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maintenance - Brunswick Marine in EMEA Center

1. a Running the boat with the trim angle of the bow too high b Running the boat with no forward hatches open 25 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 alarge wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of the boat Falling over the front of the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water 0b00312 Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over Stay back from the front end of the deck and remain seated while the boat is in motion 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
2. 0b00307 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 20 GENERAL INFORMATION Avoid serious injury or death from a sudden unexpected acceleration when starting your engine The design of this outboard requires that the remote control used with it must have a built in start in neutral only protection device o0b00308 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self locking nuts These self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death ob00655 a Self locking nuts 21 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 A lanyard stop switch can be installed as an accessory generally on the dashboard or side adjacent to the operator s p
3. ceeeeeeeeeeeeeeeentnenaaeees 77 Replacing the Propeller ccceccceeeceeeeeeeeeeeeeeeeeeeeeeeaeenaas 77 Lubrication POints ccccc cece cece eececeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeaaeaaes 80 Checking Power Trim Fluid Single Ram Trim Systems 82 Checking Power Trim Fluid Three Ram Trim Systems 83 Gearcase L bricant s siiis enisinia iia 84 Storage Storage Preparation 2 cocci edasancngecends cgasiitegesdectabssnbaueterondetsdiaeeds 87 Protecting Internal Engine Components cccccceeeeeeeees 90 Protecting External Outboard Components cccccceee 90 GOAICAS Cy esals ives cishente saeaicokt a E Se 90 Positioning Outboard For Storage cccccecceeeeeeeeeeeeeeeeeeeeeees 90 Battery StOrage ssscccceissne deteleitetetesladeuisieeceeeeivtteivieedvecteeieeae 91 vii TABLE OF CONTENTS Troubleshooting Starter Motor Will Not Crank the Engine 92 Engine WViIDNOUS arity stonsahs schcssncwadt less seaunerah uaa edewe nde tesdece 92 Engine Runs Erraticaly 21 ccieceicheccbancraAcaecudcchivcciced adenastuese 93 Performance LOSS 0e ceeeeeeceeeeseeeseeeeeeeeeeeseeeseeeseeeneeesseeees 93 Warning Horn Activates With Power LOSS ceceeeeeeeeeeeee 93 Warning Horn Activates No Power LOSS ccccceeeeeeeeeeeeees 94 Battery Will Not Hold Charge cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeees 94 Water Discharge from Idle Exhaust during O
4. 3 Tighten drain screw and reattach the hose 71 MAINTENANCE IMPORTANT Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm forcing fuel into the chamber If you experience multiple issues with water in the fuel system over a short period of time see your authorized Mercury dealer Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt P N 10 849838 and self locking nylon insert locknuts P N 11 826709113 Never replace locknuts with common nuts non locking as they will work loose vibrate off freeing link rod to disengage Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death f2 MAINTENANCE Avoid equipment damage serious injury or death Visually inspect all steering attachment components for wear lubricate all attachment hardware and check for proper torque tightness in accordance with the inspection and maintenance schedule or79 a Special washer head c Flat washer 2 bolt P N 10 849838 d Nylon Locknut used on b Nylon Locknut used on cable coupler P N head bolt P N 11 826709113 11 826709113 1 Assemble steering link rod to s
5. components IMPORTANT Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free fuel be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required Oil Recommendation Recommended Oil Premium Plus 2 Cycle TC W3 Outboard Oil TC W3 Premium Plus Outboard Oil is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or varying grades of gasoline IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Periodically consult with your dealer to get the latest gasoline and oil recommendations If Quicksilver 2 Cycle Outboard Oil is not available substitute another brand of 2 Cycle outboard oil that is NMMA Certified TC W3 The use of an inferior 2 Cycle outboard oil can reduce engine durability Damage from use of inferior oil may not be covered under the limited warranty Filling Remote Oil Tank Remove filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 gallons Replace filler cap and tighten securely 41 FUEL AND OIL IMPORTANT Always make sure the oil tank caps are threaded on tight An air leak will prevent oil flow to the engine or27 Filling Engine Mounted Oil Reservoir Tank Remove the top cowl Loosen the fill cap on the engine oil reservoir tank Run the
6. if h Timing specification applicable i Recommended spark plug and gap 63 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 Inspection And Maintenance Schedule PRIOR TO EVERY USE e Check that lanyard stop switch stops the engine e Check steering system for binding or loose components e Check the outboard for tightness on transom e Check propeller blades for damage e Visually inspect all hoses clamps fittings tubing sealing gaskets and mounting hardware for wear AFTER EACH SALTWATER OR POLLUTED WATER USE e Flush all internal passages with fresh water e Wash the power package exterior cowl mid section and gearcase with fresh water e Flush the propeller and gearcase exhaust outlet with fresh water e Remove the cowl and wipe off any saltwater spray with a damp cloth EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATER OR POLLUTED WATER USE e Spray the powerhead and all external unpainted metal surfaces except anodes with Corrosion Guard EVERY 25 HOURS OR EVERY 30 DAYS WHICHEVER OCCURS FIRST e Visually inspect the front and side cowl latches for tightness Tighten if necessary e Visually inspect t
7. increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboards durability 36 GENERAL INFORMATION Check full throttle RPM using an accurate tachometer with the engine trimmed out to a balanced steering condition steering effort equal in both directions without causing the propeller to break loose 37 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 or26 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propeller from spinning freely 38 FUEL AND OIL Avoiding Fuel Flow Restrictions Avoid engine damage Adding components to the fuel supply system such as filters valves fittings etc may restrict the fuel flow This condition may cause the engine to stall at low speeds and create lean fuel conditions at high speeds causing engine damage Fuel Requirements Use a major bra
8. Act be required 2 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 Upon receipt of this warranty registration Mercury Marine will record the registration IMPORTANT Your warranty coverage begins at the time of sale but warranty claims cannot be processed until the product is registered with Mercury Marine 3 Upon processing the warranty registration Mercury Marine will send the purchaser a Mercury Owner Resource Guide The back page of this guide contains your warranty registration information and should be saved If this registration verification is not received within 30 days please contact your selling dealer immediately Transfer Of Warranty The limited warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to products used for commercial applications 1 WARRANTY INFORMATION 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 Canada mail to Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 Upon processing the transfer of warranty Mercu
9. Haul out launch towing charges and all related transportation charges and or travel time etc 4 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 10 WARRANTY INFORMATION 5 Labor performed by other than an authorized dealer may be covered only under following circumstances When performed on emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work performed at this facility 6 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs 7 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty 8 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard 9 Water in the starter motor 10 Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commutator because of excess cranking 11 Valve or valve seat grinding required because of wear California Emissions Limited Warranty The California Air Resources Board has promulgated air emissions regulations for outboard engines The regulations apply to all outboard engines so
10. Mounted Oil Reservoir Tank 42 Filling Fuel Tank s sssssessssessrensrerrrunnninuiedesndesederrtiereseiensesscesnscess 42 Features and Controls Remote Control Features ccccccccccccceceeesseseseseseeeseseseeceeneees 44 Zero Effort Control Features 222 0 cc ccciecccreceeeeeeeeeseeseeeenecneeeene 45 Warning Systemi sikei areen eoeta as are iaeaea aitei dai 45 Overspeed Rev Litit c cceeeeeeseeeeeeeeeeeeeeeeeeeeeaeesseeeseeeees 48 Power Trim And Tilt ccccccccceccccsseccceeceeeeeeeeeeeeeeeeeeeeeeeseaaeaaes 48 Power Trim Operation ccseeeeeeeceeeeeeeeseeeseeeseeeseeeseesseeeees 49 Power Tilt Operation Single Ram Systems 51 Power Tilt Operation Three Ram Trim Systems 51 Auxiliary Tilt SWitChs 2fn fees actin ical dca iste oduatdes dtslecetdianildneddistsaste 52 Manual Tilt Operation 0 cccccceeceecceeceeeeeeeeeeeeeeeeeeeeeeeeaaeeaes 53 Operation Endine Break aa A caves sas cars cnastesvaddiol OE EAE ae Ees aiae 54 Engine Break in Fuel Mixture 0 ieee ee eeeeeeeeeeeeeeeeeeee 54 Pre Starting Check List co cc sdiccad inde ten eecdlceheeeee ecsteetneeennte eins 55 Operating at Off Idle Speeds ccccccceeeeeeeeeeeeeeeeeeeeeeaeeeees 55 Operating In Freezing Temperatures 55 Operating In Salt Water Or Polluted Water 0 e8 55 Operating at High Elevations 2 2 c ccceeceeeseeeeseeeeeeseeeneeeees 56 Ef
11. alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank The fuel system components on your Mercury 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 boats fuel system components fuel tanks fuel lines and fittings Fuel containing alcohol may increase e Corrosion of metal parts Deterioration of rubber or plastic parts e Fuel permeation through rubber fuel lines e Starting and operating difficulties 40 FUEL AND OIL When operating a Mercury engine with fuel containing alcohol avoid storing the fuel in the fuel tank for long periods of time Long storage periods common to boats create unique problems In cars alcohol blend fuels are normally consumed before they can absorb enough moisture to cause trouble However boats often sit idle long enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed protective oil films from internal
