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Mercury 8 User Manual

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See also: Service Manual , Operation & Maintenance Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping
your Mercury Product operating at peak efficiency for
maximum performance and economy. The enclosed Owner's
Registration Card is your key to trouble‑free family fun. Refer
to your Operation and Maintenance Manual for full details
of your warranty coverage.
Details
of
your
www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose?
Please check on www.marinepower.com. If necessary,
please contact your local dealer.
Declaration of Conformity
Manufacturer:
Authorized Representative:
Recreational Craft Directive:
Applicable Requirement
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engines starting (A.5.1.4)
General steering system (A.5.4.1)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Module used for exhaust emission assessment: Module H;
Certification No. RCD‑H‑2
Module used for noise emission assessment: Module H;
Certification No. RCD‑H‑2
nearest
dealer
Mercury Marine
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939 USA,
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-2800 Verviers - Belgium,
2003/44/EC amending 94/25/EC
i
can
be
found
Standards Applied
EN ISO 10240:2004
EN ISO 8665:1995
EN ISO 11547:1995
ABYC P‑17; EN ISO
10592:1995
EN ISO 8178‑1:1996
EN ISO 8665:1995
EN ISO 14509:2000
on

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Summary of Contents for Mercury 8

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
  • Page 2 RCD‑H‑2 40, 50, 60 Belgium 40, 50, 60 0P401000 RCD‑H‑2 4‑Cylinder 4/5/6 hp Beligium 4, 5, 6 0P401000 RCD‑H‑2 8/9.9 hp Belgium 8, 9.9 0P401000 RCD‑H‑2 15 hp Belgium 0P401000 RCD‑H‑2 Safety of Machinery Directive 98/37/EC Principles of safety integration ISO 12100‑1;...
  • Page 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006 European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 5: Table Of Contents

    Exhaust Emissions..............26 Selecting Accessories For Your Outboard......... 28 Safe Boating Suggestions............28 Recording Serial Number ............30 8/9.9 4‑Stroke Specifications ‑ International ......30 Component Identification ‑ Standard Models......32 Component Identification ‑ Bigfoot Models........34 Transporting Carrying, Storing and Transporting Your Outboard When...
  • Page 6 TABLE OF CONTENTS Transporting Portable Fuel Tanks..........36 Trailering Boat/Outboard ‑ Models with Power Tilt....37 Trailering Boat/Outboard ‑ Models without Power Tilt....38 Fuel and Oil Fuel Recommendations.............39 Filling Fuel Tank................41 Engine Oil Recommendations...........42 Checking Engine Oil..............42 Features and Controls Tiller Handle Features...............44 Remote Control Features............51 Warning System................52 Power Tilt (if equipped)..............52...
  • Page 7 TABLE OF CONTENTS Emergency Starting..............70 Maintenance Outboard Care................73 EPA Emissions................73 Inspection And Maintenance Schedule........74 Flushing the Cooling System.............76 Top Cowl Removal And Installation...........78 Battery Inspection ..............78 Exterior Care................79 Fuel System................79 Steering Link Rod Fasteners.............80 Corrosion Control Anode ............82 Propeller Replacement .............82 Fuse Replacement ‑...
  • Page 8 Battery Will Not Hold Charge...........100 Owner Service Assistance Local Repair Service..............101 Service Away From Home............101 Parts And Accessories Inquiries..........101 Service Assistance..............101 Mercury Marine Service Offices..........102 Engine Installation Boat Horsepower Capacity............104 Start in Gear Protection............104 Selecting Accessories For Your Outboard....... 104 Installing Outboard..............105 Remote Control Installation.............107...

  • Page 9: Warranty Information

    Warranty Registration United States And Canada 1. 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...

  • Page 10: Warranty Registration Outside The United States And Canada

    2. To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail.

  • Page 11: Fourstroke Outboard Limited Warranty United States, Canada, Europe And Confederation Of Independent States

    Independent States Outside the United States, Canada, 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 12 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 pre–delivery inspection process is completed and documented.
  • Page 13 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 14: Fourstroke Outboard Limited Warranty (Middle-East, And Africa)

    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 15 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 pre–delivery inspection process is completed and documented.
  • Page 16 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 17: Year Limited Warranty Against Corrosion

    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 18 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 pre‑delivery inspection process is completed and documented.
  • Page 19 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 20 Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty.

  • Page 21: 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 22 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 23 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 24: 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. Be sure at least one additional person on board is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 25: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 26: Remote Steering Notice

    GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 26779 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.

