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Mercury 350hp Verado Operation And Maintenance Manual

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  • Page 1 Operation Maintenance 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

    Important Safety Information Boater's Responsibilities..................1 Boat Horsepower Capacity..................1 Exhaust Emissions....................1 Outboard Remote Control Models ................ 3 Lanyard Stop Switch....................4 Staying Safe Around the Outboard............... 6 Safe Operating Practices..................6 Impact with Underwater Hazards................ 12 General Information Specifications......................
  • Page 8 Digital Throttle and Shift Controls Electronic Remote Control (ERC)................. 33 Foot Throttle......................43 Active Trim......................45 Engine Synchronization (Multiple Engines)............51 Helm Transfer......................52 Quick Steer......................54 Single‑Lever Mode (Multiple Engines)..............54 Start/Stop All Engines..................55 Throttle and Shift Operation with Three or Four Engines........56 Throttle‑Only Mode....................
  • Page 9 Maintenance EPA Emissions Regulations.................. 79 Cleaning Care Recommendations................ 80 Use of Anti‑fouling Bottom Paint................. 82 Top Cowl Removal and Installation..............83 Inspection and Maintenance Schedule..............84 Maintenance Schedule Decals................87 Battery and Electrical................... 89 Flushing the Cooling System................91 Corrosion Control Anodes..................93 Engine Oil and Filter....................
  • Page 10 Owner Service Assistance Identification Records..................125 Service Assistance....................125 Ordering Literature..................... 127 Maintenance Log Maintenance Log....................129    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: Outboard Remote Control Models

    Mooring close to another boat that has its engine operating Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for Digital Throttle and Shift (DTS). Start‑in‑gear protection is provided by the remote control system.

  • Page 14: Lanyard Stop Switch

    IMPORTANT SAFETY INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch.
  • Page 15 IMPORTANT SAFETY INFORMATION The lanyard stop switch stops the engine whenever the operator moves far enough away from the operator's position to activate the switch. This occurs • The operator accidentally falls overboard, or • The operator moves within the boat away from the operator's position. Falling overboard and accidental ejections are more likely to occur in certain types of boats such as: •...

  • Page 16: Staying Safe Around The Outboard

    IMPORTANT SAFETY INFORMATION Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition Before each use, check to ensure that the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.
  • Page 17 IMPORTANT SAFETY INFORMATION Boats with an Open Front Deck WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
  • Page 18 IMPORTANT SAFETY INFORMATION 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. 79346 Approach slowly and exercise extreme caution when boating in areas where people may be in the water.
  • Page 19 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: • Approved fire extinguishers •...
  • Page 20 (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 21 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 22: 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 23 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 24 IMPORTANT SAFETY INFORMATION Notes:   ...

  • Page 25: General Information

    GENERAL INFORMATION Specifications Parameter Specification 350hp Verado 257 kW (350 hp) Rated Power 400hp Verado, 400R 294 kW (400 hp) 350hp, 400hp Verado 5800–6400 RPM Full throttle range 400R 6000–6600 RPM Idle speed in neutral gear* 650 RPM Idle charge compensation** 650–775 RPM...
  • Page 26 NOTE: 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 27 GENERAL INFORMATION IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards, and Coast Guard regulations must be adhered to when installing the battery. Ensure that the battery cable installation meets the pull test requirements and that the positive battery terminal is properly insulated in accordance with regulations.

  • Page 28: Component Identification

    GENERAL INFORMATION Component Identification 74799 Top cowl Service access door Service access door release button Exhaust relief Lower cowl Cooling water intake holes Engine oil drain Manual tilt release (on trim cylinders) Rigging ingress Engine flush port Auxiliary tilt switch   ...

  • Page 29: Gearcase Identification

    64308 Water intake—three torpedo low water Left‑hand rotation Sport Master gearcase—LL stamped on the end of propeller shaft 64532 Propeller Selection IMPORTANT: To ensure proper fit and performance, use only Mercury or Quicksilver branded propellers and mounting hardware.   ...

  • 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 and may void the limited warranty.
  • Page 32 GENERAL INFORMATION Notes:   ...

  • Page 33: 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 34: Trailering Boat/Outboard

    Refer to Features ‑ Power Trim and Tilt. 74805 Additional clearance may be required for railroad crossings, driveways, and trailer bouncing. Contact a Mercury Marine authorized dealer for recommendations. IMPORTANT: Do not rely on the power trim/tilt system to maintain proper ground clearance for trailering.

