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2.5 EFI 2.5 EFI SS 2.5 EFI OS - Brunswick Marine in EMEA

1. 26 GENERAL INFORMATION Selecting Accessories For Your Outboard Genuine Mercury Marine Accessories have been specifically designed and tested for your outboard Mercury Marine accessories are available from Mercury Marine dealers Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Check with your dealer before installing accessories Misuse of acceptable accessories or the use of unacceptable acces sories can result in serious injury death or product failure 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 Life Jackets Have an approved life jacket of suitable size for each person aboard and have it readily accessible it is the law However we strongly recommend that everyone aboard wear their life jacket 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 wa
2. Altered from Placing Too Much Weight on Transom e Boat to Break Apart Particularly Around the Transom Area High Speed And High Performance Boat Operation 2 If you are not familiar with high performance boat operation we recommend that you first request an orientation demonstration ride with your dealer or an operator experienced with your boat outboard combination Refer to the Guide to Hi Performance Boat Operation booklet included in your literature packet 18 GENERAL INFORMATION Lanyard Stop Switch Should the operator fall out of the boat the possibility of seri ous 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 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 gen erally on the dashboard or side adjacent to the operator s position While activation of the lanyard stop switch will stop the engine im mediately 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
3. Idle Speed Pickup Timing Non Adjustable Min Water Pres 7500 RPM 83 kPa 12 psi Minimum Mercury Precision Hi Performance Gear Case Oil Gear Lube 92 802854A1 666 ml 22 5 fl oz 1000 MCA Marine Cranking Amps Battery Rating 850 CCA Cold Cranking Amps or 170 Amp Hours Charging System Output 50 amps 675 Watts GENERAL INFORMATION Specifications SPECIAL TOOLS LUBRICANTS AND ACCESSORIES 31 a ma am gf o Ba GENERAL INFORMATION Component Identification 3 o 6 7 mora I OM 9 Top Cowl 9 Cowl Latch Front 10 Cowl Latch Rear 11 Bottom Cowl 12 Water Pump Indicator Hose 13 Tell Tale Cowl Mount Trim Switch Drive Shaft Housing 8 Anti Ventilation Plate 14 15 32 lt _ 2 12 Corrosion Anode s Skeg Cooling Water Intake Holes Gear Case Trim Adjustment Bolt Transom Brackets Wiring Harness Fuel line and Control Cables Install thru bottom cowl GENERAL INFORMATION Propeller Selection Select 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 Specifications If full throttle operation is below the recommended 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 opera
4. International Service Center for your area WARRANTY INFORMATION Mercury RACING DIVISION One Year Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for one 1 year from either the date the product is first sold to a recreational use retail purchas er 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 warran ty beyond its original expiration date Unexpired warranty coverage can be transferred to a subsequent purchaser upon proper re regis tration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that pur chase 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 avail able upon proper registration of the product by the authorized deal er Inaccurate warranty registration information regarding recre ational use or subsequent change of use from recreational to commercial may void the warranty at the sole discretion of Mercury Mari
5. Maintenance Section If you keep your boat moored in the water always tilt the outboard so the gear case is completely out of water except in freezing temperature when not in use Wash down the outboard exterior and flush out the exhaust outlet of the propeller and gear case with fresh water after each use Each month spray Mercury Marine 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 Elevations Your engine automatically compensates for high elevation changes A different pitch propeller may help reduce some normal perform ance loss resulting from reduced oxygen in the air Consult your dealer 49 OPERATION a Exhaust relief hole submerged b Exhaust relief hole out of water onn2 Setting Trim Angle While Running Engine at Idle Speed 1 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 onk2 Operating in Shallow Water 2 When operating in shallow water you can tilt the outboard be yond the maximum trim range to prevent hitting bottom a Operate the engine at slow speed only Do Not exceed 1200 RPM with the outboard trimmed beyond the
6. Responsibilities J 17 Before Operating Your Outboard 17 Boat Horsepower Capacity aaa 18 High Speed And High Performance Boat Operation 18 Lanyard Stop Switch 40x 202 NA San NAGLAKAD ANA 19 Protecting People In The Water a 21 Carbon Monoxide Risk 24 paasa nka KE mann en ii ea 22 Wave And Wake Jumping ia 24 Impact With Underwater Hazards 25 Selecting Accessories For Your Outboard 27 Safe Boating Suggestions cece eee eee 27 Recording Serial Number cee ee eee 29 Specillcations T rrena ir da AN A UP 30 Component Identification a 32 Propeller Selection anon bun kaaa Dansa hamba han 33 Transporting Trailering Boat Outboard 0 0 cece eee ee 34 TABLE OF CONTENTS Fuel amp Oil Fuel Requirements cece eee eee e eee Oil Recommendation ama Man ear ma aa Gasoline Oil Mixture a a ka Sta Aa ea an Filling Gasoline Tank 2 a dead maa bere ede pasha Fuel Octane Rating Label io Features amp Controls Remote Control Features a Warning Horn System anne na Kia KAG Power Trim And Tile ee oles LELE LE BSA Power Trim Operation aa aa LEAN RB BB Tilting Operation Ke Met La AA Manual THING 742 020 Aa ea Soe oaia Sad Ra Operation Engine Break in 2 5 EFI SS And Offshore Pre starting Check List 2 v ca
7. assist you in the operation safe use and care of your outboard All of us at Mercury Racing 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 MERCURY Racing Mercury Racing N7480 County Road UU Fond du Lac WI 54935 9585 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 2003 Mercury Marine The following are registered trademarks of Brunswick Corporation AutoBlend Force Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mercury Marine Mercury Racing Quicksilver RideGuide and Thruster TABLE OF CONTENTS Warranty Information Transfer Of Warranty bina ad mangan angan gan Bintan ayal 5 Warranty Registration ui 6 Mercury RACING DIVISION One Year Limited Warranty 8 Mercury RACING DIVISION 3 Year Limited Warranty Against Corrosion Failure Lana Se naa beban SN AS aan us 12 Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products 15 General Information Boater s
8. engine and damage caused thereby will not be covered under the limited warranty Use a major brand of unleaded gasoline preferably without alcohol OCTANE REQUIREMENTS U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium 91 R M 2 or 96 RON OCTANE REQUIREMENTS OUTSIDE THE U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium 91 R M 2 or 96 RON 1 Mercury Racing does not recommend using leaded gasoline Read the information in the Gasoline Containing Alcohol section 2 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 oe FUEL amp OIL Gasoline Requirements USING REFORMULATED OXYGENATED GASOLINES 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 see the Gasoline Containing Alcohol section These reformulated fuels are acceptable for use in your Mercury engine CA277hp GASOLINE CONTAINING ALCOHOL If the fuel in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware
