1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. 1F10201BK
  6. Operation, maintenance and installation manual

Mercury 1F10201BK Operation, Maintenance And Installation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Operation
Maintenance
and
Installation
Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 1F10201BK and is the answer not in the manual?

Questions and answers

Related Manuals for Mercury 1F10201BK

Summary of Contents for Mercury 1F10201BK

  • Page 1 Operation Maintenance Installation Manual...
  • Page 3 Keep this manual with the product for ready reference whenever you are on the water. 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: Christopher D. Drees, President, Mercury Marine...
  • Page 4 The product you have purchased comes with a Mercury Marine Limited Warranty. The terms of the warranty are set forth in the Warranty Manual, which can be accessed any time on the Mercury Marine website, at http:// www.mercurymarine.com/warranty‑manual. The Warranty Manual contains a...
  • Page 5 In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.

  • Page 7: Table Of Contents

    Boat Horsepower Capacity................21 Start in Gear Protection..................21 Selecting Accessories for Your Outboard............21 Low Permeation Fuel Hose Requirement ............22 Mercury Marine Validated Engine Mounting Hardware........22 Installing Outboard.................... 23 Remote Control Installation................25 Steering Link Rod Fasteners................26 Remote Wire Harness Connection..............
  • Page 8 Fuel Requirements................... 41 Low Permeation Fuel Hose Requirement ............42 EPA Pressurized Portable Fuel Tank Requirements........42 Fuel Demand Valve (FDV) Requirement............42 Mercury Marine's Pressurized Portable Fuel Tank........... 43 Filling Fuel Tank....................44 Engine Oil Recommendations................44 Checking Engine Oil..................45 Features and Controls Tiller Handle Features..................
  • Page 9 Maintenance Cleaning Care Recommendations..............73 EPA Emission Regulations................75 Inspection and Maintenance Schedule ............76 Maintenance Schedule Decal Icons ..............77 Maintenance Schedule Decal................78 Flushing the Cooling System................78 Top Cowl Removal and Installation..............80 Battery Inspection .................... 81 Exterior Care.....................
  • Page 10 Owner Service Assistance Service Assistance..................101 Ordering Literature..................103 Maintenance Log Maintenance Log.................... 105 viii...

  • Page 11: General Information

    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 12: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 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 BOAT IS IN OPERATION People in the water cannot take quick action to avoid a boat heading in their direction. 21604 Approach slowly and exercise extreme caution when boating in areas where people may be in the water.
  • Page 16 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 17: 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 18 GENERAL INFORMATION 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 that could be struck by the outboard or the boat bottom. The most significant action you can take to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 19: 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 20 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 21: Safe Boating Recommendations

    GENERAL INFORMATION 1. Examples of poor ventilation while the boat is stationary: 21626 Operating the engine when the boat is moored in a confined space Mooring close to another boat that has its engine operating 2. Examples of poor ventilation while the boat is moving: 21628 Operating the boat with the trim angle of the bow too high Operating the boat with no forward hatches open (station wagon effect)
  • Page 22 (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 23 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 24: Recording Serial Number

    XXXXXXX Serial Number Model designation XXXXX XX XXXX XXX Year manufactured Certified Europe Mercury Marine Insignia (as applicable) Brunswick Corp. Made in Japan CAN ICES-2 / NMB-2 70060 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 using the following table.

  • Page 25: 8/9.9 Fourstroke Specifications

    GENERAL INFORMATION 8/9.9 FourStroke Specifications 9.9 Command Thrust/ Models ProKicker Power 5.9 kw (8 hp) 7.3 kw (9.9 hp) Number of cylinders Full throttle RPM range 5000–6000 RPM Idle speed in forward 900 RPM gear Piston displacement 209.8 cc (12.8 cid) Cylinder bore 55 mm (2.17 in.) Piston stroke...