  • Page 35: 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 36: 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 37: Filling The Fuel System

    Synthetic Blend Marine 4‑Stroke Engine Oil is recommended for general all‑temperature use. 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 38: Checking And Adding Engine Oil

    SAE® 25W‑40 Mineral Marine 4‑Stroke Engine Oil. • If the recommended Mercury Racing FC‑W® certified oils are not available, a major outboard manufacturer's brand of NMMA™ FC‑W® certified 4‑Stroke outboard oil of the same viscosity may be used.
  • Page 39 FUEL AND OIL 3. In the VesselView display, navigate to MERCURY ‑> MENU ‑> ENGINE DATA ‑> CHECK OIL LEVEL. 4. Select Check Oil Level. 75289 5. Confirm the conditions on the OIL ‑ LEVEL CHECK pop‑up and select Check oil level to proceed.
  • Page 40 FUEL AND OIL • Good: No action is required. The oil level is in a safe operating range. 75292 Example: Oil level check successfully completed • Low: The oil level is low (bottom of dipstick crosshatch). a. Turn the engine off. b.
  • Page 41 FUEL AND OIL Manual Oil Level Check IMPORTANT: Do not overfill. To avoid overfilling, the targeted level when adding oil should be 1/2 to 2/3 above the bottom of the dipstick crosshatch or ADD mark. The outboard must be in a vertical (not tilted) position when checking the engine oil. For accurate readings, check the oil only when the engine has not run for at least an hour.
  • Page 42 FUEL AND OIL NOTE: A quick reference decal that lists the type of oil to use is located above the oil fill cap. ADD 3.3L (3.5 U.S. qt.) Oil Type: 25W-50 Oil Volume: 9.5 L (10.0 U.S. qt.) 74820 Verado Decal Racing Decal Oil fill cap Dipstick...

  • Page 43: Digital Throttle And Shift Controls

    Digital Throttle and Shift (DTS) Features. There are several DTS ERCs that can be used with electric steering, depending on the number of engines and the desired features. The following images show the current Mercury ERCs that will function with electric steering. 71715 71712...
  • Page 44 DIGITAL THROTTLE AND SHIFT CONTROLS 71718 71719 Dual-engine console ERC - Triple-engine console ERC - premier standard 71720 71721 Triple-engine console ERC - Quad-engine console ERC - premier standard 71722 71723 Quad-engine console ERC - Five or six-engine console ERC premier The basic styles of ERC are panel mount (single‑engine only), single‑handle console (single‑engine only), and dual‑handle console (two or more engines).
  • Page 45 The light flashes when the engine is in throttle‑only mode. Increases and decreases the brightness settings Brightness (+ and –) for the lights on the ERC and Mercury helm components. Allows the boat operator to increase engine RPM THROTTLE ONLY without shifting into gear.
  • Page 46 DIGITAL THROTTLE AND SHIFT CONTROLS Control/LED Function START/STOP Starts or stops the engine. ENGINE Raises and lowers the engine/drive for best UP ▲ and DN ▼— efficiency, or for conditions such as shallow water trim control or trailering. Some boats are equipped with separately‑mounted trim controls.
  • Page 47 The light flashes when the engine is in throttle‑only mode. Increases and decreases the brightness settings Brightness (+ and for the lights on the ERC and Mercury helm –) components. Allows boat control to be transferred to a different TRANSFER helm.
  • Page 48 DIGITAL THROTTLE AND SHIFT CONTROLS Ref Control/LED Function Raises and lowers the engine/drive for best UP ▲ and DN ▼— efficiency, or for conditions such as shallow water trim control or trailering. Some boats are equipped with separately‑mounted trim controls. Pressing the mechanical lock bar allows the engine Mechanical lock to shift.
  • Page 49 Increases and decreases the brightness settings Brightness (+ and for the lights and display (if equipped) on the ERC –) and Mercury helm components. Enables the throttle and shift functions of all 1 LEVER engines to be controlled by the port lever. Refer to Single‑Lever Mode.
  • Page 50 DIGITAL THROTTLE AND SHIFT CONTROLS Ref Control/LED Function Press to start or stop the indicated engine, as START/STOP equipped: P (port), PC (port center), C (center), SC individual engines (starboard center), S (starboard) Display and display buttons (premier Refer to ERC Supplemental Display for details. ERCs only) Starts or stops all engines.
  • Page 51 DIGITAL THROTTLE AND SHIFT CONTROLS • Continue pushing forward to increase speed. • Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop. • Pull the control handle back from neutral to the first detent for reverse gear.
  • Page 52 DIGITAL THROTTLE AND SHIFT CONTROLS 3. Install the access cover after the desired tension is achieved. Panel mount ERC (ERC shown not installed, access cover removed) Handle friction adjustment screw Detent adjustment screw 71261 71976 Single-handle console ERC Access cover Detent adjustment screw Handle friction adjustment screw 71978...

