1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. GO BOLDLY 30 FourStroke
  6. Operation, maintenance and installation manual

Mercury GO BOLDLY 30 FourStroke Operation, Maintenance And Installation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operation
Maintenance
and
Installation
Manual
Scan for service and support information

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GO BOLDLY 30 FourStroke and is the answer not in the manual?

Questions and answers

Related Manuals for Mercury GO BOLDLY 30 FourStroke

Summary of Contents for Mercury GO BOLDLY 30 FourStroke

  • Page 1 Operation Maintenance Installation Manual Scan for service and support information...

  • Page 3: Read This Manual Thoroughly

    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. Read This Manual Thoroughly IMPORTANT: If you do not understand any portion of this manual, contact your dealer.

  • Page 4: California Proposition

    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 5: Copyright And Trademark Information

    Mercury Marine Limited Warranty or legal guarantee (if and where applicable) being fully or partly void.
  • Page 6   ...

  • Page 7: Table Of Contents

    Recording Serial Number..................15 Selecting Outboard Accessories................15 30/40/50/60 FourStroke Specifications.............. 16 Outboard Installation Important Installation Information..............19 Mercury Marine Validated Engine Mounting Hardware........19 Accessories Mounted to Mercury Outboard Engines......... 20 Installation Specifications..................23 Installing the Outboard..................24 Steering Cable....................... 29 Connections Through the Rigging Grommet............
  • Page 8 Fuel and Oil Fuel Requirements....................49 Fuel Additives......................50 Electric Fuel Pump ....................50 Fuel Demand Valve (FDV) Requirement.............. 50 Fuel Tank....................... 51 Low Permeation Fuel Hose Requirement ............52 Engine Oil Recommendations................53 Checking and Adding Engine Oil................53 Features and Controls Remote Control Features..................
  • Page 9 Maintenance EPA Emissions Regulations.................. 71 Cleaning Care Recommendations................ 72 Exterior Care......................74 Propeller Replacement ‑ 87.3 mm (3‑7/16 in.) Diameter Gearcase....74 Propeller Replacement ‑ 108 mm (4‑1/4 in.) Diameter Gearcase...... 77 Top Cowl Removal and Installation..............80 Inspection and Maintenance Schedule..............80 Corrosion Control Anode..................
  • Page 10 Owner Service Assistance Service Assistance....................99 Ordering Literature..................... 101 Maintenance Log Maintenance Log....................103    viii...

  • Page 11: Important Safety Information

    IMPORTANT SAFETY 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 IMPORTANT SAFETY INFORMATION Be Alert to Carbon Monoxide Poisoning Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but whenever engine exhaust can be tasted or smelled, CO is being inhaled.

  • Page 13: Outboard Remote Control Models

    IMPORTANT SAFETY INFORMATION Poor Ventilation • Boat in Motion: Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. The following shows examples of poor ventilation while the boat is moving. 79353 Operating the boat with the trim angle of the bow too high Operating the boat with no forward hatches open...

  • Page 14: Remote Steering Notice

    IMPORTANT SAFETY INFORMATION The outboard's remote control must be equipped with a start‑in‑neutral‑only protection device. The device prevents the engine from starting when the shift control is in any position other than neutral. 58237 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.
  • Page 15 IMPORTANT SAFETY 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 16: Staying Safe Around The Outboard

    IMPORTANT SAFETY INFORMATION • High performance boats • Light, sensitive‑handling fishing boats operated by a hand tiller Falling overboard and accidental ejections are also likely to occur as a result of poor operating practices such as: • Sitting on the back of the seat or gunwale at planing speeds •...