9. or other signs of deterioration or damage If any of these conditions are found the fuel line must be replaced 60 MAINTENANC a Ignition Key b Oil filter sealing ring c Removing the filter rotate counter clockwise d Installing the filter rotate clockwise Fuel System WATER SEPARATING FUEL FILTER NOT INCLUDED WITH ENGINE 1 Remove and replace filter as follows a Turn ignition key switch to OFF position b Remove filter by turning the filter counterclockwise Dump fluid in a suitable container c Lubricate the sealing ring on the filter with oil d Thread on filter and tighten securely by hand IMPORTANT Visually inspect for fuel leakage from the filter after starting the engine 61 MAINTENANCE Special washer head bolt Self locking nylon insert locknut Self locking nylon insert locknut Flat washers Steering cable coupler DOoOoco0 ohit Steering Link Rod Fasteners DUAL CABLE STEERING Installation instructions for dual cable single engine applications are included with the dual cable kit IMPORTANT The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt a Part Number 10 849838 and self locking nylon insert locknuts b amp c Part Number 11 826709113 Never replace locknuts with common nuts non locking as they will work loose vibrate off freeing link rod to disengage 62 MA
10. shaft at the recommended maintenance intervals and also each time the propeller is removed 6 Heavy Duty Prop Shaft Hub Kit Included with the engine Coat the propshaft with Anti Corrosion Grease Install prop hub assembly propeller washer belleville washer washer and propeller nut onto the shaft 7 Place a block of wood between the gear case and propeller and torgue the propeller nut O Desedpion Tm bn Bt Persema Spark Plug Inspection Inspect spark plugs at the recommended intervals 1 Remove the spark plug leads by twisting the rubber boots slight ly and pull off Inspect spark plug boots and replace if cracked 2 Remove the spark plugs to inspect and clean Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 3 Before reinstalling spark plugs clean away dirt on the spark plug seats Install plugs finger tight and tighten 1 4 turn or torque to the specification below Description Nin bin To seagPus la a 67 MAINTENANCE Battery Inspection The battery should be periodically inspected IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 2 3 4 Turn off the engine before servicing the battery Add water as necessary to keep the battery full Make sure the battery is secure Battery cable terminals should be clean tight and positive to positive and negative to negative Make sure the battery is e
11. 0 RPM to prevent engine over speed 7 A steady water stream must be present from the water pump indicator hole with engine running IMPORTANT If no water is coming out of the water pump indicator hole Immediately stop engine refer to Troubleshooting 52 OPERATION gof78 ofe15 Starting The Engine Gear Shifting IMPORTANT Observe the following e Never shift outboard into gear unless engine is at idle e Never shift outboard into Reverse without the engine run ning 1 Your outboard has three gear shift positions to provide opera tion Forward Neutral out of gear and Reverse 2 When shifting always stop at neutral position and allow the engine speed to return to idle 3 Always shift outboard into gear with a quick motion Stopping The Engine 4 Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position 53 oh MAINTENANCE Outboard Care To ensure safety and retain dependability keep your outboard in the best operating condition by performing the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule Record maintenance performed in Maintenance Log at the back of this book Save all maintenance work orders and receipts ohr1 Neglected outboard inspection and maintenance or performing maintenance or repairs you are not familiar with could result in personal injury death or product failure Submerged Ou
12. INTENANCE Steering Link Rod Fasteners 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 1 Assemble the steering link rod to the steering cable coupler with two flat washers and self locking nylon insert locknut b O Description Nm on at Tighten locknut until Self locking nylon insert locknut b it seats then loosen 1 4 turn 2 Assemble the steering link rod to the engine with the special washer head bolt and self locking nylon insert locknut c First torque the bolt then torque locknut c Description aaa Ea Self locking nylon insert locknut c al Special washer head bolt ERr 20 63 MAINTENANCE S Corrosion Control Anodes IMPORTANT Anodes help protect the metal of the outboard from galvanic corrosion by sacrificing their metal to be slowly eroded instead of the outboard metals being eroded All anodes reguire periodic inspection especially in salt water Replace any anodes before they are completely eroded Never paint or apply protective coating on the anode as effectiveness of the anode will be reduced 1 Your outboard has the following four corrosion control anodes a One plate installed under the anti ventilation plate b One bar across the bottom of the transom b
13. If the outboard motor s serial number plate contains the CE mark in the low er left hand corner the following statement applies This outboard motor manufactured by Mercury Marine Fond du Lac Wis consin USA or Marine Power Europe Inc Park Industriel de Petit Re chain Belgium complies with the reguirements of the following directives and standards as amended Recreational Craft Directive 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 PT4 2 fe IEC 61000 PT4 3 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 manufactured 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 pro cedure for servicing the product must be strictly followed and wherever practicable returned to the original intent of the de sign Maintenance replacement or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual Engines are lab
14. NOT smoke or allow open flames or sparks in the area while filling fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them Always stop engine before refilling tanks Do not completely 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 Fuel Octane Rating Label This outboard ships with a required octane rating label If this label is not already installed affix it to the boat at the fuel tank nozzle AN CAUTION USE ONLY PREMIUM 91 R M 2 OR 96 RON MINIMUM OCTANE rob12 38 og FEATURES amp CONTROLS oge5 Remote Control Features 1 Your boat may be equipped with one of the Quicksilver remote controls shown If not consult your dealer for operation of your remote control a Throttle Friction Adjustment b Control Shift Throttle Handle c Neutral Release Lever d Fast Idle Lever Raising the lever increases engine idle speed in neutral e Ignition Key Switch Choke f Lanyard Read the lanyard stop switch safety explanation and warning in the General Information Section g Lanyard Stop Switch Read the Lanyard Stop Switch safety explanation and Warning in the General Information Section h Trim Tilt Switch i Throttle Only Button Pushing the button in enables ad vanc
15. Racing Division Three Year Limited Warranty Against Corrosion Failure the Mercury Racing Division 90 Day and One 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 Mer cury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre de livery 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 Corrosion damage incurred by your 900 SC MerCruiser prod uct s is not covered under this warranty 2 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 3 Damage caused by lack of maintenance 4 Haul out launch towing charges and all related transportation charges and or travel time etc 5 Additional service work requested by customer other than that necessary to s
