Mercury 200 User Manual
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Mercury 200 User Manual

Mercury marine outboard motor user manual
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See also: Service Manual , Owner's 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
If the outboard motor's serial number plate contains the CE
mark in the lower left‑hand corner, the following statement
applies:
This outboard motor manufactured by Mercury Marine, Fond
du Lac, WI, USA or Marine Power Europe Inc. Park Industriel,
de Petit‑Rechain, Belgium complies with the requirements of
the following directives and standards, as amended:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4) ISO 11547
Fuel tanks (A.5.2.2)
General steering system
Safety of Machinery Directive
Principles of safety integration
(1.1.2)
Noise (1.5.8)
Vibration
nearest
dealer
94/25/EC
ISO 10240
ISO 8665
ISO 13591; ISO 8469
ABYC P‑17
98/37/EC
EN 292‑1; EN 292‑2; EN 1050
ICOMIA 39/94
ICOMIA 38/94
i
can
be
found
on

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Summary of Contents for Mercury 200

  • 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 EN 61000‑6‑2; EN 61000‑4‑2; EN Electrostatic discharge testing 61000‑4‑3 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 European Regulations Contact:...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer Of Warranty..............1 Warranty Registration United States And Canada......1 Warranty Registration Outside The United States And Canada .....................2 Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States..........3 Outboard Limited Warranty (Middle‑East, and Africa)....6 3 Year Limited Warranty Against Corrosion........9 Warranty Coverage And Exclusions..........13 General Information...
  • Page 4 TABLE OF CONTENTS Fuel and Oil Fuel Recommendations.............36 Oil Recommendation..............37 Fuel Requirements for Engine Break‑in........38 Avoiding Fuel Flow Restriction..........38 Filling Remote Oil Tank.............38 Filling Engine Mounted Oil Reservoir Tank.......38 Filling Fuel Tank................39 Features and Controls Remote Control Features............40 Warning System................41 Power Trim and Tilt..............44 Operation Pre‑Starting Check List..............48...
  • Page 5 Starter Motor Will Not Crank the Engine........79 Engine Will Not Start..............79 Engine Runs Erratically............. 80 Performance Loss..............80 Battery Will Not Hold Charge.............80 Owner Service Assistance Local Repair Service..............81 Service Away From Home............81 Parts And Accessories Inquiries..........81 Service Assistance..............81 Mercury Marine Service Offices..........82...
  • Page 6 TABLE OF CONTENTS Outboard Installation Important Information..............84 Avoiding Fuel Flow Restriction..........84 Boat Horsepower Capacity............85 Start in Gear Protection.............85 Selecting Accessories For Your Outboard......... 85 Fuel Tanks.................86 Filling the Fuel System..............86 Installation Specifications............87 Lifting the Outboard..............87 Steering Cable ‑ Starboard Side Routed Cable......88 Steering Link Rod Fasteners.............89 Determining Recommended Outboard Mounting Height...92 Drilling Outboard Mounting Holes..........93...

  • Page 7: 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 8: 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 9: Outboard Limited Warranty United States, Canada, Europe And Confederation Of Independent States

    Europe and Confederation of Independent States Outside the United States, Canada and Europe ‑ check with local distributor. 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 10 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 11 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 12: 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 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 pre–delivery 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: 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 16 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented.
  • Page 17 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 18 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 19: 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 20 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 21 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 22: 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 23: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Propeller Selection The propeller on your outboard is one of the most important components in the propulsion system.
  • Page 24 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 local...
  • Page 25 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 26: Outboard Remote Control Models

    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 27: 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 28: 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 29 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 30: 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 31: 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 32: 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 33: 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 34: Exhaust Emissions

    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. Exhaust Emissions...
  • Page 35 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 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 Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft.) in front of you in 5 seconds. Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to assist the skier.

  • Page 38: Recording Serial Number

    GENERAL INFORMATION Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is...
  • Page 39 60 Amps Output 1. Use only Champion QL77CC Spark Plugs or alternate spark plugs approved by Mercury Marine in these models. Consult a Mercury Marine authorized dealer before replacing spark plugs. Use of improper spark plugs may cause engine damage.

  • Page 40: Component Identification

    GENERAL INFORMATION Component Identification 29304 Top cowl Anode plate Bottom cowl Auxiliary tilt switch Water pump indicator Transom brackets hole Gearcase Driveshaft housing Cooling water intake Anti‑ventilation plate holes...

  • Page 41: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. 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.

  • Page 42: 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 43: Oil Recommendation

    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 44: Fuel Requirements For Engine Break-In

    For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. Severe engine damage may result from use of an inferior oil.

