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Mercury 150 Operation, Maintenance And Installation Manual

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  • 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: Your dealer can provide a demonstration of starting and operating procedures.

  • 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..................20 Selecting Outboard Accessories................21 Outboard Installation Important Installation Information..............23 Mercury Marine Validated Outboard Mounting Hardware......... 23 Transom Fastening Hardware................24 Accessories Mounted to the Transom Clamp Bracket........24 Fuel System......................27 Transom Cutout and Mounting Holes..............28 Checking Boat Transom Construction..............
  • Page 8 Fuel and Oil Fuel Requirements....................53 Fuel Additives......................54 Fuel Demand Valve (FDV) Requirement.............. 54 Fuel Tank....................... 55 Low Permeation Fuel Hose Requirement ............56 Quick‑Disconnect Fuel Hose Fitting..............57 Engine Oil Recommendations—Standard and Pro XS Models......57 Engine Oil Recommendations—SeaPro Models..........58 Checking and Adding Engine Oil................
  • Page 9 EPA Emissions Regulations.................. 79 Cleaning Care Recommendations................ 80 Top Cowl Removal and Installation..............82 Inspection and Maintenance Schedule..............83 Maintenance Schedule Decal (150 FourStroke)..........85 Battery Inspection ....................86 Flushing the Cooling System................86 Corrosion Control Anodes..................87 Engine Oil and Filter....................88 Fuel System......................
  • Page 10 Owner Service Assistance Identification Records..................113 Service Assistance....................113 Ordering Literature..................... 115 Maintenance Log Maintenance Log....................117    viii...

  • Page 11: Important Safety Information

    IMPORTANT SAFETY INFORMATION Boater's Responsibilities The operator (driver) is at all times responsible for the correct and safe operation of the boat and the safety of its occupants and the general public. Each operator should 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 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: Outboard Mounting Notice

    27746 To ensure optimal performance, installation of this outboard and related accessories is best done by trained technicians at a Mercury Marine Authorized Dealer. Owners choosing to install the outboard themselves should refer to the Outboard Installation section.

  • Page 15: Lanyard Stop Switch

    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 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.
  • Page 16 IMPORTANT SAFETY INFORMATION Lanyard Stop Switch and Safe Operation WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard.

  • Page 17: Staying Safe Around The Outboard

    IMPORTANT SAFETY INFORMATION • Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the boat. •...

  • Page 18: Safe Operating Practices

    IMPORTANT SAFETY INFORMATION Safe Operating Practices Passenger Safety - Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed.
  • Page 19 IMPORTANT SAFETY INFORMATION Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 79348 Protecting People in the Water While the Boat is in Operation People in the water cannot take quick action to avoid a boat heading in their direction.
  • Page 20 IMPORTANT SAFETY INFORMATION • Know and obey all nautical rules and laws of the waterways. • All powerboat operators are advised to complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and the state or provincial boating law enforcement agency provide courses.
  • 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 • Observe safe practices for using the boat for skiing, wake‑boarding, or similar activity. • A minimum of two persons should be onboard the boat whenever a skier is in the water: one to drive the boat and one to act as a spotter (facing the skier at all times).

  • 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 Reduce speed and proceed with caution when driving a boat in shallow water areas or in areas where underwater obstacles may exist that could be struck by the outboard or the boat bottom. The most significant action that can help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 25: General Information

