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i If the outboard motor`s serial number plate contains the CE mark in

1. DLE SPEED in gear FAMILY cc FEL TIMING IN DEGREES SPARK PLUG COLD VALVE INTAKE CLEARANCE mm EXHAUST 0b00366 a Idle speed f Family number b Engine horsepower g Maximum emission output c Piston displacement for the engine family d Date of manufacture h Timing specification e Valve clearance if i Recommended spark plug applicable and gap 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 BEFORE EACH USE e Check engine oil level See Fuel amp Oil Checking and Adding Engine Oil e Check that lanyard stop switch stops the engine e Visually inspect the fuel system for deterioration or leaks e Check outboard for tightness on transom e Check steering system for binding or loose components 66 MAINTENANCE Visually check steering link rod fasteners for proper tightness See Steering Link Rod Fasteners Check propeller blades for damage AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of
2. 0b00436 CHANGING OIL FILTER 1 Place a rag or towel below the oil filter to absorb any spilled oil 2 Unscrew old filter by turning the filter to the left 3 Clean the mounting base Apply film of clean oil to filter gasket Do not use grease Screw new filter on until gasket contacts base then tighten 3 4 to 1 turn 0b00437 OIL FILLING 1 Remove the oil fill cap and add oil to proper operating level 85 MAINTENANCE 2 Idle engine for five minutes and check for leaks Stop engine and check oil level on dipstick Add oil if necessary ob00651 a Oil fill cap Gearcase Lubrication For 87 3 mm 3 7 16 in Diameter Gearcase When adding or changing gearcase lubricant visually check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount of fine metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEARCASE 1 Place outboa
3. 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 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 wit
4. a SmartCraft data bus circuit 15 AMP fuse b Fuel pump idle air control fuel injector circuits SFE 20 AMP fuse c Main relay accessories 20 AMP fuse d Ignition coil circuit 20 AMP fuse e Spare 20 AMP fuse f Good fuse g Blown fuse Timing Belt Inspection 1 Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found a b C d Cracks in the back of the belt or in the base of the belt teeth Excessive wear at the roots of the cogs Rubber portion swollen by oil Belt surfaces roughened 81 MAINTENANCE e Signs of wear on edges or outer surfaces of belt i XQ el i aS Sie 0b00427 Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon e Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 0b00378 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 e Tilt Support Lever Lubricate through fitting 82 MAINTENANCE e Swivel Bracket Lubricate through fitting 0b00429 a Tilt support lever b Swivel bracket e Tilt Tube Lubricate through fitting 0b00428 The end of the s
5. 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 Coverage And Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The following information explains some of the types of services that are not covered by warranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure the International Limited Outboard Warranty and the United States and Canada Limited Outboard Warranty 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 when the consumer sale is made in the country to which distribution is authorized by us 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 chec
6. 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 and fly into the boat 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 impact 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 26 GENERAL INFORMATION 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 r
7. 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 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 WARRANTY INFORMATION 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
8. close to another boat that has its engine running 28 GENERAL INFORMATION WHILE BOAT IS MOVING 0b00318 a Running the boat with the trim angle of the bow too high b Running the boat with no forward hatches open 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 installation of accessories The misuse of acceptable accessories or the use of unacceptable accessories can result in serious injury death or product failure 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 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 Perfor
9. how to 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 2004 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 12 month service CSI Customer Satisfaction Index score above the national average e Possesses all necessary service tools test equ
10. is important to record this number for future reference The serial number is located on the outboard as shown Serial Number OTXXXXXX 0b00319 a Serial number d Year manufactured b Model year e Certified Europe Insignia as c Model designation applicable 40 50 60 4 Stroke Specifications 31 GENERAL INFORMATION ne 1 ee ae e Cylinder Bore 65 mm 2 559 in Valve Clearance Cold Intake Valve 0 15 0 25mm 0 006 0 010 in Exhaust Valve 0 25 0 35mm 0 010 0 014 in oe Spark Champion RASHC Spark Plug Gap 1 0mm 0 040 in Gear Ratio 83mm 3 1 4 in 1 83 1 Diameter Gearcase 108mm 4 1 4 in 2 31 1 or 2 33 1 Diameter Gearcase Recommended Refer to Fuel amp Oil Gasoline Recommended Oil Refer to Fuel amp Oil Gearcase Lubricant Capacity 83mm 3 1 4 in 340 ml 11 5 fl oz Diameter Gearcase 108mm 4 1 4 in 710 ml 24 0 fl oz Diameter Gearcase Engine Oil Capacity 3 0 Liter 3 Quarts Battery Rating Operation Above 465 Marine Cranking Amps MCA or 350 0 C 32 F Cold Cranking AMPS CCA Operation Below 1000 Marine Cranking Amps MCA or 750 0 C 32 F Cold Cranking AMPS CCA Ampere Hours Ah 70 100 32 GENERAL INFORMATION Component Identification ob00647 a Auxiliary tilt switch i Water pump indicator hole b Tilt support knob j Bottom cowl c Transom brackets k Top cowl d Primary cooling water l Shift handle intake m Engine st
11. of time run it at full throttle for approximately one minute every ten minutes 3 For the next eight hours of operation avoid continuous operation at full throttle for more than five minutes at a time Starting The Engine Remote Control Models Before starting read the Pre Starting Check List Special Operating Instructions and Engine Break in Procedure in the Operation section NOTE EFI models Engine must have a fully charged battery to start the engine 56 OPERATION 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 Open fuel tank vent screw in filler cap on manual venting type fuel tanks 0b00349 3 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch ob00350 Shift outboard to neutral N position gt N 0b00351 57 OPERATION 5 Move the neutral fast idle speed feature to the fully closed position 0b00353 a Fully closed position b Maximum fast idle speed position 6 Starting Flooded Engine Advance the neutral fast idle speed feature to the maximum fast idle speed position and continue to crank the engine for starting Immediately reduce engine speed after engine starts 7 Turn ignition key to the start position If eng