  • Page 45: Filling Fuel Tank

    FUEL AND OIL 1. Remove the top cowl. 2. Loosen the fill cap on the engine oil reservoir tank. Run the engine until all the air has been vented out of the oil reservoir tank and tank is filled with oil to the point of overflow. 3.

  • Page 46: 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 47: Warning System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch. 27755 Horn inside remote Horn connected to control ignition key switch WARNING HORN SIGNALS...
  • Page 48 FEATURES AND CONTROLS Warning Horn Function Sound Description Water in Fuel Four Beeps every 2 Water in the water Minutes separating fuel filter reaches the full level. Water can be removed from the filter. Refer to Maintenance - Fuel System for filter removal.
  • Page 49 Consult your dealer for assistance. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption, and engine operating hours.

  • Page 50: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.
  • Page 51 FEATURES AND CONTROLS WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully.
  • Page 52 FEATURES AND CONTROLS • 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). • In excess can cause boat porpoising (bouncing) or propeller ventilation.
  • Page 53 FEATURES AND CONTROLS 1. Turn manual tilt release valve turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 22362 AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.

  • Page 54: 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 55: Operating In Salt Water 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 56: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full‑in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs.

  • Page 57: Starting The Engine

    OPERATION b. Change engine speed approximately every two minutes, and avoid continuous operation at idle speed for more than ten minutes. Short bursts of full throttle for periods up to ten seconds are acceptable. c. Avoid trimming the outboard out (up) beyond a vertical trim position during operation.
  • Page 58 OPERATION 2. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm.
  • Page 59 OPERATION b. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. c. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. Turn the ignition key switch to the "ON"...

  • Page 60: Gear Shifting

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

  • Page 61: Stopping The Engine

    OPERATION Stopping The Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843...

  • Page 62: 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 63: 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 64: Flushing The Cooling System

    MAINTENANCE • Replace water separating fuel filter. See Fuel System. • Check corrosion control anodes. Check more frequently when used in salt water. See Corrosion Control Anodes. • Drain and replace gearcase lubricant. See Gearcase Lubrication. • Lubricate splines on the driveshaft and shift shaft. •...

  • Page 65: Top Cowl Removal And Installation

    MAINTENANCE 2. Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. 29297 Top Cowl Removal And Installation REMOVAL 1. Pull out the front cowl latch. 28431 2. Lift front of cowl to clear front latch and push toward the rear to clear rear hooks.

  • Page 66: Fuel System

    MAINTENANCE 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 67: Steering Link Rod Fasteners

    MAINTENANCE The water separating fuel filter removes moisture and also debris from the fuel. If the filter becomes filled with water, the water can be removed. If the filter becomes plugged with debris, the filter must be replaced with a new filter. 28434 1.

  • Page 68: Fuse Replacement

    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 69: Corrosion Control Anode

    MAINTENANCE The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.

  • Page 70: Battery Inspection

    MAINTENANCE Each anode requires periodic inspection, especially in salt water 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.

  • Page 71: Propeller Replacement

    MAINTENANCE Propeller Replacement 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 72 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. 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref No.
  • Page 73 MAINTENANCE 7. Flo‑Torq I Drive Hub Propellers ‑ Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c 26908 Propeller nut Continuity washer Propeller nut retainer Propeller Rear thrust hub Forward thrust washer 8.

  • Page 74: Spark Plug Inspection And Replacement

    MAINTENANCE 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection And Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion.

  • Page 75: Lubrication Points

    Install plugs finger tight, and then tighten to the specified value. Description lb. in. lb. ft. Spark plug Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Ref No. Description Where Used Part No. 92-802865Q0...
  • Page 76 Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 26902 3. Lubricate the following with Quicksilver of Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 77 MAINTENANCE • Alternator Belt Tensioner Pivot Shaft ‑ Lubricate through fitting. 29300 • Swivel Bracket ‑ Lubricate through fitting. • Tilt Support Lever ‑ Lubricate through fitting. 27873 Swivel Bracket Tilt support lever • Tilt tube ‑ Lubricate through fitting. 27874 WARNING Incorrect cable lubrication can cause hydraulic lock, leading to...

  • Page 78: Checking Power Trim Fluid

    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. 27875 Fitting Steering cable end 4. Lubricate the following with light weight oil. •...

  • Page 79: Gearcase Lubrication

    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 80 970 ml (32.8 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove vent plug/sealing washer. 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.

  • Page 81: Submerged Outboard

    MAINTENANCE 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 82: 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 83: Protecting Internal Engine Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No.

  • Page 84: Gearcase

    STORAGE Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance ‑ Gearcase Lubrication). Positioning Outboard For Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. 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.

  • Page 85: Troubleshooting

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

  • Page 86: Engine Runs Erratically

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

  • Page 87: 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 88: 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 89 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 90: Outboard Installation

    For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. Severe engine damage may result from use of an inferior oil.