  • Page 17: Safe Operating Practices

    For additional information, obtain a copy of the Guide to Hi‑Performance Boat Operation booklet from Mercury Marine, at https:// publications.brunswick.com/product‑p/ob‑om‑hp.htm. Passenger Safety - Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.
  • Page 18 IMPORTANT SAFETY 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. 79349 Boats with Front‑Mounted, Raised Pedestal Fishing Seats Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed.
  • Page 19 IMPORTANT SAFETY 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 20 IMPORTANT SAFETY INFORMATION • Check onboard safety equipment. Regulating bodies in most areas require specific safety equipment on every powered boat. Even if not required, consider carrying the following on board, and always check the condition before each outing: • Personal flotation device (one per person onboard) •...
  • Page 21 (weight) capacities (refer to the boat's capacity plate). Know the boat's operating and loading limitations. Know if the boat will float if it is full of water. When in doubt, contact a Mercury Marine Authorized Dealer or the boat manufacturer.
  • Page 22 IMPORTANT SAFETY INFORMATION • Some U.S. states and Canadian provinces require a "skier down" flag, have restrictions on spotter age, have rearview mirror requirements, and so forth. Know and obey all federal, state (provincial), and local laws and regulations. • Report accidents.

  • Page 23: Impact With Underwater Hazards

    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 a Mercury Marine Authorized Dealer inspect and repair the vessel or power package. This outboard is equipped with a hydraulic trim and tilt system that also contains a shock absorbing feature.
  • Page 24 IMPORTANT SAFETY INFORMATION Striking a floating or underwater object could result in any of a number of situations. Some of these situations could yield the following: • Part of the outboard or the entire outboard could break loose and fly into the boat.

  • Page 25: General Information

    The misuse of approved accessories or the use of nonapproved accessories can damage the product. Genuine Mercury Precision or Quicksilver accessories have been specifically designed and tested for each Mercury Marine outboard. These accessories are available from Mercury Marine dealers.   ...

  • Page 26: 30/40/50/60 Fourstroke Specifications

    GENERAL INFORMATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Read the installation, operation and maintenance manuals for all selected accessories. Refer to additional information regarding mounting accessories to the transom clamp bracket, in the Outboard Installation section.
  • Page 27 *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.   ...
  • Page 28 GENERAL INFORMATION Notes:   ...

  • Page 29: Outboard Installation

    OUTBOARD INSTALLATION Important Installation Information The process of rigging boats—including proper engine installation—has become more complex over the years. As a result, Mercury Marine recommends that engines be installed only by Mercury Marine authorized dealers. Any consumers opting to install an outboard engine on their own are hereby advised to read and comply with the following instructions in their entirety.

  • Page 30: Accessories Mounted To Mercury Outboard Engines

    OUTBOARD INSTALLATION Accessories Mounted to Mercury Outboard Engines Mercury Marine has been made aware that certain aftermarket marine accessories such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices can be mounted to the boat by use of the same fasteners that secure the outboard to the transom (or jack plate).
  • Page 31 OUTBOARD INSTALLATION Exceptions to the Unacceptable Accessory Mounting On some boats the outside of the transom area does not provide a completely flat surface to mount the engine (see Figure 2). No gap is permitted between the transom clamp bracket and the transom. An example of this is a thick cap, or other feature that prevents the engine transom clamp brackets from sitting on a flat surface [within 3.2 mm (0.125 in.)].
  • Page 32 OUTBOARD INSTALLATION Figure 3 Conventional spacer plate—must support the entire surface of each transom clamp bracket 70105 Acceptable Installations After the engine is mounted to the transom or jack plate, consistent with the engine installation instructions, it is acceptable to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 5, but only if: •...

  • Page 33: Outboard Installation

    OUTBOARD INSTALLATION Figure 5 70106 Accessory manufacturer supplied fasteners through unused transom clamp bracket holes Minimum clearance 3.2 mm (0.125 in.) Transom clamp bracket wall Radius Edge of accessory bracket Engine supplied mounting fasteners Installation Specifications 2763 Minimum transom opening Engine centerline for dual engines Minimum Transom Opening    Single engine (remote)