12. on the propeller nut retainer Secure propeller nut by bending tabs up and against the flats on the propeller nut 0b00381 a Pins b Tabs 11 Reinstall spark plug leads Propeller Replacement 108 mm 4 1 4 in Diameter Gearcase If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of 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 when you are servicing the propeller 1 Shift outboard to neutral N position 0b00363 76 MAINTENANCE Remove spark plug leads to prevent engine from starting Daa 0b00375 Straighten the bent tabs on the propeller nut retainer 0b00376 Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 0b00377 6 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon 0b00378 77 MAINTENANCE 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 e
13. person aboard and readily accessible it is the law e A ring type life buoy or buoyant cushion designed to be thrown to a person in the water e Know your boats maximum load capacity Look at the boat capacity plate e Fuel supply OK e Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat e Tell someone where you are going and when you expect to return e Itis illegal to operate a boat while under the influence of alcohol or drugs e Know the waters and area you will be boating tides currents sand bars rocks and other hazards e Make inspection checks listed in Maintenance Inspection and Maintenance Schedule 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 wate
14. pressure is noted 1 These items should be serviced by an authorized dealer 67 MAINTENANCE BEFORE PERIODS OF STORAGE e Refer to Storage procedure See Storage section Flushing The Cooling System Flush the internal water passages of the outboard 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 IMPORTANT The engine must be run during flushing in order to open the thermostat and circulate water through the water passages To avoid possible injury when flushing remove the propeller Refer to Propeller Replacement following 1 Place the outboard in either the operating position vertical or in a tilted position 2 Remove propeller Refer to Propeller Replacement 3 Thread a water hose into the rear fitting Partially open the water tap 1 2 maximum Do not open the water tap all the way as this allows a high pressure flow of water IMPORTANT Do not run engine above idle when flushing 4 Shift outboard into neutral Start the engine and flush the cooling system for at least 5 minutes Keep engine speed at idle 5 Stop the engine Turn off the water and remove hose Reinstall the propeller ob00367 68 MAINTENANCE Top Cowl Removal And Installation REMOVAL 1 2 Unlock the rear latch by pushing lever down 7 y ob00368 Lift rear of cowl and disengage fron
15. reduce any unequal steering effort a Cea NOTE Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 50 mm 2 in or more above the boat bottom 52 FEATURES amp CONTROLS MODELS WITHOUT POWER TRIM Operate your boat at normal cruising speed trimmed to desired position by installing the tilt pin in the desired tilt pin hole Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right move the trailing edge of trim tab to the right Retighten bolt and retest MODELS WITH POWER TRIM Operate your boat at normal cruising speed trimmed to desired position Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right move the trailing edge of trim tab to the right Retighten bolt and retest 53 OPERATION Pre Starting Check List e Operator knows safe navigation boating and operating procedures e An approved personal flotation device of suitable size for each
16. shift positions to provide operation Forward F Neutral out of gear and Reverse R o0b00358 61 OPERATION Remote Control Models When shifting always stop at neutral position and allow the engine speed to return to idle o0b00308 Tiller Handle Models Reduce engine speed to idle before shifting ob00359 Always shift outboard into gear with a quick motion After shifting outboard into gear advance the remote control lever or rotate the throttle grip tiller handle to increase speed Stopping The Engine 1 Remote Control Models Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position OFF ob00360 Tiller Handle Models Reduce engine speed and shift outboard to neutral position Push in the engine stop button or turn ignition key to OFF position o0b00361 Emergency Starting If the starter system fails use the spare starter rope provided and follow procedure 62 OPERATION NOTE EFI models Engine must have a fully charged battery to start the engine 1 Remove flywheel cover or manual starter assembly ob00362 2 Shift outboard to neutral N position gt N gt Nm 0b00363 When using emergency starter rope to start engine the start in gear protection device is inoperative Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear Sudden unexpected acceleration co
17. small amount of fine metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEARCASE 1 Place outboard in a vertical operating position 2 Place a drain pan below outboard 3 Remove vent plugs and fill drain plug and drain lubricant zis l 0b00441 a Vent plugs b Fill drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml 24 fl oz CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug 3 Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole At this time install the front vent plug and sealing washer 4 Continue adding lubricant until it appears at the rear vent hole 88 MAINTENANCE 5 Stop adding lubricant Install the rear vent plug and sealing washer before removing lubricant tube 6 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer 0b00442 a Front vent plug d Rear vent plug b Front vent hole e Fill drain plug and sealing c Rear vent hole washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the
18. the propeller and gearcase with fresh water if operating in salt water EVERY 100 HOURS OF USE OR ONCE YEARLY WHICHEVER OCCURS FIRST Lubricate all lubrication points Lubricate more frequently when used in salt water See Lubrication Points Change engine oil and replace the oil filter The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling See Changing Engine Oil Replace spark plugs at first 100 hours or first year After that inspect spark plugs every 100 hours or once yearly Replace spark plugs as needed See Spark Plug Inspection and Replacement Inspect thermostat visually for corrosion and broken spring Make sure thermostat closes completely at room temperature Check engine fuel filter for contaminants See Fuel System Check engine timing setup Check corrosion control anodes Check more frequently when used in salt water See Corrosion Control Anodes Drain and replace gear case lubricant See Gearcase Lubrication Lubricate splines on the drive shaft Check and adjust valve clearance if necessary Check power trim fluid See Checking Power Trim Fluid Inspect battery See Battery Inspection Check control cable adjustments Inspect timing belt See Timing Belt Inspection Check tightness of bolts nuts and other fasteners EVERY 300 HOURS OF USE OR THREE YEARS Replace water pump impeller more often if overheating occurs or reduced water
