Mercury 250 Pro XS OptiMax Manual
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Mercury 250 Pro XS OptiMax Manual

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See also: Service Manual , Owner's Manual
Thank You
for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Marine, a
world leader in marine technology and outboard
manufacturing since 1939. These years of experience have
been committed to the goal of producing the finest quality
products. This led to Mercury Marine's reputation for strict
quality control, excellence, durability, lasting performance,
and being the best at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use, and care of your outboard.
All of us at Mercury Marine took pride in building your
outboard and wish you many years of happy and safe
boating.
Again, thank you for your confidence in Mercury Marine.
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States are
certified to the United States Environmental Protection
Agency as conforming to the requirements of the regulations
for the control of air pollution from new outboard motors.
This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of
the design. Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine engine repair establishment or
individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth
defects or other reproductive harm.
eng
WARNING
!
i

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  • Page 1 This manual has been prepared to assist you in the operation, safe use, and care of your outboard. All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating.
  • Page 2 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not...
  • Page 3 • Provides timely service for all Mercury Marine customers. • Offers extended service hours and mobile service, when appropriate. • Uses, displays, and stocks adequate inventory of genuine Mercury Precision Parts. • Offers a clean, neat shop with well organized tools and service literature.
  • Page 4 1.5L OptiMax 75, 80, 90, 115, 1B227000 RCD‑H‑2 125 hp 2.5L OptiMax 135, 150, 175 hp 1B227000 RCD‑H‑2 3.0L OptiMax 200, 225 hp 1B227000 RCD‑H‑2 other Please specify in normative technical more detail Essential standards...
  • Page 5 Name / function: Mark D. Schwabero, President, Mercury Outboard Date and place of issue:July 24, 2008 Fond du Lac, Wisconsin, USA...

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration..............1 Transfer of Warranty..............2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada......... 2 Outboard Limited Warranty............3 3 Year Limited Warranty Against Corrosion........ 7 Warranty Coverage and Exclusions.......... 11 U.S. EPA Emissions Limited Warranty........13 Emission Control System Components........
  • Page 8 Transporting Trailering Boat/Outboard ............43 Fuel and Oil Avoiding Fuel Flow Restrictions..........44 Fuel Requirements..............44 Low Permeation Fuel Hose Requirement ......... 46 Oil Recommendation..............46 Filling Remote Oil Tank............. 47 Filling Engine Mounted Oil Reservoir Tank....... 47 Filling Fuel Tank................ 47 Features and Controls Remote Control Features............
  • Page 9 Maintenance Power Package Care..............67 Submerged Power Package............67 Replacement Parts for Your Power Package......67 EPA Emissions Regulations............68 Inspection and Maintenance Schedule........69 Flushing the Cooling System (Powerhead)....... 72 Flushing the Cooling System (Lower Unit)........ 73 Top Cowl Removal and Installation........... 74 Cleaning Care for Top Cowl............
  • Page 10 Warning Horn Activates (No Power Loss)....... 101 Battery Will Not Hold Charge........... 101 Owner Service Assistance Local Repair Service..............103 Service Away from Home............103 Parts and Accessories Inquiries..........103 Service Assistance..............103 Mercury Marine Service Offices..........104 Ordering Literature..............105...
  • Page 11 Outboard Installation Important Information............... 106 Avoiding Fuel Flow Restriction..........106 Boat Horsepower Capacity............107 Start in Gear Protection............107 Selecting Accessories for Your Outboard........ 107 Fuel Tanks................108 Low Permeation Fuel Hose Requirement ....... 108 Filling the Fuel System............108 Installation Specifications............

  • Page 13: Warranty Information

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

  • Page 14: Transfer Of Warranty

    To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and...

  • Page 15: Outboard Limited Warranty

    Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
  • Page 16 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 17 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 18 No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and...

  • Page 19: Year Limited Warranty Against Corrosion

    RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Year Limited Warranty Against Corrosion WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser...
  • Page 20 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 21 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 22 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.

  • Page 23: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
  • Page 24 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants, or fluids changed as a matter of normal...

  • Page 25: U.s. Epa Emissions Limited Warranty

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

  • Page 26: California Emissions Limited Warranty

    California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System...
  • Page 27 Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
  • Page 28 Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Marine's sole and...
  • Page 29 California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 30: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    Also included may be hoses, belts, connectors, and other emission‑related assemblies. Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.