16. ad P O Box 1939 Fond du Lac WI 54936 1939 Attn Warranty Registration Department A new Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Mercury Marine Service Office closest to you oul WARRANTY INFORMATION Warranty Registration UNITED STATES AND CANADA 1 It is important that your selling dealer fills out the Warranty Regis tration Card completely and mails it to the factory immediately upon sale of the new product It identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address The dealer also certifies that you are the original purchaser and user of the product Upon receipt of the Warranty Registration Card at the factory you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be re quired Warranty claims will not be accepted without presenta tion of this card A temporary Owner Warranty Registration Card will be pres ented to you when you purchase the product It is valid only for 30 days from date of sale while your plas
17. ally inspect the fuel system for deterioration or leaks Check outboard for tightness on transom Check steering system for binding or loose components Visually check steering link rod fasteners for proper tightness Check propeller blades for damage Sb On ON PIO NO Check level and condition of gear case lubricant AFTER EACH USE 1 Flush out the outboard cooling system if operating in salt or polluted water 2 If operating in salt water wash off salt deposits and flush propeller and gear case exhaust outlet with fresh water EVERY 50 HOURS OF USE OR ONCE A SEASON IMPORTANT Increased lubrication and corrosion mainte nance is required if unit is used in salt water 1 Lubricate all lubrication points 2 Lubricate splines on the drive shaft 3 Lubricate entire length of driveshaft with anti corrosion grease 4 Replace water pump impeller more often if overheating occurs or reduced water pressure is noted Lubricate splines on the propeller shaft 5 6 Drain and replace gear case lubricant 7 Inspect and clean replace spark plugs 8 Inspect fiberglass reeds These items should be serviced by a authorized dealer 56 oh ohd10 MAINTENANCE Inspection And Maintenance Schedule EVERY 50 HOURS OF USE OR ONCE A SEASON 9 10 11 12 13 14 15 16 17 18 19 Check fuel pressure Check injector spray pattern Check control cable adjustments Check engine timing setup I
18. and Maintenance Manual incorpo rated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT NESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DIS CLAIMED TO THE EXTENT THAT THEY CANNOT BE DIS CLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESSED WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EX CLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIM ERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WAR RANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY 11 WARRANTY INFORMATION Mercury RACING DIVISION 3 Year Limited Warranty Against Corrosion Failure Applicable Only to the United States Canada and Australia WHAT IS COVERED We warrant each new Mercury Mariner Mercury Racing Sport Jet M2 Jet Drive Tracker by Mercury Marine Outboard MerCruiser In board or sterndrive engine Product rendered inoperative as a di rect result of corrosion for the period of time described below 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 u
19. anual 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 obb1 Before Operating Your Outboard Read this manual carefully Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage If you have any questions contact your dealer This manual as well as safety labels posted on the outboard use safety alerts to draw your attention to special safety instructions that must be followed WARNING Hazards or unsafe practices which could result in severe personal injury or death CAUTION Hazards or unsafe practices which could result in minor injury or product or property damage 17 GENERAL INFORMATION gob12 U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX obc1 Boat Horsepower Capacity 1 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 Overpowering a Boat Can Cause e Serious injury death or boat damage e Loss of Boat Control e Flotation Characteristics of Boat to be
20. apan 283 1 Anshin cho 81 53 423 2500 81 53 423 2510 Hamamatsu Shizuoka 435 0005 Japan Asia Singapore Mercury Marine Singapore 65 546 6160 65 546 7789 72 Loyang Way Singapore 508762 85 CA752 Ordering Literature Before ordering literature please have the following information about your power package available Model Horsepower Serial Number Year 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 Telephone Fax Mercury Marine Attn Publications Department 920 929 5110 920 929 4894 P O Box 1939 Fond du Lac WI 54936 1939 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 86
21. ater pump indicator hole or flow is intermittent e Stop engine and check cooling water intake holes for obstruction e If no obstruction is found this may indicate a blockage in the cooling system or a water pump problem e Have the outboard checked by your dealer b If a steady stream of water is coming out of the water pump indicator hole and the warning horn continues to sound e There may be insufficient cooling water or an engine problem e Stop engine and have it checked by your dealer 41 FEATURES amp CONTROLS a Trim switch b 20 range of travel Power Trim And Tilt Outboard position can be adjusted by pressing trim switch This range is used while operating your boat on plane 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 trimming out or up The term trim e Generally refers to the adjustment of the outboard within the first 20 range of travel The term tilt e 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 42 osf1 FEATURES amp CONTROLS Power Trim Operation With most boats operating a
22. ater pump or overheating of the engine never start or run your outboard even momentarily without an adequate water supply to the engine 3 Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for ten minutes to allow treated fuel to fill the fuel system hid1 Protecting Internal Engine Components NOTE Before performing the following steps make sure the fuel system has been prepared for storage Refer to Fuel System 1 Remove the spark plugs and inject a five second spray of Storage Seal Rust Inhibitor around the inside of each cylinder 2 Rotate the flywheel manually several times to distribute the storage seal in the cylinders Reinstall spark plugs 3 Remove the water separating fuel filter and empty contents in a suitable container Refer to Maintenance Section for removal and installation of filter Replace fuel filter annually or every 100 Hours of operation or if large amount of fuel contamination is present 77 STORAGE Protecting External Outboard Components 1 Lubricate all outboard components listed in the Inspection and Maintenance Schedule Touch up any paint nicks See dealer for touch up paint Spray Corrosion Guard on external metal surfaces Do not apply on corrosion control anodes oie1 Gear Case 1 Drain and refill the gear case lubricant refer to maintenance procedure BATTERY STORAGE 1 Follow the battery manufacturers instr
23. atisfy the warranty obligation 15 WARRANTY INFORMATION Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products cont 6 9 Labor performed by other than an authorized dealer may be cov ered 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 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condi tion which could result in a failure condition responsible for noise should be corrected under the warranty Lower unit and or propeller damage caused by striking a sub merged object is considered a marine hazard 10 Water in the starter motor 11 Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commutator because of excess cranking 12 Valve or valve seat grinding required because of wear 16 GENERAL INFORMATION Boater s Responsibilities The boat driver is responsible for 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 m