  • Page 34: Installing The Outboard

    OUTBOARD INSTALLATION Minimum Transom Opening    Single engine (tiller) 76.2 cm (30 in.)    Dual engines 101.6 cm (40 in.) Engine Centerline    Minimum 66 cm (26 in.) Installing the Outboard Lifting Outboard Use the lifting eye on the engine. 28510 Installing Outboard Drilling Outboard Mounting Holes 1.
  • Page 35 OUTBOARD INSTALLATION Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom Mounting Bolts Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description...
  • Page 36 OUTBOARD INSTALLATION Available Outboard Mounting Bolts Part Number Description 8M0028080 ½‑20 x 7.50 in. long (2.75 in. thread) 8M0032860 ½‑20 x 8.00 in. long (2.75 in. thread) Checking Boat Transom Construction IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking.
  • Page 37 Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area.
  • Page 38 OUTBOARD INSTALLATION Installation 1. Apply marine sealer to the shanks of the bolts, not to the threads. 2. Fasten the outboard with the correct mounting hardware. Tighten the locknuts to the specified torque. IMPORTANT: Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening.

  • Page 39: Steering Cable

    OUTBOARD INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Steering Cable Steering Cable - Starboard Side Routed Cable 1. Lubricate the entire cable end. 10261 Description Where Used...
  • Page 40 OUTBOARD INSTALLATION 3. Tighten the nut to the specified torque. 2 506 Description lb‑in. lb‑ft 47.5 – Steering Cable Seal 1. Mark tilt tube 6.4 mm (0.25 in.) from end. Install seal components. 2. Thread cap to the mark. 8041 6.4 mm (1/4 in.) Plastic spacer O‑ring seal...
  • Page 41 OUTBOARD INSTALLATION IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head screw and self‑locking nylon insert locknuts as shown in the following illustration. These locknuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.

  • Page 42: Connections Through The Rigging Grommet

    OUTBOARD INSTALLATION 4. Tighten the locknut at the steering bracket to the specified torque. Description lb‑in. lb‑ft Nylon insert locknut at the – steering bracket Connections Through the Rigging Grommet Remote Wiring Harness Installation 1. Remove two screws and remove the access cover. 79124 Screws Access cover...
  • Page 43 OUTBOARD INSTALLATION 3. Connect the 14‑pin connector to the engine harness and fasten the harness with the retainer. 41014 Remote wiring harness Retainer 14‑pin connector Battery Cable Connections Single Outboard Red sleeve ‑ Positive (+) Black sleeve ‑ Negative (–) Cranking battery 15496   ...
  • Page 44 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Black sleeve ‑ Negative (–) Ground cable Cranking battery Fuel Hose Connection - Remote Control Models Remote Fuel Hose Size Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.).
  • Page 45 OUTBOARD INSTALLATION Fuel Hose Connection Fasten the remote fuel hose to the fitting with a metal hose clamp or the plastic type hose clamp that is provided with the outboard. Hose clamp Remote fuel hose 28511 Shift Cable Installation Install the cables into the remote control following the instructions provided with the remote control.
  • Page 46 OUTBOARD INSTALLATION 3. Position the remote control handle into neutral. 58237 4. Fit the shift cable through the rubber grommet. Rubber grommet Shift cable 28489 5. Attach the shift cable to the shift lever with a bow tie clip retainer.   ...
  • Page 47 OUTBOARD INSTALLATION 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. 28487 Cable end guide Bow tie clip retainer Center mark Cable barrel Barrel latch 7.
  • Page 48 OUTBOARD INSTALLATION Throttle Cable Installation Install the cables into the remote control following the instructions provided with the remote control. 1. Position the remote control into neutral. 58237 2. Fit the throttle cable through the rubber grommet. Rubber grommet Throttle cable 28491 3.
  • Page 49 OUTBOARD INSTALLATION 5. Fasten the throttle cable to the mounting stud with a flat washer and locknut. Tighten the locknut to the specified torque. 28494 Cable end guide Bow tie clip retainer Flat washer Locknut Cable barrel Description lb‑in. lb‑ft Throttle cable locknut –...