  • Page 31: Emission Certification Star Label

    WARRANTY INFORMATION As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists.
  • Page 32 WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust 42538 emission standards.

  • Page 33: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 34: Intended Boat Application

    When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your...
  • Page 35 RPM. IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material.
  • Page 36 GENERAL INFORMATION Diameter ‑ The diameter is the distance across the imaginary circle that is made when the propeller rotates. The correct diameter for each propeller has been predetermined for the design of your outboard. However, when more than one diameter is available for the same pitch, use a larger diameter for heavy boat applications and a smaller diameter for lighter applications.

  • Page 37: Outboard Remote Control Models

    GENERAL INFORMATION PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats. Stainless steel is over five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies.

  • Page 38: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 39 GENERAL INFORMATION The lanyard is a cord 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 snap on the other end for attaching to the operator. 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 40 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.
  • Page 41 GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.

  • Page 42: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 43 GENERAL INFORMATION Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness, drowsiness, and nausea. WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death.
  • Page 44 GENERAL INFORMATION Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a...

  • Page 45: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION 2. Examples of poor ventilation while the boat is moving: 21628 Operating the boat with the trim angle of the bow too high Operating the boat with no forward hatches open (station wagon effect) Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.
  • Page 46 GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 47: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat reenters the water.

  • Page 48: Impact With Underwater Hazards

    GENERAL INFORMATION Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 49: Selecting Accessories For Your Outboard

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard.
  • Page 50 GENERAL INFORMATION Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible. Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate).
  • Page 51 GENERAL INFORMATION Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when operating the boat above idle speed.

  • Page 52: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. OTXXXXXX XXXX 24125 Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) Specifications Models Cylinder configuration 60°...
  • Page 53 GENERAL INFORMATION Models 0.8 mm Spark plug gap 1.06 mm (0.042 in.) (0.031 in.) Firing order 1‑2‑3‑4‑5‑6 Fuel line pressure 655 ± 13.8 kPa (95 ± 2 psi) Air pressure 58 ± 13.8 kPa (110 ± 2 psi) Gear ratio 1.75:1 Required fuel Refer to Fuel and Oil...

  • Page 54: Component Identification

    GENERAL INFORMATION Component Identification Top cowl Front cowl latch Auxiliary tilt switch Clamp/swivel bracket Gearcase Cooling water intake Skeg Anti‑ventilation plate Anodes (one per side) 10 - Driveshaft housing 11 - Bottom cowl 7493 12 - Water pump indicator (tell‑tale) 13 - Side cowl latches (both sides)

  • Page 55: Trailering Boat/Outboard

    TRANSPORTING Trailering Boat/Outboard Ensure the outboard is in forward gear before trailering. This prevents the propeller from spinning freely during transportation. NOTICE Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running can cause misalign the clutch, preventing proper shifting.

  • Page 56: Fuel And Oil

    MINIMUM POSTED OCTANE 92 RON Unleaded premium 1. Mercury Marine does not recommend using leaded gasoline. Read the information in the Fuel Containing Alcohol section. 2. Mercury Marine does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, exhaust passageway corrosion may occur due to the accumulation of exhausted lead particles.
  • Page 57 Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section. These reformulated fuels are acceptable for use in your Mercury engine. FUEL CONTAINING ALCOHOL If the fuel in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur.

  • Page 58: Low Permeation Fuel Hose Requirement

    Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Recommended Oil Engine Oil Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended for your engine. If Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium Plus 2‑Cycle Oil.

  • Page 59: Filling Remote Oil Tank

    FUEL AND OIL Filling Remote Oil Tank Remove filler cap and fill with the specified oil. Oil tank capacity is 11.5 liters (3 gallons). Replace filler cap and tighten securely. IMPORTANT: Always make sure the oil tank caps are threaded on tight.
  • Page 60 FUEL AND OIL • Always stop engine before refilling tanks. • Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled.

  • Page 61: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle ‑...

  • Page 62: Zero Effort Control Features

    FEATURES AND CONTROLS Zero Effort Control Features Throttle lever Trim switch Shift lever 4090 Warning System The warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or under the dash connected to the ignition key switch. 27755 Inside the remote control Under the dashboard...
  • Page 63 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. Refer to the Troubleshooting section for specific information. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft product information.

  • Page 64: Water Pressure

    MAP Sensor Failure Temperature Sensor Failure Ignition Coil Failure Injector Failure SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this power package. A few functions the instrument packages display are: • Engine RPM • Coolant temp •...