24. aw is yee yee die de Exe eet Operating In Freezing Temperatures Operating In Salt Water Or Polluted Water Operating At High Elevations 000 cee eeee Setting Trim Angle While Running Engine at Idle Speed Operating in Shallow Water 00 cece eee eee Starting The Engine Xa kaong KABAITAN ee he ana Gear SNMING 2 oc cnn KALA se od BPs Rb la RRS NAG Stopping The Engine 0 0 c eee e eee eee TABLE OF CONTENTS Maintenance Outboard Care sce EA KENA an eta ang 54 Submerged Outboard nannaa aaa 54 Selecting Replacement Parts For Your Outboard 54 EPA Emissions Regulations 4 webm seba tae 55 Inspection And Maintenance Schedule 56 Flushing the Cooling System eee eee 58 Top Cowl Removal and Installation 59 Fuel System Sisk SANA DA cerns vad UNS bald KAMANG KANG 60 Steering Link Rod Fasteners a 62 Corrosion Control Anodes 4 doa maa Mana mn ear 64 Propeller Replacement in 65 Spark Plug Inspection 272 243 Mania aa KAG angan al ah 67 Battery Inspection a Ta ma aa Bala Ne ata NG 68 Lubrication Points 2 00 00 c eee eee ee 69 Checking Power Trim Fluid 00 eee eee 70 Gear Case Lubricant 0 oke mana mna naa 71 Maintenance Log Maintenance LOG esai Temu ERA SE Aa an 74 Storage Storage Preparation 4 ox Pana sand na aka 76 Positioning Out
25. board for Storage 76 Protecting Internal Engine Components 77 Gear CaSO ck tk Pelee A Re LAN ai ma aki a Biel Atte 78 TABLE OF CONTENTS Troubleshooting Starter Motor Will Not Crank the Engine 79 Engine Will Not Start oma sunnah ea nana 79 Engine Runs Erratically oo nana aon 80 Performance LOSS a a ka SIRA banana penengah ia 80 Battery Will Not Hold a Charge oo 81 Engine Overheating Continuous Horn Sound 81 Owner Service Assistance Local Repair Service ii 82 Service Away From Home Wa 82 Parts And Accessories Inquiries 82 Service Assistance 234000 anG Sear eneeses ANGAL 83 Mercury Marine Service Offices J 84 Ordering Literature Ordering Literature 20h ANG eek teh manga AG NANANA Bu BN NAA 3 86 WARRANTY INFORMATION Transfer Of Warranty The limited warranty is transferable to a subseguent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to products used for commercial applications DIRECT SALE BY OWNER The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Can ada mail to Mercury Marine W6250 W Pioneer Ro
26. boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power 19 GENERAL INFORMATION Lanyard Stop Switch Avoid serious injury or death from deceleration forces resulting from in accidental stop switch activation The boat operator should never leave the operator s station without first disconnecting the stop switch lanyard cord from themself Accidental or unintended activation of the Lanyard Stop Switch during normal operation is a possibility and could cause any or all of the following potentially hazardous situations e Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller e Loss of power and directional control in heavy seas strong cur rent or high winds e Loss of control when docking 20 GENERAL INFORMATION gob3 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 speed 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 even with the outboard in neutral position there is sufficient force by the water to rotate the propeller This neutral prop
27. d fly into the boat e The boat could move suddenly in a new direction Such a sharp change in direction or turn 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 even out of the boat e Impact damage to the outboard and or boat 25 GENERAL INFORMATION Impact With Underwater Hazards Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situations 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 the outboard 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 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 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
28. d an electrical interconnection be tween the warranted product and the paint Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances cov ered by this warranty and those that are not see the Warranty Cov erage section of the Operation and Maintenance Manual incorpo rated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT NESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DIS CLAIMED TO THE EXTENT THAT THEY CANNOT BE DIS CLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESSED WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EX CLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIM ERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WAR RANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY 14 WARRANTY INFORMATION Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The fol lowing 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
29. d to prepare your outboard for out of season storage or prolonged storage two months or longer Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of outboard If outboard is stored tilted up in freezing temperature water may enter the propeller exhaust outlet in the gear case and could freeze causing damage to the outboard oib11 FUEL SYSTEM IMPORTANT Gasoline containing alcohol ethanol or methanol can cause a formation of acid during storage and can damage the fuel system If the gasoline being used contains alcohol it is advisable to drain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system To prevent varnish or gum buildup during extended storage we recommend adding Fuel System Treatment and Stabilizer to the fuel tank and operation of the engine to introduce the additives to the system 76 STORAGE Fuel System 1 Portable Fuel Tank Pour the reguired amount of Fuel System Treatment and Stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel 2 Permanently Installed Fuel Tank Pour the required amount of Fuel System Treatment and Stabilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixture into fuel tank Prevent damage to the w
30. dy run ning 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 prod uct 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 pay ments 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 prod uct 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 affirma tion representation or warranty regarding the product other than those contained in this limited warranty and if made shall not be en forceable against Mercury Marine 10 WARRANTY INFORMATION Mercury RACING DIVISION One Year Limited Warranty For additional information regarding events and circumstances cov ered by this warranty and those that are not see the Warranty Cov erage section of the Operation
31. eled with an Emission Control Information de cal as permanent evidence of EPA certification The engine exhaust from this product contains chemi cals known to the state of California to cause cancer birth defects or other reproductive harm 90 848711041 503 2 5 EFI 2 5 EFI SS 2 5 EFI OS 2003 Mercury Marine Warranty Message The product you have purchased comes with a limited war ranty 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 to best ob tain warranty coverage important disclaimers and limita tions of damages and other related information Please re view this important information 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 Racing a unit of Mercury Marine the 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 has led to Mercury Racing 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