12. anodes use alloys that are insufficiently pure to adequately protect critical drive components for the duration of the anodes expected life Anodes help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of other metals 74 MAINTENANCE This model has three corrosion control anodes two above and one below the anti ventilation plate A fourth anode is located on the bottom of the clamp swivel bracket assembly ri or42 1 a Corrosion control anodes three on gearcase b Corrosion control anode one on clamp swivel bracket All anodes require periodic inspection especially in salt water refer to the Inspection and Maintenance Schedule Replace any anodes before they are 50 corroded Never paint or apply protective coating on the anode as effectiveness of the anode will be reduced Spark Plug Inspection and Replacement Avoid serious injury or death from fire or explosion caused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to remove spark plug boots 75 MAINTENANCE Remove the spark plug leads Twist the rubber boots slightly 0b00375 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blis
13. 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 gear case or propeller e Loss of power and directional control in heavy seas strong current or high winds e Loss of control when docking Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction even at slow speeds 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving even coasting and the gear shift is in neutral there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury 23 GENERAL INFORMATION WHILE BOAT IS STATIONARY Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gearcase or any solid device rigidly attached to a moving boat or gearcase Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboar
14. 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 Re tighten the fill cap Stop the engine and replace the top cowl or28 NOTE Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated Filling Fuel Tank e Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them e Always stop engine before refilling tanks 42 FUEL AND OIL e Donotcompletely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled Avoid serious injury or death from a gasoline fire or explosion Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks 43 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 0b00329 a Control handle forward neutral reverse b Neutral release lever c Trim tilt switch if equipped Refer to Features amp Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Ref
15. has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or any authorized Mercury Marine dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the service office e Your name and address e Daytime telephone number 96 OWNER SERVICE ASSISTANCE e Model and serial number of your outboard The name and address of your dealership e 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 Fax Mercury Marine W6250 W Pioneer Road 920 929 5040 920 929 5893 P O Box 1939 Fond du Lac WI 54936 1939 United States Mercury Racing Telepho
16. improper service use of an accessory or part not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see Fuel and Oil alteration or removal of parts or water entering the engine through the fuel intake air intake or exhaust system Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty 13 WARRANTY INFORMATION Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal and or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty Non warranty maintenance replacement or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual The use of non Mercury parts for non warranty maintenance or repairs will not be grounds for disallowing other warranty work The use of add on as defined at section 1900 b 1 and b 10 of Title 13 of the California Code of Regulations or modified parts not exempted by the California Air Resources Board may be grounds for disallo
17. lubricant to the steering cable when fully extended could cause the steering cable to become hydraulically locked causing loss of steering control Tube Ref No Where Used Part Number Steering Cable and 2 4 C with Teflon Grease Fitting on Belt 92 802859A1 Tensioner Pulley Light weight oil Steering Cable Obtain Locally 81 MAINTENANCE Checking Power Trim Fluid Single Ram Trim Systems 1 Place outboard in the full down in position 2 Check the fluid level in the trim pump reservoir The level should be between the MIN and MAX level marks on the reservoir 3 If necessary remove the yellow fill cap and add Power Trim and Steering Fluid until the level in the reservoir reaches the MIN level mark It is acceptable to fill the reservoir beyond the MIN level mark but do not overfill past the MAX level mark LS C MAX MIN 15033 Power Trim and 82 MAINTENANCE 4 Trim the outboard down to bleed air out of the system The fluid level may drop Add more Power Trim and Steering Fluid if necessary but do not overfill past the MAX level mark 5 Replace the fill cap Checking Power Trim Fluid Three Ram Trim Systems 1 Tilt outboard to the full up position and engage the tilt support lock D or47 1 a Tilt support lock Tube Ref No Where Used Part Number ower Trim and Steering Fillhole 92 80
18. milky color to lubricant Water in gear lubricant will e Result in premature bearing failure In freezing temperatures turn to ice and damage gearcase DRAINING THE GEARCASE a SportMaster Gearcase d Fill Drain plug and sealing vertical operating ring position e Drain pan b Fleet Torque Master gearcase vertical operating position c Vent plug and sealing ring 1 Place the outboard in a vertical operating position 2 Place a drain pan below outboard 85 MAINTENANCE 3 Remove the vent plug upper plug and sealing ring 4 Remove the fill drain plug lower plug and sealing ring and drain lubricant GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml 24 oz 86 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 Follow these storage procedures to prepare your outboard for out of season or prolonged storage two months or longer Never start or operate your outboard even momentarily without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump running dry or overheating of the engine FUEL SYSTEM IMPORTANT Fuel containing alcohol ethanol or methanol can cause a formation of acid during storage that can damage the fuel system If the fuel being used contains alcohol Mer
19. other engine components caused by the failure of a warranted part will also be repaired under warranty DURATION OF COVERAGE This limited warranty provides coverage for the components of the emissions control systems of new 2001 model year and later outboards sold to retail customers in California for 4 years from either the date the product is first sold or first put into service whichever occurs first or the accumulation of 250 hours of engine operation as determined by the engines hour meter if any Emission related normal maintenance items such as spark plugs and filters that are on the warranted parts list see following are warranted up to their first required replacement interval only See Maintenance Inspection and Maintenance Schedule The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to a subsequent purchaser See instructions on transfer of warranty 12 WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer please notify Mercury Marine and M
20. overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Warning horn failure Engine block pressure sensor or coolant temperature sensor failure Guardian is activated Warning Horn Activates With Power Loss POSSIBLE CAUSES Intermittent horn sound e The oil level in the engine mounted oil reservoir tank is low Refill the reservoir tank and the remote oil tank Refer to Fuel and Oil for details e Battery voltage is out of limits 93 TROUBLESHOOTING Throttle position sensor failure Continuous horn sound e The oil level in the engine mounted oil reservoir tank is critically low Refill the reservoir tank and the remote oil tank Refer to Fuel and Oil for details The oil pump has failed halting the oil supply to the engine e Engine speed exceeds the maximum allowable RPM The system limits the engine to within the allowable range If the overspeed condition continues Guardian places the engine into power reduction Overspeed may be caused by incorrect propeller pitch engine height trim angle etc High engine temperature or low block water pressure e Cooling system clogged e Incorrect transom height water pickups not getting adequate water supply Warning Horn Activates No Power Loss POSSIBLE CAUSES Warning horn activates on start up This is normal operation Water is detected in the water separating fuel filter Refer to Maintenance for
21. procedures on removing water from the filter Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator 94 TROUBLESHOOTING Water Discharge from Idle Exhaust during Off Idle Operation Normal operation This outboard is designed to discharge water though the idle exhaust boot located at the aft end of the bottom cowl when operating at speeds above idle The volume of discharged water increases with boat speed as a result of the engine cooling system 95 OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools equipment and genuine parts and accessories to properly service your engine should the need occur He knows your engine best Service Away From Home 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 The dealer
22. propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of Anti Corrosion Grease to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 78 MAINTENANCE 1 Lubricate the propeller shaft splines with Anti Corrosion Grease 2 Install the propeller hub assembly propeller washer Belleville washer washer and propeller nut onto the propeller shaft 1 5 2693 a Propeller hub d Belleville washer assembly e Washer b Propeller f Propeller nut c Washer Eor Anti Corrosion Propeller shaft 92 802867A1 Grease splines 3 Place a block of wood between the gearcase and propeller and torque the propeller nut 79 MAINTENANCE Decin i f en f e Proen f e o 4 Disengage the safety stop switch by placing it in the RUN position and return the keys to the ignition switch Lubrication Points Tube Ref No Where Used Part Number Special Lubricant 101 Trim Rod Ball Ends 92 802865A1 80 MAINTENANCE Prop Shaft Swivel Bracket E 95 Cp 2 4 C with Teflon 92 802859A1 Tilt Support Lever Tilt Tube NOTE Turn the ball ends to work the lubricant into the ball sockets Lubricate through fittings Avoid serious injury or death The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding
23. side of the boat while returning to assist the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water 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 complete loss of the boat Seek further assistance from local law enforcement 31 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 Serial Number OTXXXXXX b 0b00319 a Serial number d Year manufactured b Model year e Certified Europe Insignia c Model designation as applicable Specifications 300XS OptiMax Attribute Specifications Propshaft Horsepower 300 HP 224 kw Engine Displacement 3158 cc 193 cid won 30 in Fleet Master 242 kg 533 Ib 32 GENERAL INFORMATION Se See ne Master Fe Fe Sern Retin omens Ft Cylinder Bore 92 075 mm 3 625 in RecommendedSpark Plug NGK IZFR7M Mercury Part Number 8M0009927 Firing Order 1 2 3 4 5 6 33 GENERAL INFOR
24. speed Sit only in seats designated for traveling at faster speeds 26 GENERAL INFORMATION Any unexpected sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat 0b00313 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done with sufficient speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water 0b00314 The primary concern is the boat changing direction while in the midst of the jump In such case the landing may cause the boat to veer violently in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to a boat hand hold 27 GENERAL INFORMATION 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 This will bring the boat to a nearly instantaneous stop and can send the
25. the bow to a point at which the boat begins to plow with the bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered 49 FEATURES AND CONTROLS LIMITING TRIM IN In rare circumstances the owner may decide to limit the trim in to avoid unsafe handling or steering conditions at planing speeds Avoid possible serious injury or death Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel Avoid possible injury or death Always perform a water test to examine boat handling and steering after making any trim in limiting adjustments Operating a boat with a full trim angle without the aid of a trim in limiting device may result in undesirable or unsafe steering conditions IMPORTANT Some boat engine combinations not using a trim angle adjustment device or trimmed to the full trim in position may not exhibit any undesireable or unsafe handling or steering conditions In these cases a trim limiting device may not be adventageous to accelleration or planing Always perform a water test to determine if these characteristics apply to a particular boat engine combination To limit trim in on models with a t
26. the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage abuse or improper service corrosion to accessories instruments steering systems corrosion to factory installed jet drive unit damage due to marine growth replacement parts parts purchased by customer products used in a commercial application Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes WARRANTY INFORMATION Corrosion damage caused by stray electrical currents on shore power connections nearby boats submerged metal is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system such as the 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 If anti fouling protection is required Tri Butyl Tin Adipate TBTA base aanti fouling paints are recommended on Outboard and MerCruiser boating appl
27. 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 If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle rom range refer to the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us operation with fuels oils or lubricants which are not suitable for use with the product Refer to the Operation and Maintenance Manual alteration or removal
28. 2880A1 2 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add fluid if required 83 MAINTENANCE Gearcase Lubricant CHECKING REFILLING GEARCASE LUBRICANT a SportMaster gearcase d Vent plug and sealing vertical operating washer position e Fill drain hole b Fleet Torque Master f Fill drain plug gearcase vertical operating position c Vent hole Tube Ref No Where Used Part Number f 87 O maT Performance Gear Fil Drain Hole 92 802854A1 Place the outboard in a vertical operating position Remove the vent plug upper plug and sealing washer Remove the fill drain plug lower plug Quickly place lubricant tube into the fill hole Slowly add lubricant until it flows from the upper vent hole Stop adding lubricant Install the upper vent plug and sealing washer before removing the lubricant tube IMPORTANT Replace sealing washers if damaged oa RWN 84 MAINTENANCE NOTE Examine the magnetic fill drain plug for metal particles A small amount of metal filings or fine metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips should be checked by an authorized dealer 7 Remove lubricant tube and reinstall cleaned lower fill drain plug and sealing washer Water in gear lubricant may Settle to bottom and drain out with the lubricant e Be mixed with lubricant giving a
29. AGE Select emission control parts from model year 2001 and later outboard engines are warranted for 4 years or for 250 hours of use whichever occurs first However warranty coverage based on the hourly period is only permitted for outboard engines and personal watercraft equipped with appropriate hour meters or their equivalent If any emission related part on your engine is defective under warranty the part will be repaired or replaced by Mercury Marine OWNER S WARRANTY RESPONSIBILITIES As the outboard engine owner you are responsible for the performance of the required maintenance listed in the Maintenance section Mercury Marine recommends that you retain all receipts covering maintenance on your outboard engine but Mercury Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the outboard engine owner you should however be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications 16 WARRANTY INFORMATION You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact Mercury Mar
30. 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 Industrel de Petit Rechain Belgium complies with the requirements of the following directives and standards as amended 94 25 EC std ISO 8665 ISO 11547 Machinery Directive 98 37 EC EMC Directive 89 336 EC std EN50081 1 SAE J551 CISPR Pub 12 EN 50082 1 IEC 61000 fe PT4 2 IEC 61000 PT4 3 Recreational Craft Directive Patrick C Mackey President Mercury Marine Fond du Lac WI USA European Regulations Contact Product Environmental Engineering Department Mercury Marine Fond du Lac WI USA 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 Emi
31. MATION Attribute OE Specifications Specifications 1 62 1 Torque Master 175 4 Gear Ratio 1 62 1 Sport Master 1751 Fleet Master 1 75 1 Premium Unleaded 91 R M 2 octane 96 RON Recommended Oil Premium Plus TC W3 2 Cycle Gearcase Lubricant Capacity 710 ml 24 fl oz 1000 MCA Marine Cranking Amps Battery Rating 800 CCA Cold Cranking Amps 105 Amp Hours1 Charging System Output 50 Amps Max NOTE Where applicable specifications are derived at sea level Reaured Fue Reaured Fue Special Tools and Kits Stainless Steel Tilt Pin Three Ram Trim Systems 17 49930A1 Oil Syringe 91 803976T Flushing Attachment for Torque Fleet Master gearcase 44357T2 Flushing Attachment for Sport Master gearcase 848998A1 Dual Water Pick Up Flush Seal Kit Fleet Torque Master 881150K1 gearcase 1 Battery manufacturers may rate and test their batteries to different standards Consult with the specific battery manufacturer for comparison ratings 34 GENERAL INFORMATION Component Identification H 2 Fa 4 5 6 rae Q gt PERCURY 22453 Top cowl 8 Skeg Side cowl latches both 9 Anode plate sides 10 Anti ventilation plate Front cowl latch 11 Drive shaft housing Auxiliary tilt switch 12 Water pump indicator Clamp Swivel bracket 13 Bottom cowl Gearcase Cooling water intake location dependen t on gearcase 35 GENERAL INFORMATION Propeller Selection P
32. ME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY If you have any questions regarding your warranty rights and responsibilities you should contact Mercury Marine at 1 920 929 5040 15 WARRANTY INFORMATION CALIFORNIA AIR RESOURCES BOARD EXPLANATION OF YOUR CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board is pleased to explain the emission control system warranty on your 2001 model year and later outboard engine In California new outboard engines must be designed built and equipped to meet the State s stringent anti smog standards Mercury Marine must warrant the emission control system on your outboard engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your outboard engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine will repair your outboard engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVER
33. N For additional information regarding events and circumstances covered by this warranty and those that are not refer to the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY Products Sold to Government Agencies Contact the Mercury Racing Sales Department for a copy of the Government Agencies Warranty Packet Kit which explains the conditions required for government agencies to receive warranty when purchasing Mercury Racing Outboard or Sterndrive product Mercury Racing Sales Department N7840 County Road UU Fond du Lac WI 54935 920 921 5330 Fax 920 921 6533 3 Year Limited Warranty Against Corrosion WHAT IS COVERED Mercury Marine warrants that each new Mercury Mariner Mercury Racing Outboard Sport Jet M Jet Drive Tracker by Mercury Ma
34. act damage during an impact is control the boat speed Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles After striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures or water leaks Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat If continued running is necessary do so at greatly reduced speeds Avoid serious injury or death from loss of boat control Continued boating with major impact damage can result in sudden outboard component failure with or without subsequent impacts Have the outboard thoroughly inspected and any necessary repairs made 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 Check with your dealer before installing accessories The misuse of approved accessories or the use of non approved accessories can result in product failure serious injury or death 29 GENERAL INFORMATION Some accessories not manufactured or sold by Mercury M