  • Page 65: Overspeed Rev Limit

    Guardian diagnostics. The SmartCraft instrument package will display critical engine alarm data and potential problems. Refer to the Mercury SmartCraft Operator’s Supplement provided with the power package for the warning functions monitored on your power package and basic operation of the SmartCraft Instrument package.

  • Page 66: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt Your 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. Moving the outboard in closer to the boat transom is called trimming in or down.
  • Page 67 FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and...
  • Page 68 FEATURES AND CONTROLS • In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired.
  • Page 69 FEATURES AND CONTROLS MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.
  • Page 70 FEATURES AND CONTROLS AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system. Auxiliary tilt switch 2745...

  • Page 71: Operation

    OPERATION Engine Break‑in 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. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.

  • Page 72: 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. Do not spray on corrosion control...

  • Page 73: Operating At High Elevations

    OPERATION Operating at High Elevations Your engine automatically compensates for high elevation changes. A different pitch propeller may help reduce some normal performance loss resulting from reduced oxygen in the air. Consult your dealer. Effects of Elevation and Weather on Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems:...

  • Page 74: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION • Reduces the possibility of detonation • Enhances overall reliability and durability of the engine Setting Trim Angle While Running Engine at Idle Speed Submerging the exhaust relief hole on the outboard can happen on some boats if you trim full in while running at idle speed, resulting in, exhaust restriction, rough idle, excessive smoke, and fouled spark plugs.

  • Page 75: Starting The Engine

    OPERATION Models with a single‑ram trim system: The outboard will remain at the selected tilt position, regardless of engine RPM. 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.
  • Page 76 OPERATION 2. Open the fuel tank filler cap vent screw (manual venting fuel tanks). 19748 3. 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 77 If no water exits the water pump indicator hole, stop the engine and check the cooling water intake holes for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system, which can overheat the engine. Have an authorized Mercury Marine dealer check the system.

  • Page 78: Gear Shifting

    OPERATION Gear Shifting NOTICE Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running can cause misalign the clutch, preventing proper shifting. Always shift the gearcase into gear when the engine is operating at idle.

  • Page 79: Power Package Care

    Perform all procedures as described in this manual. If you are not familiar with proper maintenance or service procedures, consign the work to an authorized Mercury Marine dealer. To ensure safety and retain dependability, keep your power...

  • Page 80: Epa Emissions Regulations

    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 81: Inspection And Maintenance Schedule

    MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.
  • Page 82 MAINTENANCE • Flush the propeller and gearcase exhaust outlet with fresh water. • Remove the cowl and wipe off any saltwater spray with a damp cloth. EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATER OR POLLUTED WATER USE • Spray the powerhead and all external, unpainted metal surfaces (except anodes) with Corrosion Guard.
  • Page 83 MAINTENANCE Tube Description Where Used Part No. Ref No. Anti-Corrosion Entire length of driveshaft 92-802867Q 1 Grease • Lubricate splines on the propeller shaft. • Drain and replace gearcase lubricant. • Inspect all belts, pulleys, and idler pulleys for deterioration. •...

  • Page 84: Flushing The Cooling System (Powerhead)

    MAINTENANCE • Replace spark plugs at first 100 hours or first year. After that, inspect spark plugs every 100 hours or once yearly. Replace spark plugs as needed. • Replace the water separating fuel filter. • Use QuicKleen in fuel. •...

  • Page 85: Flushing The Cooling System (Lower Unit)

    MAINTENANCE 2. Attach a water hose to the fitting. Turn on the water and flush for three to five minutes. NOTE: The engine can be stopped or operated at idle speed when flushing the cooling system. Do not flush engine using a water system that exceeds 310 kPa (45 psi).

  • Page 86: Top Cowl Removal And Installation

    MAINTENANCE 4. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups or nose cone cup to ensure the engine receives an adequate supply of cooling water. 5.

  • Page 87: Fuel System

    MAINTENANCE CLEANING AND WAXING PROCEDURE 1. Before washing, rinse the top cowl with clean water to remove the dirt and dust that may scratch the surface. 2. Wash the top cowl with clean water and a mild non‑abrasive soap. Use a soft clean cloth when washing. 3.
  • Page 88 MAINTENANCE WATER SEPARATING FUEL FILTER This filter removes moisture and debris from the fuel. If the filter becomes filled with water, the water can be removed. If the filter becomes plugged with debris, replace the filter. The warning system engages when water in the fuel filter reaches the full level.
  • Page 89 MAINTENANCE 2. Install the fuel filter and tighten securely. 3. Reconnect the link rod. IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm, forcing fuel into the filter. DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on.

