Mercury 25 EFI FourStroke User Manual
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Mercury 25 EFI FourStroke User Manual

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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
!
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Do you have a question about the 25 EFI FourStroke and is the answer not in the manual?

Questions and answers

Dominic Perron
June 3, 2025

La lumière faute de surchauffe est restée allumée et ne démarre plus Comment la faire éteindre

0
2 comments:
Mr. Anderson
June 3, 2025

To turn off the overheating warning light on a Mercury 25 EFI FourStroke, you must first fix the cause of the overheating. Check for a water pump failure or blockages in the cooling system. Ensure there is sufficient cooling water reaching the engine. Once the engine cools down after resolving the issue, the warning light should turn off automatically.

This answer is automatically generated

0
Dominic Perron
June 3, 2025

@Mr. Anderson Water pumps are fix but the light stay on and 20HP mercury 2021 will not want start

0
Arti
April 27, 2025

Runs fine just Fuel leaking from bottom of motor

0
1 comments:
Mr. Anderson
May 14, 2025

Fuel could be leaking from the bottom of a Mercury 25 EFI FourStroke motor due to:

- Deterioration of rubber or plastic fuel system parts
- Fuel permeation through rubber fuel lines
- Corrosion of metal parts
- Loose, swollen, hardened, or cracked fuel lines or components
- Old or contaminated gasoline causing seal breakdown
- Fuel line disconnection or kinks
- Faulty primer bulb or check valve
- Obstructed or damaged fuel filter or fuel tank filter

Any sign of leakage or deterioration requires replacement before operating the engine.

This answer is automatically generated

0
michel desrochers
February 2, 2025

I don't have fire on sprkplug

0
1 comments:
Mr. Anderson
February 10, 2025

A lack of spark on the spark plug for the Mercury 25 EFI FourStroke could be due to several reasons:

1. Blown Fuse – If the SFE 20 amp fuse protecting the electric starting circuit is blown, the engine may not start. Check the fuse holder and replace a blown fuse with one of the same rating.

2. Damaged Spark Plug Boots – If the spark plug boots are damaged, they may emit sparks elsewhere or fail to deliver power to the spark plug.

3. Faulty Spark Plug – A worn or damaged spark plug may not produce a spark. Inspect and replace if necessary.

4. Electrical Issues – A problem with the ignition system, such as a faulty ignition coil or wiring issue, could prevent the spark plug from firing.

Checking and addressing these issues should help restore spark to the engine.

This answer is automatically generated

0
John Mech
January 30, 2025

How do I adjust the manual tilt on my 25MH to automatically tilt if I hit something under power

0
1 comments:
Mr. Anderson
May 14, 2025

To allow the Mercury 25 EFI FourStroke outboard to tilt automatically if you hit something under power, turn the manual tilt release valve 3 turns counterclockwise. This loosens the valve and enables manual tilting.

This answer is automatically generated

0

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Summary of Contents for Mercury 25 EFI FourStroke

  • 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 Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Tohatsu Marine Corporation (TMC) Mercury Marine Joint Venture Address: Shimodaira 4495‑9 Town: Komagane‑City, Post Code: 399‑4101...
  • Page 4 Conformity assessment ☒ B ☐ B ☐ B ☐ B ☐ G ☐ H module used for exhaust emissions: ☐ Stage II of ☐ Directive or engine type approved according to: Directive 97/68/EC 88/77/EC Conformity assessment ☐ A ☒ Aa ☐...
  • Page 5 I declare on behalf of the engine manufacturer that the engines mentioned preceding complies with all applicable essential requirements in the way specified. 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 FourStroke Outboard Limited Warranty........2 FourStroke Outboard Limited Warranty........6 FourStroke Outboard Limited Warranty........10 3 Year Limited Warranty Against Corrosion......14 Warranty Coverage and Exclusions.......... 17 GENERAL INFORMATION Boater's Responsibilities............20 Before Operating Your Outboard..........
  • Page 8 TRANSPORTING Trailering Boat/Outboard ............48 Transporting Your Outboard When Removed From Boat..48 Transporting Portable Fuel Tanks..........49 FUEL and OIL Fuel Recommendations............. 51 Low Permeation Fuel Hose Requirement ......... 53 Filling Fuel Tank................ 53 Engine Oil Recommendations........... 54 Checking And Adding Engine Oil..........54 FEATURES and CONTROLS Remote Control Features............
  • Page 9 MAINTENANCE Outboard Care................93 EPA Emissions................94 Inspection and Maintenance Schedule........95 Flushing the Cooling System............. 96 Top Cowl Removal and Installation........... 99 Exterior Care................99 Battery Inspection ..............100 Fuel System................100 Steering Link Rod Fasteners........... 102 Corrosion Control Anode............103 Propeller Replacement............
  • Page 10 OWNER SERVICE ASSISTANCE Local Repair Service..............125 Service Away from Home............125 Parts and Accessories Inquiries..........125 Service Assistance..............125 Mercury Marine Service Offices..........126 INSTALLATION Installation Information............. 128 Installing Outboard..............130 Electrical Harness, Battery Connection, Fuel Tanks....140 Control Cable Installation............145...