35. all spark plugs Protecting External Outboard Components e Lubricate all outboard components listed in Maintenance Inspection and Maintenance Schedule e Touch up any paint nicks See your dealer for touch up paint e Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces except corrosion control anodes 20 Cn Corrosi n Guard External metal 92 802878 5 surfaces 5 Gearcase e 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 90 STORAGE If outboard is stored tilted up in freezing temperature trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard Battery Storage e Follow the battery manufacturer s instructions for storage and recharging e Remove the battery from the boat and check water level Recharge if necessary e Store the battery in a cool dry place e Periodically check the water level and recharge the battery during storage 91 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 Ignition key switch failu
36. arine 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 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 Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate If in doubt contact your dealer or the boats manufacturer Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made 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 Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT Make sure everyone in the boat is properly seated Do not allow anyone to sit or ride on any part of the boat that was not intended for such use This includes the back of seats gunwales transo
37. arine specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial may void the warranty at the sole discretion of Mercury Marine Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a 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
38. cury Marine recommends draining as much of the remaining fuel as possible from the fuel tank remote fuel line and engine fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on their respective containers to the fuel tank before the final operation of the boat prior to storage Fuel Stabilizer helps prevent the formation of varnish and gum in the fuel Quickleen helps clean and lubricate the fuel injectors 1 Pour additives into the fuel a Portable Fuel Tank Pour the required amount of fuel stabilizer into fuel tank Close the tank and tip back and forth to mix b Permanently Installed Fuel Tank Pour the required amount of fuel stabilizer into a separate container Add approximately one quart of fuel to the container Mix and pour into the fuel tank 87 STORAGE 2 Remove the drain hose from the aft hose fitting right side of the chamber Hold the unattached end of the hose over a suitable container 0b01352 a Filter drain screw b Drain hose c Aft hose fitting 3 Loosen the filter drain screw left side of the chamber and allow the contents to drain NOTE If little or no liquid drains from the hose loosen the red filter to vent the chamber 4 Tighten drain screw and reattach the hose 88 STORAGE 5 Remove the drain hose from the forward hose fitting le
39. ded may result in minor or moderate injury or property damage It may also be used to alert against unsafe practices Boat Horsepower Capacity Using an outboard that exceeds the maximum horsepower limit of a boat can 1 cause loss of boat control 2 place too much weight at the transom altering the designed flotation characteristics of the boat or 3 cause the boat to break apart particularly around the transom area Overpowering a boat can result in serious injury death or boat damage 19 GENERAL INFORMATION Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 0b00306 High Speed And High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat outboard combination For additional information obtain a copy of our Hi Performance Boat Operation booklet from your dealer distributor or Mercury Marine
40. ds sterndrives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea Avoid the combination of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes Example of desired air flow through the boat 24 GENERAL INFORMATION POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide WHILE BOAT IS STATIONARY 2 a A EAE 21626 a Running the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine running WHILE BOAT IS MOVING
41. e speed and shift outboard to neutral position Turn ignition key to OFF position OFF 7 0b00360 61 LYVLS MAINTENANCE Power Package Care Avoid equipment damage serious injury or death from improper or neglected maintenance repairs or inspections of the power package If you are not familiar with proper maintenance or service procedures have the work performed by an authorized Mercury Marine dealer To ensure safety and retain dependability keep your power package in the best operating condition by performing the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule Record maintenance performed in the Maintenance Log at the back of this book Save all maintenance work orders and receipts Submerged Power Package A submerged power package requires prompt service by an authorized dealer after recovery This immediate attention is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine Replacement Parts for Your Power Package Using a replacement part that is inferior to the original part could result in personal injury death or product failure Mercury recommends using original Mercury Precision replacement parts and lubricants 62 MAINTENANCE EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the
42. edule for the proper maintenance interval 69 MAINTENANCE Removal a O ring seals b Filter c Raised bosses 1 Disconnect the link rod 2 Use the shaft of a screwdriver between the filter cap bosses and unscrew the filter Installation 1 Lubricate the o ring seals with oil 2 Install the fuel filter and tighten securely 3 Reconnect the link rod IMPORTANT Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm forcing fuel into the filter 70 MAINTENANCE DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE If a sufficient amount of water accumulats in the fuel filter chamber the engine s warning system alerts the operator with the warning horn Some SmartCraft gauges are capable of alerting the operator of this and other operating conditions faults Refer to Warning System in the Features and Controls section of this manual for more information If the warning system alerts you to this condition drain the water from the fuel filter chamber 0b01679 a Drain hose b Aft hose fitting c Filter drain screw 1 Remove the drain hose from the aft hose fitting right side of the chamber Hold the unattached end of the hose over a suitable container 2 Loosen the filter drain screw left side of the chamber and allow the contents to drain NOTE If little or no liquid drains from the hose loosen the red filter to vent the chamber
43. emote Control Models 20 Remote Steering Notice cccecceeeccccceeeeeeeseeeeeneeeenteeeneseenes 21 Lanyard Stop SWIC sire sescnsotnschtatatietotiesshtanaatataidehjetadsetasannedeuael 22 Protecting People In The Water 23 Exhaust EMiSSiOns cccccccccecceeceeeceeeececeeeeeeeeeeeeeeeeeeeeeseeesaas 24 Passenger Safety Message Pontoon Boats And Deck Boats 26 Wave And Wake JUMPING sic s0 ceeridieieucs Seicbaetimntenioes 27 Impact With Underwater Hazards cccccceecceeeeeeeeeeeeeeeeeeeees 28 Selecting Accessories For Your Outboard 0 eeeee 29 Safe Boating Suggestions ccccccccccccecenceeeeeeeendeeeseeeeeenenteees 30 Recording Serial NUMDEI 2 s eccceeceeteesedeecesneeeseeeeeeeeeeee 32 Specifications 300XS OptiMax cccccceeeeeeeeeeeeeeeeeeseeeeees 32 Special Tools and Kits ccccceseeeeeeeeeeeeeeeeeeeeeeeaeaeaaeeeeeeseees 34 Component Identification ccceceeeeeeceeeeeeeeeeaeeeneeeeeeeneeeeeees 35 Propeller Selection cecceeceeeeeeeeeeeeqeeneeensensaeneneneneesseeees 36 TABLE OF CONTENTS Transporting Trailering Boat Outboard 2s caries MAM 38 Fuel and Oil Avoiding Fuel Flow Restrictions 39 Fuel Requirement ccccccccceeeeeeeeeeeeeeeeeeeeeeaaaensseneeeeeeeeeeeees 39 Oil Recommendation ccccccccceccceeeeeeeeeeeeeeeeeeeeeeeeeeeeaaaeeaas 41 Filling Remote Oil Tank 41 Filling Engine
44. er e Check the spark plug gap and replace if necessary BEFORE PERIODS OF STORAGE e Refer to Storage section Flushing the Cooling System Powerhead Flush the internal water passages of the engine with fresh water after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages N a Plug located on fitting b Water hose or36 1 1 Remove the plug from fitting in the bottom cowl 2 Attach a water hose to the fitting Turn on the water and flush for three to five minutes NOTE The engine can be stopped or operated at idle speed when flushing the cooling system Do not flush engine using a water system that exceeds 310 kPa 45 psi 66 MAINTENANCE Flushing the Cooling System Lower Unit a Fleet Master and c Water hose Torque Master d Flushing attachments gearcase b Sport Master gearcase 1 Remove the propeller Refer to Propeller Replacement 2 Fleet Master and Torque Master gearcases Install the appropriate flushing attachment so the rubber cups fit tightly over the strut intake holes Attach the Dual Water Flush Seal over the nose inlets 3 Sport Master gearcases Install the appropriate flushing attachment so the nose cone cup fits tightly over the intake holes 4 Attach a water hose to the flushing attachment Turn on the water and adjust the flow so water is leaking around the rubber cups or nose c
45. er to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON START h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer to Operation Starting the Engine 44 FEATURES AND CONTROLS Zero Effort Control Features a Throttle lever b Trim switch c Shift lever Warning System The warning system incorporates a warning horn inside the boat The warning horn may be located inside the remote control or under the dash connected to the ignition key switch ob00662 a Inside the remote control b Under the dashboard WARNING HORN SIGNALS When the key switch is turned to the ON position the horn will turn on for a moment as a test to tell you the horn is working 45 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps This will alert the operator and help identify the following listed situations Refer to the Troubleshooting section for specific information For visual display of the specific engine functions and for additional engine data refer to SmartCraft product information ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems The system will respond to a problem by emitting a continuous beep and or reduci