  • Page 53: Foot Throttle

    DIGITAL THROTTLE AND SHIFT CONTROLS Zero Effort Controls Zero Effort controls allow the operator to control the shifting and throttle with separate control handles. Zero Effort controls are available in single, and multiple engine applications including shadow mode operation. 58266 Foot Throttle Foot Throttle Requirements for Operation Engine speed is controlled from idle to WOT by either the foot throttle or the...
  • Page 54 DIGITAL THROTTLE AND SHIFT CONTROLS DTS Foot Throttle Operation DTS foot throttle operation is generally used on boats that can reach significant speeds. The use of a foot throttle allows the operator to keep both hands on the steering wheel at all speeds, which allows the operator greater control of the boat.

  • Page 55: Active Trim

    NOTE: If the transfer fails, the hand throttle light will blink twice. Active Trim Introduction to Active Trim Active Trim is Mercury Marine’s patented GPS‑based automatic trim system. This intuitive, hands‑free system continually adjusts engine or drive trim for changes in operating conditions to improve performance, fuel economy, and ease of operation.
  • Page 56 Active Trim system is immediately overridden, returning full control to the operator. 61899 Setup and Configuration Contact a Mercury Marine authorized dealer for setup and configuration instructions. Active Trim ERC Controls IMPORTANT: Authorized Mercury dealers have the ability to disable the Active Trim feature.
  • Page 57 DIGITAL THROTTLE AND SHIFT CONTROLS Use the buttons and lights on the ERC to control the Active Trim feature. 71956 Active Trim controls on the ERC Control/LED Function ACTIVE TRIM Turns the Active Trim feature on or off. button Provides Active Trim status information: •...
  • Page 58 DIGITAL THROTTLE AND SHIFT CONTROLS • Active Trim will maintain the last known trim position when operating at speeds in excess of 80 km/h (50 mph). • Operation above 80 km/h (50 mph) may require trim adjustments using the panel‑mounted or control handle trim position switch. •...
  • Page 59 DIGITAL THROTTLE AND SHIFT CONTROLS What Trim Is The trim angle of an outboard or sterndrive is the angle between the boat bottom and the propeller shaft formed by moving the engine or sterndrive closer to the boat transom. This movement is called trimming in or down. Moving the engine or sterndrive further away from the transom is called trimming out or up.
  • Page 60 DIGITAL THROTTLE AND SHIFT CONTROLS If the engine or drive is trimmed out too far, the propeller may lose its hold on the water, fast V‑bottom boats may start to walk from side to side (chine walking), steering torque will increase in the opposite direction to that when trimmed in, and getting on plane may be difficult or labored.

  • Page 61: Engine Synchronization (Multiple Engines)

    DIGITAL THROTTLE AND SHIFT CONTROLS Single Flashing Red 61841 Light (on or off) Interval Fault Condition Description Notes GPS signal GPS signal has achieved fix, but Indicates loss of GPS intermittent is dropping out intermittently. signal. Indicates obstructed GPS signal GPS has not achieved fix since GPS antenna or weak unavailable...

  • Page 62: Helm Transfer

    The helm transfer will not succeed until the levers at the helms are moved to neutral and the transfer is requested again. Some fault codes may appear on the Mercury‑approved multifunction display if other control or navigation functions are attempted after the helm transfer procedure is started.
  • Page 63 DIGITAL THROTTLE AND SHIFT CONTROLS Requesting Helm Transfer To request the transfer of boat control from one helm to another: 1. All of the ignition keys must be in the ON position. 2. All of the boat's ERC levers must be in the neutral position. 3.