  • Page 26: Component Identification - Standard Models

    GENERAL INFORMATION Component Identification ‑ Standard Models STARBOARD SIDE VIEW Cowl latch Throttle only button Throttle friction adjustment knob Water pump indicator hole Oil drain plug Transom angle preset knob Engine flush plug Gear lubricant level plug Water inlet Gear lubricant fill/drain plug Trim tab 60883...
  • Page 27 GENERAL INFORMATION FRONT VIEW 57671 Choke/fast idle knob Oil pressure light Fuel line connector Start switch (electric tiller handle) Lanyard safety switch Copilot tension adjustment...
  • Page 28 GENERAL INFORMATION PORT VIEW 60884 Tiller lock release lever Start switch (electric tiller handle model) Steering friction adjustment lever (tiller model only) Tilt lock knob...

  • Page 29: Component Identification - Command Thrust/Prokicker Models

    GENERAL INFORMATION Component Identification ‑ Command Thrust/ProKicker Models 60798 Transom bracket Tilt support lever Gear lubricant level plug Primary water inlet Gear lubricant fill/drain plug Secondary water inlet Anti‑ventilation plate Engine flush plug Water pump indicator hole Cowl latch Oil drain screw Power tilt Kicker strap Throttle only button...
  • Page 30 GENERAL INFORMATION Throttle grip friction knob Power tilt button...

  • Page 31: 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 32: Low Permeation Fuel Hose Requirement

    1527 ‑ marine fuel hose. 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 33: Installing Outboard

    INSTALLATION Installing Outboard 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. BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat.
  • Page 34 INSTALLATION 1. Place the outboard on the centerline of the transom. 27005 2. Tighten the transom bracket clamp screws. 28501 3. Nonpower tilt models ‑ To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts.

  • Page 35: Remote Control Installation

    Description lb‑in. lb‑ft Transom bracket mounting bolts 13.5 – Remote Control Installation STEERING CABLE 1. Lubricate the entire cable end with Mercury Precision or Quicksilver 2‑4‑C with PTFE. 28722 Tube Ref Description Where Used Part No. 2-4-C with PTFE Steering cable end...

  • Page 36: Steering Link Rod Fasteners

    INSTALLATION 2. Insert the steering cable into the tilt tube. 28723 3. Tighten the steering cable nut to the specified torque. Steering cable nut 28724 Description lb‑in. lb‑ft Steering cable nut 47.5 – Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine.
  • Page 37 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 38: Remote Wire Harness Connection

    INSTALLATION Remote Wire Harness Connection 1. Remove the cover and cable receptacle bracket from the bottom cowl. 28003 Cover Cable receptacle bracket 28107 2. Route the remote wiring harness through the rubber grommet.
  • Page 39 INSTALLATION 3. Open up the clamp in the bottom cowl and position the remote wiring harness below the clamp. Connect the 8‑pin connector to the engine harness. Push the clamp down and secure the remote wiring harness into the bottom cowl. 28798 Clamp Remote wiring harness...

  • Page 40: Control Cable Installation

    INSTALLATION Description lb‑in. lb‑ft Cable receptacle bracket – Control Cable Installation THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control. 1. Position the remote control handle into full forward throttle position. NOTE: The throttle cable is the second cable to move when moving the control box out of neutral.
  • Page 41 INSTALLATION IMPORTANT: Make sure that the throttle cable end guide does not contact the remote wiring harness when the throttle cable is at full throttle position. If necessary, position and clamp the remote wiring harness. 28079 Cotter pin retainer Flat washer Full throttle stop Throttle lever Cable barrel...
  • Page 42 INSTALLATION b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark ("b") on the cable next to the end guide. c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the end guide with this center mark when installing cable to the engine.
  • Page 43 INSTALLATION 6. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. 28096 Flat washer Cotter pin retainer End guide Center mark Rubber grommet Shift cable Cable barrel Barrel receptacle...

  • Page 44: Battery Installation - Electric Start Models

    INSTALLATION 7. Install the access cover with two bolts. Tighten the bolts to the specified torque. 28097 Access cover Description lb‑in. lb‑ft Access cover bolt – 8. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear.