  • Page 50: Propeller Installation

    Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Apply Quicksilver or Mercury Precision Lubricants Extreme Grease to the propeller shaft. 26902...
  • Page 51 OUTBOARD INSTALLATION Description Where Used Part No. Extreme Grease Propeller shaft 8M0190472 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 52 OUTBOARD INSTALLATION 4. Flo‑Torq III drive hub propellers ‑ Install the forward thrust hub, replaceable drive sleeve, propeller, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. Propeller nut Propeller nut retainer Rear thrust hub Propeller Replaceable drive a b c d e f 3223...
  • Page 53 OUTBOARD INSTALLATION 1. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Extreme Grease. 26902 Description Where Used Part No. Extreme Grease Propeller shaft 8M0190472 2. Flo‑Torq I drive hub propellers ‑ Install the forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft.

  • Page 54: Trim-In Stop Adjustment - Power Trim Models

    OUTBOARD INSTALLATION 5. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer. Secure the propeller nut by bending the tabs up and against the flats on the propeller nut. Pins Tabs 26906 6. Install the spark plug leads. Trim‑In Stop Adjustment ‑...

  • Page 55: Transporting

    TRANSPORTING Aquatic Invasive Species (AIS) STOP AQUATIC HITCHHIKERS!™ Be A Good Steward. Clean. Drain. Dry. For additional information, visit StopAquaticHitchhikers.org. 68805 About AIS 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 56: Transporting Portable Fuel Tanks

    TRANSPORTING Additional clearance may be required for railroad crossings, driveways, and trailer bouncing. If additional clearance is required, tilt the outboard up by using an accessory outboard support device. Refer to an authorized dealer for recommendations. 28517 IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering.
  • Page 57 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 58 TRANSPORTING Notes:   ...

  • Page 59: Fuel And Oil

    Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in Mercury Marine engines. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).

  • Page 60: Fuel Additives

    Fuel Additives To minimize carbon deposit buildup in the engine, add Mercury or Quicksilver Quickstor fuel stabilizer to the engine's fuel at each tank fill throughout the boating season. Use additive only as directed on the container.

  • Page 61: Fuel Tank

    34.4 kPa (5.0 psi). Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a portable pressurized fuel tank that meets the preceding EPA requirements. This fuel tank is available as an accessory and is provided with certain portable outboard models.

  • Page 62: Low Permeation Fuel Hose Requirement

    FUEL AND OIL 4. Press down on the tab lock again and remove the cap. Fuel cap Manual vent screw Tab lock 46290 Using the Pressurized Portable Fuel Tank • When installing the fuel tank cap, turn the cap to the right until there is an audible click.

  • Page 63: Engine Oil Recommendations

    4‑stroke outboard oil may be used. 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 64 FUEL AND OIL 3. Pull the dipstick back out again and observe the oil level. If the oil level is low, remove the oil filler cap and fill to (but not over) the upper oil level with the recommended oil. IMPORTANT: Inspect oil for signs of contamination.

  • Page 65: Features And Controls

    FEATURES AND CONTROLS Remote Control Features The following image highlights the features of some common Mercury Precision and Quicksilver remote controls. 58240 Trim/tilt switch – Refer to Power Trim and Tilt Ignition key switch – OFF, ON, START Throttle only button – Refer to Operation – Starting the Engine...
  • Page 66 Guardian will allow the engine to reach a normal operating speed. SmartCraft Product A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.

  • Page 67: Power Trim And Tilt

    FEATURES AND CONTROLS The SmartCraft instrument package will also aid in Engine Guardian diagnostics. The SmartCraft instrument package will display critical engine alarm data and potential problems. Power Trim and Tilt The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch.
  • Page 68 FEATURES AND CONTROLS The most significant side effect of changing the trim away from the middle of the range is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the propeller shaft no longer being parallel to the water surface.
  • Page 69 FEATURES AND CONTROLS • Lower the outboard to rest on the tilt support lever. To disengage the tilt support lever: • Tilt the outboard up slightly. • Rotate the knob to bring the support lever down. • Lower the outboard. Tilt support lever Knob 28931...

  • Page 70: Trim Tab Adjustment

    FEATURES AND CONTROLS Shallow Water Operation When operating the boat in shallow water, the outboard can be tilted beyond the maximum trim range to prevent hitting bottom. 1. Reduce engine speed below 2000 RPM. 2. Tilt outboard up, keeping the water intake holes submerged at all times. 3.
  • Page 71 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 72 FEATURES AND CONTROLS Notes:   ...