  • Page 90: Steering Link Rod Fasteners

    MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 91 MAINTENANCE WARNING Worn, loose, or seized steering components can lead to loss of boat control. Inspect all steering attachment components for wear, lubricate all attachment hardware, and check all fasteners for proper tightness in accordance with the inspection and maintenance schedule. 2767 Special washer head bolt (P/N 10‑849838) Nylon insert locknut (P/N 11‑826709113) ‑...

  • Page 92: Fuses

    MAINTENANCE Description lb‑in. lb‑ft Special washer head bolt Fuses IMPORTANT: Always carry spare 5 and 20 amp fuses. The electrical wiring circuits on the engine are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload.

  • Page 93: Corrosion Control Anode

    Electric fuel pump/ECM driver power/oil pump circuit/ injectors ‑ 20 amp fuse Corrosion Control Anode NOTICE Anodes made of insufficiently pure aluminum alloys may not adequately protect critical drive components from corrosion. We recommend using anodes sold through Mercury Precision Parts only.

  • Page 94: Spark Plug Inspection And Replacement

    MAINTENANCE Anodes help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of other metals. This model has three corrosion control anodes—two above and one below the anti‑ventilation plate. A fourth anode is located on the bottom of the clamp/swivel bracket assembly.
  • Page 95 MAINTENANCE 1. Remove the spark plug leads. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, or blistered, or if the precious metal is not visible on the plug's electrode.

  • Page 96: Battery Inspection

    MAINTENANCE 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight and then tighten 1/4 turn or torque to specifications. Description lb‑in. lb‑ft Spark plug Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability.

  • Page 97: Charging System Fusible Link

    With the fusible link open, the engine can be started; however, the run time is limited, because the alternator is not charging the boat battery. If the fusible link circuit becomes open, contact your authorized Mercury Marine dealer. 3797 Propeller Replacement ‑...
  • Page 98 5. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/ Quicksilver products: Tube Description Where Used Part No.
  • Page 99 MAINTENANCE 6. Flo‑Torq I drive hub propellers ‑ Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. Propeller nut Propeller nut retainer Rear thrust hub Continuity washer Propeller 45018 Forward thrust hub 7.

  • Page 100: Propeller Replacement - 31.75 Mm (1-1/4 In.) Diameter Propeller Shaft

    3. Pull propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 4. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/ Quicksilver products:...
  • Page 101 MAINTENANCE Tube Description Where Used Part No. Ref No. Anti-Corrosion Propeller shaft splines 92-802867Q 1 Grease 2-4-C with Propeller shaft splines 92-802859A 1 PTFE NOTE: Propellers used on the 31.75 mm (1‑1/4 in.) diameter propeller shaft require the heavy‑duty propeller hub kit. 5.

  • Page 102: Lubrication Points

    MAINTENANCE 6. Place a block of wood between the gearcase and propeller and tighten the propeller nut to the specified torque. 2691 Description lb‑in. lb‑ft Propeller nut Lubrication Points 7723...
  • Page 103 MAINTENANCE Tube Ref Description Where Used Part No. Special Trim Rod Ball Ends 92-802865Q02 Lubricant 101 2-4-C Marine Prop Shaft, Swivel Bracket, Tilt Lubricant with 92-802859A 1 Support Lever, Tilt Tube PTFE NOTE: Turn the ball ends to work the lubricant into the ball sockets.

  • Page 104: Checking Power Trim Fluid

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

  • Page 105: Gearcase Lubrication

    MAINTENANCE Gearcase Lubrication 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 106 MAINTENANCE Gearcases with 31.75 mm (1‑1/4 in.) diameter propeller shaft ‑ 760 ml (25.7 fl oz) GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position.

  • Page 107: Storage

    Adding Fuel Stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will help clean and lubricate the fuel injectors.
  • Page 108 Left side fitting Drain screw Drain hose 29451 6. Premix the following in a container: • 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision Quickleen lubricant. • 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision Fuel Stabilizer.

  • Page 109: Protecting Internal Engine Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes).