  • Page 64: Quick Steer

    DIGITAL THROTTLE AND SHIFT CONTROLS • Route mode (waypoint sequencing) control of the route and display of route data on the chartplotter does not automatically transfer to the chartplotter at the active helm. Turn on the chartplotter at the selected active helm, input the waypoint route to be tracked, and engage route mode.

  • Page 65: Start/Stop All Engines

    DIGITAL THROTTLE AND SHIFT CONTROLS Start/Stop All Engines Dual‑handle console ERCs have a START/STOP ALL ENGINES button, which allows starting or stopping all engines with a single button push. The exact behavior of the engines depends on: • How many engines are running when the button is pressed (none, all, or some) •...

  • Page 66: Throttle And Shift Operation With Three Or Four Engines

    DIGITAL THROTTLE AND SHIFT CONTROLS Some (Not All) Engines Running - Stop Engines When some but not all engines are running (and the corresponding engine status LEDs are lit), press the START/STOP ALL ENGINES button to stop all running engines. All engine status LEDs (individual and the ALL ENGINES LED) will turn off.
  • Page 67 DIGITAL THROTTLE AND SHIFT CONTROLS Port Center Starboard Control Handle Function Engine Engine Engine Port engine throttle and shift = Running controlled by port control handle Starboard engine throttle and shift Running = controlled by starboard control handle (ignition Off (ignition Center engine throttle and shift key switch Running...
  • Page 68 DIGITAL THROTTLE AND SHIFT CONTROLS Port Starboard Port Outer Starboard Control Handle Inner Inner Engine Outer Engine Function Engine Engine Port inner and outer engine throttle and shift Running Running = controlled by port control handle Starboard inner and outer engine throttle Running Running and shift = controlled...

  • Page 69: Throttle-Only Mode

    DIGITAL THROTTLE AND SHIFT CONTROLS Port Starboard Port Outer Starboard Control Handle Inner Inner Engine Outer Engine Function Engine Engine Port inner engine throttle and shift = controlled by port Off (ignition control handle (ignition Running Running key switch key switch Starboard inner engine turned ON) turned ON)
  • Page 70 DIGITAL THROTTLE AND SHIFT CONTROLS 2. Press THROTTLE ONLY. The throttle‑only light will turn on and the neutral lights will blink. 3. Place either ERC lever into forward or reverse detent position. The warning horn will beep each time the levers are moved into or out of gear while in throttle‑only mode, but the drive will remain in neutral.

  • Page 71: Adaptive Speed Control

    Engine Guardian system. Refer to Engine Guardian System. Contact a Mercury Marine authorized dealer at the earliest convenience. In either of the preceding scenarios, the horn will sound only one time. The horn signal will sound again upon shut down and restart, if the fault that triggered the signal is still present.
  • Page 72 FEATURES Low engine oil level. Refer to Fuel and Oil ‑ Checking and Adding Engine • Oil. Engine Guardian System The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian is functional whenever the engine is operating, so there is never a concern about whether or not the engine is protected.

  • Page 73: Power Trim And Tilt

    3. If there is no blockage and the condition persists, return to port immediately. 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 NOTE: When exceeding 4250 RPM, the electronic control unit (ECU) will begin Engine Guardian protection. 74867 Trim switch Tilt range Trim range Power Trim Operation WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat.
  • Page 75 FEATURES Refer to Outboard Operating Angle Considerations for the benefits and detriments of changing the trim angle either in or out from the middle of the range. Outboard Operating Angle Considerations Before adjusting the outboard operating angle from the middle of the range, consider the following benefits and detriments of changing the angle.
  • Page 76 FEATURES 3. Disengage the tilt support bracket by raising the outboard up and rotating the tilt support lever up. Lower the outboard. Tilt support lever Tilt support bracket 28922 Manual Tilting If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
  • Page 77 FEATURES Auxiliary Tilt Switch The auxiliary tilt switch is located on the port side of the engine near the top of the lower cowl. This switch can be used to tilt the outboard up or down using the power trim system. 74872   ...
  • Page 78 FEATURES 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. NOTE: Before starting an engine that has run out of fuel, refer to Ran Out of Fuel Condition—Priming the Fuel System.
  • Page 81 OPERATION 4. Set the lanyard stop switch to the RUN position. Refer to Important Safety Information ‑ Lanyard Stop Switch. 19791 5. Shift the outboard to the neutral (N) position. Forward Neutral Reverse 71986 6. Turn the ignition key to the START position and release the key. •...