19. the lever down Lower the outboard 0b00336 a Tilt support lever b Knob MANUAL TILTING If the outboard cannot be tilted using the power trim tilt switch the outboard can be manually tilted 1 Turn out the manual tilt release valve 3 turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 0b00339 NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation 49 FEATURES amp CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system 0b00340 a Auxiliary tilt switch SHALLOW WATER OPERATION When operating the boat in shallow water the outboard can be tilted beyond the maximum trim range to prevent hitting bottom E lt 2 ob00334 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range 50 FEATURES amp CONTROLS Throttle Grip Friction Adjustment Tiller Handle Models Throttle Grip Friction Knob Turn friction knob to set and maintain the throttle at desired speed Turn knob clockwise to tighten friction and t
20. 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 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 occupants flying forward The boat may also steer sharply to one side 25 GENERAL INFORMATION 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 24 to 40 km h 15 to 25 MPH Poe lt M a a ST 0b00315 To avoid serious injury or death from all or part of an outboard coming into the
21. 160 Mercury Marine Singapore 72 Loyang Way Fax 5467789 Singapore 508762 96 MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts 97
22. 6 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 part number 90 848481 from your dealer distributor or Mercury Marine a ob00307 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 19 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 TI 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 o0b00308 Disengagement of a steering link rod can result in the boat taki
23. F 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 If you have any questions regarding your warranty rights and responsibilities you should contact Mercury Marine at 1 920 929 5040 14 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 igni
24. ION 4 Shift outboard to neutral N position gt N lt o0b00355 o0b00356 a Start position b Half way position 6 Starting Flooded Engine Set the throttle grip to half way position 7 Turn ignition key to the start position If engine fails to start in ten seconds return key to on position wait 30 seconds and try again OFF 0b00354 RAPID ACCELERATION HAZARD Before shifting your outboard from neutral into gear decrease engine speed to slow This will prevent a rapid acceleration that can cause people in the boat to be thrown from their seats or out of the boat causing injury or death 60 OPERATION 8 Check for a steady stream of water flowing out of the water pump indicator hole 4 0b00331 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated may cause serious engine damage WARMING UP ENGINE Before beginning operation allow the engine to warm up at idling speed for 3 minutes Gear Shifting IMPORTANT Observe the following e Never shift outboard into gear unless engine speed is at idle e Do not shift outboard into reverse when the engine is not running e Your outboard has three gear
25. 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 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 fe EN 50082 1 IEC 61000 PT4 2 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 40 50 60 4 Stroke 90 10223050 204 2004 Mercury Marine 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 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 r
26. LOW 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 3 Year Limited Warranty Against Corrosion WHAT IS COVERED Mercury Marine warrants that each new Mercury Mariner Mercury Racing Sport Jet M2 Jet Drive Tracker by Mercury Marine Outboard MerCruiser Inboard or sterndrive engine Product will not be rendered inoperative as a direct 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 under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to subsequent noncommercial use 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 Marine specified pre delivery inspect
27. N 89 STORAGE Storage Preparation sa aora a Kaa edited 90 Protecting External Outboard Components eeeeeeseeeeeeseeeereeeeerrseeree 91 Protecting Internal Engine Component sseeeeeeesseereseerrrsseeerreseeeres 91 GOArCASC E E elededlug ede ceeci eed eel E aneddees eat 91 Positioning Outboard For Storage cccceeeeeeeeeeeeeeeeeeeeeeseeeseeeeesenaaes 91 Battery Storag s issi iwidan dedi chain aasad daraa a aiai 91 TROUBLESHOOTING Starter Motor Will Not Crank The Engine Electric Start Models 92 Engine Will Not Start iaseran e a r raa A ATN 92 Engine Runs Erratically aaeseeaaeneisicesinnnerirrennririieneeiiasdennnnedatannnanenan 92 Performance LOSE raa oa E EEA AAA 93 Battery Will Not Hold Charge ssssesesssrsserrrecesrnessrnneerrnnesennnnedrnnnaseennnns 93 OWNER SERVICE ASSISTANCE Local Repair Service cccccccececeeeeceeeeeeceeeeeeeeaneeceeeeseeeeaeeeeeteeeeenaees 94 Service Away From HOMe cccccccecceeceeeeseeeeeeeseneeeeeeeeeeeeeeseneaeeeeeeenaees 94 Parts And Accessories INQUuIri S c ceeeeeeeceeeeeeeeeeteeececaeeeeeeeeettees 94 Service ASSIStANCE cccccccceee cee ceeeeeeceeeeeeceeeeeeseeeeeeeaeaaeeeeeeeeeesteeeeeees 94 Mercury Marine Service Off1CES ce eeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeenaees 95 vi Maintenance Log TABLE OF CONTENTS MAINTENANCE LOG vii viii WARRANTY INFORMATION Transfer Of Warranty The limited war
28. OUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants Using a replacement part that is inferior to the original part could result in personal injury death or product failure EPA Emissions Regulations All new outboards manufactured by Mercury Marine 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 spark ignition SI engine repair establishment or individual 65 MAINTENANCE 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 LZERCURY EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U S EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUST MENTS
29. PA Emissions Regulations cccccccceeeeeeeeeeeneeeeeeeeneeeeeeenaeeeeeeenaees 65 Inspection And Maintenance Schedule 2 e eeeeeceeeceeeeeeeeeeees 66 Flushing The Cooling SyStem ccceeeecseeeeeeneeeeeeeaeeeeeeneeeeesenaeeeeeeaees 68 Top Cowl Removal And Installation 0 cccccseeeeceeeeeeeeeeeeeeeeeeeeeteees 69 EXtenor OIE Siatisstitdsta ne adits as hag aa tiaatiat ne E aaah ee 69 Battery Inspection ise cccelct iets ee chesieee the cies edbeelsecedediasedeiveieantneenecceneeel 69 TABLE OF CONTENTS puel System ss nS esteeeha eet Ge eae 70 Steering Link Rod Fasteners ccccceceeeeeeeeeeeeeeeeseeeeaeeeeeeenaeeeeeeeaaes 71 Corrosion Control ANOE ccccceecceeeeeeeeeeeeeseeeeeeeeseeeeeeeeeseeeeaeeeteeenaees 73 Propeller Replacement 87 3 mm 3 7 16 in Diameter Gearcase 73 Propeller Replacement 108 mm 4 1 4 in Diameter Gearcase 76 Spark Plug Inspection And Replacement 2 ccccecceceeeeeeeetteeteees 79 Fuse Replacementt cc ccccccceceeeeeeneeaeeceeeeeeeeaeeeeeeseseeaeeeeeseeeeeeeenaees 80 Timing Belt Inspection asioi a A E 81 Lubrication FON asasini aa E S 82 Checking Power Tri Fid Saicnosiienanins e 84 Changing Engine Ollares sserrep doyle sdetbeeathentes 84 Gearcase Lubrication For 87 3 mm 3 7 16 in Diameter Gearcase 86 Gearcase Lubrication For 108 mm 4 1 4 in Diameter Gearcase 88 Submerged Outboard cc sses er EEE EEEE NEA