46. ercury 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 If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury WHAT MERCURY WILL DO Mercury Marine s sole and exclusive obligation under this warranty is limited to at our expense and at our option repairing or replacing defective parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see General Information Specifications operation of the product in a manner inconsistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product
47. fects of Elevation and Weather on Performance 56 Setting Trim Angle While Running Engine at Idle Speed 57 vi TABLE OF CONTENTS Operating in Shallow Watter cccceeeeeeeeeeeeeeeeeeeeaeanaes 57 Starting The Engine 2 cccc0c is gesseedeacelascespecuteesteecetectenseetteeeeiees 58 Gear SIMMS a nnie screed atid tated tele tind eatin Talat Bate tet Made 61 Stopping The SEMIN es csttes atts catactenstiade authccralin Sicehcpaarnbaautans 61 Maintenance Power Package Cale ii ciwdcintnednminie eae aadia Gnas 62 Submerged Power Package ccccccieeeseeseeeeeeeeeeeeecceneeeneee 62 Replacement Parts for Your Power Package 62 EPA Emissions Regulations 63 Inspection And Maintenance Schedulle cccccssscceseeeeeeees 64 Flushing the Cooling System Powerhead sscceeeeee 66 Flushing the Cooling System Lower Uniit eee 67 Top Cowl Removal and Installation c cccccccsesseseeeeeeeeeeees 68 Cleaning Care for Top Cowl c cccccctessecccnesseneeteeeeneeeeeeeees 68 F el System arrr e aai 69 Steering Link Rod Fasteners e seseeeeeseeeneneneeeeeeneees 72 AOLE E cs geetessstussavivceriveesveueiteceaiectivecitietia news teas 73 Corrosion Control ANG s c6 ca sited eee ane eines 74 Spark Plug Inspection and Replacement esseeseeeree 75 Bateryli SOC CuOn siisii a iabea aiiin 76 Charging System Fusible Link
48. ff Idle Operation side Diath ASE al a Nie ne te ea ie A ur 95 Owner Service Assistance Local Repair Service cccccccccccccceccececeecceeeeeeceeeeeeeeeeeeeesteess 96 Service Away From Home 2 0 ccccccccseseseseseeseeeeeceeceteeeeteeeese 96 Parts And Accessories INQuiri S cceeeeeeeeeeeeeeeeeeeeees 96 Service FAS SIS UA CS coca cic other cre cnet ntaescaustiyta stadia teabande teach 96 Mercury Marine Service Offices 97 Ordering Literature sig ccsacseyshue i sedentadandetuen dest beeiavheileiediduateeued 98 Maintenance Log Maintenance LOg ccccccecececececeaeeeaeeeceeeeeeeeeeeeeeeeeeeeeeaeeneaas 100 viii WARRANTY INFORMATION Warranty Registration United States And Canada Outside United States and Canada Check with your local distributor 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 department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States should a safety recall notification under the Federal Safety
49. ft side of the chamber Hold the unattached end of the hose over a suitable container 0b01589 a Forward hose fitting c Drain hose b Float chamber drain screw 6 Loosen the float chamber drain screw right side of the chamber and allow the contents to drain 7 Tighten drain screw and reattach the hose 8 Premix the following in a container e 8 cc 0 3 oz or 2 teaspoons of Mercury Precision Quickleen lubricant e 8 cc 0 3 oz or 2 teaspoons of Mercury Precision Fuel Stabilizer 9 Remove the fuel filter Refer to Fuel System in the Maintenance section of this manual 10 Pour the mixture into the fuel filter opening 11 Install the fuel filter 12 Prime the fuel system as described in the Starting the Engine in the Operation section of this manual 89 STORAGE 13 Place the outboard in water or use the flushing attachment for circulating cooling water Start the engine and run at idle speed for 5 minutes to allow the treated fuel to fill the fuel system Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceeding IMPORTANT Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark plug leads 1 Remove the spark plugs and add approximately 30 ml 1 oz of engine oil into each spark plug hole 2 Rotate the flywheel manually several times to distribute the oil in the cylinders 3 Re inst
50. he fuel and oil systems for deterioration or leaks 64 MAINTENANCE Visually check steering link rod fasteners for wear Lubricate all components refer to the Installation Manual for lubrication specifications Check all attachment hardware for proper torque tightness Check level and condition of gearcase lubricant Check alternator belt tension EVERY 50 HOURS OR ONCE A YEAR WHICHEVER OCCURS FIRST Lubricate all lubrication points Lubricate splines on the drive shaft Lubricate entire length of drive shaft with anti corrosion grease Lubricate splines on the propeller shaft Drain and replace gearcase lubricant Check the spark plug gap Clean and replace plugs if necessary Inspect all belts pulleys and idler pulleys for deterioration Check fuel pressure Check control cable adjustments Inspect battery Check corrosion control anodes Check tightness of bolts nuts and other fasteners Check power trim fluid Remove engine deposits with Power Tune Engine Cleaner EVERY 100 HOURS OR ONCE A YEAR WHICHEVER OCCURS FIRST Replace water pump impeller more often if overheating occurs or reduced water pressure is noted Use QuicKleen in fuel EVERY 100 HOURS OF OPERATION Inspect Carbon Fiber reeds for chipping or cracks 1 These items should be serviced by a authorized dealer 65 MAINTENANCE EVERY 200 HOURS OR ONCE EVERY TWO YEARS WHICHEVER OCCURS FIRST e Replace water separating fuel filt
51. hree ram trim system purchase a stainless steel tilt pin from your dealer and insert it in whichever adjustment hole is desired 50 FEATURES AND CONTROLS To limit trim in on models with a single ram trim system use the cadmium plated bolt shipped with the engine H It O7E 15923 a Stainless steel tilt pin Three Ram trim system b Bolt shipped with engine Single Ram trim system Trimming out or up can Lift the bow higher out of the water e Generally increase top speed e Gain clearance over submerged objects or a shallow bottom e Increase steering torque or pull to the left at a normal installation height with the normal right hand rotation propeller e In excess cause boat porpoising bouncing or propeller ventilation e Cause engine overheating if any cooling water intake holes are above the water line Power Tilt Operation Single Ram Systems To tilt the outboard shut off the engine and press the trim tilt switch or the auxiliary tilt switch to the up position The outboard tilts up until the switch is released or it reaches the maximum tilt position The hydraulic system is fully capable of supporting the outboard during normal tilting operation However if trailering the boat in the trim tilt position use an accessory outboard support device Power Tilt Operation Three Ram Trim Systems To tilt the outboard shut off the engine and press the trim tilt switch or the auxiliary tilt swi
52. ications In areas where TBTA base paints are prohibited by law copper base paints can be used on the hull and transom Do not apply paint to the outboard or MerCruiser product In addition care must be taken to avoid an electrical interconnection between the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY WARRANTY INFORMATION Warranty Coverage and Exclusions for Mercury Racing Outboard Products The purpose of this
53. ine at 1 920 929 5040 Star Label Outboards are labeled on the cowl with one of the following star labels The Symbol for Cleaner Marine Engines Means Cleaner Air and Water for a healthier lifestyle and environment Better Fuel Economy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources Longer Emission Warranty Protects consumer for worry free operation One Star Low Emission The One Star label identifies engines that meet the Air Resources Board s 2001 exhaust emissions standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines 17 WARRANTY INFORMATION Two Stars Very Low Emission VERT LOY The Two Star label identifies RNIA EMISSIONS Stay a ee gt engines that meet the Air Resources Board s Personal i Watercraft and Outboard marine engine 2004 exhaust emissions standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003 2008 exhaust emission standards Engines meeting these standards have 65 lo
54. ld to retail consumers in California and which were manufactured for the 2001 model year and later Mercury Marine in compliance with those regulations provides this limited warranty for the emission control systems see the components of the emission control system listed following and further warrants that the outboard engine was designed built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code For information regarding the limited warranty for the non emissions related components of the outboard please see the limited warranty statement for your outboard 11 WARRANTY INFORMATION WHAT IS COVERED Mercury Marine warrants the components of the emissions control systems see the components of the emission control system listed following of its new 2001 model year and later outboards sold by a California dealer to retail customers residing in California to be free from defects in material or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board for the period of time and under the conditions identified below The cost to diagnose a warranty failure is covered under the warranty if the warranty claim is approved Damage to
55. m bow decks raised fishing seats any rotating fishing seat or anywhere that an unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard 30 GENERAL INFORMATION Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the outboard into neutral is not sufficient 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 operators view when operating the boat above idle speed 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
