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Mercury 10 FOURSTROKE Installation Operation Maintenance Warranty Manual

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Summary of Contents for Mercury 10 FOURSTROKE

  • Page 1 Outboard Installation Operation Maintenance Warranty Manual...
  • Page 3 Declaration of Conformity – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Tohatsu Marine Corporation (TMC) Mercury Marine Joint Venture Address: Shimodaira 4495‑9 Town: Post Code: 399‑4101 Country: Japan Komagane‑City, Nagano...
  • Page 4 Identification of Engines Covered by This Declaration of Conformity EC Type–examination Name of engine model or Starting serial certificate or type–approval engine family number certificate number 8, 9.9 hp 0R098000 RCD‑H‑2 Rev 4 9.9 hp Command Thrust 0R285784 RCD‑H‑2 Rev 4 10 hp Norway 0R285784 RCD‑H‑2 Rev 4...
  • Page 5 Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States 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.
  • Page 6 Please review this information. The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, and to change specifications, designs, methods, or procedures without notice and without incurring obligation.

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration United States and Canada..........1 Transfer of Warranty United States and Canada..........1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada.................. 2 3 Year Limited Warranty Against Corrosion............2 Warranty Coverage and Exclusions..............5 U.S.
  • Page 8 Fuel Recommendations..................40 Low Permeation Fuel Hose Requirement ............41 EPA Pressurized Portable Fuel Tank Requirements........41 Fuel Demand Valve (FDV) Requirement............41 Mercury Marine's Pressurized Portable Fuel Tank........... 42 Filling Fuel Tank....................43 Engine Oil Recommendations................43 Checking Engine Oil..................44 Features and Controls Tiller Handle Features..................
  • Page 9 Maintenance Outboard Care....................78 EPA Emission Regulations................78 Inspection and Maintenance Schedule............. 79 Flushing the Cooling System................81 Cowl Removal and Installation................. 82 Battery Inspection .................... 83 Exterior Care..................... 83 Fuel System...................... 83 Steering Link Rod Fasteners................84 Corrosion Control Anode ................. 85 Propeller Replacement ..................
  • Page 10 Owner Service Assistance Service Assistance..................106 Ordering Literature..................108 Engine Installation Boat Horsepower Capacity................110 Start in Gear Protection.................. 110 Selecting Accessories for Your Outboard............110 Low Permeation Fuel Hose Requirement ............111 Lifting the Outboard..................111 Installing Outboard..................111 Steering Cable Installation................

  • Page 11: Warranty Information

    Federal Safety Act be required. You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 12: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.
  • Page 13 COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 14 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.

  • Page 15: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...

  • Page 16: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use warranty, whichever occurs first, to the retail customer, that the engine is designed, built,...

  • Page 17: California Emissions Limited Warranty

    The regulations apply to all outboard engines sold to retail consumers in California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the...
  • Page 18 Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
  • Page 19 California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 20: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

  • Page 21: Warranty Policy-Australia And New Zealand

    90% lower emissions than One Star ‑ Low Emission engines. Warranty Policy—Australia and New Zealand MERCURY/MARINER OUTBOARD LIMITED WARRANTY–AUSTRALIA AND NEW ZEALAND POLICY This limited warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia...
  • Page 22 WARRANTY INFORMATION What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.
  • Page 23 The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au.
  • Page 24 Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this...
  • Page 25 You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s...

  • Page 26: Global Warranty Charts Outboard And Jets

    WARRANTY INFORMATION Global Warranty Charts Outboard and Jets UNITED STATES WARRANTY CHARTS–OUTBOARD AND JET Standard Limited Standard Limited Product Corrosion Warranty Warranty FourStroke (2.5–350 hp including Verado, Pro FourStroke and Jet 3 years 3 years outboards) OptiMax (75–250 hp including Pro 3 years 3 years XS and Jet outboards)
  • Page 27 WARRANTY INFORMATION Racing Product Standard Limited Standard Limited (Recreation use only) Warranty Corrosion Warranty OptiMax (250 XS) 2 years 3 years OptiMax (225 Sport XS) 2 years 3 years OptiMax (300 XS) 2 years 3 years Verado (400R) 2 years 3 years Outside of Canada For product purchased outside of Canada, contact the distributor in your...
  • Page 28 WARRANTY INFORMATION ASIA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 1 year 3 years Contact the Marine FourStroke 1 year 3 years Power Service Center OptiMax 1 year 3 years closest to you Verado 1 year...
  • Page 29 WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Contact the Marine Verado 400R 2 years 3 years Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 30 WARRANTY INFORMATION SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 years 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years closest to you Verado...