30. an approved receptacle Any fuel system service must be performed 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 ENGINE FUEL FILTER Check the fuel filter for water accumulation or sediment If water is in the fuel remove the sight bowl and drain the water If the filter appears to be contaminated remove and replace REMOVAL 1 Read Fuel System servicing information and Warning proceeding 2 Pull out the filter assembly from mount Hold onto the cover to prevent it from turning and remove the sight bowl Empty contents into an approved container 70 MAINTENANCE 3 Pull out the filter element and replace it if necessary S 4 Z e aiea Ke a WS SIN D D sy Hy ob00649 a Cover c O ring seal b Filter element d Sight bowl INSTALLATION IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter 1 Push the filter element into the cover 2 Place the O ring seal into its proper position on the sight bowl and screw the sight bowl hand tight into the cover 3 Push filter assembly back into mount Steering Link Rod F
31. are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product California Emissions Limited Warranty The California Air Resources Board has promulgated air emissions regulations for outboard engines The regulations apply to all outboard engines sold 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 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 materia
32. as the Purchaser 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 identification and should be retained by you for future use when required Should you ever require 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 prepare the warranty claim forms 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 Registration 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 WARRANTY INFORMATION IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim pro
33. asteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt e Part Number 10 856680 and self locking nylon insert locknuts b amp d Part Number 11 826709113 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage 71 MAINTENANCE 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 0b00373 a Spacer 12 71970 b Nylon insert locknut 11 826709113 c Flat washer 2 d Nylon insert locknut 11 8267091 13 e Special washer head bolt 10 856680 Dacwien a BR onset ar Nylon insert locknut d Tighten until seats then back off 1 4 turn Sanse a Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt locknut and spacer First torque bolt then locknut to specification 72 MAINTENANCE Corrosion Control Anode Your outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instea
34. 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 by the outboard 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 speed Sit only in seats designated for traveling at faster speeds 24 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
35. beep or intermittent short beeps This will alert the operator and help identify the following listed situations For visual display of the specific engine functions and for additional engine data refer to SmartCraft Product information following Start Up Normal System Test Engine Fault Six Beeps at Start Up The horn sounds or While Driving when there may be a problem with one of the engine functions Have your dealer check the engine soon 43 FEATURES amp CONTROLS Engine Fault Three Beeps every 4 Engine problem has Minutes occurred Engine will run rough and or stall Engine may not start Advancing the remote control neutral fast idle feature or advancing the tiller handle throttle grip half way may assist starting Have your dealer check the engine Engine Fault Intermittent Beep Engine problem has occurred Engine will not run Have your dealer check the engine Cooling System Continuous Engine Guardian Problem System is activated Power limit will vary with level of overheat Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole If no water is coming out of the water pump indicator hole or flow is intermittent stop engine and check water intake holes for obstruction 44 FEATURES amp CONTROLS Low Oil Pressure Engine Overspeed Battery Voltage to High or to Low Coolant Sensor Failure Continuous Continuous Conti
36. cessing refer to the International Warranty Four Stroke Outboard Limited Warranty UNITED STATES AND CANADA Outside the United States and Canada Check with your local distributor California residents that have purchased a 2001 model year outboard from a California dealer receive coverage in addition to that identified below for emissions related components Please see the California Emission Warranty Statement provided by your dealer 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 three 3 years from 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 Commercial users of these products receive warranty coverage of one 1 year from the date of first retail sale or one 1 year from the date on which the product was first put into service whichever occurs first 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 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 c
37. combination of the following American Petroleum Institute API Service Classification SH SG SF CF 4 CE CD CDII Severe engine damage may result from use of an inferior oil 0b00327 Recommended SAE Viscosity for Engine Oil a SAE 25W 40 viscosity oil may be used at temperatures above 4 C 40 F b SAE 10W 30 viscosity oil is recommended for use in all temperatures Checking And Adding Engine Oil IMPORTANT Do not overfill Be sure that the outboard is upright not tilted when checking oil 1 Turn the engine off Have the outboard in a level operating position Remove the top cowl 40 FUEL amp OIL 2 Flip the handle up and pull out the dipstick Wipe it with a clean rag or towel and push it back in all the way 3 Pull the dipstick back out again and observe the oil level If the oil level is low remove the oil filler cap and fill to but not over the upper oil level with the recommended oil 0b01456 IMPORTANT Inspect oil for signs of contamination Oil contaminated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 4 Push the dipstick back in all the way then flip the handle down to lock the dipstick in place Reinstall the oil filler cap and hand tighten securely A o0b00648 a Dipstick b Oil filler cap 41 FEATURES amp CONTROLS Remote Cont
38. d of the outboard metals Each anode requires periodic inspection especially in salt water which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode One anode is installed on the bottom of the transom bracket assembly The trim tab is also an anode on the 87 3 mm 3 7 16 in diameter gearcase The 108 mm 4 1 4 in diameter gearcase has three anodes One of the anodes is the trim tab and the other two anodes are located on each side of the gearcase 0b00374 som bracket assembly b Anode 2 on each side of gearcase c Trim tab Propeller Replacement 87 3 mm 3 7 16 in Diameter Gearcase If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of 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 when you are servicing the propeller 73 MAINTENANCE Shift outboard to neutral N position 0b00363 Remove the spark plug leads to prevent engine from starting Daa 0b00375 Straighten the bent tabs on the propeller nut retainer e mM 0b00376 Place a block of wood between gearcase and propeller to ho
39. duct Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured 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 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 U S EPA EMISSIONS LIMITED WARRANTY Consistent with the obligations created by 40 CFR Part 91 Subpart M Mercury Marine provides a two year limited warranty to the retail purchaser that the engine is designed built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine i