  • Page 11: 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 12: 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 13 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 14 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 15 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 16: Fourstroke Outboard Limited Warranty

    EUROPE AND CONFEDERATION OF INDEPENDENT STATES Outside Europe and Confederation of Independent States ‑ check with local distributor. WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
  • Page 17 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 18 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 19 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 20: Fourstroke Outboard Limited Warranty

    RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. FourStroke Outboard Limited Warranty MIDDLE-EAST AND AFRICA WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below.
  • Page 21 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 22 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 23 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 if made, shall not be enforceable against Mercury Marine.

  • Page 24: Year Limited Warranty Against Corrosion

    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 25 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 26 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 27: 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 28 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 29 WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product.

  • Page 30: 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 31: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

  • Page 32: Propeller Selection

    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 33 GENERAL INFORMATION Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. The first number represents the diameter of the propeller and the second number represents the pitch.
  • Page 34 RPM range when under normal full throttle operation. 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.

  • Page 35: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death.

  • Page 36: Lanyard Stop Switch

    GENERAL INFORMATION 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 37 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 38 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 39 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 40: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 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 41: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 42: Wave And Wake Jumping

    GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

  • Page 43: Impact With Underwater Hazards

    GENERAL INFORMATION WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.

  • Page 44: Safety Instructions For Hand-Tilled Outboards

    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. Safety Instructions for Hand‑Tilled Outboards No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.

  • Page 45: Exhaust Emissions

    GENERAL INFORMATION MODELS WITH CLAMP SCREWS: Some outboards come with transom bracket clamp screws. The use of clamp bracket screws alone, is insufficient to properly and safely secure the outboard to the transom. Proper installation of the outboard includes bolting the engine to the boat through the transom.
  • Page 46 GENERAL INFORMATION WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide. GOOD VENTILATION Ventilate passenger area, open side curtains or forward hatches to remove fumes.

  • Page 47: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.

  • Page 48: Safe Boating Suggestions

    GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. 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.
  • Page 49 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 50: 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. XXXXXXXX XXXX 39255 Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) Specifications Models Power 18.4 kw (25 hp)
  • Page 51 GENERAL INFORMATION Models Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity 350 ml (11.8 fl oz) Engine oil capacity 1.8 liter (1.9 US qt) 465 marine cranking amps (MCA) or 350 Battery rating cold cranking amps (CCA) Emission control system Electronic engine control (EC) Sound at drivers ear (ICOMIA 80.9...

  • Page 52: Component Identification

    GENERAL INFORMATION Component Identification MANUAL TILT MODEL 15873 Top cowl Manual start handle Engine stop switch Throttle friction adjustment knob Throttle only button Transom brackets Tilt lock lever Primary cooling water intake Gearcase Secondary cooling water intake Anti‑ventilation plate...
  • Page 53 GENERAL INFORMATION Oil drain screw -Water pump indicator hole Bottom cowl Cowl latch Warning light Starting button (electric start models) Lanyard stop switch Steering friction adjustment lever...
  • Page 54 GENERAL INFORMATION MANUAL GAS ASSIST TILT MODEL 15882 Top cowl Manual start handle Engine stop switch Throttle friction adjustment knob Throttle only button Tilt support lever Gas assist tilt lever Primary cooling water intake Gearcase Secondary cooling water intake Anti‑ventilation plate Chaps...
  • Page 55 GENERAL INFORMATION -Water pump indicator hole Cowl latch Warning light Starting button (electric start models) Lanyard stop switch Steering friction adjustment lever...
  • Page 56 GENERAL INFORMATION POWER TRIM MODEL 39260 Transom brackets Tilt support lever Top cowl Cowl latch Bottom cowl Auxiliary tilt switch Chaps Anti‑ventilation plate Secondary cooling water intake Gearcase Primary cooling water intake...
  • Page 57 GENERAL INFORMATION Manual tilt release valve...