  • Page 82: 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 83: Stopping The Engine

    OPERATION 3. Advance the throttle lever to apply power. Dual-engine control shown, others similar Shift levers in neutral position Throttle levers at the idle position 79618 Stopping the Engine IMPORTANT: Turning the key to the START position while the engine is running will result in engine shut down, while leaving the DTS system active.

  • Page 84: Operating At High Elevations

    Leading edge of anti‑ventilation plate 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 85: 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 86: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION 2. Tilt the outboard up. Make sure all the cooling water intake holes stay submerged at all times. • Below 2000 RPM the engine can be trimmed or tilted to any range. Caution is advised when operating the engine past the trim range. Ensure the water pickups are submerged.
  • Page 87 7. If the fuel system will not prime within 15 full eight second cranking events, contact an authorized Mercury Marine dealer to prime the fuel system with a fuel rail purge line.   ...
  • 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: Use Of Anti-Fouling Bottom Paint

    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: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation NOTE: Remove and install the cowl while standing inside the boat. Removal 1. Tilt the outboard up so the top of the cowl is facing toward the boat. 2. Press the service access door release button. The service access door will open.

  • Page 94: Installation

    MAINTENANCE 4. Push the handle toward the aft until it clicks into the cowl lift position. 75219 Handle locked in the cowl lift position 5. With a firm grip on the handle, carefully lift the cowl off the engine. Installation 1.
  • Page 95 MAINTENANCE Before Each Use I/R/D Check that the lanyard stop switch stops the engine. Check the propeller for damage. Inspect the hydraulic steering fittings and hoses for leaks or damage, if equipped. Check the steering system for binding or loose components. Check the engine oil level.
  • Page 96 MAINTENANCE 100 Hour Maintenance I/R/D (Every 100 Hours of Use or Once Yearly, Whichever Occurs First) Inspect the battery cables and clean power harness. Refer to Battery Cables and Clean Power Harness. Inspect the corrosion control anodes. Refer to Corrosion Control Anodes.

  • Page 97: Maintenance Schedule Decals

    MAINTENANCE Maintenance Schedule Decals Maintenance Schedule Decal Icons A maintenance schedule decal is located on the engine to remind the owner or operator when the power package important maintenance items require attention. The following table shows the icons and a general description of the scheduled maintenance items.
  • Page 98 MAINTENANCE V10 Verado Models Maintenance Schedule Decal 74956   ...

  • Page 99: Battery And Electrical

    MAINTENANCE 400R Maintenance Schedule Decal MAINTENANCE SCHEDULE EVERY 100 HOURS OF USE OR ONCE YEARLY Engine Oil And Filter REPLACE Gearcase Lubricant Anodes Thermostat INSPECT Spark Plugs* Low Pressure Fuel Filter EVERY 300 HOURS OF USE OR THREE YEARS Spark Plugs* Low Pressure Fuel Filter REPLACE Accessory Drive Belt...
  • Page 100 MAINTENANCE The clean power harness connects to the engine rigging center and the engine starting battery. 71862 Engine rigging center Clean power harness Engine starting battery The engine starting battery cables and the clean power harness wires must be secured to the engine starting battery with nuts. Wing nuts are not acceptable.

  • Page 101: Flushing The Cooling System

    MAINTENANCE If the clean power harness fuse is open, try to locate and correct the cause of the overload. If the cause is not found, the fuse may open again. Remove the clean power fuse and look at the silver band inside the fuse. If the band is broken (open), replace the fuse with the same rating (30‑amp) and type fuse.
  • Page 102 MAINTENANCE 1. With the engine turned off, place the outboard in either the operating position (vertical) or in a tilted position. 2. Remove the flush connector from the bottom cowl on the port side of the engine. 3. Remove the cover from the flush connector and thread a water hose into the flush connector.

  • Page 103: Corrosion Control Anodes

    MAINTENANCE 3. Locate the engine flush port on the boat transom and insert the quick‑connect fitting. Flush quick connector Engine flush port on transom 72593 4. Turn on the water tap. 5. Press the start button on the boat‑mounted automatic outboard flushing system, or the remote‑mounted button if equipped.