32. eller rotation can cause serious injury WHILE BOAT IS STATIONARY Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat 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 gear case or any solid device rigidly attached to a moving boat or gear case 21 GENERAL INFORMATION gob4 Courtesy of ABYC Carbon Monoxide Risk Avoid the combination of a running engine and poor ventila tion Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death Carbon monoxide is a deadly gas that is odorless colorless and tasteless and is present in the exhaust fumes of all internal combus tion engines Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizzi ness drowsiness and nausea SUFFICIENT FRESH AIR FLOW 1 Example of desired air flow through the boat a Ventilate passenger area open side curtains or forward hatches to remove carbon monoxide fumes 22 GENERAL INFORMATION gob39 Courtesy of ABYC obi3 Carbon Monoxide Risk INSUFFICIENT FRESH AIR FLOW Under certain conditions enclosed or canvas enclosed cabins or cockp
33. ene trate under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occupants flying forward The boat may also steer sharply to one side 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 any boat hand hold 24 GENERAL INFORMATION gob4 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you re driving a boat in shallow water areas or in areas where the waters are sus pected of having underwater obstacles that 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 float ing or underwater object is control the boat speed Under these conditions boat speed should be kept to a minimum planing speed 15 to 25 mph 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 e Part of the outboard or the entire outboard could break loose an
34. evel up to the FULL mark on the dipstick DO NOT OVERFILL 3 To purge system of air raise the outboard 2 or 3 times Recheck oil level and add oil if necessary 4 Reinstall fill vent screw by turning it all the way in then back it out one and a half 1 1 2 turns Fill Vent screw MUST BE backed out one and a half 1 1 2 turns after bottoming out to vent pump reservoir FAILURE TO BACK SCREW OUT COULD RESULT IN DAMAGE TO PUMP 70 MAINTENANCE a SportMaster gear case vertical operating position b Vent hole c Vent plug and sealing washer d Fill Drain hole e Fill Drain plug Tube Reference Description Where Used Number geo Hirerformance Gear FilyDrain Hole Gear Case Lubricant Water in gear lubricant may e Settle to bottom and drain out with the lubricant e Be mixed with lubricant giving a milky color to lubricant Water in gear lubricant will e Result in premature bearing failure e In freezing temperatures turn to ice and damage gearcase 71 MAINTENANCE Gear Case Lubricant 1 Checking Gear Case Lubricant Refilling Gear Case a Place the outboard in a vertical operating position b Remove the vent plug upper plug and sealing washer c Remove the fill drain plug lower plug 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 large
35. guipped with nonconductive terminal shields to prevent accidental shorting of battery terminals 68 MAINTENANCE Lubrication Points Tube Reference Description Where Used Number fea fea Anti Corrosion Grease Corrosion Grease Prop Shaft Splines Shaft Splines 2 4 iso Marine Lubricant SS Link Rod with Teflon Grease Fittings Light Weight Engine Oil Swivel Bracket Grease Obtain Locally Fittings NOTE Propeller Shaft Refer to Propeller Replacement for removal and installation The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant thru grease fitting Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked An hydraulically locked steering cable could cause loss of steering control possibly resulting in serious injury or death MAINTENANCE a Trim pump fillvent screw b FULL level c ADD oil level Checking Power Trim Fluid 1 Place outboard in the full down in position 2 Remove trim pump fill vent screw e Wipe fill vent screw with a clean lint free cloth and reinstall DO NOT THREAD INTO PUMP e Remove fill vent screw and note oil level Oil level must be be tween the ADD and FULL marks on dipstick e If necessary add Power Trim amp Steering Fluid or SAE 10W 30 or 10W 40 motor oil through the fillvent screw hole to bring l
36. ilted by the following procedures The engine must be supported during lowering in the follow ing steps or the engine may drop rapidly and personal injury as well as damage to the engine could occur NOTE Place a suitable container below the connection and wrap the connection with a cloth to collect any fluid which may be dis pelled during the following operations 1 TILTING DOWN IN e Loosen the starboard right facing engine from front hydraulic connection at the front of the swivel bracket e Slowly lower the engine to the desired position and reconnect the hydraulic connection 2 TILTING UP OUT e Loosen the port left facing engine from front hydraulic connec tion at the front of the swivel bracket e Slowly lift the engine and engage the tilt lock lever Reconnect the hydraulic connection IMPORTANT If the hydraulic lines are disconnected and fluid is lost the power trim pump must be refilled and the lines purged of air 46 OPERATION Engine Break in 2 5 EFI SS And Offshore Severe damage to the engine can result by not complying with the Engine Break in Procedure During Break in mix oil and gasoline at a 40 1 ratio 2 5 e AVOID REMAINING AT A CONSTANT SPEED FOR MORE THAN 2 MINUTES e AVOID SUSTAINED IDLE OR RUNNING BELOW 1500 RPM fisthour Do not exceed 1 2 throttle or 3500 RPM 2nd hour Do not exceed 4500 RPM Do not operate at wide open throttle for more than 2 minutes Gas
37. ing the control handle and increase engine idle speed without shifting outboard into gear 39 FEATURES amp CONTROLS a Horn located inside the remote control b Horn connected to the ignition switch Warning Horn System 1 A warning horn may be located inside the remote control or under the dash connected to the ignition key switch 2 When the ignition key is initially turned on the warning horn will sound for a moment as a test to tell you the system is working Failure of this test indicates a problem Have the outboard checked by your dealer The warning horn will emit a continuous beep to alert the operator that the engine is above normal operating temperature over heated NOTE If you are in a stranded situation stopping the engine and allowing it to cool down will usually allow some additional low speed idle running time before the engine starts to overheat again IMPORTANT The overheat problem must be corrected before you can resume normal operation 40 FEATURES amp CONTROLS a Water pump indicator hole Warning Horn System 3 If the engine overheats immediately reduce throttle speed to idle Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole Operating the engine while overheated will cause engine damage The overheat problem must be corrected before you can resume normal operation a If no water is coming out of the w
38. its with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although rare on a very calm day swimmers and passengers in an open stationary boat with a running engine or near a running engine may be exposed to a hazardous level of carbon monoxide Insufficient Air Flow Could Occur If 2 While boat is stationary a Boat moored in a confined space with the engine running b Boat is moored close to another boat with its engine running 3 While boat is moving a Running the boat with the trim angle of the bow too high b Running the boat with no forward hatches open station wagon effect 23 ob GENERAL INFORMATION gob4 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating However when this activity is done with speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water 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 violently veer in a new direction Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat 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 p