  • Page 91: Boat Horsepower Capacity

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

  • Page 92: Fuel Tanks

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

  • Page 93: Installation Specifications

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

  • Page 94: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. 24290 Lifting eye 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead assembly...

  • Page 95: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION Tube Ref No. Description Where Used Part No. 2-4-C Marine O-ring seal and entire 92-802859A1 Lubricant with Teflon cable end 2. Insert steering cable into tilt tube. 3725 3. Torque nut to specification. 3727 Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering...
  • Page 96 OUTBOARD INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat.
  • Page 97 OUTBOARD INSTALLATION 3. Torque the head bolt, then the locknut to specifications. Description lb. in. lb. ft. Tighten locknut until it seats, then Cable Coupler Nylon Locknut "d" loosen ¼ turn. Head Bolt Nylon Locknut "b" Special washer head bolt...

  • Page 98: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 24305 The solid line is recommended to determine the outboard mounting height.

  • Page 99: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions.
  • Page 100 OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. or69-1 Drill guide holes Transom centerline Transom drilling fixture Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 101: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 10‑67755‑1 Transom bolt 1/2‑20 x 4.50 in. long (2.25 in. thread) 11‑826711‑17 Nylon insert locknut 1/2‑20 12‑28421 Washer ‑...
  • Page 102 OUTBOARD 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 103 OUTBOARD INSTALLATION NOTE: For more accurate torque, whenever possible turn/tighten the mounting locknuts rather than turning the mounting bolts. 3729 Flat washer (4) Locknut (4) 1/2 in. diameter bolt Flat washer (4) Shank of bolt Description lb. in. lb. ft. Outboard mounting locknuts and bolts...

  • Page 104: Electrical, Hoses, Control Cables And Front Clamp

    OUTBOARD INSTALLATION Electrical, Hoses, Control Cables and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl. Connect remote harness to the 14 pin connector on the engine harness. 11035 14 pin connector Remote 14 pin boat...

  • Page 105: Single Outboard

    OUTBOARD INSTALLATION Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting...
  • Page 106 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Ground cable Black sleeve ‑ Negative Cranking battery (–) HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate fuel line/fuel tank pickup for each engine.
  • Page 107 OUTBOARD INSTALLATION This outboard has a speedometer water pick‑up located in the leading edge of the gearcase. If you want to use this water pickup for the speedometer, disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl. Install the coupler provided with the outboard on the end of the tubing.
  • Page 108 OUTBOARD INSTALLATION Locating the Center Point of the Shift Cable IMPORTANT: Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustment of the shift cable. 1. Mark the forward position as follows: a.
  • Page 109 OUTBOARD INSTALLATION 3. Mark the center on the shift cable midway between the forward and reverse marks. 4361 Center mark 4. Align the cable end guide against this center mark when installing the cable to the engine. 5. Position the remote control and outboard into neutral position. 6.
  • Page 110 OUTBOARD INSTALLATION 2. Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder. 3. Secure the shift cable to the anchor pin with the retainer clip. 28749 Cable barrel Retainer clip...
  • Page 111 OUTBOARD INSTALLATION 2. Attach the throttle cable to the throttle lever. Secure with a washer and locknut. Tighten the locknut to the specified value. or107 Nylon washer Locknut Description lb. in. lb. ft. Throttle cable locknut "b" Tighten then loosen 1/4 turn. 3.
  • Page 112 OUTBOARD INSTALLATION c. Place a thin piece of paper between the idle adjustment screw and the idle stop. The adjustment is correct when the paper can be removed without tearing, but has some drag on it. IMPORTANT: The idle stop screw must be touching the stop. or109 Idle stop screw Idle stop...
  • Page 113 OUTBOARD INSTALLATION 2. Place the neoprene wrap around the wiring, hoses, and control cables, and place into the lower half of the front clamp. 29073 Neoprene wrap Lower half of the front clamp 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties.

  • Page 114: Filling The Fuel System

    OUTBOARD INSTALLATION 5. Reinstall the cowl seal. 29075 Retainer Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: 1.

  • Page 115: Oil Injection Set-Up

    OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1. Fill the remote oil tank with the recommended oil. Refer to Oil Recommendation. Tighten the fill cap securely. 2683 Fill cap 2. Remove the cap and fill the engine oil tank with oil. Reinstall the fill cap and tighten securely.
  • Page 116 OUTBOARD INSTALLATION PRIMING OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose or internal passages. 24291 Oil injection pump Oil supply hose IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump.

  • Page 117: Trim In Pin

    OUTBOARD INSTALLATION d. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. 26846 e. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. f.
  • Page 118 OUTBOARD INSTALLATION Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to be trimmed further in or under. This greater trim under capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations.

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