  • Page 104: Engine Oil And Filter

    MAINTENANCE Each anode requires periodic inspection, especially in saltwater, which will accelerate the corrosion. To maintain corrosion protection, always replace the anode before it is completely corroded. Never paint or apply a protective coating on the anode, as this will reduce the effectiveness of the anode. Bottom of transom bracket Bottom of each power trim ram (2)
  • Page 105 MAINTENANCE 5. Remove the dipstick and observe the oil level. Add oil as necessary to reach the target oil level (1/2 to 2/3 above the bottom of the dipstick crosshatch or ADD mark). 71928 Safe operating range Add 3.3 liter (3.5 US qt) of oil Target oil level (1/2 to 2/3 above bottom of crosshatch) 6.
  • Page 106 MAINTENANCE 5. Loosen the oil drain valve 2‑1/2 turns to allow oil to drain. Do not exceed 2‑1/2 turns. 75221 Oil drain valve, loosen 2‑1/2 turns maximum Drain hose 6. After the oil has drained, hand‑tighten the oil drain valve (clockwise) and remove the oil drain hose.
  • Page 107 Service access door in open position 4. Remove the dipstick. 79624 5. Install the oil drain hose onto the crankcase oil pump. Verify the hose is securely attached. 63845 Crankcase oil pump (Mercury Marine P/N 802889A1) Oil drain hose (Mercury Marine P/N 8M0129230)   ...
  • Page 108 MAINTENANCE 6. Install the crankcase oil pump assembly onto the dipstick tube. Verify the pump is securely attached to the tube by pulling it up lightly NOTE: A lock button secures the hose in place on the tube. Oil drain hose (from crankcase oil pump assembly) Lock button...
  • Page 109 MAINTENANCE Oil Filter Wrench 91‑889277002 Aids in the removal of the oil filter. 5221 Oil filter Drain hose 75227 4. Allow the oil in the trough to drain into an appropriate container. 5. Clean the remaining oil from the oil trough and filter mounting base area. 6.

  • Page 110: Fuel System

    MAINTENANCE NOTE: Do not check the oil level immediately after changing the oil. The engine must be run for a while and then turned off for one hour or longer before checking the oil level. Refer to Checking Engine Oil Level. Fuel System WARNING Fuel is flammable and explosive.
  • Page 111 MAINTENANCE 1. Verify the ignition key switch is in the OFF position and that the lanyard switch is positioned so the engine cannot start. 2. Shut off the fuel supply to the engine. 3. Locate the boat‑mounted fuel filter. 4. Disconnect the water‑in‑fuel (WIF) sensor harness. Fuel filter base Fuel filter assembly WIF sensor connection...
  • Page 112 MAINTENANCE Installation 1. Using a hex wrench, remove the plug from the end of the new fuel filter. 2. Verify that the O‑ring is installed on the water‑in‑fuel (WIF) sensor. Lubricate the O‑ring with clean engine oil. Plug removed WIF sensor O‑ring 72234 3.

  • Page 113: Gearcase Lubricant

    MAINTENANCE 5. Lightly lubricate the fuel filter O‑ring with clean engine oil. Thread the fuel filter clockwise onto the fuel filter base until the O‑ring makes contact with the base. Then tighten the filter another 2/3–1 turn. Fuel filter base Lubricate fuel filter O‑ring Fuel filter assembly WIF sensor connection...
  • Page 114 MAINTENANCE Gearcase Lubricant Capacity ‑ V10 350hp and 400hp Verado Right‑hand rotation 1580 mL (53.4 fl oz) 163 mm (6.4 in.) Left‑hand rotation 1380 mL (46.7 fl oz) Gearcase Lubricant Capacity ‑ 400R Right‑hand rotation 137 mm (5.44 in.) HD 820 mL (27.7 fl oz) Left‑hand rotation Right‑hand rotation...
  • Page 115 MAINTENANCE 4. Remove the vent plug and fill/drain plug. Allow a sufficient amount of time for the gearcase to drain. Depending on the ambient air temperature, it may take 30 minutes for the gearcase to completely drain. 63496 Vent plug Fill/drain plug Filling the Gearcase 1.