39. nder this war ranty does not extend the life of this warranty beyond its original ex piration date Unexpired warranty coverage can be transferred to subsequent noncommercial use purchaser upon proper re regis tration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that pur chase 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 avail able upon proper registration of the product by the authorized deal er Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine main tenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Ma rine reserves the right to make warranty coverage contingent upon proof of proper maintenance 12 WARRANTY INFORMATION Mercury RACING DIVISION 3 Year Limited Warranty Against Corrosion Failure 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 wi
40. ne Routine maintenance outlined in the Operation and Mainte nance Manual must be timely performed in order to maintain warran ty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WARRANTY INFORMATION Mercury RACING DIVISION One Year Limited Warranty 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 re serves the right to improve or modify products from time to time with out assuming an obligation to modify products previously manufac tured 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 inspec tion to a Mercury dealer authorized to service the product If pur chaser 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 re lated transportation charges and or travel time If the service pro vided is not covered by this warranty purchaser shall pay for all re lated labor and material and any other expenses associated wi
41. ng information will be needed by the service office Your name and address Daytime telephone number Model and serial number of your outboard The name and address of your dealership Nature of problem Mercury Marine Service Offices are listed on the next pages 83 OWNER SERVICE ASSISTANCE Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax correspondence Telephone Fax United States Mercury Marine W6250 W Pioneer Road 920 929 5040 920 929 5893 PO Box 1939 Fond du Lac WI 54936 1939 United States Mercury Racing Mercury Racing 920 924 2088 920 924 2096 N7480 County Rd UU Fond du Lac WI 54935 9585 Canada Mercury Marine Ltd 905 567 6372 905 567 8515 2295 Meadowpine Blvd Mississauga Ontario Canada L5N 7W6 Australia Pacific Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Europe Middle East Africa Marine Power Europe Inc Parc Industriel de Petit Rechain 32 87 32 3211 32 87 31 1965 B 4800 Verviers Belgium Mexico Central America South America Caribbean Mercury Marine Latin America amp Caribbean 305 385 9585 305 385 5507 9010 S W 137th Ave Suite 226 Miami FL 33186 U S A 61 3 9791 5822 61 3 9793 5880 84 OWNER SERVICE ASSISTANCE ord Mercury Marine Service Offices cont Telephone Japan Mercury Marine J
42. nspect battery Check corrosion control anodes Check tightness of bolts nuts and other fasteners including powerhead and gearcase fasteners Check power trim fluid Remove engine deposits with Mercury Marine Power Tune Engine Cleaner Replace Water separating fuel filter Replace final fuel filter element These items should be serviced by a authorized dealer BEFORE PERIODS OF STORAGE 1 Refer to Storage procedure 57 MAINTENANCE NG Flushing the Cooling System To avoid possible injury when flushing remove the propeller Refer to Propeller Replacement 1 2 en Remove propeller refer to Propeller Replacement Install the flushing attachment to fit tightly over the cooling water intake Attach a water hose to the flushing attachment Turn on the water and adjust the flow so water is leaking around the flushing attachment to ensure the engine receives an adeguate supply of cooling water Start the engine and run it at idle speed in neutral shift position Adjust water flow so excess water continues leaking out from around the flushing attachment to ensure the engine is receiving an adequate supply of cooling water Check for a steady stream of water flowing out of the water pump indicator hoses Continue flushing the outboard for 3 to 5 minutes carefully monitoring water supply at all times Stop the engine turn off the water and remove the flushing attachment Rein
43. 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 36 oe FUEL amp OIL FUEL CONTAINING ALCOHOL MAY INCREASE Corrosion of metal parts Deterioration of rubber or plastic parts Fuel permeation through rubber fuel lines e e e e Starting and operating difficulties When operating a Mercury engine with fuel containing alcohol avoid storing the fuel in the fuel tank for long periods Long storage periods common to boats create unique problems In cars alcohol blend fuels are normally con sumed before they can absorb enough moisture to cause trouble but 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 components IMPORTANT Because of possible adverse effec
44. oline Recommendation Refer to the Fuel and Oil section Oil Recommendation Use 2 Cycle Performance Blend Outboard Oil 47 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 _ Remote control in Neutral _ Top cowl latches secure Make inspection checks listed in the Inspection and Maintenance Schedule Refer to Maintenance Section onf2 Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperature keep the outboard tilted down at all times so the gear case is submerged This prevents trapped water in gear case 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 drive shaft housing it will block water flow to the engine causing possible damage 48 OPERATION Operating In Salt Water Or Polluted Water We recommend flushing the internal water passages of your outboard with fresh water after each use in salt or polluted water to prevent a buildup of deposits from clogging the water passages Refer to Flushing The Cooling System procedure in the
45. ot attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel 1 The trim in limit may be set by inserting the tilt pin into the desired transom bracket hole Trimming OUT UP can Lift the bow higher out of the water Generally increase top speed Gain clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a normal installation height with the normal right hand rotation propeller In excess cause boat porpoising bouncing or propeller ventilation Cause engine overheating if any cooling water intake holes are above the water line 44 FEATURES amp CONTROLS Tilting Operation To tilt outboard shut off the engine and press the trim tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Push in on the tilt support release knob 2 Move tilt support lever into locking position and lower 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 up until it locks Lower the outboard 45 FEATURES amp CONTROLS Manual Tilting If the outboard cannot be tilted using the power trim tilt switch the outboard can be manually t
46. out 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 in 5 seconds will overtake a fallen skier who was 61 m 200 ft in front of you 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 val ue exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement 28 GENERAL INFORMATION Recording Serial Number Serial Number OGXXXXXX Record the following numbers from your engine as shown for future reference a Serial Number b Model Year c Model Designation d Year Manufactured e Certified Europe Insignia 29 GENERAL INFORMATION Specifications GENERAL mover Jesemenss Eros 182 kg 400 1 Piston Displacement 2507 cc 153 cu in 89 mm 3 50 in Recommended Spark Plug Champion QL77CC Firing Order 1 2 3 4 5 6
47. per service corrosion to accesso ries instruments steering systems corrosion to factory installed jet drive unit damage due to marine growth product sold with less than a one year limited Product warranty replacement parts parts pur chased 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 occa sionally used for such purposes 13 WARRANTY INFORMATION Mercury RACING DIVISION 3 Year Limited Warranty Against Corrosion Failure 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 anti fouling paints are recommended on Outboard and MerCruiser boating applications In areas where TBTA base paints are prohib ited by law copper base paints can be used on the hull and transom Do not apply paint to the outboard or MerCruiser product In addi tion care must be taken to avoi