  • Page 73: Operation

    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 3500 RPM or at approximately half throttle.

  • Page 74: Prestarting Instructions

    OPERATION Prestarting Instructions 1. Check the engine oil level. 28525 2. Make sure the cooling water intake is submerged. 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.
  • Page 75 OPERATION 1. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 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.
  • Page 76 OPERATION 5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. Fully closed position Maximum fast idle speed position 26840 6. Starting a flooded engine: Advance the throttle‑only lever or control handle to the maximum throttle‑only position, and continue to crank the engine for starting.

  • Page 77: Emergency Starting

    OPERATION Emergency Starting WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. WARNING The exposed moving flywheel can cause serious injury. Keep hands, hair, clothing, tools, and other objects away from the engine when starting or running the engine.

  • Page 78: Gear Shifting

    OPERATION 3. Turn the ignition key to the ON position. 26846 4. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 5. Pull the starter rope to start the engine. 26848 Gear Shifting IMPORTANT: Observe the following: •...

  • Page 79: Stopping The Engine

    OPERATION • The outboard has three gear positions: forward, neutral (out of gear), and reverse. 58239 Remote control models ‑ When shifting, always stop at the neutral • position and allow the engine speed to return to idle. 58237 • Always shift the outboard into gear with a quick motion.

  • Page 80: Operating In Freezing Temperatures

    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. Exercise care to not spray the corrosion control anodes, as this will reduce the anodes' effectiveness.

  • Page 81: Maintenance

    MAINTENANCE EPA Emissions 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 82: Cleaning Care Recommendations

    Record all maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. Selecting Outboard Replacement Parts For best results, use only 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...
  • Page 83 Keep water spray out of the air 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 84: Exterior Care

    MAINTENANCE Description Where Used Part No. External metal surfaces of the powerhead and Corrosion Guard 92-802878 55 powerhead components. Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes. Propeller Replacement ‑...
  • Page 85 (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and each time the propeller is removed. 6. Apply Quicksilver or Mercury Precision Lubricants Extreme Grease to the propeller shaft. 26902...
  • Page 86 MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install the forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft. Propeller nut Propeller nut retainer Propeller Forward thrust hub 26903 8. Flo‑Torq II drive hub propellers ‑ Install the forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft.

  • Page 87: Propeller Replacement - 108 Mm (4-1/4 In.) Diameter Gearcase

    MAINTENANCE Propeller Replacement ‑ 108 mm (4‑1/4 in.) Diameter Gearcase WARNING Rotating the propeller shaft may cause the engine to crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always turn the ignition key or lanyard stop switch to the OFF position and remove the spark plug leads from the spark plugs while servicing.
  • Page 88 (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and each time the propeller is removed. 6. Apply Quicksilver or Mercury Precision Lubricants Extreme Grease to the propeller shaft. 26902...
  • Page 89 MAINTENANCE 8. Flo‑Torq II drive hub propellers ‑ Install the forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft. Propeller nut Propeller nut retainer Thrust hub Propeller Replaceable drive sleeve Forward thrust hub 26941 ‑...

  • Page 90: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation Removal Pull out the rear lock lever and remove the top cowl. 28439 Installation 1. Lower the top cowl over the engine. 2. Bring the front of the cowl down first and engage the front hook. Lower the cowl into its seated position and apply downward pressure to the back of the cowl to lock it in place.
  • Page 91 MAINTENANCE Before Each Use Check the steering system for binding. Check the propeller for damage. Inspect the hydraulic steering fittings and hoses for leaks or damage, if equipped. Check the hydraulic steering fluid level, if equipped. After Each Use Wash the power package exterior with fresh water. Flush the outboard cooling system if operating in saltwater or brackish water.

  • Page 92: Corrosion Control Anode

    9.9 hp to 150 hp. These kits contain a new filter, oil, and any additional parts required for a complete oil change. The kits are available in both Mercury Marine and Quicksilver brands. Refer to the following chart for details.