56. manuals and parts books Employs at least one Certified or Master technician e Provides timely service for all Mercury Marine customers e Offers extended service hours and mobile service when appropriate e Uses displays and stocks adequate inventory of genuine Mercury Precision Parts e Offers a clean neat shop with well organized tools and service literature TABLE OF CONTENTS Warranty Information Warranty Registration United States And Canada 065 1 Transfer Of Warranty sinis reen oun Nec toiora ouiet 1 Mercury Racing Division 2 Year Limited Warranty OptiMax XS Series OULDOALAS ssi seecesevenceieescdaddvenceceteh sdeneeccneecevaecdstecelenceeeneaees 2 Products Sold to Government Agencies 6 3 Year Limited Warranty Against Corrosion 6 Warranty Coverage and Exclusions for Mercury Racing Outboard PROGUGIS ss siscxsastvabsndteSenkivanha bay yt ded taeda sivahinaeteecdeacieaviocauendegaaladadia 10 California Emissions Limited Warranty ccccceceeeeeeeeeeeeees 11 Star LADS eccstetas salons cinta nS as has ne aru neta hand sansa etna TEE EENE 17 General Information Boater s Responsibilities cccccccccccccececenecceeeeeeeeeeeeseeenseeees 19 Before Operating Your Outboard eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneee 19 Boat Horsepower Capacity cceeeeeeeeeeeeeeeeeeeeeaeeeeaaeaaes 19 High Speed And High Performance Boat Operation 20 Outboard R
57. ming out or up 48 FEATURES AND CONTROLS e The term trim generally refers to the adjustment of the outboard within the first 20 range of travel The term tilt generally refers to adjusting the outboard further up out of the water With the engine turned off the outboard can be tilted out of the water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation Power Trim Operation With most boats operating around the middle of the trim range will give satisfactory results Trimming your outboard all the way in or out may improve performance but cause some potential control hazards Avoid possible serious injury or death When the outboard is trimmed in or out beyond a neutral steering condition a pull on the steering wheel in either direction may result Failure to keep a continuous firm grip on the steering wheel when this condition exists can result in loss of boat control as the outboard can turn freely The boat can now spin out or go into a very tight maximum turn which if unexpected can result in occupants being thrown within the boat or out of the boat Consider the following lists carefully Trimming in or down can e Lower the bow of the boat e Result in quicker planing off e Generally improve the ride in choppy water e Increase steering torque or pull to the right with the normal right hand rotation propeller e In excess lower
58. nd of unleaded gasoline preferably without alcohol Use of improper fuel can seriously damage your engine Engine damage resulting from use of improper fuel is considered misuse of the engine and damage caused thereby will not be covered under the Mercury Racing limited warranty OCTANE REQUIREMENTS U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium 91 R M 2 OCTANE REQUIREMENTS OUTSIDE THE U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium 2 96 RON 1 Mercury Racing does not recommend using leaded gasoline Read the information in the Fuel Containing Alcohol section Mercury Racing does not recommend using leaded gasoline Leaded gasoline is acceptable in areas where unleaded gasoline is not available however exhaust passageway corrosion may occur due to the accumulation of exhausted lead particles Automotive fuels that contain fuel injector cleaner are recommended for added internal cleanliness 39 N FUEL AND OIL USING REFORMULATED OXYGENATED FUELS USA ONLY This type of fuel is required in certain areas of the U S The two types of oxygenates used in these fuels are alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to the Fuel Containing Alcohol section These reformulated fuels are acceptable for use in your Mercury engine FUEL CONTAINING ALCOHOL If the fuel in your area contains either methanol methyl
59. ne Fax Mercury Racing N7480 County Rd UU 920 924 2088 920 924 2096 Fond du Lac WI 54935 9585 Canada Telephone Fax Mercury Marine Ltd 2395 Meadowpine Blvd 905 567 6372 905 567 8515 Mississauga Ontario L5N 7W6 Canada Australia Pacific Telephone Mercury Marine Australia 132 140 Frankston Road 61 3 9791 5822 61 3 9793 5880 Dandenong Victoria 3164 Australia 97 OWNER SERVICE ASSISTANCE Europe Middle East Africa Telephone Fax Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 32 87 32 32 11 32 87 31 19 65 Verviers Belgium Mexico Central America South America Caribbean Telephone Mercury Marine 11650 Interchange Circle North 954 744 3500 954 744 3535 Miramar FL 33025 U S A Japan Telephone Mercury Marine Japan 283 1 Anshin cho Hamamatsu 81 53 423 2500 81 53 423 2510 Shizuoka 435 0005 Japan Asia Singapore Telephone Mercury Marine Singapore 72 Loyang Way 5466160 5467789 Singapore 508762 Ordering Literature Before ordering literature please have the following information about your power package available Engine melee Morsepowers Serial UNITED STATES AND CANADA For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact MERCURY MARINE Mercury Marine Attn Publications Departme
60. ng engine power in order to provide engine protection If Guardian System is activated the system must be reset before the engine will operate at higher speeds Moving throttle lever back to idle position resets the system Percentage of Problem Monitor Guardian Full Engine Display Activated Power Available Power Up i System Check Single Beep During Engine No m Break In Low Oil in Engine Oil 95 Tank From 100 down to 4 From 100 down to 4 4 Beeps 2 Minutes Off Critically Low Oil in Engine Oil Continuous Beep Tank Oil Pump Electrical Continuous Beep Yes Failure 46 5 Throttle Position Sensor Failure Overspeed Continuous Beep pigi Engine Continuous Beep Temperature Low Block Water Pressure Continuous Beep Continuous N N Intermittent Beeping Y Y A o Yes Yes Yes Yes es es es con Y FEATURES AND CONTROLS Percentage of Monitor Guardian Full Engine Display Activated Power Available Problem Faulty Sensor Block psi Coolant Temp lt 10 v 0 Single lt 11 5 v 50 Battery Voltage Beep Continuous f Out of Limits Beep when Guardian Engages gt 16 v 50 gt 17 v 0 4 Beeps 2 Minutes MAP Sensor Failure Air Temperature Sensor Failure Ignition Coil Failure Injector Failure No SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this power package A few functions some of the i
61. nstrument packages will display are engine RPM coolant temp water pressure battery voltage fuel consumption and engine operating hours The SmartCraft Instrument package will also aid in Engine Guardian diagnostics The SmartCraft Instrument package will display critical engine alarm data and potential problems Refer to the Mercury SmartCraft Operator s Supplement provided with the power package for the warning functions monitored on your power package and basic operation of the SmartCraft Instrument package 47 FEATURES AND CONTROLS Overspeed Rev Limit The PCM does not allow the engine to exceed the rev limit Refer to Specifications to determine this engine s RPM limit Upon reaching the rev limit the Guardian System activates the warning horn If the operator does not reduce engine speed within five seconds the Guardian Systems reduces available engine power To reset the Guardian System protection 1 Completely reduce throttle for two to three seconds 2 Re engage the throttle If the engine does not respond repeat step one Power Trim And Tilt NOTE Outboard position can be adjusted by pressing trim switch This range is used while operating your boat on plane or30 1 a Trim switch b Trim range c Tilt range e Pressing DN Moves the outboard in closer to the boat transom called trimming in or down e Pressing UP Moves the outboard further away from the boat transom called trim
62. nt 920 929 5110 920 929 4894 P O Box 1939 Fond du Lac WI 54936 1939 98 OWNER SERVICE ASSISTANCE OUTSIDE THE UNITED STATES AND CANADA Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature 99 MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Maintenance Performed 100
63. o best obtain warranty coverage important disclaimers and limitations of damages and other related information Please review this important information The description and specifications contained herein were in effect at the time this manual was approved for printing Mercury Marine whose policy is one of continued improvement reserves the right to discontinue models at any time to change specifications designs methods or procedures without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2006 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort M with Waves logo Mercury with Waves logo and SmartCraft logo are all registered trademarks of Brunswick Corporation Mercury Product Protection logo is a registered service mark of Brunswick Corporation Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of Mercury Premier to those demonstrating an exceptional commitment to service Earning a Mercury Premier Service rating means a dealer e Achieves a high 12 month service CSI Customer Satisfaction Index score for warranty service e Possesses all necessary service tools test equipment
64. o prevent damage to the water pump running dry or overheating of the engine INITIAL STARTING PROCEDURE NOTE For initial start up of a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled according to the following procedure 1 Squeeze the fuel line primer bulb until it feels firm 2 Turn the ignition key switch to the ON position for three seconds This operates the electric fuel pump 3 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 position again for three seconds Continue this procedure until the fuel line primer bulb stays firm Before starting read the Pre Starting Check List Special Operating Instructions in the Operation Section 58 OPERATION STARTING PROCEDURE Lower the outboard to the RUN position Make sure all the cooling water intake holes are submerged Open fuel tank filler cap vent screw manual venting fuel tanks fi V3 Squeeze the fuel line primer bulb several times until it feels firm 19748 19779 Set the lanyard stop switch to the RUN position Read the Lanyard Stop Switch safety explanation and warning in the General Information section 59 OPERATION Shift the outboard to the neutral position 0b00351 Do not advance the neutral fast idle speed feature on the rem