40. ducts sold in the United States should a safety recall notification under the Federal Safety Act be required 2 WARRANTY INFORMATION To be eligible for warranty coverage the product must be registered with Mercury Marine At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration Upon processing the warranty registration Mercury Marine will send registration verification by mail to the purchaser of the product If this registration verification is not received within 30 days please contact your selling dealer immediately Warranty coverage is not effective until your product is registered with Mercury Marine Warranty Registration Outside The United States And Canada 1 3 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and address product model and serial numbers 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
41. e of some potential control hazards The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface 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 or tiller handle in either direction may result Failure to keep a continuous firm grip on the steering wheel or tiller handle 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 e Result in quicker planing off especially with a heavy load or a stern heavy boat e Generally improve the ride in choppy water e Increase steering torque or pull to the right with the normal right hand rotation propeller 47 FEATURES amp CONTROLS e In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered Avoid poss
42. educed 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 Safety Instructions For Hand Tilled Outboards No person or cargo should occupy the area directly in front of the outboard while the boat is in motion If an underwater obstacle is struck the outboard will tilt up and could seriously injure anyone occupying this area MODELS WITH CLAMP SCREWS Some outboards come with transom bracket clamp screws The use of clamp bracket screws alone is insufficient to properly and safely secure the outboard to the transom Proper installation of the outboard includes bolting the engine to the boat through the transom Refer to Installation Installing Outboard for more complete installation information Avoid serious injury or death from being struck by a disconnected outboard Do not accelerate above idle speed in water suspected of containing underwater obstacles if the outboard is not attached to the transom correctly If an obstacle is struck at planing speed and the outboard is not securely fastened to the transom it is possible the outboard could lift off the transom and land in the boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all inter
43. eeeeeteeeeeeeeea 36 FUEL amp OIL Gasoline Recommendations cccceeceeeneeceeeenteeeeenaeeeseenaeeeeenaeeeeeeaaes 38 Filling Fue Tanks sat ihe cane ia ad een oe de 39 Engine Oil Recommendations ccccccceeeeeeeceeeeeeeeceeeeeeeeeeeeeeeeeeeeees 40 Checking And Adding Engine Oil eee eceeceeeeeneeeeeeaeeeeeenaeeeeenaeeeeeeaaes 40 FEATURES amp CONTROLS Remote Control Features nianie penie EA EE i Ea 42 Warning SYSTEM ss eae E E S T 43 Power Trim and Tilt If EQuipped eceeeeeeecceececeeeeeeeeseeneeeaeeeeeeeeees 46 Throttle Grip Friction Adjustment Tiller Handle Models 51 Steering Friction ACjUStMENL eee ee scence ee enneeeeeeaeeeeeaeeeeeeaeeeeeeaas 51 Trin Tab AGjUStMents vsceccerisssidsa assoc E aa heds eee a 52 OPERATION Pr Starting CHECK Listare EEE EEA tenet thee 54 Operating In Freezing Temperatures cccceeeesseeeeeeeeeeeeeneeeeeeenaeeeeeaas 54 Operating In Salt Water Or Polluted Water cccceseeceeeeetreeeeenteeeees 54 Pre Starting IMstuctionS eseon iaa A 55 Engine Break in Procedura scorse aiai erea EE EAE S 56 Starting The Engine Remote Control Models cceeceeeeeeeeeeeeeees 56 Starting The Engine Tiller Handle Models 0 ccceeesteeeeeeeteteeeeeees 59 Gear SMMING Seea r A AA A eae 61 SHOPPING Fhe ENGINE zerie ea a E A 62 Emergency Staring ieeeos ia a A E 62 MAINTENANCE Outboard Care suis ariin a E e a A Ea a 65 E
44. eeeseaeeeeseenneeeeeeaes 19 Remote Steering Notice 0 ccccecceeeeeeeeeeeeeeeeeeeeeeneeeeeeaeeeetiaeeeeetneeeenea 20 Lanyard Stop SWitChs ices a R A 21 Protecting People In The Water essssesiresssrinessrresnernerrrnssrnneernnnesnnnnes 23 Passenger Safety Message Pontoon Boats And Deck Boats 24 Wave And Wake JUMPING ceceecceeeeeeeeeeeeeeeeeceeeeeetaeeeeeeettaeeeeeeened 25 Impact With Underwater Hazards ccccceeceeeeeeeeceeeeeeeseeeseneeeeeeeeees 26 Safety Instructions For Hand Tilled Outboards ceeeseeeeeeeeeeeeenees 27 Exhaust EMISSIONS menie bk ET E EEE EORR KER AE AAEREN 27 Selecting Accessories For Your Outboard eesseseeesesrrsseerreserreseers 29 Safe Boating SUGGESTIONS ersin eeeeene eee nE Er E eia E EE 29 Recording Serial NUMber sssssessssrieesrsrrnesrerrneesennnussrenannenntnneesnnnnnennnan 31 40 50 60 4 Stroke Specifications cccccccecceeeeeeeeeeeeeceeeeeeeeeeeeeeseees 31 Component Identification cceceeeceeecee cece ee eeeeeeeeeaeceeeeeeeesessnneeaaeeeeees 33 INSTALLATION InStalliG QUUG OAC sso oh och a aaa a Bidet tints heheh teed ee 34 Propeller Selection ccccccccccceceeeeeeeeeaeeeeeeceeeesaeeeeeeeesenaeeeeeeeeeseeeenaees 35 TRANSPORTING Trailering Boat OUtbOard 0 eeeceeeeeeeeeeeeeeseeeaeeeeseeaaeeeeeeenaaeeeeeneeaas 36 TABLE OF CONTENTS Transporting Portable Fuel Tanks ccccceeeceeeeeeeeeeteeee
45. effects are due to the tendency of gasoline containing alcohol to absorb moisture from the air resulting in a phase of water and alcohol which separates from the gasoline in the fuel tank 38 FUEL amp OIL The adverse effects of alcohol are more severe with methanol and are worse with increasing content of alcohol Filling Fuel Tank 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 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 PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions 39 FUEL amp OIL Engine Oil Recommendations We recommend the use of Mercury or Quicksilver SAE 10W 30 multi viscosity 4 stroke outboard oil for general all temperature use If SAE 25W 40 multi viscosity oil is preferred use Mercury MerCruiser 4 cycle engine oil or Quicksilver sterndrive amp inboard 4 cycle engine oil Never use 4 cycle engine oil that is not certified to meet or exceed any one or
46. epair establishment or individual Engines are labeled with an Emission Control Information decal as permanent evidence of EPA certification The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm 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
47. 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 a Storage 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 Electric Start Models POSSIBLE CAUSES Blown 20 Amp fuse in the starting circuit Refer to Maintenance section Outboard is not shifted to neutral position Weak battery or battery connections are loose or corroded 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 Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Blown 20 AMP fuse Refer to Maintenance section Ignition syste
48. ge 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 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 product sold with less than a one year limited Product warranty 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 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