  • Page 31: 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 32: 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 33: 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 (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 34 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 35 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 36: 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 37 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 38: 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 39: 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 40: 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. 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 41 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 42: 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 43 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 44 (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 45: Recording Serial Number

    Brunswick Corp. Made in Japan 32300 Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) 10 FourStroke Specifications Model Power 7.4 kw (10 hp) Full throttle RPM range 5000–6000 RPM Idle speed in forward gear 950 ± 50 RPM...
  • Page 46 GENERAL INFORMATION Model Exhaust valve 0.18–0.22 mm (0.007–0.008 in.) Recommended spark plug NGK DCPR6E Spark plug gap 0.8–0.9 mm (0.031–0.035 in.) Gear ratio 2.15:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity 370 ml (12.5 fl oz) Engine oil capacity 1.0 liter (1.1 US qt)

  • Page 47: Transporting

    TRANSPORTING Carrying, Storing, and Transporting Your Outboard when Removed from Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run the engine until it stops.

  • Page 48: Trailering Boat/Outboard

    TRANSPORTING MANUAL VENTING TYPE FUEL TANK Close the fuel tank air vent when transporting tank. This will prevent escape of fuel or vapors from tank. 26793 AUTO-VENTING TYPE FUEL TANK 1. Disconnect the remote fuel line from tank. This will close the air vent and prevent escape of fuel or vapors from tank.
  • Page 49 TRANSPORTING 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. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing. 32176 IMPORTANT: Do not rely on the power tilt system or the tilt support lever to maintain proper ground clearance for trailering.

  • Page 50: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump octane rating of 87 (R+M)/2 minimum.

  • Page 51: Low Permeation Fuel Hose Requirement

    IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided.

  • Page 52: Mercury Marine's Pressurized Portable Fuel Tank

    Vent/water drain holes 46273 Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 53: Filling 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 54: 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 55 Outboard engines can typically handle large amounts of oil dilution without causing durability problems. However, to ensure extended life of the outboard engine, Mercury recommends that the oil and filter be changed regularly following the oil change interval and using the recommended oil quality.

  • Page 56: Features And Controls

    FEATURES AND CONTROLS Tiller Handle Features • A decal on the tiller handle is a quick reference guide for starting a cold or hot engine. 57622 • Tiller handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage. 28535 •...
  • Page 57 FEATURES AND CONTROLS • Tiller handle lock cap ‑ Remove and retain the lock cap on the top of the tiller handle to lock in the up position. Push the tiller lock release lever to release the handle from the locked up position. Install the lock cap to prevent the tiller handle from locking in the up position.
  • Page 58 FEATURES AND CONTROLS • Power tilt switch ‑ Push to tilt the engine up or down. 4639 • Throttle grip friction knob ‑ Turn the friction knob to set and maintain the throttle at desired speed. Turn the knob clockwise to tighten friction or turn the knob counterclockwise to loosen friction.
  • Page 59 FEATURES AND CONTROLS • Throttle grip ‑ Controls engine speed and shifting. The outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). 31971 • Choke/fast idle ‑ Pull out when starting a cold engine. •...

  • Page 60: Remote Control Features

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 58240 Trim/tilt switch Ignition key switch—OFF, ON, START...

  • Page 61: General Features

    FEATURES AND CONTROLS GEAR SHIFTING IMPORTANT: Observe the following: • Never shift the drive into gear unless the engine speed is at idle. • Do not shift the drive into reverse when the engine is not running. • Your power package has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R).
  • Page 62 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 63: Manual Tilt Features And Operation