  • Page 45: Battery Connections

    Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Tube Ref Description Where Used Part No.
  • Page 46 INSTALLATION 3. Place a block of wood between gearcase and propeller to prevent rotation and tighten propeller nut. Secure propeller nut to the shaft with the cotter pin. Cotter pin Propeller nut Rear thrust washer Propeller Front thrust washer 27094...

  • Page 47: Transporting

    TRANSPORTING Aquatic Invasive Species (AIS) STOP AQUATIC HITCHHIKERS!™ Be A Good Steward. Clean. Drain. Dry. For additional information, visit StopAquaticHitchhikers.org. 68805 AIS and their spread can detrimentally impact the boating experience and the future of the boating lifestyle. Reducing the spread of AIS has led to significant national efforts to inspect boats moving between water bodies or across state and federal boundaries and could lead to delayed or denied access if AIS are suspected or found on board.
  • Page 48 TRANSPORTING 1. With the outboard still in the water, disconnect the remote fuel line and run engine until it stops. This will drain fuel from the carburetor. Install the protector cap over the fuel connector. Protector cap 28530 2. Remove outboard and hold it upright until the water is drained out. Keep the outboard in an upright position when carrying.

  • Page 49: Trailering Boat/Outboard - Models With Power Tilt

    TRANSPORTING 4. 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 39058 Trailering Boat/Outboard ‑ Models with Power Tilt Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device.
  • Page 50 TRANSPORTING Shift the outboard to forward gear. This prevents the propeller from spinning freely.

  • Page 51: 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 52: Low Permeation Fuel Hose Requirement

    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 53: Mercury Marine's Pressurized Portable Fuel Tank

    Vent/water drain holes 46453 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 54: Filling Fuel Tank

    As an optional choice, Mercury or Quicksilver SAE 25W‑40 Mineral Marine 4‑Stroke Engine Oil or SAE 25W‑40 Synthetic Blend Marine 4‑Stroke engine oil may be used. If the recommended Mercury or Quicksilver NMMA FC‑W certified oils are not available, a major outboard manufacturer's brand of NMMA FC‑W certified 4‑Stroke outboard oil of similar...

  • Page 55: Checking Engine Oil

    FUEL AND OIL IMPORTANT: Nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), full synthetic oils, low quality oils, and oils that contain solid additives are not recommended.

  • Page 56: Features And Controls

    FEATURES AND CONTROLS Tiller Handle Features IMPORTANT: Avoid engine flooding ‑ Do not rotate the throttle grip while engine is not running. Doing so will inject fuel into the engine and cause a possible hard starting flooded condition. • A decal on the tiller handle is a quick reference guide for starting a cold or hot engine.
  • Page 57 FEATURES AND CONTROLS • Tiller lock release lever ‑ Push the lever to move tiller handle from one position to another. Tiller lock release lever 3274 • Tiller handle lock cap ‑ Remove the lock cap on top of the tiller handle to lock in the up position.
  • Page 58 FEATURES AND CONTROLS • Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch. 19791 • Engine stop switch ‑ Push in to stop the engine. 57673 • Power tilt switch ‑ Push to tilt engine up/down. 4639 •...
  • Page 59 FEATURES AND CONTROLS • Throttle only button ‑ Pressing the button in while the outboard is in neutral disables the gear shift control of the tiller handle. 28550 • Throttle grip ‑ Controls the engine speed and shifting. 57674 Reverse gear throttle Forward gear throttle •...
  • Page 60 FEATURES AND CONTROLS • Low oil pressure warning light ‑ Warns the operator the engine has low oil pressure. When the low oil pressure light is on or is blinking, the engine will run rough and will not exceed 3000 RPM. 57676 •...
  • Page 61 FEATURES AND CONTROLS • Tilt lock knob ‑ Locks the engine in the full tilt position. 28564 • Trim position knob ‑ Presets the trim position. 28551 • Kicker strap (power tilt models) ‑ Prevents the engine from turning while tilted up.