49. h 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 Mercury 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 12 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 rec
50. h 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 e Model and serial number of your outboard The name and address of your dealership e Nature of problem 94 OWNER SERVICE ASSISTANCE Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax correspondence United States Telephone 920 929 5040 Mercury Marine W6250 W Pioneer Road www mercurymarine com Fond du Lac WI 54936 1939 Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Fax 905 567 8515 Mississauga Ontario L5N 7W6 Canada Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Fax 61 3 9793 5880 Dandenong Victoria 3164 Australia Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Rechain Fax 32 87 31 19 65 5 4800 Verviers Belgium Mexico Central America South America Caribbean Telephone 954 744 3513 Mercury Marine 11650 Interchange Circle North Fax 954 744 3535 Miramar FL 33025 U S A 95 OWNER SERVICE ASSISTANCE Japan Telephone 81 53 423 2500 Mercury Marine Japan 283 1 Anshin cho Hamamatsu Fax 81 53 423 2510 Shizuoka 435 0005 Japan Asia Singapore Telephone 5466
51. he following Safety Information before proceeding 21 GENERAL INFORMATION Important Safety Information The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boats high performance boats and light sensitive handling fishing boats operated by a hand tiller Falling overboard and accidental ejections are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds standing at planing speeds sitting on elevated fishing boat decks operating at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel or tiller handle that is pulling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers 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 p
52. ible 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 or tiller handle e In rare circumstances the owner may decide to limit the trim in This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets are desired Trimming Out or Up can Lift the bow higher out of the water e Generally increase top speed e Increase 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 can cause boat porpoising bouncing or propeller ventilation e Cause engine overheating if any cooling water intake holes are above the water line TILTING OPERATION To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 48 FEATURES amp CONTROLS 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating
53. ine fails to start in ten seconds return key to on position wait 30 seconds and try again OFF 0b00354 8 After engine starts check for a steady stream of water flowing out of the water pump indicator hole 0b00331 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage 58 OPERATION WARMING UP ENGINE Before beginning operation allow the engine to warm up at idling speed for 3 minutes Starting The Engine Tiller Handle Models Before starting read the Pre Starting Check List Special Operating Instructions and Engine Break in Procedure in the Operation section NOTE EFI models Engine must have a fully charged battery to start the engine 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 1 Open fuel tank vent screw in filler cap on manual venting type fuel tanks ob00349 3 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 2 ob00350 OPERAT
54. ion 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 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 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 arran
55. ipment manuals and parts books e 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 Transfer Of Warranty correa hen edie ene Beale tienes 1 Warranty Registration United States And Canada 1 Warranty Registration Outside The United States And Canada 2 Four Stroke Outboard Limited Warranty 0 ccceeeeeeeeeeeeeceeeeeeeneeeeeeaas 3 3 Year Limited Warranty Against Corrosion cc ccececeeeeeettteeeeeeetees 6 Warranty Coverage And EXCIUSIONS ccceeeeeeeeeeeeeeeeeeteeeeeeetnaeeeeee 9 California Emissions Limited Warranty ccccccceeceeeeeeeeeneeeeseeeneeeees 11 Star Label sci Saiar es ei Hdtv dead aa Ee erie Taa aa 16 GENERAL INFORMATION Boater s ResponsibilitieS cccccceeeeceeceeceeeeeeeeeeeneaeeeeeeseeeeneeeeeeeeteee 18 Before Operating Your Outboard eceecceeeseeeeeeeeeeeeeeeeneeeseeneeeeseaaes 18 Boat Horsepower Capacity c cccccceccceeeeeeeceeceeeeeeeeeeesenaeceeeeeeeteeeneees 18 High Speed And High Performance Boat Operation ceeeeeeees 19 Outboard Remote Control Models 0 cceccecceeeseneee
56. king cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection with normal services 10 11 12 13 WARRANTY INFORMATION Factory installed jet drive units Specific parts excluded from the warranty are The jet drive impeller and jet drive liner damaged by impact or wear and water damaged drive shaft bearings as a result of improper maintenance Damage caused by neglect lack of maintenance accident abnormal operation or improper installation or service Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reasonable access must be provided to the product for warranty service Customer must deliver product to an authorized dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation 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 All incidental and or consequential damages storage charges telephone or rental charges of an
57. l 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 other engine components caused by the failure of a warranted part will also be repaired under warranty 11 WARRANTY INFORMATION 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 HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury wit
58. ld propeller and remove propeller nut Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 0b00377 74 MAINTENANCE 6 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon 0b00378 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 7 Flo Torq Drive Hub Propellers Install forward thrust hub propeller propeller nut retainer and propeller nut onto the shaft SS a Propeller nut c Propeller b Propeller nut retainer d Forward thrust hub 8 Flo Torq Il Drive Hub Propellers Install forward thrust hub propeller replaceable drive sleeve rear thrust hub propeller nut retainer and propeller nut onto the shaft Nig lt o 0b00380 a Propeller nut d Replaceable drive sleeve b Propeller nut retainer e Propeller c Rear thrust hub f Forward thrust hub 75 MAINTENANCE 9 Place propeller nut retainer over pins Place a block of wood between gearcase and propeller and tighten propeller nut to specifications 10 Align flat sides of the propeller nut with tabs