  • Page 27: Lanyard Stop Switch

    GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch.
  • Page 28 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 29: Protecting People In The Water

    GENERAL INFORMATION Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller.

  • Page 30: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. Passenger Safety Message ‑ Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers.

  • Page 31: 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 32: 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.
  • Page 33 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 34: 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 35 GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 21622 Example of desired air flow through the boat 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.

  • Page 36: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of non‑approved 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 37 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) The Red Cross and 4) your state boating law enforcement agency.

  • Page 38: Recording Serial Number

    XXXX XXXX 28498 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation 8/9.9 4‑Stroke Specifications ‑ International Models 9.9 Bigfoot Horsepower Kilowatts Weight 38.3 kg (84 lb.) 39.2 kg (86 lb.) 43.5 kg (95.9 lb.) MXLH 45 kg (99.2 lb.)
  • Page 39 Number of Cylinders Full Throttle RPM Range 5000‑6000 RPM Idle Speed in Forward 900 RPM Gear Piston Displacement 209.8 cc (12.8 cu. in.) Cylinder Bore 55 mm (2.17 in.) Piston Stroke 44 mm (1.73 in.) Valve Clearance (Cold) Intake Valve 0.13‑0.17 mm (0.0051‑0.0067 in.)

  • Page 40: Component Identification - Standard Models

    GENERAL INFORMATION Component Identification ‑ Standard Models STARBOARD SIDE VIEW 28508 Cowl latch Engine flush plug Throttle only button Gear lubricant level plug Throttle friction Water inlet adjustment knob Gear lubricant fill/drain Water pump indicator plug hole Trim tab Oil drain plug Transom angle preset knob...
  • Page 41 GENERAL INFORMATION FRONT VIEW 28527 Choke/fast idle knob Start switch (electric tiller handle) Fuel primer Lanyard safety switch Oil pressure light Trim/tilt position indicator Fuel line connector PORT VIEW 28529 Tiller lock release lever Steering friction adjustment lever (tiller Start switch (electric model only) tiller handle model) Tilt lock knob...

  • Page 42: Component Identification - Bigfoot Models

    GENERAL INFORMATION Component Identification ‑ Bigfoot Models 4538 Transom bracket Cowl latch Tilt support lever Oil drain screw Gear lubricant level plug Power tilt Water inlet Kicker strap Gear lubricant fill/drain -Throttle only button plug Throttle grip friction knob Anti‑ventilation plate Power tilt button Engine flush plug Water pump indicator...

  • Page 43: Transporting

    TRANSPORTING Carrying, Storing and Transporting Your Outboard When Removed From Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run engine until it stops.

  • Page 44: Transporting Portable Fuel Tanks

    TRANSPORTING 3. Carry, transport or store the outboard only in one of the four positions shown. These positions will prevent oil from draining out of the crankcase. 10375 Upright position Front side up Tiller handle down Front side down 4. Never carry, store or transport the outboard in the position shown.

  • Page 45: Trailering Boat/Outboard - Models With Power Tilt

    TRANSPORTING MANUAL VENTING TYPE FUEL TANK 1. Close fuel tank air vent when transporting tank. This will prevent escape of fuel or vapors from tank. 26793 AUTO-VENTING TYPE FUEL TANK 1. Disconnect the remote fuel line from tank. This will close the air vent and prevent escape of fuel or vapors from tank.

  • Page 46: Trailering Boat/Outboard - Models Without Power Tilt

    TRANSPORTING 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. Additional clearance may be required for railroad crossings, driveways and trailer bouncing. 26792 IMPORTANT: Do not rely on the power tilt system or tilt support lever to maintain proper ground clearance for trailering.

  • Page 47: 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 48 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 49: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

  • Page 50: Engine Oil Recommendations

    FUEL AND OIL Engine Oil Recommendations We recommend the use of Mercury or Quicksilver SAE 10W‑30 multi‑viscosity 4‑Stroke Outboard Oil for general, all‑temperature use. If SAE 25W‑40 multi‑viscosity oil is preferred, use Mercury MerCruiser 4‑cycle engine oil or Quicksilver sterndrive & inboard 4‑cycle engine oil.
  • Page 51 FUEL AND OIL 1. Turn the engine off. Have the outboard in a level operating position. Remove the top cowl. 2. Remove dipstick. Wipe dipstick with a clean rag or towel and push it back in all the way. 3. Pull the dipstick out again and observe the oil level. If oil level is low, remove oil filler cap and fill to (but not over) the full mark with the recommended oil.