65. oat handling situation Increasing trim under can place greater load on an engine and enhance breakin At higher speeds increasing trim under could produce a dangerous boat handling situation It is the boat operator s responsibility to always drive in a safe manner Break in Procedure Ist Hour o O approximately three quarter throttle e Avoid trimming the outboard out up beyond a vertical trim position during operation e Avoid using hydraulic jack plate if equipped to raise engine during break in cycle Next 3 Hours Change engine speed every 10 minutes Engine Break in Fuel Mixture Avoid engine damage Do not add oil to the gasoline in the fuel tank The Propulsion Control Module PCM controls oil and fuel mixture during engine break in 54 OPERATION Pre Starting Check List _ Engine lowered to run position with all water intake holes submerged _ Fuel tank vent cap open or fuel drain valve on _ Fuel supply OK _ Lanyard stop switch in RUN position and cord connected L Remote control in neutral L Top cowl latches secure _ Make inspection checks listed in the Inspection and Maintenance Schedule Refer to Maintenance section Operating at Off Idle Speeds Unlike other OptiMax engines this outboard is designed to discharge water though the idle exhaust boot located at the aft end of the bottom cowl when operating at speeds above idle The volume of discharged water increases wi
66. occupants flying forward The boat may also steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed Under these conditions boat speed should be kept to a minimum planing speed of 24 to 40 km h 15 to 25 MPH To 9b00315 To avoid serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater obstacle maintain a top speed no greater than minimum planing speed Striking a floating or underwater object could result in an infinite number of situations Some of these situations could result in the following Part of the outboard or the entire outboard could break loose and fly into the boat 28 GENERAL INFORMATION e The boat could move suddenly in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat e A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or imp
67. of parts water entering the engine through the fuel intake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far The commercial use of the product defined as any work or employment related use of the product or any income generating use of the product even if such use is only occasional will void the warranty Use of the product for racing or other competitive activity at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income tournament fees club fees prize money or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal and or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty 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 WARRANTY INFORMATIO
68. olish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth Fuel System FUEL SYSTEM SERVICE INFORMATION Avoid serious injury or death from gasoline fire or explosion Carefully follow all fuel system service instructions Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system IMPORTANT Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Before servicing any part of the fuel system e Stop engine and disconnect the battery e Drain the fuel system completely e Perform fuel system service in a well ventilated area Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced WATER SEPARATING FUEL FILTER This filter removes moisture and debris from the fuel If the filter becomes filled with water the water can be removed If the filter becomes plugged with debris replace the filter The warning system engages when water in the fuel filter reaches the full level Refer to Warning System in Features amp Controls Refer to the Inspection and Maintenance Sch
69. one cup to ensure the engine receives an adequate supply of cooling water 5 Start the engine and run it at idle speed in neutral shift position 6 Adjust water flow so excess water continues leaking out from around the rubber cups or nose cone cup to ensure the engine is receiving an adequate supply of cooling water 67 MAINTENANCE 7 Check for water coming out of the water pump indicator hole Continue flushing for three to five minutes carefully monitoring water supply at all times 8 Stop the engine turn off the water and remove the flushing attachment Re install the propeller Top Cowl Removal and Installation REMOVAL Release the front and side cowl latches Lift the top cowl from the outboard or38 INSTALLATION Position the top cowl over the engine Make sure the bottom rubber seal fits properly and lock the front and side latches Cleaning Care for Top Cowl IMPORTANT Dry wiping wiping the plastic surface when it is dry will result in minor surface scratches Always wet the surface before cleaning Follow cleaning and waxing procedure CLEANING AND WAXING PROCEDURE 1 Before washing rinse the top cowl with clean water to remove dirt and dust that may scratch the surface 2 Wash the top cowl with clean water and a mild non abrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 68 MAINTENANCE 4 Wax the surface using a non abrasive automotive p
70. ons Your engine automatically compensates for high elevation changes A different pitch propeller may help reduce some normal performance loss resulting from reduced oxygen in the air Consult your dealer Effects of Elevation and Weather on Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems e Above sea level elevations e High temperature e Low barometric pressure e High humidity These conditions above reduce air density to the engine which in turn lowers the following Boost pressure on supercharged engines Horsepower and torque throughout the RPM range e Peak RPM e Cranking compression EXAMPLE An engine run at an elevation of 8 000 feet will have over a 30 power loss while a loss of engine power on a hot and humid day could be as much as 14 These losses apply to normally aspirated and supercharged engines Compensating for power robbing conditions e Switch to lower pitch propeller e Change gear ratio 56 OPERATION Some boat performance can be regained by dropping to a lower pitch propeller but engine performance will still remain lower In some cases a gear ratio reduction may be more beneficial To optimize engine performance prop the engine to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Other advantages to propeller or gear
71. osition While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power RUN GaN 21629 a Lanyard cord b Lanyard stop switch We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator 22 GENERAL INFORMATION 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 This could cause any or all of the following potentially hazardous situations e Occupants could be thrown forward
72. ote control for starting if equipped ob00560 Turn the ignition key to the START position Release the key when the engine starts If the engine fails to start in ten seconds return the key to the OFF position wait one second and try again aoe ply 5E 19804 Check for water coming out of the water pump indicator hole or55 NOTE The electronic starting system will automatically prime choke the engine and increase idle speed for starting 60 OPERATION Avoid possible engine damage If no water is coming out of the water pump indicator hole stop the engine and check the cooling water intake holes for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your authorized Mercury Marine dealer Operating the engine while overheated will cause engine damage Gear Shifting IMPORTANT Never shift into gear unless the engine is at idle Never shift into reverse without the engine running e Your outboard has three gear shift positions to provide operation forward neutral out of gear and reverse N F R 0b00557 e When shifting always stop at neutral position and allow the engine speed to return to idle e Always shift into gear with a quick motion e After shifting into gear advance the lever further to increase speed Stopping The Engine Reduce engin
73. pen contact your authorized Mercury Marine dealer MU Replacing the Propeller Avoid serious injury or death Place the remote control in neutral and remove the ignition key from the switch before removing and or installing the propeller Place a block of wood between the anti ventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating when removing the propeller nut T7 MAINTENANCE REMOVING THE PROPELLER NOTE If propeller is seized to the shaft and cannot be removed consult your authorized Mercury dealer 1 Shift the outboard to neutral 2 Remove the keys from the ignition and engage the safety stop switch 3 Straighten the bent tabs on the propeller nut retainer if applicable 4 Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut 0b00377 5 Remove the propeller and associated hardware from the propeller shaft INSTALLING THE PROPELLER Avoid engine damage Prop the engine so engine speed is limited to the required full throttle rom range An under propped engine may occasionally initiate the rev limiter This may result in internal powerhead damage Mercury Racing applications use 19 spline propeller shafts and require installation of the Heavy Duty Propeller Hub kit included with most Mercury Racing propellers IMPORTANT To prevent the
74. ratio changes e Reduces the possibility of detonation e Enhances overall reliability and durability of the engine Setting Trim Angle While Running Engine at Idle Speed Submerging the exhaust relief hole on the outboard can happen on some boats if you trim full in while running at idle speed resulting in exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim outboard up until exhaust relief hole is out of the water or35 1 a Relief hole submerged wrong b Relief hole above water line correct Operating in Shallow Water When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom Avoid engine or transom damage Do not exceed 2000 RPM when the outboard is being operated in the tilt range 1 Reduce engine speed below 2000 RPM 57 OPERATION 2 Tilt outboard up Make sure all the cooling water intake holes stay submerged at all times 3 Operate the engine at slow speed only Models with a three ram trim system If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range Models with a single ram trim system The outboard will remain at the selected tilt position regardless of engine RPM Starting The Engine Never start or operate your outboard even momentarily without water circulating through all the cooling water intake holes in the gearcase t
75. re Wiring or electrical connection faulty Starter motor solenoid or slave solenoid failure Engine Will Not Start POSSIBLE CAUSES Lanyard stop switch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine e Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed e Primer bulb check valve is faulty e Fuel filter is obstructed Refer to Maintenance section Fuel pump failure e Fuel tank filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section 92 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 Stuck anti siphon valve on built in fuel tank d Fuel line is kinked or pinched e Injector plugged Threaded connection of an air hose is loose Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not opening fully Damaged propeller or improper propeller size Boat
76. replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a corroded part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a 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 If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship
77. requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory standards 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 spark ignition SI engine repair establishment or individual 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 YEAR CALIFORNIA AND U S EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS IDLE SPEED in gear XXX RPM FAMILY XXXXXX HP XXXX cc FEL XX XXXX g kWh ING IN DEGREES XXXXXXXXX PART NO SPARK PLUG XXXXXXXX 37 XXXXXX GAP _X X MM X X IN COLD VALVE INTAKE 0 XX 0 XX MM CLEARANCE mm EXHAUST _0 XX 0 XX MM JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC 21096 a Idle speed f Family number b Engine horsepower g Maximum emission c Piston displacement output for the engine d Date of manufacture family e Valve clearance
78. rine Outboard Mercury MerCruiser Inboard or Sterndrive Engine Mercury Racing Bravo style sterndrive engine Product will not be rendered inoperative as a direct result of corrosion for the period of time described below WARRANTY INFORMATION DURATION OF COVERAGE This limited corrosion warranty provides coverage for three 3 years from either the date the product is first sold or the date on which the product is first put into service whichever occurs first The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to subsequent non commercial use purchaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN 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 Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the
79. ropping the engine at the higher end of the RPM range may increase acceleration but decrease top boat speed Conversely propping the engine at the lower end of the range may increase top boat speed but hinder acceleration Mercury Marine recommends selecting a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded refer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed All L models 20 in and some XL models 25 in are capable of operating at engine speeds of up to 6000 RPM This increased engine speed gives the operator a greater range of pitch selection However propping at the uppermost limit of the RPM range may not necessarily result in improved high speed performance Boat weight and hull design influence the effectiveness of this increased engine speed and may decrease top boat speed If full throttle operation is below the recommended full throttle range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal wear or damage Generally there is a 200 300 RPM change between propeller pitches If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations
80. ry Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Mercury Racing Division 2 Year Limited Warranty OptiMax XS Series Outboards WHAT IS COVERED Mercury Marine warrants its new OptiMax XS series Outboard products and remanufactured OptiMax XS series Outboard products sold under the trade name Pacemaker to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for two 2 years from either the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to a subsequent purchaser upon proper re registration of the product WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN 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 M
81. 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 Mercury Racing Division Three Year Limited Warranty Against Corrosion Failure the Mercury Racing Division One and Two Year Limited Warranties Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship Installation errors accidents normal wear and a variety of other causes that affect the product are not covered Warranty is limited to defects in material or workmanship but 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 Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor or EFI settings filters belts controls and checking lubrication made in connection with normal services 2 Damage caused by lack of maintenance 3
82. ssion Control Information decal as permanent evidence of EPA certification 90 8M8020316 406 300XS OptiMax 2006 Mercury Marine The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm 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 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 covered the duration of coverage how t
83. tch located on the cowl to the up position The outboard tilts up until the switch is released or it reaches the maximum tilt position 51 FEATURES AND CONTROLS 1 Engage the tilt support lever by pushing the metal stop and rotating the knob to bring the support lever upward or33 1 a Tilt support lever b Metal stop c Knob 2 Lower the outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever until it locks Lower the outboard Auxiliary Tilt Switch This switch can be used to tilt the outboard up or down using the power trim system a Auxiliary tilt switch 52 FEATURES AND CONTROLS Manual Tilt Operation If the outboard cannot be tilted using the power trim tilt switch the outboard can be tilted manually 1 Turn out the manual tilt release valve three turns counter clockwise This allows manual tilting of the outboard or34 1 2 Tiltthe outboard to the desired position and tighten the manual tilt release valve NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation 53 OPERATION Engine Break in Severe damage to the engine can result by not complying with the engine break in proceedure Engine damage may not be covered by the limited warranty Avoid loss of boat control or an unsafe b
84. teering cable coupler with two flat washers c and a self locking nylon insert locknut d Tighten the sckaut until it seats then loosen turn 2 Assemble the steering link rod to the engine with the special washer head bolt a and self locking nylon insert locknut b 3 Torque the head bolt then the locknut to specifications Decin i J em e Tighten locknut until it seats then Cable Coupler Nylon Locknut d loosen 1 4 turn Pea sonyon oaas a O a Soecarwasrerne a7 _ a _ Fuses IMPORTANT Always carry spare 5 and 20 amp fuses 73 MAINTENANCE The electrical wiring circuits on the engine are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse 2 Replace fuse with a new fuse with the same rating The fuses and circuits are identified as follows IAs ay KK gt R SEJ tE ty LS y q Ya a SmartCraft data bus c Ignition Coil Circuit 20 circuit 5 amp fuse amp fuse b Accessories 20 amp d Electric fuel pump ECM fuse driver power Oil pump circuit SFE 20 amp fuse Corrosion Control Anode Avoid corrosion damage Mercury Marine recommends using anodes sold through Mercury Precision Parts only Some other manufacturers of aluminum
85. tered or fouled s 3 Set the spark plug gap to specifications FJ Spark Plug Gap 0 81 mm 0 032 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or torque to specifications Dessin m fen J oe Sao a l a 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 Add water as necessary to keep the battery full 3 Make sure the battery is secure against movement 4 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative 76 MAINTENANCE 5 Make sure the battery is equipped with a non conductive shield to prevent accidental shorting of battery terminals Charging System Fusible Link This model has a 100 ampere fusible link between the alternator and the 12 volt stud This fusible link protects the alternator from damage due to accidental reverse battery connection If the battery cables are reversed the fusible link creates an open circuit protecting the alternator With the fusible link open the engine can be started however the run time is limited because the alternator is not charging the boat battery If the fusible link circuit becomes o
86. th boat speed as a result of the engine cooling system Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at all times so the gearcase is submerged This prevents trapped water in gearcase from freezing and causing possible damage to the water pump and other components If there is a chance of ice forming on the water the outboard should be removed and drained completely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing The Cooling System 55 OPERATION If you keep your boat moored in the water always tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use 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 Operating at High Elevati
87. wer emissions than One Star Low Emission engines Four Stars Super Ultra Low Emission The Four Star label identifies engines that meet the Air ae EMISSIONS gf ms Ol Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines 18 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 Before Operating Your Outboard Read this manual carefully Learn how to operate your outboard properly If you have any questions contact your dealer This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation that if not avoi
88. wing a warranty claim at the discretion of Mercury Marine Failures of warranted parts caused by the use of a non exempted add on or modified part will not be covered COMPONENTS OF THE EMISSIONS CONTROL SYSTEM 1 Fuel Metering System a Carburetor and internal parts and or pressure regulator or fuel injection system b Cold start enrichment system c Intake valves 2 Air Induction System a Intake manifold b Turbocharger or supercharger systems where applicable 3 Ignition System a Spark plugs b Magneto or electronic ignition system c Spark advance retard system d Ignition coil and or control module e Ignition wires 4 Lubrication System 4 Stroke engines excluded a Oil pump and internal parts 14 WARRANTY INFORMATION b Oil injectors c Oil meter 5 Exhaust system a Exhaust manifold b Exhaust valves 6 Miscellaneous Items Used in Above Systems a Hoses clamps fittings tubing sealing gaskets or devices and mounting hardware b Pulleys belts and idlers c Vacuum temperature check and time sensitive valves and switches d Electronic controls DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SO

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