  • Page 58: Trailering Boat/Outboard

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. Shift the engine into reverse. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations.

  • Page 59: Transporting Portable Fuel Tanks

    TRANSPORTING 1. To prevent problems which can be caused by oil entering the cylinders from the sump, transport and store the outboard only in one of the two positions shown. Upright Tiller handle side down 15930 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion.
  • Page 60 TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidentally pushed‑in, allowing fuel or vapor to escape. Connector stem Tether cap 26794...

  • Page 61: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum.
  • Page 62 FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 63: Low Permeation Fuel Hose Requirement

    FUEL AND OIL Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009 must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.

  • Page 64: Engine Oil Recommendations

    IMPORTANT: The use of detergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 65 Outboard engines can typically handle large amounts of oil dilution without causing durability problems. However, to ensure extended life of the outboard engine, Mercury recommends that the oil and filter be changed regularly following the oil change interval and using the recommended oil quality.
  • Page 66 FUEL AND OIL 4. Push the dipstick back in all the way. Reinstall the oil fill cap hand tight.

  • Page 67: 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 68: Tiller Handle Model Features

    FEATURES AND CONTROLS Tiller Handle Model Features • Throttle only button ‑ Pressing in the button while the outboard is in neutral allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. 15894 • Steering friction adjustment ‑...

  • Page 69: Warning System

    FEATURES AND CONTROLS • Warning light ‑ The warning light will turn on or flash to alert the operator to the warning system situations. Refer to Warning System. 15732 • Electric start button (electric start models) ‑ Press to start the engine.
  • Page 70 FEATURES AND CONTROLS • Tiller handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage. 28535 • Tiller lock release lever ‑ Push lever to move tiller handle from one position to another. Tiller lock release lever 3274...
  • Page 71 FEATURES AND CONTROLS • Tiller handle lock cap ‑ Remove the lock cap on top of tiller handle to lock in up position. Push tiller lock release lever to release the handle from the locked up position. 3273 Lock cap Locking mechanism •...

  • Page 72: Warning System

    FEATURES AND CONTROLS • Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch. 19791 Warning System WARNING HORN Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. Tiller handle models will have the warning horn located in the engine cowl.
  • Page 73 FEATURES AND CONTROLS Warning System Engine Speed Warning Function Sound Description Limited to Light 2800 On for 5 Normal system Start up One beep seconds test Engine over Continuous Engine overheat temperature Low oil pressure Continuous Low oil pressure Engine speed Engine exceeds Continuous...

  • Page 74: Tiller Handle Models With Manual Gas Assist Tilt

    FEATURES AND CONTROLS If a steady flow of water is coming out of the water pump indicator hole and the engine continues to overheat, consult your dealer. Operating an overheated engine will cause engine damage. NOTE: Should overheating occur and you are stranded, stop the engine and allow it to cool down.
  • Page 75 FEATURES AND CONTROLS Before operating, the outboard must be locked in its tilt position by moving the lock lever to the lock position. WARNING Operating the engine without engaging the tilt lock lever can cause serious injury or death. The outboard can tilt upwards when decelerating or operating in reverse, causing loss of boat control.
  • Page 76 FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating your boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle. Operate your outboard at slow speed while tilted up for shallow water operation. Keep the cooling water intake holes submerged in the water and continue to check for water discharge from the water pump indicator hole.
  • Page 77 FEATURES AND CONTROLS 2. Move lock lever to the lock position. 9703 OPERATING ANGLE ADJUSTMENT The transom brackets have four holes for adjusting the vertical operating angle (forward stop movement) of the outboard. Use the tilt pin for adjustments in the four holes. Transom bracket holes FREE Tilt pin...
  • Page 78 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 10263 Too much angle (bow up) ‑ adjust in Not enough angle (bow down) ‑ adjust out Angle adjusted properly (bow slightly up) NOTE: The outboard should be locked against the tilt pin during operation by setting the tilt lock lever to the lock position.