48. r particles chips should be checked by an authorized dealer d Quickly place lubricant tube into the fill hole e Slowly add lubricant until it flows from the upper vent hole IMPORTANT Replace sealing washers if damaged f Stop adding lubricant Install the upper vent plug and seal ing washer before removing the lubricant tube g Remove lubricant tube and reinstall cleaned lower fill drain plug and sealing washer 72 MAINTENANCE a SportMaster gear case vertical operating position b Vent plug and sealing ring c Fill Drain plug and sealing ring d Drain pan Gear Case Lubricant 1 Draining Gear Case a b c d ohv8 Place the outboard in a vertical operating position Place a drain pan below outboard Remove the vent plug upper plug and sealing ring Remove the fill drain plug lower plug and sealing ring and drain lubricant GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is approximately 666 ml 22 5 fl oz 13 ok MAINTENANCE LOG Record here all maintenance performed on your outboard Be sure to save all work orders and receipts Date Maintenance Performed engine 74 MAINTENANCE LOG Date Maintenance Performed Dano 75 oi STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust corrosion and freezing water damage The following storage procedures should be followe
49. r s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identifica tion and should be retained by you for future use when reguired Should you ever reguire warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to pre pare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registra tion Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty IMPORTANT Registration lists must be maintained by the fac tory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be neces sary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the fac tory copy to the Marine Power
50. racket assembly c Two bars one in each side of the driveshaft housing above the anti ventilation plate 64 oh MAINTENANCE goh112 Propeller Replacement If the propeller is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this accidental engine starting and possible serious injury caused from being struck by a rotating propeller always shift outboard to neutral position and remove spark plug leads before you service the propeller 1 Shift outboard to neutral N position 2 Remove spark plug leads to prevent engine from starting 3 Place a block of wood between gear case and propeller to hold propeller and remove propeller nut 4 If propeller is seized to the shaft and cannot be removed consult an authorized dealer 65 oh MAINTENANCE p KE ala a Prop hub assembly b Propeller c Washer d Belleville washer e Washer f Propeller nut Tube Reference Description Where Used Number Anti Corrosion Grease Prop Shaft Propeller Replacement 5 Coat the propeller shaft with Mercury Precision Anti Corrosion Grease 66 MAINTENANCE Propeller Replacement IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propel ler
51. rom 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 Outside the United States and Canada contact the nearest Marine Power International Service Center or7 Parts And Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer The dealer 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 82 OWNER SERVICE ASSISTANCE Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem guestion or concern about your outboard product contact your dealer or any Authorized Mercury Marine Dealership If additional assistance is reguired take these steps i Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealer WC Ship 2 Should you have a guestion concern or problem that cannot be resolved by your eR dealership please contact Mercury Marine Balang S Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The followi
52. round 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 out board 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 DOWN Can Lower the bow of the boat Result in quicker planing off Generally improve the ride in choppy water Increase steering torque or pull to the right with the normal right hand rotation propeller In excess lower 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 43 a Tilt pin osf1 Power Trim Operation 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 n
53. side supports of the swivel bracket b Tilt outboard up Make sure all the cooling water intake holes stay submerged at all times 50 OPERATION Starting The Engine Before starting read the Pre Starting Check List Special Operating Instructions in the Operation Section Never start or run your outboard even momentarily without water circulating through all the cooling water intake holes in the gear case to prevent damage to the water pump running dry or overheating of the engine 1 Lower the outboard to the run position Make sure all the cooling water intake holes are submerged 2 Open fuel tank filler cap vent screw manual venting fuel tanks 3 Set the lanyard stop switch to RUN position Read the Lanyard Stop Switch safety explanation and Warning in the General Information Section 4 Shift outboard to the Neutral position 51 OPERATION a Fast idle speed lever b Throttle lever Starting The Engine 5 Turn the ignition key to START Release the key when engine starts If engine fails to start in 10 seconds return the key to ON position wait 30 seconds and try again 6 Starting Flooded Engine Raise the fast idle speed lever or push in throttle only button and advance throttle lever to the maximum position Crank engine for 10 seconds Wait 30 seconds and repeat if reguired Immediately reduce engine speed after engine starts After starting keep engine speed below 250
54. stall the propeller 58 oh MAINTENANCE a Rear latch b Front latch c Cowl Top Cowl Removal and Installation Avoid Serious Injury or Death Do Not attempt to remove or install cowl while engine is running 1 Removal a Rotate rear latching handle clockwise b Pull out on front latching handle and at the same time lift front of cowl c Lift cowl from engine 2 Installation a Lower top cowl into position over engine b Rotate the rear latch counterclockwise to secure the rear cowl latch c Pull out on front latching handle and push down on the front of the cowl to engage the front latch 59 oh MAINTENANCE Fuel System 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 Before servicing any part of the fuel system e Stop engine and disconnect the battery e Drain the fuel system completely e Fuel system service must be performed in a well ventilated area e Inspect any completed service work for sign of fuel leakage 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 FUEL LINE INSPECTION Visually inspect the fuel line for cracks swelling leaks hardness
55. tboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered This immediate attention is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine Selecting Replacement Parts For Your Outboard We recommend using original Mercury Marine replacement parts and Lubricants Using a replacement part that is inferior to the original part could result in personal injury death or product failure 54 oh MAINTENANCE EPA Emissions Regulations Outboards manufactured by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the reguirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the factory procedure for servicing the product must be strictly followed and wherever practicable returned to the original intent of the design Maintenance replacement or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual Engines are labeled with an Emission Control Information decal as permanent evidence of EPA certification 55 oh In MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE 1 Check that lanyard stop switch stops the engine Visu