    GENERAL INFORMATION Specifications Specifications - 150 Parameter Specification Rated power 110 kW (150 hp) Full throttle range 5000–5800 RPM Cold warm‑up 650–800 RPM At operating Idle speed in neutral 650 RPM temperature gear Idle charging 650–800 RPM compensation* Number of cylinders Piston displacement 3.0 L (183 cid)
  • Page 26 GENERAL INFORMATION Specifications - 150 Pro XS Parameter Specification Power 110 kW (150 hp) Full throttle range 5200–6000 RPM Cold warm‑up 650–800 RPM At operating Idle speed in neutral 650 RPM temperature gear Idle charging 650–800 RPM compensation* Number of cylinders Piston displacement 3.0 L (183 cid)
  • Page 27 GENERAL INFORMATION Specifications - 150 SeaPro Parameter Specification Power 110 kW (150 hp) Full throttle range 4800–5300 RPM Cold warm‑up 650–800 RPM At operating Idle speed in neutral 650 RPM temperature gear Idle charging 650–800 RPM compensation* Number of cylinders Piston displacement 3.0 L (183 cid)
  • Page 28 800 A for 8 second minimum at 20 °F Minimum cranking amps (‑7 °C) Peak charge acceptance 165 A 20‑130 °F (‑7‑55 °C) for one minute Max charge/alternator size 150 A 20‑130 °F (‑7‑55 °C) Max charge voltage/alternator 14.8 V output Reserve Capacity (RC25 at 135 minutes 80 °F)

  • Page 29: Component Identification

    Engine oil drain Water pump indicator hole Propeller Selection IMPORTANT: To ensure proper fit and performance, use only Mercury or Quicksilver branded propellers and mounting hardware. The propeller is one of the most important components in the propulsion system. An improper propeller choice can significantly affect boat performance and could result in damage to the outboard engine.

  • Page 30: Recording Serial Number

    Such requirements may be listed in General Information ‑ Specifications. Be aware that any published propeller requirement is subject to change without notice. It is always best to consult a Mercury Marine Authorized dealer before purchasing a new propeller.

  • Page 31: Selecting Outboard Accessories

    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. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system.
  • Page 32 GENERAL INFORMATION Notes:   ...

  • Page 33: 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 34: Transom Fastening Hardware

    Always ensure that the engine fasteners are tightened to the specified torque. Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors,...
  • Page 35 OUTBOARD INSTALLATION Acceptable Accessory Mounting After the engine is mounted to the transom or jack plate in accordance 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.
  • Page 36 OUTBOARD INSTALLATION Unacceptable Accessory Mounting IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. • Do not mount an accessory to the transom clamp bracket in an unsupported condition.

  • Page 37: Fuel System

    Fuel Demand Valve (FDV) Requirement • EPA Pressurized Portable Fuel Tank Requirements • Mercury Marine's Pressurized Portable Fuel Tank Fuel Tanks Portable Fuel Tank Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place.

  • Page 38: Transom Cutout And Mounting Holes

    OUTBOARD INSTALLATION Priming the Fuel Supply Module IMPORTANT: The fuel supply module must be primed before the engine is run. Refer to the Fuel Supply Module Priming Procedure in the Operation section. Transom Cutout and Mounting Holes Installation Specifications 18552 Minimum transom opening Engine centerline for dual engines ‑...
  • Page 39 OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 47710 The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions...
  • Page 40 Clearance must be maintained between the boat transom and the outboard transom bracket relief radius area. 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 41 OUTBOARD INSTALLATION • The fixture's drill guide holes mark the proper drilling locations. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 42: Checking Boat Transom Construction

    OUTBOARD INSTALLATION Checking Boat Transom Construction IMPORTANT: 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. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 43 OUTBOARD INSTALLATION 4. Connect a hoist that has a minimum lift capacity of 450 kg (1000 lb) to the lifting eye. 5. Lift the outboard and place it on the transom. Lifting base Lifting eye 47706 Flywheel Puller/Lifting Ring 91‑895343T02 Removes flywheel from engine.
  • Page 44 OUTBOARD INSTALLATION Steering Cable - Starboard Side Routed Cable 1. Lubricate the O‑ring seal and entire cable end. 79611 Description Where Used Part No. Extreme Grease O-ring seal and entire cable end 8M0190472 2. Insert the steering cable into the tilt tube. 3.
  • Page 45 OUTBOARD INSTALLATION • The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed) Outboard Installation 1. Apply marine sealer to the shanks of the bolts, not to the threads. 2.
  • Page 46 OUTBOARD INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 47: Steering Link Rod Installation

    OUTBOARD INSTALLATION A decal on the transom bracket reminds the operator to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Steering Link Rod Installation WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.