59. 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 Transporting Portable Fuel Tanks Avoid serious injury or death from a gasoline fire or explosion Follow portable fuel tank transporting instructions Transport the fuel tank in a well ventilated area away from open flame or sparks MANUAL VENTING TYPE FUEL TANK 1 Close fuel tank air vent when transporting tank This will prevent escape of fuel or vapors from tank Foes hay 0b00325 36 TRANSPORTING AUTO VENTING TYPE FUEL TANK 1 Disconnect the remote fuel line from tank This will close the air vent and prevent escape of fuel or vapors from tank 2 Install tether cap over the fuel line connector stem This will protect the connector stem from being accidently pushed in thus allowing fuel or vapor to escape 0b00326 a Connector stem b Tether cap 37 FUEL amp OIL Gasoline Recommendations UNITED STATES AND CANADA Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 87 Mid grade automotive gasolines that contain fuel injector cleaner are preferred for added internal engine cleanliness Leaded gasoline is not recommended INTERNATIONAL Use a major brand of automotive unleaded gasoline with a minimum pos
60. m component failure Spark plugs fouled or defective Refer to Maintenance section sao Oo9 a9 oD Engine Runs Erratically POSSIBLE CAUSES Guardian System activated Refer to Features amp Controls Warning System Spark plugs fouled or defective Refer to Maintenance section 92 TROUBLESHOOTING 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 located on permanently built in type fuel tanks d Fuel line is kinked or pinched Fuel pump failure Ignition system component failure Fuel injection component failure EFI Models Performance Loss POSSIBLE CAUSES Engine Guardian System activated Refer to Features amp Controls Warning System Throttle not fully open Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged 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 93 OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise
61. m safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made 29 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squadron 3 The Red Cross and 4 your state boating law enforcement agency 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 transom 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 Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back ste
62. nal combustion engines This includes the outboards 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 27 GENERAL INFORMATION 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 0b00316 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide 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 7 Toz PAL 7 0b00317 a Running the engine when the boat is moored in a confined space b Mooring
63. nal injury and product damage 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 A DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury 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 avoided 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 18 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 o0b0030
64. ng a full sudden sharp turn This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death o0b00309 a Self locking nuts 20 GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote control units are equipped with a lanyard stop switch A lanyard stop switch can be installed as an accessory generally on the dashboard or side adjacent to the operator s position The lanyard is a cord usually between 122 and 152 cm 4 and 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard a 6 gt RUN iF GaN 0b00310 a Lanyard cord b Lanyard stop switch Read t
65. ng in his her direction even at slow speed 0b00311 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 coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury 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 outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat 23 GENERAL INFORMATION Passenger Safety Message Pontoon Boats And Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of 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
66. ng type lower unit 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 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 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 WARRANTY INFORMATION 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 AL
67. nspection 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 79 MAINTENANCE 1 Remove the spark plug leads Twist the rubber boots slightly and pull off 0b00375 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 0b00423 3 Set the spark plug gap to specification mi O ob00424 Spark Plug Gap 0 8 0 9 mm 0 031 0 035 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 Fuse Replacement IMPORTANT Always carry spare 20 AMP fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 80 MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same rating ob00650
68. ntire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 7 Flo Torq Drive Hub Propellers Install thrust washer propeller continuity washer thrust hub propeller nut retainer and propeller nut onto the shaft 0b00382 a Propeller nut d Continuity washer b Propeller nut retainer e Propeller c Thrust hub f Thrust washer 8 Flo Torq I Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft P zji a 0b00421 a Propeller nut d Propeller b Propeller nut retainer e Replaceable drive sleeve c Thrust hub f Forward thrust hub NOTE Stainless Steel Applications Installation of a Flo Torg Il drive hup propeller is recommended 78 MAINTENANCE 9 Flo Torq Ill Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft 65 a sji 3223 a Propeller nut d Propeller b Propeller nut retainer e Replaceable drive sleeve c Rear thrust hub f Forward thrust hub 10 Place a block of wood between gearcase and propeller and torque propeller nut to specifications 11 Secure propeller nut by bending three of the tabs into the thrust hub grooves 0b00422 Spark Plug I
69. nuous Continuous 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 reducing engine power in order to provide engine protection 45 Engine Guardian System is activated Power will be limited to 2000 RPM First stop the engine and check the oil level Add oil if necessary The warning horn is activated any time engine speed exceeds the maximum allowable RPM The system will limit the engine speed to within the allowable range Engine overspeed indicates a condition that should be corrected Overspeed could be caused by incorrect propeller pitch engine height trim angle etc Engine Guardian System is activated Power limit will restrict engine speed to 75 Engine Guardian System is activated Power limit will restrict engine speed to 50 FEATURES amp CONTROLS If Guardian System has been activated reduce throttle speed The horn will turn off when throttle speed is within the allowable limit Consult your dealer for assistance SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard A few of the functions the instrument package will display are engine RPM coolant temperature battery voltage fuel consumption and engine operating hours The SmartCraft Instrument package will also aid in Engine Gua
70. of gasoline 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 e Remove the fuel filter sight bowl and empty contents in a suitable container Refer to Maintenance Fuel System for removal and installation of filter Add 3 cc 1 2 tsp of gasoline stabilizer into the fuel filter sight bowl and reinstall e Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for 15 minutes to fill the engine fuel system 90 STORAGE 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 Protecting Internal Engine Components e Remove the spark plugs and inject a small amount of engine oil inside of each cylinder e Rotate the flywheel manually several times to distribute the oil in the cylinders Reinstall spark plugs e Change the engine oil 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 If outboard is stored tilted up in