  • Page 93: Changing Engine Oil

    8M0188357 8M0107513 69221 Changing Engine Oil Engine Oil Capacity Capacity Fluid Type Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil 3.0 Liter (3 U.S. Engine oil Quarts) Mercury or Quicksilver SAE 10W‑30 4‑Stroke Marine Engine Oil Oil Changing Procedure 1.

  • Page 94: Flushing The Cooling System

    MAINTENANCE Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew the old filter by turning the filter to the left. 3. Clean the mounting base. Apply a film of clean oil to the filter gasket. Do not use grease.

  • Page 95: Fuel System

    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 activate the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

  • Page 96: Installation

    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 the 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 97: Gearcase Lubricant

    MAINTENANCE Gearcase Lubricant Gearcase Lubrication - For 87.3 mm (3-7/16 in.) Diameter Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
  • Page 98 MAINTENANCE 5. Remove the lubricant tube and install a cleaned fill/drain plug and sealing washer. 26975 Vent hole Vent plug Fill/drain plug Gearcase Lubrication - For 108 mm (4-1/4 in.) Diameter Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
  • Page 99 MAINTENANCE 3. Remove the vent plugs and fill/drain plug and drain the lubricant. Vent plugs Fill/drain plug 26977 Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 710 ml (24 fl oz). Checking Lubricant Level and Filling Gearcase 1. Place the outboard in a vertical operating position. 2.

  • Page 100: Lubrication Points

    MAINTENANCE Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Extreme Grease. Description Where Used Part No. Propeller shaft, tilt support lever, swivel bracket, Extreme Grease 8M0190472 tilt tube, steering cable grease fitting • Propeller shaft • Tilt support lever ‑ Lubricate through fitting.

  • Page 101: Spark Plug Inspection And Replacement

    MAINTENANCE • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 28468 Fitting Steering cable end 2. Lubricate the steering link rod pivot points with lightweight oil. 28471 Steering link rod pivot points Spark Plug Inspection and Replacement...

  • Page 102: Transom Tightness Inspection

    MAINTENANCE 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3. Set the spark plug gap to specification. 26947 Spark Plug    Spark plug gap 1.0 mm (0.040 in.) 4.

  • Page 103: Storage

    Protecting External Outboard Components Lubricate all outboard components listed in Maintenance ‑ Inspection • and Maintenance Schedule. • Touch up any paint nicks. See a Mercury Marine Authorized Dealer for touch‑up paint.   ...

  • Page 104: Protecting Internal Engine Components

    STORAGE • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Description Where Used Part No. Corrosion Guard External metal surfaces 92-802878 55 Protecting Internal Engine Components • Remove the spark plugs and add approximately 30 ml (1 oz) of engine oil or inject a five second spray of storage seal into each spark plug hole.

  • Page 105: Troubleshooting

    TROUBLESHOOTING Fuse Replacement IMPORTANT: Always carry spare fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Open the fuse holder and look at the silver colored band inside the fuse.

  • Page 106: Engine Runs Erratically

    TROUBLESHOOTING • Incorrect starting procedure. Refer to Operation section. • Old or contaminated gasoline. • Engine flooded. Refer to Operation section. • Fuel is not reaching the engine. a. Fuel tank is empty. b. Fuel tank vent not open or restricted. c.

  • Page 107: Battery Will Not Hold Charge

    TROUBLESHOOTING • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge Possible Causes • Battery connections are loose or corroded. • Worn out or inefficient battery. •...
  • Page 108 TROUBLESHOOTING Notes:   ...

  • Page 109: 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 110 Satisfaction with your Mercury Marine 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 Mercury Marine Authorized Dealer. If you need additional assistance: 1.

  • Page 111: 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 Attn: Publications Department (920) 929‑5110...
  • Page 112 OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total Total Due       ...

  • Page 113: 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:

Go boldly 40 fourstrokeGo boldly 50 fourstrokeGo boldly 60 fourstroke

Table of Contents