  • Page 62: 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 Tilt switch Ignition key switch—OFF, ON, START...

  • Page 63: Warning System

    FEATURES AND CONTROLS GEAR SHIFTING IMPORTANT: Observe the following: • Never shift the outboard into or out of gear unless the engine speed is at idle. Shifting at higher than engine idle speed could cause damage to the gearcase. • Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed.

  • Page 64: Power Tilt (If Equipped)

    FEATURES AND CONTROLS Power Tilt (if equipped) This outboard has a tilt control called power tilt. This enables the operator to easily adjust the position of the outboard by pressing the tilt switch. With the engine turned off, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up to permit shallow water operation.
  • Page 65 FEATURES AND CONTROLS TILTING OPERATION To tilt the outboard, shut off the engine and press the tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. Tiller handle models have a kicker strap located on each side of the outboard, preventing the outboard from turning when tilted up.

  • Page 66: Setting The Transom Angle Of Your Outboard

    FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and lifting the knob. Lower the outboard. Tilt support lever Knob 4650 Setting the Transom Angle of your Outboard The vertical transom angle of your outboard is adjusted by changing the position of the preset tilt knob in one of the three adjustment holes provided.
  • Page 67 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 28533 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: Adjusting Transom Angle

    FEATURES AND CONTROLS • In excess can cause boat porpoising (bouncing) or propeller ventilation. Adjusting Transom Angle 1. Stop the engine. Shift the outboard into forward. Raise the engine to one of the tilt release positions. Change the preset knob position and lower the outboard to the preset transom angle position.

  • Page 69: Tilting Outboard

    FEATURES AND CONTROLS 2. To release the shallow water drive, stop the engine and tilt the outboard up to one of the tilt release position. Gently lower the outboard to the preset transom angle. 28592 Shallow water drive positions Tilt release positions Water Intake Tilting Outboard 1.

  • Page 70: Trim Tab Adjustment

    FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 71: 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 72: 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 73: 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 74 OPERATION 3. Set the lanyard stop switch to RUN position. Refer to General Information—Lanyard Stop Switch. 19791 4. Set the tiller handle gear shift to the neutral start position. 57677 5. Cold engine ‑ • Pull the choke knob out two detent positions for starting a cold engine. The choke is closed in this position.
  • Page 75 OPERATION 6. Manual starting models ‑ Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until the engine starts. After the engine has started, push in the choke knob.

  • Page 76: 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 77 OPERATION 3. Set the lanyard stop switch to RUN position. Refer to General Information—Lanyard Stop Switch. 19791 4. Ensure the remote control handle is in the neutral position. IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle when the engine is not running.

  • Page 78: Starting A Hot Engine

    OPERATION 6. Turn the ignition key to the START position. If the engine is cold, push the key in to choke the engine while cranking. If the engine fails to start in ten seconds, wait 30 seconds and try again. If the engine begins to stall, push the key in (choke) until the engine is running smoothly.

  • Page 79: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift the outboard into or out of gear unless the engine speed is at idle. Shifting at higher than engine idle speed could cause damage to the gearcase. • Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed.

  • Page 80: Stopping The Engine

    OPERATION Stopping the Engine 1. Remote control models ‑ Reduce the engine speed and shift the outboard to neutral position. Turn the ignition key to "OFF" position. 26843 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to neutral position.
  • Page 81 OPERATION 4. Remove the three screws holding the flywheel cover on. 28614 Flywheel cover screws (3) Recoil neutral interlock Fuse holder 5. Remove the flywheel cover. 6. Remote control models ‑ Ensure the key switch is in the "ON" position. WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.
  • Page 82 OPERATION 8. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 28616 9. Pull the starter rope quickly.

  • Page 83: 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 84 Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 85: Epa Emission Regulations

    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 86: Inspection And Maintenance Schedule

    MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Inspection and Maintenance Schedule DAILY CHECKS • Check the engine oil level • Check the lanyard stop switch •...

