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Mercury Four Stroke Installation Manual

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Section 1D - Outboard Motor Installation

Table of Contents

Electric Fuel Pump
. . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity
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. . . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine.
If necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1.
cause loss of boat control 2. place too much weight at the transom, altering the de-
signed flotation characteristics of the boat or 3. cause the boat to break apart, par-
ticularly around the transom area. Overpowering a boat can result in serious injury,
death, or boat damage.
90-888465 JUNE 2002
IMPORTANT INFORMATION
1D-1
. . . . . . . . . . . . . . .
1D-1
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. . .
. . . . . . .
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER
MAXIMUM PERSON
CAPACITY (POUNDS)
MAXIMUM WEIGHT
CAPACITY
OUTBOARD MOTOR INSTALLATION
. . . . . . . . . . . . . . . . . . . . . .
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XXX
XXX
XXX
WARNING
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Page 1D-1
1
D

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Summary of Contents for Mercury Four Stroke

  • Page 1: Table Of Contents

    OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents Electric Fuel Pump ..... . 1D-1 Installing Outboard .

  • Page 2: Start In Gear Protection

    MAINTENANCE Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protec- tion device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine.

  • Page 3: Lifting Outboard

    OUTBOARD MOTOR INSTALLATION Lifting Outboard Use 3 point strap 91-883705T. 3 point lift strap 91-883705T Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate entire cable end. 2-4-C Marine Lubricant with Teflon 90-888465 JUNE 2002 Page 1D-3...

  • Page 4: Steering Cable Seal

    MAINTENANCE 2. Insert steering cable into tilt tube. 3. Torque nut to 47.5 Nm (35 lb. ft). Steering Cable Seal Install O-ring seal and cap. O-ring Seal Page 1D-4 90-888465 JUNE 2002...

  • Page 5: Steering Link Rod

    OUTBOARD MOTOR INSTALLATION Steering Link Rod 1. Install steering link rod to rear hole on steering arm per illustration. Special Bolt (10-856680) Torque to 27.1 Nm (20 lb. ft) Nylon Insert Locknut (11-34932) Torque to 27.1 Nm (20 lb. ft) Flat Washer Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn...

  • Page 6: Installing Outboard

    MAINTENANCE Installing Outboard 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (lo- cated in the installation manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line with the bottom of the boat. Anti-Ventilation Plate 4.

  • Page 7: Front Cable Clamp Assembly

    OUTBOARD MOTOR INSTALLATION Front Cable Clamp Assembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, and fuel hose routed between cable clamp and engine attachment point, to relieve stress. 1. Bundle the fuel line, battery cables and wiring together and wrap with the piece of foam (provided) as shown.

  • Page 8: Remote Wiring Harness

    MAINTENANCE 4. Install the top half of the cable clamp and reinstall the cowl bracket. 5. Slide the rigging tube onto the cable clamp and fasten with collar and hose clamp. Top Half Cable Clamp Collar Cowl Bracket Hose Clamp Rigging Tube Remote Wiring Harness Route wiring harness through the front cable clamp.

  • Page 9: Battery Cable Connections To The Engine

    OUTBOARD MOTOR INSTALLATION Battery Cable Connections to the Engine Route battery cables through the front cable clamp. Connect the battery cables to the termi- nals on the engine as shown. NOTE: Bolts for fastening the battery cables terminals are located in the same packaging kit that contains the front cable clamp.

  • Page 10: Battery Cable Connections To The Battery

    MAINTENANCE Battery Cable Connections to the Battery SINGLE OUTBOARD (–) Red Sleeve (Positive) Black Sleeve (Negative) Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between nega- tive (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) –...

  • Page 11: Fuel Hose Connection

    OUTBOARD MOTOR INSTALLATION Fuel Hose Connection PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.

  • Page 12: Shift Cable Installation

    MAINTENANCE Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. 1.
  • Page 13 OUTBOARD MOTOR INSTALLATION 4. Place shift cable on the shift pin. Adjust cable barrel so it slips freely into the barrel holder. 5. Fasten cable to the shift pin with hairpin cotter. Cable Barrel Hair Pin Cotter 6. Check shift cable adjustments as follows: a.

  • Page 14: Throttle Cable Installation

    MAINTENANCE Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote con- trol. 1. Position remote control into neutral. 2. Install throttle cable to the throttle arm with hairpin cotter. 3. Adjust the cable barrel until the alignment mark on the cam lines up with center of the roller.

  • Page 15: Propeller Installation

    OUTBOARD MOTOR INSTALLATION Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine start- ing and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.

  • Page 16: Trim Tab Adjustment

    MAINTENANCE Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2.

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