering hook plate Spacer Clip Neck of remote control cable Shift remote control cable Washer Sleeve guide B: Connect remote control cable to shift lever Shift lever Advance arm Ball joint...
  • Page 88 ENGINE INSTALLATION 12. Throttle side: Slide a grommet onto an end of the cable, put a holder cap on it, and lock it with a nut, as shown. 37502 Throttle cable Holder cap 13. Shift side: Attach the sleeve guide B to the shift remote control cable, and lock it with a nut.
  • Page 89 ENGINE INSTALLATION 17. Attach the cord assembly: Connect the cord assembly from the remote control box to respective terminals through the lower cowl as illustrated. Fasten the cord assembly with clamps. 37505 Cord assembly Black terminal Brown terminal Green terminal Red terminal Rectifier Terminal holder...
  • Page 90 ENGINE INSTALLATION Starter solenoid bracket Lower cowl Grommet To remote control box Clamp Screw...
  • Page 91 ENGINE INSTALLATION 18. Connect the cables to their respective terminals at the cable terminal holder. c d e f g h 37500 Magnet lead wire Magnet lead wire Cord assembly Fuse wire CD unit Cord assembly CD unit Starter solenoid Rectifier lead wire Stop switch Choke solenoid...

  • Page 92: Attaching The Steering Link Rod

    ENGINE INSTALLATION WIRE COLOR CODE ABBREVIATIONS Wire Color Abbreviations Black Blue Brown Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Attaching the Steering Link Rod WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.

  • Page 93: Battery Installation

    ENGINE INSTALLATION The steering link rod parts are available and assembled as illustrated below. Spacers may or may not be required depending on cable brands. 37507 Grease Spacer (optional) Bolt Washer B Rubber cushion Spring Spacer Collar Locknut Washer A Seal ring Battery Installation MOUNTING BATTERY...

  • Page 94: Propeller Selection

    ENGINE INSTALLATION BATTERY CONNECTIONS Connect a red cable to the positive (+) terminal first and a black cable to the negative (–) terminal of the battery. Put a red cap on the positive terminal. When disconnecting battery cables, be sure to disconnect the black cable first, and then the red cable.
  • Page 95 ENGINE INSTALLATION Alternative propellers are available for specific boating requirements. See your outboard dealer. AVAILABLE PROPELLERS Light‑duty boat — Heavy‑duty boat Mark 14 (E) 13 (D) 11 (C) 10 (B) 9 (A) 8 (F) Dimensions (blade x 3 x 252 3 x 252 3 x 250 3 x 250...

  • Page 96: Associated Parts

    ASSOCIATED PARTS Associated Parts Name Quantity Dimensions Tool bag Pliers Socket wrench 10 x 13 mm Service tools Socket wrench 21 mm Socket wrench handle Screwdriver Starter rope 1000 mm NGK B7HS‑10 or Spare parts Spark plug Champion L82C (Gap: 1.0 mm ‑...

  • Page 97: Accessories

    ACCESSORIES Accessories OPTIONAL ACCESSORIES 37846 Speedometer (50 MPH) Speedometer (75 MPH) Fuel meter Tachometer Hour meter Genuine engine oil Genuine grease (50 g, 250 g) Genuine gear oil (260 cc, 500 cc)
  • Page 98 ACCESSORIES Touch‑up spray paint (300 ml) Stop switch Extension cord, light Meter lamp switch 37540 Turnbuckle plate Twin remote control turnbuckle assembly...
  • Page 99 ACCESSORIES 37506 Steering spacer Steering link assembly (standard: EP type)
  • Page 100 ACCESSORIES 37493 Twin remote control box kit 3 screws (included in kit) 3 spacers (included in kit) 6 spacers Hull 6 washers 3 nuts...
  • Page 101 ACCESSORIES 37504 Automatic reverse lock kit...

  • Page 102: Wiring Diagrams

    WIRING DIAGRAMS Wiring Diagrams 37842...
  • Page 103 WIRING DIAGRAMS Remote control box Battery 12 V, 800 W (DC) Extension cord (optional) Fuse (15 amp) Rectifier (optional) Extension cord, light (optional) Receptacle plug (optional) Lamp (12 V, 80 W) (AC) 10 - Tachometer (optional) 11 - Separate cord (yellow) (optional) 12 - Separate cord (white) (optional) 13 -...
  • Page 104 WIRING DIAGRAMS 37843...
  • Page 105 WIRING DIAGRAMS Starter motor Starter solenoid Fuse (15 amp) Rectifier Tachometer lead wire (optional) Tachometer (optional) Separate cord (yellow) (optional) Separate cord (white) (optional) Flywheel magneto 10 - Ignition coil 11 - Spark plug 12 - CD unit 13 - Stop switch (optional) 14 - Stop switch...
  • Page 106 WIRING DIAGRAMS 37844...
  • Page 107 WIRING DIAGRAMS Assist cord (black) (optional) Tachometer lead wire (optional) Rectifier Fuse wire (15 amp) Starter solenoid Separate cord (white) (optional) Separate cord (yellow) (optional) Starter cord Starter motor 10 - Alternator 11 - Trigger coil 12 - Flywheel magneto 13 - Exciter coil 14 -...
  • Page 108 WIRING DIAGRAMS 37845...
  • Page 109 WIRING DIAGRAMS Neutral switch Main switch Stop switch Cord assembly Meter lead wire (optional)

  • Page 110: 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 111 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 112: 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 113 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 114: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

This manual is also suitable for:

30 twostroke

Table of Contents

Save PDF