  • Page 79: Tiller Handle Models With Manual Tilt

    FEATURES AND CONTROLS • In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is attempted or if a significant wave is encountered.
  • Page 80 FEATURES AND CONTROLS TILTING OUTBOARD TO FULL UP POSITION 1. Stop the engine. 2. Shift the outboard to forward gear position. 3. Position the tilt lever to the tilt position. 4. Take hold of the top cowl grip and tilt the outboard all the way up until it locks in place.
  • Page 81 FEATURES AND CONTROLS 5. To release the outboard out of shallow water drive, position the tilt lever to the release position, and slightly lift up the outboard, and than gently lower it down. 15925 SETTING THE OPERATION ANGLE OF YOUR OUTBOARD The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the six adjustment holes provided.
  • Page 82 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 15927 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.
  • Page 83 FEATURES AND CONTROLS Adjusting the outboard away from the boat transom can: • Lift the bow out of the water. • Generally increase top speed. • Increase clearance over submerged objects or a shallow bottom. • Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller).

  • Page 84: Power Trim And Tilt (If Equipped)

    FEATURES AND CONTROLS Power Trim and Tilt (if Equipped) 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 85 FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.
  • Page 86 FEATURES AND CONTROLS 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 87 FEATURES AND CONTROLS 3. Disengage the tilt support lever, by slightly tilting up the outboard and releasing the tilt support bracket. Lower the outboard. 9703 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 88 FEATURES AND CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. 9974 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 89: Trim Tab Adjustment

    FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal result from your outboard not trimmed with the propeller shaft parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.
  • Page 90 FEATURES AND CONTROLS If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right.

  • Page 91: Operation

    OPERATION Prestarting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 92: Operating In Saltwater Or Polluted Water

    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 anodes as this will reduce the effectiveness of the anodes.

  • Page 93: Engine Break-In Procedure

    OPERATION 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. 3. Make sure the cooling water intake is submerged. 26837 Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures...
  • Page 94 OPERATION 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. NOTE: If the outboard has run out of fuel, or has been in storage for an extended period of time, additional attempts to start the engine will be required to purge the fuel system of air.
  • Page 95 OPERATION 4. Shift outboard to neutral ("N") position. 26838 5. Move the neutral fast idle speed feature to the fully closed position. NOTE: Starting flooded engine ‑ Advance the neutral fast idle speed feature to the maximum fast idle speed position and continue to crank the engine for starting.

  • Page 96: Starting The Engine - Tiller Handle Models

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat.
  • Page 97 OPERATION 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. 27348 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after the engine has warmed up.
  • Page 98 OPERATION 6. Manual starting models ‑ Pull the starter rope slowly, until you feel the starter engage, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until engine starts. 10173 7. Electric starting models ‑ Push the starter button and crank the engine.

  • Page 99: Gear Shifting

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat.

  • Page 100: Stopping The Engine

    OPERATION • After shifting outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed. Stopping the Engine 1. Remote control models ‑ Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position.
  • Page 101 OPERATION 1. Remove flywheel cover or manual starter assembly. 10004 2. Shift outboard to neutral ("N") position. NEUTRAL START 26838 10051 WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear.
  • Page 102 OPERATION WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests. WARNING The exposed moving flywheel can cause serious injury.

  • Page 103: Outboard Care

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.

  • Page 104: Epa Emissions

    MAINTENANCE EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS...

  • Page 105: Inspection And Maintenance Schedule

    MAINTENANCE Inspection and Maintenance Schedule BEFORE EACH USE • Check engine oil level. See Fuel and Oil ‑ Checking and Adding Engine Oil. • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. •...

  • Page 106: Flushing The Cooling System

    MAINTENANCE • Replace the high pressure fuel filter. • Check engine timing setup. • Check corrosion control anodes. Check more frequently when used in saltwater. See Corrosion Control Anode. • Drain and replace gear case lubricant. See Gearcase Lubrication. • Lubricate splines on the driveshaft.
  • Page 107 MAINTENANCE Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages. WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 108 MAINTENANCE 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 27259 3. Start the engine and run it at idle speed in neutral shift position.

  • Page 109: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation REMOVAL 1. Unlock the rear latch by pulling lever up. 10190 2. Lift rear of cowl and disengage front hook. 10191 INSTALLATION 1. Lower the top cowl over the engine. Bring the front of the cowl down first and engage the front hook, then lower the cowl into its seated position with the bottom cowl.

  • Page 110: Battery Inspection

    MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3.
  • Page 111 MAINTENANCE FUEL FILTER (LOW PRESSURE) Check the fuel filter for water accumulation or sediment. If water is in the fuel, remove the sight bowl and drain the water. If the filter appears to be contaminated, remove and replace. REMOVAL 1. Read Fuel System servicing information and Warning, preceding.

  • Page 112: Steering Link Rod Fasteners

    MAINTENANCE Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine. Never replace the locknuts (11‑16147‑‑3) with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.