    FEATURES AND CONTROLS • Fuel connector protector cap ‑ Place over the fuel connector when the fuel hose is disconnected. Fuel connector protector cap 32122 • Cooling water intakes ‑ The outboard has two water intakes for cooling the engine, the primary water intake and the secondary water intake. Secondary water intake Primary water intake 32141...
  • Page 64 FEATURES AND CONTROLS • Tilt pin ‑ Set the vertical operating angle on the outboard. Refer to Setting the Operation Angle of the Outboard. Tilt lever Tilt pin 32138 BASIC TILTING OPERATION The tilt feature allows the operator to tilt the outboard to a higher tilt angle for operation in shallow water, or tilt the outboard to the full up position.
  • Page 65 FEATURES AND CONTROLS 4. Take hold of the top cowl grip and tilt the outboard all the way up until it locks in place. 32150 LOWERING OUTBOARD DOWN TO RUN POSITION Position the tilt lever to the release position. Raise the outboard slightly to release it from its locked position and gently lower it.
  • Page 66 FEATURES AND CONTROLS 5. To release the outboard out of shallow water drive, position the tilt lever to the release position, slightly lift up the outboard, and gently lower it down. 32151 SETTING THE OPERATION ANGLE OF THE OUTBOARD The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the six adjustment holes provided.
  • Page 67 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 32152 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.

  • Page 68: Power Tilt Features And Operation

    FEATURES AND CONTROLS • In excess, can cause boat porpoising (bouncing) or propeller ventilation Power Tilt Features and Operation POWER TILT Models equipped with power tilt allows the operator to use the tilt switch to adjust the tilt position of the outboard from full down to full up. This tilt system is designed to be adjusted when the engine speed is at idle speed or with the engine turned off.
  • Page 69 FEATURES AND CONTROLS 3. Disengage the tilt support lever by slightly tilting up the outboard and releasing the tilt support bracket. Lower the outboard. Tilt support lever 31919 PROKICKER CENTERING STRAPS FEATURE ProKicker centering straps (if equipped) will center the outboard and prevent the outboard from turning while the outboard is tilted up.
  • Page 70 FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating your boat in shallow water, the outboard can be tilted up to a higher tilt angle. Reduce engine speed to idle for tilting. Operate the outboard at slow speed while tilted up for shallow water operation. Keep the cooling water intake holes submerged in the water and continue to check for water discharge from the water pump indicator hole.
  • Page 71 FEATURES AND CONTROLS The adjustment of the tilt‑in stop pins will set the vertical operating angle of your outboard. Proper adjustment allows the boat to run stable, achieve optimum performance, and minimize steering effort. Tilt‑in stop pins 32192 NOTE: Refer to the following lists when adjusting the operating angle of your outboard.

  • Page 72: Warning System Features And Operation

    FEATURES AND CONTROLS Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom can: • Lower the bow • Result in quicker planing off, especially with a heavy load or a stern heavy boat •...

  • Page 73: Trim Tab Adjustment

    FEATURES AND CONTROLS ENGINE OVERHEAT Check for a steady stream flowing out of the water pump indicator hole. If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check cooling water intake holes for obstruction. If no obstruction is found, this may indicate a blockage in the cooling system or a water pump problem.
  • Page 74 FEATURES AND CONTROLS If adjustment is necessary, loosen the trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right, move the trailing edge of trim tab to the right.

  • Page 75: 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 76: Operating Outboard As An Auxiliary Engine

    OPERATION Operating Outboard as an Auxiliary Engine If the outboard is used as an auxiliary engine, stop the engine and tilt the outboard out of the water when using the main power source. IMPORTANT: The outboard must be restrained from bouncing while operating the boat using the main power source.

  • Page 77: Engine Break-In Procedure

    OPERATION 3. Make sure the cooling water intake is submerged. 26837 4. Tiller handle models with manual or electric start, have a quick reference decal on the tiller handle that shows the sequence for starting the engine. Use this quick reference for cold or hot starting. 57622 Tiller handle starting sequence decal Engine Break‑in Procedure...
  • Page 78 OPERATION 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after the engine has warmed up.
  • Page 79 OPERATION • After the engine starts to warm up, push the choke knob in. The choke is open in this position. Choke is open Choke is partially open Choke is closed 57690 IMPORTANT: Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery.
  • Page 80 OPERATION 8. Flooded engine ‑ If the engine will not start, push in the throttle only button and advance the throttle grip to fast throttle speed. Push the choke knob all the way in and try to start the engine. After the engine has started, immediately reduce throttle speed to idle.

  • Page 81: Starting The Engine - Remote Control Models

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat.
  • Page 82 OPERATION 4. Set the remote control handle to the neutral position. IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle while engine is not running. This will inject fuel into the engine and may cause a hard starting flooded condition. 26838 IMPORTANT: Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery.
  • Page 83 OPERATION NOTE: Starting flooded engine ‑ Advance the throttle only feature and continue to crank the engine for starting. 7. Turn the ignition key to the START position and start the engine. If the engine is cold, push in on the key to choke the engine while cranking. If the engine fails to start in ten seconds, wait 30 seconds and try again.