  • Page 48: Rigging The Engine

    OUTBOARD INSTALLATION Description lb‑in. lb‑ft Nylon insert locknut at the – steering arm 47709 Special washer head screw (856680) Flat washers Nylon insert locknut (8M0204726) Nylon insert locknut (8M0204726) Rigging the Engine Routing Items Through the Rigging Ingress IMPORTANT: Route all items through the rigging adapter prior to completing the connections at the engine.
  • Page 49 OUTBOARD INSTALLATION The following image shows the rigging ingress, grommet, and adapter, as well as indicating which grommet openings should be used for which rigging items. Keep this arrangement in mind, when routing items through the rigging ingress. 79549 Rigging adapter Rigging grommet Rigging ingress Speedometer tube opening...
  • Page 50 OUTBOARD INSTALLATION 3. Fasten the harness with the retainer. Remote 14‑pin boat harness Retainer 14‑pin connector 47717 SmartCraft Harness and Accessory Harness Connection If the boat is equipped with a SmartCraft or other accessory harness, route the harness through the rigging adapter, and connect it to the appropriate connector on the engine.
  • Page 51 OUTBOARD INSTALLATION 2. Center the shift cable anchor pin with the neutral detent alignment mark. 47736 Shift cable anchor pin Neutral detent alignment mark 3. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a.
  • Page 52 OUTBOARD INSTALLATION 5. Fit the shift cable through the appropriate hole in the rigging grommet. 47738 6. Position the remote control into neutral. 7. Place the barrel cup into the barrel pocket. 8. Align the shift cable end guide with the center mark made in step 3. 9.
  • Page 53 OUTBOARD INSTALLATION 11. Lock the barrel in place with the cable latch. 47744 Cable latch 12. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b.
  • Page 54 OUTBOARD INSTALLATION 2. Fit the throttle cable through the rigging grommet. 47739 3. Install the throttle cable to the throttle arm with the bow tie clip retainer. 4. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
  • Page 55 OUTBOARD INSTALLATION 6. Lock the cable in place with the cable latch. Cable latch 47748 Fuel Hose Fuel Hose Size The minimum fuel hose inside diameter (ID) is 9.5 mm (3/8 in.). There must be a separate fuel hose/fuel tank pickup for each engine. Fuel Hose Connection NOTICE Inspect the position of the hose clamp to ensure that it will not chafe or...
  • Page 56 OUTBOARD INSTALLATION Rigging Grommet and Adapter Installation IMPORTANT: Leave sufficient slack in wiring harnesses, battery cables, and hoses that are routed through the rigging ingress, to relieve stress and prevent hoses from being kinked or pinched. 1. Ensure that all hoses, wiring, and cables are routed through the rigging adapter.

  • Page 57: Battery Cable Connections

    OUTBOARD INSTALLATION Description lb‑in. lb‑ft Screws 53.1 – NOTICE Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring harnesses. 6. Use a cable tie to hold the wiring, hoses, and cables together. Cable tie 47753 Battery Cable Connections...
  • Page 58 OUTBOARD INSTALLATION American Wire Gauge (AWG) Maximum Length 12.2 m (40 ft) 15.2 m (50 ft) 19.6 m (64 ft) 24.4 m (80 ft) Single Outboard Red sleeve ‑ positive (+) Black sleeve ‑ negative (–) Cranking battery 15496   ...
  • Page 59 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   ...
  • Page 60 OUTBOARD INSTALLATION Notes:   ...

  • Page 61: 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 62 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 a Mercury Marine authorized dealer for recommendations. 47333 IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering.

  • Page 63: 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 64: Fuel Additives

    Fuel Additives To minimize carbon deposit buildup in the engine, add Mercury or Quicksilver Quickleen Engine and Fuel System Cleaner to the engine's fuel tank periodically throughout the boating season. Use the additive as directed on the container.