56. terways 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 Hot line 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT 27 GENERAL INFORMATION Safe Boating Suggestions Make sure everyone in the boat is properly seated Don t allow anyone to Sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat anywhere that sudden 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 They impair your judgment and greatly reduce your ability to react guickly Prepare other boat operators Instruct at least one person on board in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard 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 look
57. th that service Purchaser shall not unless reguested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is reguested in order to obtain coverage WARRANTY INFORMATION Mercury RACING DIVISION One Year Limited Warranty 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 the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended opera tion duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installation proper instal lation 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 see the Operation and Maintenance Manual alteration or removal of parts water entering the engine through the fuel intake air intake or ex haust system or damage to the product from insufficient cooling wa ter caused by blockage of the cooling system by a foreign bo
58. th new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury re serves the right to improve or modify products from time to time with out assuming an obligation to modify products previously manufac tured 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 inspec tion to a Mercury dealer authorized to service the product If pur chaser 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 re lated transportation charges and or travel time If the service pro vided is not covered by this warranty purchaser shall pay for all re lated 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 The warranty registration card is the only valid registration identification and 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 impro
59. tic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will attach it to your warranty claim form Because of your selling dealer s continuing personal interest in your Satisfaction the product should be returned to him for war ranty service If your plastic card is not received within 30 days from date of new product sale please contact your selling dealer The product warranty is not effective until the product is regis tered at the factory NOTE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notification un der the Federal Boat Safety Act be required ou2 WARRANTY INFORMATION Warranty Registration OUTSIDE THE UNITED STATES AND CANADA 1 It is important that your selling dealer fills out the Warranty Regis tration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warran ty registration claim program for your area The Warranty Registration Card identifies your name and ad dress product model and serial number s date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product A copy of the Warranty Registration Card designated as the Purchase
60. ting rpm range will cause higher than normal wear and or damage Generally there is a 200 300 rpm change between propeller pitches Rpm loss may require a change to a lower pitch propeller due to the following conditions Warmer weather and greater humidity Operating in a higher elevation Operating with a damaged propeller or dirty boat bottom Operating with increased load additional passengers pulling skiers etc 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 33 TRANSPORTING Trailering Boat Outboard 1 Trailer your boat with the outboard tilted down when ever possible vertical operating position 2 If additional ground clearance is reguired for railroad crossings driveways or trailer bouncing support the outboard using a support device Contact your local dealer for recommendations IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailer ing The outboard tilt support lever is not intended to support the outboard for trailering To prevent the propeller from spinning freely shift into forward gear 34 oe FUEL amp OIL Fuel Requirements Use of improper fuel can seriously damage your engine Engine damage resulting from use of improper fuel is considered misuse of the
61. tructed Water separating filter or In Line filter clogged Stuck anti siphon valve on built in fuel tank Fuel line is kinked or pinched OP Oh ae ee Reed valve open or broken e Fuel pump failure e Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not opening fully Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed Excessive waiter in bilge Boat bottom is dirty or damaged 80 TROUBLESHOOTING Battery Will Not Hold a Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Inefficient battery Excessive use of electrical accessories Defective alternator or voltage regulator Engine Overheating Continuous Horn Sound POSSIBLE CAUSES Cooling system clogged Engine overloaded cannot attain recommended RPM Incorrect ignition timing Incorrect transom height water pickups not getting adeguate water supply Not enough oil in fuel mixture Lean fuel mixture 81 OWNER SERVICE ASSISTANCE 0r6 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 and eguipment and the 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 f
62. ts 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 Use Mercury Precision 2 Cycle Performance Blend Oil Emergency Use Only If Mercury Precision 2 Cycle Performance Blend Oil is not available Mercury Precision Premium Plus 2 Cycle TC W3 Outboard Oil may be substituted This oil should not be used on a regular basis Periodically consult with your dealer to get the latest gasoline and oil recommendations If Mercury Precision 2 Cycle TC W3 Outboard Oil is not available substitute a 2 Cycle outboard manufacturers oil that is NUMA Certified TC W3 or 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 37 FUEL amp OIL Gasoline Oil Mixture Use a 40 1 2 5 gasoline oil mixture in your fuel tank GASOLINE OIL MIXING RATIO CHART Fuel to Oil Mixing This Much Fuel Requires This Ratio Much Oil 3 81 1 U S gal 95 ml 3 2 fl oz 11 51 3 U S gal 283 ml 9 6 fl oz 23 6 U S gal 566 mi 19 2 fl oz Filling Gasoline Tank Avoid serious injury or death from a gasoline fire or explosion Always stop the engine and DO
63. uctions for storage and recharging 2 Remove the battery from the boat and check water level Recharge if necessary 3 Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage 78 TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES Blown 20 Amp fuse in the starting circuit Refer to Maintenance Section Outboard is not shifted to neutral position Weak battery or battery connections are loose or corroded Ignition key switch failure Wiring or electrical connection faulty Starter motor or starter solenoid failure Engine Will Not Start POSSIBLE CAUSES Lanyard stop switch not in RUN position Incorrect starting procedure Refer to Operating Section Old or contaminated gasoline Engine flooded Refer to Operating Section Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Maintenance Section Ka Bay ees NO ra Fuel pump failure 6 Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance Section 79 TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES e Spark plugs fouled or defective Refer to Maintenance Section e Incorrect setup and adjustments e Fuel is being restricted to the engine Fuel injectors obstructed Fuel tank filter obs

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