  • Page 113: Corrosion Control Anode

    MAINTENANCE Assemble steering link rod to engine with bolt, locknut, spacer, and flat washers. Torque locknut to specifications. 9691 Bolt (10‑898101018) Flat washer (12‑95392‑10) Spacer (23‑853826001) Nylon insert locknut (11‑16147‑‑3) Install steering link rod into side hole Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off 1/4 turn) Description lb.
  • Page 114 MAINTENANCE Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. One anode is installed in the engine block.

  • Page 115: Propeller Replacement

    MAINTENANCE The second anode is the trim tab and the third anode is installed on the transom brackets. 10239 10243 10236 Trim tab Transom bracket anode ‑ long Transom bracket anode ‑ short Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 116 MAINTENANCE 2. Remove spark plug leads to prevent engine from starting. 26899 3. Straighten and remove cotter pin. 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.
  • Page 117 MAINTENANCE 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. 10087 Tube Description Where Used Part No. Ref No. Anti-Corrosion Propeller shaft 92-802867Q 1 Grease 2-4-C with Propeller shaft 92-802859A 1 PTFE 7.

  • Page 118: Spark Plug Inspection And Replacement

    MAINTENANCE 9. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. 28353 28351 Description lb. in. lb. ft. Propeller nut 10. Install the spark plug leads. Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite...

  • Page 119: Fuse Replacement - Electric Start Models

    MAINTENANCE 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3. Set the spark plug gap to specifications. 27848 Spark Plug Gap Spark plug 0.80–0.90 mm (0.031–0.035 in.) 4.

  • Page 120: Timing Belt Inspection

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 15917 Good fuse Blown fuse Timing Belt Inspection Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found.

  • Page 121: Lubrication Points

    MAINTENANCE Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Description Where Used Part No. Ref No. Anti-Corrosion Propeller shaft 92-802867Q 1 Grease 2-4-C with Propeller shaft 92-802859A 1 PTFE •...
  • Page 122 MAINTENANCE • Swivel Bracket ‑ Lubricate through fitting. 10169 • Tilt Tube ‑ Lubricate through fittings. 15915 • Lubricate threads on transom clamp screws (if equipped). 15914...
  • Page 123 MAINTENANCE • Steering Cable Grease Fitting (If equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 10161 Fitting Steering cable end WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

  • Page 124: 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 Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 125 MAINTENANCE OIL CHANGING PROCEDURE 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall.

  • Page 126: Gearcase Lubrication

    MAINTENANCE 2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. Oil fill cap 9737 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 127 9836 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 350 ml (11.8 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position.

  • Page 128: Submerged Outboard

    MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 129: Storage

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

  • Page 130: Protecting External Outboard 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). Tube Description Where Used Part No.

  • Page 131: 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. Battery Storage •...

  • Page 132: Troubleshooting

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

  • Page 133: Engine Runs Erratically

    TROUBLESHOOTING • Spark plugs fouled or defective. Refer to Maintenance section. Engine Runs Erratically POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Spark plugs fouled or defective. Refer to Maintenance section. •...
  • Page 134 TROUBLESHOOTING • Worn out or inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator.

  • Page 135: 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 136: 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 137 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944...

  • Page 138: Installation

    INSTALLATION Installation Information BOAT HORSEPOWER CAPACITY WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating.
  • Page 139 The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.

  • Page 140: Installing Outboard

    INSTALLATION Installing Outboard INSTALLATION SPECIFICATIONS 2763 Minimum transom opening Engine center line for dual engines Minimum Transom Opening Single engine (remote) 48.3 cm (19 in.) Single engine (tiller) 76.2 cm (30 in.) Dual engines 101.6 cm (40 in.) Engine Center Line Minimum 66 cm (26 in.) TOP COWL REMOVAL AND INSTALLATION...