  • Page 87: Maintenance Schedule Decal Icons

    MAINTENANCE • Check the remote control cable adjustment, if equipped—dealer item • Replace the high‑pressure fuel filter, if equipped—dealer item • Replace the accessory drive belt, if equipped—dealer item • Check the power trim fluid level, if equipped—dealer item • Inspect the engine motor mounts—dealer item Maintenance Schedule Decal Icons A maintenance schedule decal is located on the engine to remind the owner or...

  • Page 88: Maintenance Schedule Decal

    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 89 MAINTENANCE 1. Remove the propeller. Refer to Propeller Replacement. Install the flushing attachment so the rubber cups fit tightly over the cooling water intake. 27256 Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

  • Page 90: 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 91: Battery Inspection

    MAINTENANCE 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. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3.

  • Page 92: Steering Link Rod Fasteners

    MAINTENANCE FUEL LINE FILTER Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. 58658 IMPORTANT: Inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware...
  • Page 93 MAINTENANCE 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 94: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your outboard has a corrosion control anode installed to the gearcase. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. The anode requires periodic inspection especially in saltwater which will accelerate the erosion.
  • Page 95 MAINTENANCE 2. Move the gear shift lever into neutral (N). 26838 57677 3. Straighten and remove the cotter pin. 4. Place a block of wood between the gearcase and propeller to hold the propeller and remove the propeller nut. 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.

  • Page 96: Fuse Replacement - Electric Start Models

    MAINTENANCE Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 7. Install the front thrust washer, propeller, rear thrust washer, and propeller nut onto the shaft. 8. Place a block of wood between the gearcase and propeller to prevent rotation and tighten the propeller nut.

  • Page 97: Spark Plug Inspection And Replacement

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace the fuse with a new fuse with the same rating. Identifying a blown fuse Good fuse Blown fuse 28619 Spark Plug Inspection and Replacement WARNING...

  • Page 98: Timing Belt Inspection

    MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.9 mm (0.035 in.) 4. Before installing spark plug, clean off any dirt on the spark plug seat. Install plug finger‑tight, and then tighten 1/4 turn or torque to specifications.
  • Page 99 MAINTENANCE OIL CHANGING PROCEDURE 1. Lock the outboard in the full tilt up position. 2. Position the outboard so the drain hole is facing downward. 3. Remove the drain plug and drain the engine oil into an appropriate container. IMPORTANT: Do not use a crankcase oil pump when changing the oil or engine damage may occur.

  • Page 100: Lubrication Points

    MAINTENANCE Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref Description Where Used Part No. Swivel bracket, transom clamp screws, Extreme Grease tilt tube, throttle and shift cables, 8M0071842 steering cable grease fitting Swivel bracket, transom clamp screws, 2-4-C with PTFE tilt tube, throttle and shift cables, 92-802859A 1...
  • Page 101 MAINTENANCE • Lubricate the throttle and shift cable moving components, pivot locations, and shift detent. 57719 • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting.

  • Page 102: Gearcase Lubrication

    MAINTENANCE 3. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller.
  • Page 103 Standard model gearcase: Approximately 320 ml (10.8 fl oz). Command Thrust model gearcase: Approximately 370 ml (12.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position.

  • Page 104: Checking Power Tilt Fluid

    4530 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 105: Submerged Outboard

    MAINTENANCE Tube Ref Description Where Used Part No. Power Trim and Power tilt 92-858074K01 Steering Fluid Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 106: 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 107: 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 108: 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 39058 Battery Storage • Follow the battery manufacturer's instructions for storage and charging. •...

  • Page 109: 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 110: Performance Loss

    TROUBLESHOOTING c. Stuck anti‑siphon valve located on permanently built in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Low oil pressure. Check the oil level. •...
  • Page 111 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 112 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 113 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 114 OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total Total Due...
  • Page 115 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:

Fourstroke 9.9Fourstroke 9.9 command thrust prokickerFourstroke 9.9 prokickerFourstroke 8

Table of Contents

Save PDF