  • Page 84: Gear Shifting

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat.

  • Page 85: Stopping The Engine

    OPERATION Stopping the Engine 1. Remote control models ‑ Reduce the engine speed and shift the outboard to the neutral position. Turn the ignition key to the "OFF" position. 26843 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to the neutral position.
  • Page 86 OPERATION 3. Remove and retain the hardware securing the rewind starter. Remove the rewind starter and move it to the side. 31984 Rewind starter 4. Remote control models ‑ Ensure the key switch is in the "ON" position. WARNING High voltage is present when starting or operating the engine. Do not touch any ignition component, wiring, or spark plug lead when starting or operating the engine.
  • Page 87 OPERATION 7. Pull the starter rope quickly.

  • Page 88: Outboard Care

    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 89: Inspection And Maintenance Schedule

    FAMILY : 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 Family number Engine family description Engine power ‑...
  • Page 90 MAINTENANCE AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST •...

  • Page 91: 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 thermostat and circulate water through the water passages.

  • Page 92: Cowl Removal And Installation

    MAINTENANCE 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 27259 3. Start the engine and run it at idle speed in neutral shift position. IMPORTANT: Do not run engine above idle when flushing.

  • Page 93: Battery Inspection

    MAINTENANCE 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 31925 INSTALLATION 1. Engage the front hook and position the cowl over the engine. 2. Lock the rear latch. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability.

  • Page 94: Steering Link Rod Fasteners

    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 95: Corrosion Control Anode

    MAINTENANCE Assemble the steering link rod to the engine with bolt, locknut, spacer, and flat washers. Torque the locknut to specifications. 31917 Bolt (12‑71970) Flat washer Spacer Nylon insert locknut (11‑16147‑‑3) Steering bracket Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off 1/4 turn) Description lb‑in.
  • Page 96 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. POWER TILT MODELS One anode is the trim tab and another anode is installed on the swivel bracket.

  • Page 97: 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 98 MAINTENANCE 5. Pull the propeller straight off of the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 31926 Cotter pin Rear thrust washer Front thrust hub IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed.

  • Page 99: Fuse Replacement - Electric Start Models

    MAINTENANCE 9. Place a block of wood between the gearcase and the propeller to prevent rotation and tighten the propeller nut to the specified torque. NOTE: If the propeller nut doesn't align with the propeller shaft hole after tightening, tighten the nut further to align with the hole. 10.

  • Page 100: Spark Plug Inspection And Replacement

    MAINTENANCE The voltage regulator circuit and the electric starting circuit are protected from overload by a 20 amp fuse. If the fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. 32119 Voltage regulator circuit ‑...

  • Page 101: Timing Belt Inspection

    MAINTENANCE 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs to inspect. Replace the spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3.

  • Page 102: Changing Engine Oil

    MAINTENANCE • Signs of wear on edges or outer surfaces of belt 31931 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 1.0 liter (1.1 U.S. quart). OIL CHANGING PROCEDURE 1. Lock the outboard in the full tilt up position. 2.
  • Page 103 MAINTENANCE 5. Lubricate the seal on the drain plug with oil and install. Tighten to the specified torque. 31922 4537 Description lb. in. lb. ft. Drain plug 23.7 CHANGING OIL FILTER 1. Position the outboard in a level operating position. 2.
  • Page 104 MAINTENANCE 4. Unscrew the old filter by turning the filter to the left. 5. Clean the mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw the new filter on until the gasket contacts the base, then tighten 3/4 to 1 turn.

  • Page 105: Lubrication Points

    MAINTENANCE 3. Idle engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref Description Where Used Part No.
  • Page 106 MAINTENANCE • Steering cable lubrication fitting (if equipped) ‑ Steer the outboard to fully retract the steering cable end into the outboard tilt tube. Lubricate the steering cable through the fitting. 31937 Steering cable lubrication fitting Steering cable end WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

  • Page 107: Gearcase Lubrication

    MAINTENANCE Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft. 31927 Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of...
  • Page 108 GEARCASE LUBRICANT CAPACITY Approximately 370 ml (12.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place the outboard in a vertical operating position. 2. Remove the vent plug from the vent hole.