  • Page 52: Features And Controls

    FEATURES AND CONTROLS Tiller Handle Features IMPORTANT: Avoid engine flooding ‑ Do not rotate the throttle grip while engine is not running. Doing so will inject fuel into the engine and cause a possible hard starting flooded condition. • Tiller Handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage.
  • Page 53 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 54 FEATURES AND CONTROLS • Engine Stop Switch ‑ Push in to stop engine. 28537 • Power Tilt Switch ‑ Push to tilt engine up/down. 4639 • Throttle Grip Friction Knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction or turn knob counterclockwise to loosen friction.
  • Page 55 FEATURES AND CONTROLS • Throttle Only Button ‑ Pressing the button in while the outboard is in neutral disables the gear shift control of the tiller handle. 28550 • Throttle Grip ‑ Controls engine speed and shifting. 28543 Reverse Forward •...
  • Page 56 FEATURES AND CONTROLS • Low oil pressure warning light ‑ Warns the operator the engine has low oil pressure. When the low oil pressure light is on or is blinking, the engine will run rough and will not exceed 3000 RPM.
  • Page 57 FEATURES AND CONTROLS • Steering Friction Adjustment ‑ Adjust this lever to achieve the desired steering friction (drag) on the tiller handle. Move lever to the left to tighten, or move lever to the right to loosen. 28546 Tighten Loosen •...
  • Page 58 FEATURES AND CONTROLS • Kicker Strap (Power Tilt Models) ‑ Prevents the engine from turning while tilted up. 4676...

  • Page 59: Remote Control Features

    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 60: Warning System

    FEATURES AND CONTROLS Warning System The warning system on this engine does not have a warning horn. Instead, there is an oil pressure light located on the front of the engine. If oil pressure drops below 25 kPa (3.6 PSI) the oil pressure light will illuminate, the Engine Guardian System will be activated, and engine RPM will be limited to 3000.
  • Page 61 FEATURES AND CONTROLS TILTING OPERATION To tilt outboard, shut off the engine and press the tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. Tiller handle models have a kicker strap located on each side of the outboard, preventing the outboard from turning when tilted up.

  • Page 62: Setting The Transom Angle Of Your Outboard

    FEATURES AND CONTROLS 3. Disengage the tilt support lever, by raising the outboard off the support lever and lifting the knob. Lower the outboard. 4650 Tilt support lever Knob Setting The Transom Angle Of Your Outboard The vertical transom angle of your outboard is adjusted by changing the position of the preset tilt knob in one of the three adjustment holes provided.
  • Page 63 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 28533 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 64: Adjusting Transom Angle

    FEATURES AND CONTROLS • 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. •...

  • Page 65: Tilting Outboard

    FEATURES AND CONTROLS 2. To release the shallow water drive, stop engine and tilt outboard up to one of the tilt release position. Gently lower the outboard to the preset transom angle. 28592 Shallow water drive Water Intake positions Tilt release positions Tilting Outboard 1.

  • Page 66: Trim Tab Adjustment

    FEATURES AND CONTROLS 5. Raise the outboard to the tilt release position and gently lower the outboard to the preset trim position. 28587 Tilt lock knob in lock position Tilt lock knob in unlock position Tilt range indicator Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction.
  • Page 67 FEATURES AND CONTROLS Operate your boat at normal cruising speed, trimmed to the desired position. Turn your boat left and right and note the direction the boat turns more easily. If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time.

  • Page 68: Operation

    OPERATION Pre‑Starting 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 69: Operating Outboard As An Auxiliary Engine

    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 70: Engine Break-In Procedure

    OPERATION NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Provide a sufficient supply of water at 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 can...
  • Page 71 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. IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after engine has warmed up.
  • Page 72 28586 8. Electric start tiller handle models ‑ Push the starter button and crank the engine. Release button when the engine starts. Do not operate the starter motor continuously for longer than ten seconds at a time.

  • Page 73: Starting The Engine - Remote Control Models

    OPERATION 9. Flooded engine - If the engine will not start, push in the throttle only button and advance the throttle grip to fast throttle speed. Push in the choke knob and retry starting the engine. After the engine has started, immediately reduce throttle speed to idle.
  • Page 74 OPERATION 1. Open the fuel tank vent screw in the filler cap on manual venting type tanks. 19748 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.
  • Page 75 OPERATION IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle while engine is not running. This will inject fuel into the engine and may cause a hard starting flooded condition. 26838 IMPORTANT: Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery. Damage to the charging system may result.