  • Page 110: Gearcase

    STORAGE Tube Description Where Used Part No. Ref No. Corrosion External metal surfaces 92-802878 55 Guard Gearcase • Drain and refill the gearcase lubricant (refer to Gearcase Lubrication). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of the outboard.

  • Page 111: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 112: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c.

  • Page 113: Warning Horn Activates (No Power Loss)

    TROUBLESHOOTING • The oil level in the engine‑mounted oil reservoir tank is low. Refill the reservoir tank and the remote oil tank. Refer to Fuel and Oil for details. • Battery voltage is out of limits. • Throttle position sensor failure. •...
  • Page 114 TROUBLESHOOTING • Defective rectifier, alternator, or voltage regulator.

  • Page 115: Owner Service Assistance

    If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

  • Page 116: Mercury Marine Service Offices

    • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English ‑ (920) 929‑5040...

  • Page 117: Ordering Literature

    Serial Model year: Number: UNITED STATES AND CANADA For information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature contact your nearest dealer or contact: MERCURY MARINE Telephone Mail Mercury Marine Attn: Publications Department (920) 929‑5110 (920) 929‑4894...

  • Page 118: Outboard Installation

    IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3. The use of an inferior 2‑Cycle outboard oil can reduce engine durability.

  • Page 119: Boat Horsepower Capacity

    The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting in gear. Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.

  • Page 120: Fuel Tanks

    OUTBOARD INSTALLATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories. Fuel Tanks...

  • Page 121: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33‑3/8 in.) Dual engine 151.8 cm (59‑3/4 in.) Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death.

  • Page 122: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. Lifting eye 28495 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead...

  • Page 123: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 2. Insert steering cable into tilt tube. 3725 3. Torque nut to specification. 3727 Description lb‑in. lb‑ft 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 124 OUTBOARD INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat.
  • Page 125 OUTBOARD INSTALLATION 2. Assemble the steering link rod to the engine with the special washer head bolt "a" and self‑locking nylon insert locknut "b." 3. Torque the head bolt, then the locknut to specifications. Description lb‑in. lb‑ft Cable coupler nylon insert locknut Tighten locknut until it seats, then "d"...

  • Page 126: Determining Recommended Outboard Mounting Height

    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.) 24305 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 127: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions.

  • Page 128: Fastening The Outboard To The Transom

    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 129 OUTBOARD INSTALLATION Available Outboard Mounting Bolts Part Number Description 10‑8M0033366 ½‑20 x 5.00 in. long (3.25 in. thread) 10‑67755‑003 ½‑20 x 5.50 in. long (3.25 in. thread) 10‑67755‑2 ½‑20 x 6.50 in. long (2.75 in. thread) 10‑8M0028080 ½‑20 x 7.50 in. long (2.75 in. thread) 10‑8M0032860 ½‑20 x 8.00 in.
  • Page 130 OUTBOARD INSTALLATION Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate.
  • Page 131 OUTBOARD INSTALLATION NOTE: For more accurate torque, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 1/2 in. diameter outboard mounting bolt (4) 7/8 in. flat washer (4) Nylon insert locknut (4) 1‑1/2 in. flat washer (4) Marine sealer ‑ apply to the shank of the bolts, not the threads Description lb‑in.

  • Page 132: Electrical, Hoses, Control Cables, And Front Clamp

    OUTBOARD INSTALLATION Electrical, Hoses, Control Cables, and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl. Connect remote harness to the 14 pin connector on the engine harness. 28742 14 pin connector BATTERY INFORMATION...