  • Page 116: Checking Power Trim Fluid

    Pedestal 29312 5. The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 117: Propeller Replacement-350Hp And 400Hp Verado Models

    75270 3. 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. 4. To aid in future removal of the propeller, liberally coat the propeller shaft splines with Extreme Grease.
  • Page 118 MAINTENANCE Propeller Installation—Revolution X® Propeller 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.
  • Page 119 MAINTENANCE 6. Install the locknut onto the propeller shaft. 75254 Locknut Flat washer Propeller hub Propeller Thrust washer Propeller shaft 7. Place a block of wood between the gearcase and the propeller. 8. Tighten the locknut to the specified torque. Description lb‑in.

  • Page 120: Propeller Replacement-400R Models

    29592 3. 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. 4. To aid in future removal of the propeller, liberally coat the propeller shaft splines with Extreme Grease.
  • Page 121 MAINTENANCE 1. Apply Extreme Grease to the machined pilot diameter area of the HD propeller hub prior to installation into the propeller. Machined pilot diameter area 75288 Description Where Used Part No. Extreme Grease Machined pilot diameter area of propeller hub 8M0190472 2.
  • Page 122 MAINTENANCE 7. Install the locknut onto the propeller shaft. 75286 Propeller locknut 0.75‑16 brass hex nut Washer Propeller HD propeller hub Propeller shaft 8. Place a block of wood between the gearcase and the propeller. 9. Tighten the propeller nut to the specified torque. 2691 Description lb‑in.

  • Page 123: Checking Power Steering Fluid (If Equipped)

    MAINTENANCE Checking Power Steering Fluid (if Equipped) WARNING Dirt or contaminants in the hydraulic steering system can damage the steering system's internal components. Damaged components can lead to serious injury or death due to loss of boat control. Do not allow dirt or contamination to enter the helm, lines, or cylinder of this steering system and perform all hydraulic inspections, service, or assembly procedures in a clean work area.

  • Page 124: Transom Tightness Inspection

    The accessory drive belt is located under the flywheel shroud–intake air induction plenum. The accessory drive belt inspection must be completed by an authorized Mercury dealer at the recommended interval. Refer to Inspection and Maintenance Schedule. Inline Fuel Filter Inspection This engine is equipped with an inline fuel filter installed inside the quick‑connect fitting near the back of the engine.

  • Page 125: Storage Preparation

    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 126: Protecting Internal Engine Components

    Corrosion Guard External metal surfaces 92-802878 55 Protecting Internal Engine Components Contact an authorized Mercury Marine dealer to execute the following: IMPORTANT: Refer to the appropriate service manual for spark plug inspection, removal, and replacement procedures. • Remove the high tension spark plug leads and spark plugs.

  • Page 127: Battery Storage

    STORAGE NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position. 79273 In-Water Storage Positioning If the boat is kept moored in the water, tilt the outboard up to its highest...
  • Page 128 STORAGE Notes:   ...

  • Page 129: Troubleshooting

    TROUBLESHOOTING DTS Wiring System WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system.

  • Page 130: Fuses

    TROUBLESHOOTING Fuses IMPORTANT: Always carry spare fuses. IMPORTANT: An ATC fuse has the fuse element enclosed or sealed inside the plastic housing. This type of fuse must be used for marine applications. Marine applications are exposed to environments that may have the potential to accumulate explosive vapors. ATO fuses have exposed elements and should never be used in marine applications.
  • Page 131 TROUBLESHOOTING Rig Center Fuse Panel The rig center fuse panel is equipped with five fuses. Refer to the following image for identification. Four spare fuses are attached to a harness on the inside of the rig center. A 30‑amp spare for battery clean power is also included here.
  • Page 132 TROUBLESHOOTING 2. Remove the rigging panel cover by pulling outward. 75241 Rigging panel cover 3. Remove the suspected open fuse and look at the silver band inside the fuse. If the band is broken (open), replace the fuse. To remove and replace the fuse: IMPORTANT: Replace the fuse with a new fuse with the same amp rating.

  • Page 133: Starter Motor Will Not Crank The Engine

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine Possible causes • Lanyard stop switch not in RUN position. • Open clean power harness circuit fuse. Refer to Maintenance section. • Remote control is not shifted to the neutral position. • Shift actuator failure.

  • Page 134: Performance Loss

    TROUBLESHOOTING a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c. Stuck anti‑siphon valve located on permanently built‑in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel system is not primed. •...

  • Page 135: 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 136 Engine model and serial number are required to order correct parts. Resolving a Problem 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.

  • Page 137: 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 138 (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 139: 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:

400hp verado400r

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