  • Page 76: Starting A Hot Engine

    OPERATION 6. Turn the ignition key to the "START" position and start the engine. If the engine is cold, push in on the key to choke the engine while cranking. If the engine fails to start in ten seconds, wait 30 seconds and try again. If the engine begins to stall, re‑choke (push the key in) until the engine is running smoothly.

  • Page 77: Gear Shifting

    OPERATION REMOTE CONTROL MODELS 1. Crank the engine over while pushing the key in to engage the choke solenoid. 2. After the engine has started, release the key. Gear Shifting IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into reverse when the engine is not running.

  • Page 78: Stopping The Engine

    OPERATION Stopping The Engine 1. Remote Control Models ‑ Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843 2. Tiller Handle Models ‑ Reduce engine speed and shift outboard to neutral position. Push in the engine stop button or turn ignition key to "OFF"...
  • Page 79 OPERATION 4. Remove the three screws holding the flywheel cover on. 28614 Flywheel cover Fuse holder screws (3) Recoil neutral interlock 5. Remove the flywheel cover. 6. Remote Control models ‑ Ensure the key switch is in the "ON" position. WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.
  • Page 80 OPERATION 8. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 28616 9. Pull the starter rope quickly.

  • Page 81: Maintenance

    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. EPA Emissions EMISSION CERTIFICATION LABEL...

  • Page 82: 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 emissions levels to exceed their predetermined factory specifications.
  • Page 83 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. See Spark Plug Inspection and Replacement. • Inspect thermostat visually for corrosion and broken spring. Make sure thermostat closes completely at room temperature.

  • Page 84: Flushing The Cooling System

    This will help prevent a buildup of deposits from clogging the internal water passages. 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.
  • Page 85 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. IMPORTANT: Do not run engine above idle when flushing.

  • Page 86: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal And Installation REMOVAL 1. Pull out the front cowl latch. 4936 2. Lift front of cowl to clear front latch and push toward the rear to clear rear hook. 3. Lift top cowl to remove. INSTALLATION 1.

  • Page 87: Exterior Care

    MAINTENANCE Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes. Fuel System WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 88: Steering Link Rod Fasteners

    MAINTENANCE FUEL LINE FILTER Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. 28620 IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. 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...
  • Page 89 MAINTENANCE 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 90: Corrosion Control Anode

    MAINTENANCE Assemble steering link rod to engine with bolt, locknut and spacer and flat washers. Torque locknut to specifications. Corrosion Control Anode Your outboard has a corrosion control anode installed to the gearcase. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals.
  • Page 91 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 27095 Tube Ref No.

  • Page 92: Fuse Replacement - Electric Start Models

    7. Install front thrust washer, propeller, rear thrust hub, and propeller nut onto the shaft. 8. Place a block of wood between gearcase and propeller to prevent rotation and tighten propeller nut. Secure propeller nut to the shaft with cotter pin.

  • Page 93: Spark Plug Inspection And Replacement

    MAINTENANCE The electric starting circuit is protected from overload by a 20 AMP fuse. If the fuse is blown try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. 28618 Spare fuse Circuit protecting fuse...

  • Page 94: Timing Belt Inspection

    MAINTENANCE 1. Remove the spark plug boots. 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, blistered or fouled. 26946 3.

  • Page 95: Changing Engine Oil

    MAINTENANCE b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. 27578 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 800 ml (27 fl. oz.). OIL CHANGING PROCEDURE 1.

  • Page 96: Lubrication Points

    2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101.
  • Page 97 MAINTENANCE Tube Ref No. Description Where Used Part No. Swivel bracket, transom clamp screws, tilt tube, 92-802865Q0 Special Lubricant 101 throttle/shift cables, steering cable grease fitting Swivel bracket, transom clamp screws, tilt tube, 2-4-C with Teflon 92-802859A1 throttle/shift cables, steering cable grease fitting •...
  • Page 98 MAINTENANCE • Lubricate the throttle and shift cable moving components, pivot locations, and shift detent. 28621 Throttle/shift cables Shift detent • Steering Cable Grease Fitting (If Equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 27351 Steering cable grease fitting Steering cable end...
  • Page 99 MAINTENANCE • Steering Link Rod Pivot Points ‑ Lubricate points. 27352 Steering link rod pivot points 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No.