  • Page 109: Checking Power Tilt Fluid

    MAINTENANCE 5. Remove the lubricant tube and install the cleaned fill/drain plug and new sealing washer. 31933 Vent plug and new sealing washer Vent hole Fill/drain plug and new sealing washer Checking Power Tilt Fluid 1. Tilt the outboard to the full up position and engage the tilt support lever. Tilt support lever 31919...

  • Page 110: Submerged Outboard

    MAINTENANCE 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Mercury or Quicksilver Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 111: Storage

    STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 112: Protecting Internal Engine Components

    STORAGE • 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. Corrosion Guard External metal surfaces...

  • Page 113: Battery Storage

    STORAGE • Never carry, store, or transport the outboard in the two positions shown. Engine damage could result from oil draining out of the crankcase. Tiller handle up Front side up 39346 Battery Storage • Follow the battery manufacturer's instructions for storage and charging. •...

  • Page 114: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • 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 115: Performance Loss

    TROUBLESHOOTING • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Low oil pressure. Check the oil level. • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. •...

  • Page 116: 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 117 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 118: 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 119 (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...

  • Page 120: Engine Installation

    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...

  • Page 121: Low Permeation Fuel Hose Requirement

    ENGINE INSTALLATION Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.
  • Page 122 ENGINE INSTALLATION INSTALLING OUTBOARD ON TRANSOM WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware.

  • Page 123: Steering Cable Installation

    Transom bracket clamp screw 28971 Description lb‑in. lb‑ft Transom bracket mounting bolts 13.5 Steering Cable Installation 1. Lubricate the entire cable end with Mercury or Quicksilver 2‑4‑C with PTFE. 28722 Tube Ref Description Where Used Part No. 2-4-C with PTFE...

  • Page 124: Steering Link Rod Fasteners

    ENGINE INSTALLATION 2. Insert the steering cable into the tilt tube. 32081 3. Tighten the steering cable nut to the specified torque. 4. Thread the steering cable seal onto the end of the tilt tube. 32082 Steering cable nut Steering cable seal Description lb‑in.
  • Page 125 ENGINE INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

  • Page 126: Remote Wiring Harness And Control Cable Installation

    ENGINE INSTALLATION Description lb‑in. lb‑ft Tighten until it seats, then back off 1/4 Nylon insert locknut "f" turn Remote Wiring Harness and Control Cable Installation REMOTE WIRE HARNESS CONNECTION 1. Remove the two bolts and remove the access cover. 32048 Access cover 2.
  • Page 127 ENGINE INSTALLATION 4. Connect the 8 pin connector to the engine harness. If the outboard is equipped with power tilt, connect the power tilt wire connections. BLUE/WHITE BLUE/WHITE GREEN/WHITE GREEN/WHITE 32064 BROWN/WHITE 8 pin connector Remote wiring harness Rubber grommet Power tilt wire connections 5.
  • Page 128 ENGINE INSTALLATION a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to neutral. Place a mark ("a") on the cable next to the end guide. b. Move the remote control handle from neutral into reverse and advance the handle to full speed position.
  • Page 129 ENGINE INSTALLATION 4. Attach the shift cable to the shift lever with a washer and cotter pin retainer. 32105 Cotter pin retainer Flat washer Shift cable Shift lever 5. Manually shift the outboard into neutral (propeller will rotate freely). 6. Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle.
  • Page 130 ENGINE INSTALLATION 7. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. 32068 End guide Center mark Cable barrel Rubber grommet 8. Check shift cable adjustments as follows: a. Shift the remote control into forward. The propeller shaft should be locked in gear.
  • Page 131 ENGINE INSTALLATION 4. Position the throttle cable into the rubber grommet and place the cable barrel into the barrel receptacle. 32069 Carburetor lever Full throttle stop Cotter pin retainer Flat washer Cable barrel Rubber grommet Throttle lever...

  • Page 132: Battery Installation - Electric Start Models

    ENGINE INSTALLATION 5. Install the access cover with two bolts. Tighten the bolts to the specified torque. 32112 Access cover Description lb. in. lb. ft. Access cover bolt Battery Installation ‑ Electric Start Models MOUNTING BATTERY Follow the battery manufacturer's instructions carefully. Mount battery in the boat so it is secured against movement, preferably in a battery box.
  • Page 133 ENGINE INSTALLATION DISCONNECTING OUTBOARD BATTERY CABLES First, disconnect the black battery cable from the (–) negative terminal and then disconnect the red battery cable from the (+) positive terminal. 27158...

  • Page 134: 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...

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