  • Page 65: 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 66: 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 67: Quick-Disconnect Fuel Hose Fitting

    Engine Oil Recommendations—Standard and Pro XS Models IMPORTANT: The use of 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, or oils that contain solid additives is not recommended.

  • Page 68: Engine Oil Recommendations-Seapro Models

    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 viscosity may be used.

  • Page 69: Checking And Adding Engine Oil

    FUEL AND OIL 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 viscosity may be used. 6.0 L (6.3 US qt) 60105 Checking and Adding Engine Oil IMPORTANT: Do not overfill.
  • Page 70 FUEL AND OIL 5. Pull the dipstick out again and observe the oil level. Oil should be in the operating range (between the top bar and bottom bar). Oil level operating range Top bar Bottom bar 79612 IMPORTANT: Do not try to fill the oil level to the top bar. Oil level is correct as long as it appears in the operating range.

  • Page 71: 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 72 FEATURES AND CONTROLS A few of the noncritical conditions indicated by the intermittent short beeps for six seconds can be corrected by the operator. These operator correctable conditions are as follows: • Water in the boat‑mounted water‑separating fuel filter (optional accessory).

  • Page 73: Power Trim And Tilt

    FEATURES AND CONTROLS 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 74 FEATURES AND CONTROLS Power Trim Operation WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
  • Page 75 FEATURES AND CONTROLS • Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller) • Cause engine overheating if any cooling water intake holes are above the waterline • In excess, cause boat porpoising (bouncing) or propeller ventilation Tilting Operation To tilt the outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position.

  • Page 76: Trim Tab Adjustment

    FEATURES AND CONTROLS 3. Tighten the manual tilt release valve. 47663 Auxiliary Tilt Switch This switch can be used to tilt the outboard up or down using the power trim system. Auxiliary tilt switch 47704 Trim Tab Adjustment Propeller steering torque may cause a boat to pull in one direction. Steering torque normally occurs at or above planing speeds.
  • Page 77 FEATURES AND CONTROLS 1. Loosen the trim tab fastener. 2. Make only a small adjustment. • If the boat turns more easily to the left, move the trailing edge of the trim tab to the left. • If the boat turns more easily to the right, move the trailing edge of the trim tab to the right.
  • Page 78 FEATURES AND CONTROLS Notes:   ...

  • Page 79: 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 two hours of operation, run the engine at varied throttle settings up to 4500 RPM or three‑quarter throttle.

  • Page 80: Starting The Engine

    OPERATION Starting the Engine 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. Before starting, read the Prestarting Checklist. 1.
  • Page 81 OPERATION 4. Set the lanyard stop switch to the RUN position. Refer to Important Safety Information ‑ Lanyard Stop Switch. 19791 Lanyard stop switch appearance may vary 5. Shift the outboard to the neutral (N) position. 58237 6. For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, turn the ignition key switch to the ON position for approximately five seconds.

  • Page 82: Gear Shifting

    Either of these conditions will cause the engine to overheat, resulting in engine damage. • Have the outboard checked by a Mercury Marine authorized dealer. 9. If the engine does not start: a. Push in the throttle‑only button, and advance the remote control handle slightly to open the throttle.

  • Page 83: Stopping The Engine

    26843 Operating at High Elevations Mercury Marine engines automatically compensate for high elevation changes, but there will still be some performance loss, due to the reduced oxygen in the air. A different pitch propeller may help reduce this normal performance loss.

  • Page 84: Operating In Saltwater Or Polluted Water

    Recommendations) 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 85: Setting Trim Angle At Idle Speed

    OPERATION Setting Trim Angle at Idle Speed When idling, a portion of the engine's exhaust is ported through the idle relief muffler. If the engine is trimmed too far in, it is possible for the relief hole to be below the surface of the water. Always ensure that the relief hole is above the waterline, whenever the engine is at idle.
  • Page 86 OPERATION Fuel Pressure Gauge Kit 91‑881833A03 Tests the fuel pump pressure; can be used to relieve fuel pressure. 2807 4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel. 58370 Fuel pressure gauge purge valve Schrader valve Purge hose to appropriate container 5.
  • Page 87 OPERATION 7. Remove the fuel pressure gauge. 8. Turn the ignition key on. When the fuel pumps stop running, start the engine. • The engine may not start on the first attempt. • The engine will run rough at idle for up to two minutes while the residual air is purged from the fuel system.
  • Page 88 OPERATION Notes:   ...