  • Page 141: Lifting Outboard

    INSTALLATION 2. Lift up on the rear of the cowl and disengage the front hook. 10170 Top Cowl Installation 1. Engage the front hook and push the top cowl onto the lower cowl. 2. Push the cowl latch down to lock the cowl in place. LIFTING OUTBOARD Use the lifting eye located aft of the flywheel to support the engine when installing the outboard.
  • Page 142 INSTALLATION INSTALLING THE OUTBOARD ON THE TRANSOM (MANUAL TILT MODELS) IMPORTANT: Models not equipped with power trim or gas assist must have the transom clamps contacting the top of the transom, and the clamp screws tightened, prior to drilling the mounting bolt holes through the transom.
  • Page 143 INSTALLATION 4. Apply marine sealer to shanks of bolts. Do not apply marine sealer to the threads of the bolts. 5. Secure the engine to the transom with the mounting hardware supplied with the engine. Tighten mounting hardware securely. Bolt (2) Washer (2) Locknut (2) 15729...
  • Page 144 INSTALLATION When first determining transom strength, use a dial torque wrench. 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 145 INSTALLATION 1. Use the transom drilling fixture for drilling the transom mounting holes. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.
  • Page 146 INSTALLATION 3. Install the outboard so that the anti‑ventilation plate is in‑line or within 25 mm (1 in.) of the bottom of the boat. Anti‑ventilation plate In‑line or within 25 mm (1 in.) 8045 4. Apply marine sealer to shanks of bolts. Do not apply marine sealer to the threads of the bolts.
  • Page 147 INSTALLATION 2. Lubricate entire steering cable end with 2‑4‑C with PTFE. 10261 Tube Description Where Used Part No. Ref No. 2-4-C with Steering cable end 92-802859A 1 PTFE 3. Install the steering cable seal onto the tilt tube. 4. Install the steering cable and tighten the steering cable nut to the specified torque.
  • Page 148 INSTALLATION STEERING LINK ROD FASTENERS IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine. Never replace the locknuts (11‑16147‑‑3) with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 149 INSTALLATION Assemble steering link rod to engine with bolt, locknut, spacer, and flat washers. Torque locknut to specifications. 9691 Bolt (10‑898101018) Flat washer (12‑95392‑10) Spacer (23‑853826001) Nylon insert locknut (11‑16147‑‑3) Install steering link rod into side hole Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off 1/4 turn) Description lb.

  • Page 150: Electrical Harness, Battery Connection, Fuel Tanks

    INSTALLATION Electrical Harness, Battery Connection, Fuel Tanks REMOTE WIRING HARNESS 1. Remove the three access cover bolts. Remove the access cover and cable rubber grommet. 10113 2. Remove the cotter pin retainers and washers from the shift actuating lever, shift link, and throttle actuating lever. 3.
  • Page 151 INSTALLATION 4. Loosen the bolt securing the control harness retainer bracket. 10114 Shift link, cotter pin retainer, and washer Shift actuating lever, cotter pin retainer, and washer Throttle actuating lever, cotter pin retainer, and washer Shift link Bolt securing harness retainer bracket 5.
  • Page 152 INSTALLATION 8. Route the harness between the barrel support. 10128 Harness connector Shift actuating lever pin Harness retainer bracket Barrel support 9. Ensure the harness retainer bracket is over the remote harness. Secure harness retainer bracket with bolt. Tighten bolt to the specified torque. 10.
  • Page 153 INSTALLATION Description lb. in. lb. ft. Bolt BATTERY CABLE CONNECTIONS IMPORTANT: To prevent damage to the engine charging system when the battery cables are not connected to a battery, ensure the battery cable ends are thoroughly insulated. Single Outboard Red sleeve ‑ positive (+) Black sleeve ‑...
  • Page 154 INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ positive (+) Black sleeve ‑ negative (–) Ground cable Cranking battery FUEL TANKS Portable Fuel Tank Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place.

  • Page 155: Control Cable Installation

    INSTALLATION Control Cable Installation THROTTLE CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control. 1. Move the remote control handle from neutral into forward and advance the handle to full speed position. NOTE: The throttle cable is the second cable to move when moving the control box out of neutral.
  • Page 156 INSTALLATION 6. Readjust the throttle cable barrel if the cam roller is touching the cam. 15952 Throttle cam Cam roller SHIFT CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control. 1. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a.
  • Page 157 INSTALLATION c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the cable end guide with this center mark when installing cable to the engine. 6098 2. Ensure the engine is in neutral. 3. Ensure the control box is in neutral. 4.
  • Page 158 INSTALLATION a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end.

  • Page 159: Installing Propeller

    INSTALLATION 9. Install the access cover and secure with three bolts. Tighten bolts to the specified torque. 15858 Description lb. in. lb. ft. Access cover bolt (3) Installing 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 engage the lanyard stop switch to prevent the engine from starting.
  • Page 160 INSTALLATION 2. Remove spark plug leads to prevent engine from starting. 26899 3. Coat the propeller shaft with Anti‑Corrosion Grease or 2‑4‑C with PTFE. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed.
  • Page 161 INSTALLATION NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut further to align it with the hole in the propeller shaft. 6. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.

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