  • Page 100: Gearcase Lubrication

    2. Place drain pan below outboard. 3. Remove fill/drain plug and vent plug and drain lubricant. 28652 Vent plug Fill/drain plug GEARCASE LUBRICANT CAPACITY Standard model gearcase: Approximately 320 ml (10.8 fl. oz.). Bigfoot model gearcase: Approximately 370 ml (12.5 fl. oz.).
  • Page 101 MAINTENANCE 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. 2. Remove vent plug from vent hole. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.

  • Page 102: Checking Power Tilt 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 103: 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 104: 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 Ref No. Description Where Used Part No.

  • Page 105: Positioning Outboard For Storage

    STORAGE Positioning Outboard For 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. •...
  • Page 106 STORAGE • Remove the battery from the boat and check water level. Recharge if necessary. • Store the battery in a cool, dry place. • Periodically check the water level and recharge the battery during storage.

  • Page 107: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Blown 20 Amp 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 108: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Low oil pressure. Check oil level. • 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.

  • Page 109: Owner Service Assistance

    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 110: Mercury Marine Service Offices

    Model and serial number of your outboard • 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 Telephone (920) 929‑5040...
  • Page 111 OWNER SERVICE ASSISTANCE Japan Telephone 81‑053‑423‑2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81‑053‑423‑2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 5467789 Singapore, 508762...

  • Page 112: Engine Installation

    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 your outboard. These accessories are available from Mercury Marine dealers.

  • Page 113: Installing Outboard

    The misuse of approved accessories or the use of non‑approved 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 114 ENGINE INSTALLATION INSTALLING OUTBOARD ON TRANSOM 1. Place the outboard on the center line of the transom. 27005 2. Tighten the transom bracket clamp screws. 28501 3. Non‑power trim models ‑ To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts.

  • Page 115: Remote Control Installation

    Description lb. in. lb. ft. Transom bracket mounting bolts 13.5 Remote Control Installation STEERING CABLE 1. Lubricate the entire cable end with Mercury Precision or Quicksilver 2‑4‑C with Teflon. 28722 Tube Ref No. Description Where Used Part No. 2-4-C Marine...

  • Page 116: Steering Link Rod Fasteners

    ENGINE INSTALLATION 2. Insert the steering cable into the tilt tube. 28723 3. Tighten the steering cable nut to the specified torque. 28724 Steering cable nut Description lb. in. lb. ft. Steering cable nut 47.5 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.
  • Page 117 ENGINE 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 118: Remote Wire Harness Connection

    ENGINE INSTALLATION Assemble steering link rod to steering cable with flat washer and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with bolt, locknut and spacer and flat washers. Torque locknut to specifications. Remote Wire Harness Connection 1.
  • Page 119 2. Route the remote wiring harness through the rubber grommet. 3. Open up the clamp in the bottom cowl and position the remote wiring harness below the clamp. Connect the 8 pin connector to the engine harness. Push the clamp down and secure the remote wiring harness into the bottom cowl.

  • Page 120: Control Cable Installation

    ENGINE INSTALLATION 4. Reinstall the cable receptacle bracket with two bolts and hex nuts. Tighten the bolts to the specified torque. 29044 Cable receptacle bracket Description lb. in. lb. ft. Cable receptacle bracket Control Cable Installation THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 121 ENGINE INSTALLATION IMPORTANT: Make sure that the throttle cable end guide does not contact the remote wiring harness when the throttle cable is at full throttle position. If necessary, reposition and clamp the remote wiring harness. 28079 Cotter pin retainer Cable barrel Flat washer Throttle cable end guide...
  • Page 122 ENGINE INSTALLATION b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark ("b") on the cable next to the end guide. c.
  • Page 123 ENGINE INSTALLATION 6. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. 28096 Flat washer Rubber grommet Cotter pin retainer Shift cable End guide cable barrel Center mark Barrel receptacle...
  • Page 124 Description lb. in. lb. ft. Access cover bolt 8. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable guide. b. Shift remote control into reverse while turning propeller.

  • Page 125: Battery Installation - Electric Start Models

    ENGINE INSTALLATION Battery Installation ‑ Electric Start Models MOUNTING BATTERY Follow the battery manufacturer's instructions carefully. Mount battery in the boat so it is secured against movement, preferably in a battery box. Make sure battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.
  • Page 126 ENGINE INSTALLATION 1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/ Quicksilver products: Tube Ref No. Description Where Used Part No. Anti-Corrosion Propeller shaft 92-802867Q Grease splines 2-4-C Marine...

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