  • Page 89: 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 90: 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 91 Remove the applied wax by hand using a clean soft cloth. 5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1). IMPORTANT: Do not rinse the cowls with water when the outboard is in a tilted position, as this could allow water to enter the air intakes (if equipped).

  • Page 92: Top Cowl Removal And Installation

    MAINTENANCE 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 93: Inspection And Maintenance Schedule

    MAINTENANCE 3. Lower the cowl into the seated position and apply pressure to the back of the cowl to lock it in place. 79574 4. Ensure that the cowl is securely fastened by trying to pull up on the back of the cowl.
  • Page 94 MAINTENANCE 100 Hour Maintenance Dealer (Every 100 Hours of Use or Once Yearly, Whichever Occurs First) Item Change the engine oil and filter. Refer to Engine Oil and Filter. Change more frequently when the engine is operated under adverse conditions, such as extended trolling. Change the gearcase lubricant.

  • Page 95: Maintenance Schedule Decal (150 Fourstroke)

    Replace the alternator drive belt. Refer to the Storage section for maintenance requirements for storage preparation. Maintenance Schedule Decal (150 FourStroke) The following table shows the icons and a general description of the maintenance schedule decal located on the engine.

  • Page 96: Battery Inspection

    MAINTENANCE Icon Definition Icon Definition Spark plugs Thermostat 58253 58254 Low pressure fuel filter Anodes 58256 58255 Accessory drive belt Water pump impeller 58257 58258 Battery Inspection IMPORTANT: Read the safety and maintenance instructions that accompany the engine starting battery. Inspect the battery at periodic intervals to ensure proper engine starting capability.

  • Page 97: Corrosion Control Anodes

    MAINTENANCE 3. Remove the cover from the flush connector and thread a water hose into the flush connector. 47592 4. Turn on the water tap (½ maximum) and let the water flush through the cooling system for about 15 minutes. 5.

  • Page 98: Engine Oil And Filter

    Mercury Marine offers convenient oil change kits for several outboard models ranging from 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.
  • Page 99 MAINTENANCE 5. Loosen the oil drain valve 2‑1/2 turns to allow oil to drain. Do not exceed 2‑1/2 turns. 48870 Oil drain valve Drain hose Loosen 2‑1/2 turns maximum 6. After the oil has drained, hand‑tighten the oil drain valve (clockwise) and remove the oil drain hose.
  • Page 100 MAINTENANCE 2. Remove the old filter by turning the filter counterclockwise. Turn counterclockwise Oil filter Oil trough Drain hose 47562 3. Allow oil in the trough to drain, and remove the oil drain hose. 4. Clean any oil from the oil trough, and install the plug. 5.

  • Page 101: Fuel System

    MAINTENANCE NOTE: Checking the oil level within five minutes of engine shutdown can falsely read up to 1 liter (1 US qt) low. Allow the engine to cool for at least an hour before checking the oil level. Fuel System WARNING Fuel is flammable and explosive.
  • Page 102 MAINTENANCE 2. Move the lift handle so that the locking tab clears the bracket. 47535 Lift handle Locking tab secured under bracket 3. Use the lift handle and pull the fuel filter out of its opening. If necessary, move the fuel hose so that it clears the bracket while lifting the fuel filter. 4.