  • Page 133: Single Outboard

    OUTBOARD INSTALLATION IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements. The decal needs to be placed on or near the battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut is supplied per battery for wing nut replacement.
  • Page 134 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 HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate fuel line/fuel tank pickup for each engine.
  • Page 135 OUTBOARD INSTALLATION Water Pressure and Speedometer Hose or Tubing NOTE: This applies to models without SmartCraft gauges. This outboard has a speedometer water pickup located in the leading edge of the gearcase. If you want to use this water pickup for the speedometer, disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl.
  • Page 136 OUTBOARD INSTALLATION Make the water pressure gauge hose connection to the tubing as shown. 29069 Water pressure tube Speedometer water pickup tube (if required) Coupler Plug Barb hose fitting Speedometer hose or tubing Water pressure tube Remote fuel hose Hose clamp Oil hose with blue stripe Oil hose without blue stripe Cable tie...
  • Page 137 OUTBOARD INSTALLATION INSTALLING THE SHIFT CABLE - MODELS WITH 25.4 MM (1.0 IN.) DIAMETER PROPELLER SHAFT IMPORTANT: The shift cable is the first cable to move when the remote control handle is moved out of neutral, so install/connect it to the engine first. Locating the Center Point of the Shift Cable IMPORTANT: Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustment of the shift...
  • Page 138 OUTBOARD INSTALLATION c. Place a mark on the shift cable against the cable end guide. 29077 Reverse position mark 3. Mark the center on the shift cable midway between the forward and reverse marks. 4361 Center mark 4. Align the cable end guide against this center mark when installing the cable to the engine.
  • Page 139 OUTBOARD INSTALLATION Adjusting the Shift Cable 1. Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable. 4362 Center mark 2. Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder.
  • Page 140 OUTBOARD INSTALLATION c. Shift the remote control into reverse while turning the propeller shaft. If the propeller shaft does not lock solidly in gear, adjust the barrel away from the cable end guide. Repeat steps a through c. d. Return the remote control handle to neutral. If the propeller shaft does not turn freely without drag, adjust the barrel closer to the cable end guide.
  • Page 141 OUTBOARD INSTALLATION a. Move the remote control handle into reverse and advance the handle to the full speed position. Ensure the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the handle back to the neutral detent position.
  • Page 142 OUTBOARD INSTALLATION 7. Center the anchor pin between these resistance points. Anchor pin 2675 Adjusting the Shift Cable To adjust the shift cable: 1. Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable. 4362 Center mark 2.
  • Page 143 OUTBOARD INSTALLATION 3. Secure the shift cable to the anchor pin with a nylon washer and locknut. Tighten the locknut to the specified value. 2677 Cable barrel Cable latch Locknut Nylon washer Description lb‑in. lb‑ft Shift cable locknut Tighten, then loosen 1/4 turn 4.
  • Page 144 OUTBOARD INSTALLATION INSTALLING THE THOTTLE CABLE - MODELS WITH 25.4 MM (1.0 IN.) DIAMETER PROPELLER SHAFT IMPORTANT: Attach the shift cable to the engine prior to attaching the throttle cable. 1. Shift the remote control into the neutral position. 2. Attach the throttle cable to the throttle lever. Secure with a washer and locknut.
  • Page 145 OUTBOARD INSTALLATION a. Shift the outboard into gear a few times to activate the throttle linkage. Rotate the propeller shaft while shifting into reverse. b. Return the remote control to neutral. c. Place a thin piece of paper between the idle adjustment screw and the idle stop.
  • Page 146 OUTBOARD INSTALLATION 2. Attach the throttle cable to the throttle lever. Secure with a washer and locknut. Tighten the locknut to the specified value. Nylon washer Locknut 2678 Description lb‑in. lb‑ft Throttle cable locknut "b" Tighten, then loosen 1/4 turn 3.
  • Page 147 OUTBOARD INSTALLATION IMPORTANT: The idle stop screw must be touching the stop. Idle stop screw Idle stop 2680 d. Adjust the cable barrel if necessary. 5. Lock the barrel holder in place with the cable latch. 2682 FRONT CLAMP ASSEMBLY INSTALLATION IMPORTANT: There must be sufficient slack in the engine wiring harness, battery cables, fuel hose, and oil hoses, between clamp and engine attachment point, to relieve stress and prevent hoses...
  • Page 148 OUTBOARD INSTALLATION 2. Place the neoprene wrap around the wiring, hoses, and control cables, and place into the lower half of the front clamp. 29073 Neoprene wrap Lower half of the front clamp 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties.

  • Page 149: Filling The Fuel System

    OUTBOARD INSTALLATION 5. Install the cowl seal. Retainer 29075 Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system.

  • Page 150: Oil Injection Set-Up

    OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten fill cap. Fill cap 2683 2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
  • Page 151 OUTBOARD INSTALLATION PRIMING OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. 3768 Oil supply hose Oil injection pump IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump.
  • Page 152 OUTBOARD INSTALLATION d. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. 26846 e. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. f.

  • Page 153: Trim In Pin

    OUTBOARD INSTALLATION Trim In Pin 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. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 154 OUTBOARD INSTALLATION The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired. A nonstainless steel shipping bolt should not be used in this application other than on a temporary basis.

  • Page 155: 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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