  • Page 103: Gearcase Lubrication

    MAINTENANCE 6. Remove the fuel filter from the lift handle. 47441 Fuel hose release tab Low‑pressure fuel filter Hose holder Installation 1. Place the lift handle onto the fuel filter. Install the new fuel filter so the arrow points toward the engine. 2.
  • Page 104 Right‑hand rotation 830 ml (28.1 fl oz) Left‑hand rotation Gearcase Lubricant Recommendation Mercury or Quicksilver High Performance Gear Lubricant. Checking Lubricant Level and Refilling Gearcase 1. Place the outboard in a vertical operating position. 2. Remove the vent plug/sealing washer.

  • Page 105: Lubrication Points

    MAINTENANCE 3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole. 22693 Vent hole Fill hole IMPORTANT: Replace the sealing washers if damaged. 4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
  • Page 106 MAINTENANCE • Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 47623 2. Lubricate the steering cable grease fitting (if equipped) with Extreme Grease. • Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube.

  • Page 107: Checking Power Trim Fluid

    2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. 47647 3. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid, as required. If not available, use automotive automatic transmission fluid (ATF).
  • Page 108 26901 4. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by a Mercury Marine authorized dealer. IMPORTANT: To prevent the propeller hub from corroding and seizing to...
  • Page 109 MAINTENANCE Description Where Used Part No. Extreme Grease Propeller shaft 8M0190472 Flo-Torq II Propellers 1. Install the propeller onto the shaft with the supplied components as shown. 2. Place the locknut retainer over the raised pins on the drive sleeve adapter, and tighten the locknut to the specified torque.

  • Page 110: Propeller Bore Sleeve Inspection-If Equipped

    MAINTENANCE 3. Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter. 45248 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer Locknut Tabs bent into grooves Description lb‑in. lb‑ft Propeller nut –...

  • Page 111: Spark Plug Inspection And Replacement

    MAINTENANCE The propeller bore sleeve is an important integral component of the gear housing and should be inspected whenever the propeller is removed. The propeller bore sleeve is designed to enhance engine characteristics and boat performance by minimizing engine exhaust escaping between the outside of the propeller and the gear housing.
  • Page 112 MAINTENANCE 2. Remove the spark plugs to inspect. 47662 3. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode. IMPORTANT: The color of the plug may not accurately reflect its condition.

  • Page 113: Transom Tightness Inspection

    MAINTENANCE c. If an adjustment is necessary, do not pry or apply any force on the center electrode. This is critical with any type of spark plug that has a wear surface, such as platinum or iridium added to either the ground electrode or the center electrode.

  • Page 114: Maintenance

    MAINTENANCE Notes:   ...

  • Page 115: Storage

    STORAGE Storage Preparation The major consideration in preparing an outboard for storage is to protect it from rust, corrosion, and damage caused by the freezing of trapped water. The following storage procedures should be used to prepare an outboard for out of season storage or prolonged storage (90 days or longer).

  • Page 116: Protecting Internal Engine Components

    STORAGE • Touch up any paint nicks. See an authorized dealer for touch‑up paint. • 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...
  • Page 117 STORAGE • Periodically check the battery voltage during storage. Charge if necessary.   ...
  • Page 118 STORAGE Notes:   ...

  • Page 119: Troubleshooting

    TROUBLESHOOTING Effects of Elevation and Weather on Performance Power Robbing Conditions The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems: • High elevations • High ambient temperature • Low barometric pressure •...

  • Page 120: Starter Motor Will Not Crank The Engine

    TROUBLESHOOTING Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 47408 Cover Spare fuse holders Fuse holder Fuse 4 ‑...

  • Page 121: Engine Runs Erratically

    TROUBLESHOOTING • Fuel is not reaching the engine. • Fuel tank is empty. • Fuel tank vent not open or restricted. • Fuel line is disconnected or kinked. • Fuel filter is obstructed. Refer to Maintenance section. • Fuel pump failure. •...

  • Page 122: Battery Will Not Hold Charge

    TROUBLESHOOTING Battery Will Not Hold Charge Possible Causes • Battery connections are loose or corroded. • Worn out or inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator. • Open circuit in the alternator output wire (fused link). Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 123: 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 124 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 125: 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 126 (920) 929‑4894 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 127: 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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