71. ommended 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 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 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 par
72. op switch e Gearcase n Throttle friction adjustment f Trim tab knob g Anti ventilation plate o Lanyard stop switch h Driveshaft housing p Steering friction adjustment lever tiller handle models 33 INSTALLATION Installing Outboard Before operation the outboard must be correctly installed with the required mounting hardware as shown Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury death or property damage We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the transom with the four 12 7 mm 1 2 in diameter mounting bolts and locknuts provided Install two bolts through the upper set of holes and two bolts through the lower set of holes ob00658 MAXIMUM OUTBOARD MOUNTING HEIGHT The mounting height of the outboard must not exceed 635 mm 25 in for EL models and 762 mm 30 in for EXL models Mounting the outboard higher may cause damage to the gearcase components ob00659 INSTALLATION Propeller Selection For best all around performance from your outboard boat combination select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range
73. overage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re registration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer 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 Marine 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 unless properly re registered 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 pro
74. ower 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 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 22 GENERAL INFORMATION Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations 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 gearcase 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 standing or floating in the water to take quick action to avoid a boat headi
75. r This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing The Cooling System 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 54 OPERATION Wash down 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 Pre Starting Instructions 1 Connect the remote fuel line to the outboard Make sure connector is snapped into place 0b00345 0b00346 55 OPERATION 3 Make sure the cooling water intake is submerged 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 0b00347 Severe damage to the engine can result by not complying with the Engine Break in Procedure 1 For the first hour of operation run the engine at varied throttle settings up to 3500 RPM or at approximately half throttle 2 For the second hour of operation run the engine at varied throttle settings up to 4500 RPM or at three quarter throttle and during this period
76. r 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 15 WARRANTY INFORMATION If you have any questions regarding your warranty rights and responsibilities you should contact Mercury Marine 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 ob00708 EMissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines Two Stars Very Low Emission The two Star Label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards Engines 0b00709 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 Re
77. ranty 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 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 Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Upon processing the transfer of warranty Mercury 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 Mercury Marine Service Office closest to you Warranty Registration United States And Canada 1 You may change your address at any time including at time of warranty claim by calling Mercury Marine or sending a letter or fax with your name old address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54935 1939 920 929 5054 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine pro
78. rd in a vertical operating position 2 Place a drain pan below outboard 86 MAINTENANCE 3 Remove vent plug and fill drain plug and drain lubricant 0b00439 a Vent plug b Fill drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 340 ml 11 5 fl oz CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug 3 Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer a Vent hole c Fill drain plug b Vent plug 87 MAINTENANCE Gearcase Lubrication For 108 mm 4 1 4 in Diameter Gearcase When adding or changing gearcase lubricant visually check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A
79. rdian diagnostics The SmartCraft Instrument package will display critical engine alarm data and potential problems Power Trim and Tilt If Equipped Your outboard has a trim tilt control called power trim This enables the operator to easily adjust the position of the outboard by pressing the trim switch Moving the outboard in closer to the boat transom is called trimming in or down Moving the outboard further away from the boat transom is called trimming out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating your boat on plane The term tilt is generally used when referring 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 0b00338 a Remote control trim switch c Tilt range of travel b Panel mount trim switch d Trim range of travel 46 FEATURES amp CONTROLS POWER TRIM OPERATION With most boats operating around the middle of the trim range will give satisfactory results However to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out Along with an improvement in some performance aspects comes a greater responsibility for the operator and this is being awar
80. rn 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 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 30 GENERAL INFORMATION Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It
81. rol 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 Refer 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 42 FEATURES amp CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch Tiller handle models will have the warning horn located in the ignition key panel 0b00332 a Horn inside remote control c Horn in ignition key panel b Horn connected to ignition key switch 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 The warning horn will emit either a continuous
82. s free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations 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 RPM range see 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 jet pump impellers and liners 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 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 Use of the product for racing or other competitive activity or operating with a raci
83. sources 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 lower emissions than One Star Low Emission engines o0b00710 16 WARRANTY INFORMATION Four Stars Super Ultra Low Emission The four Star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also 0b00711 comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines 17 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 Safety and operating information that is practiced along with using good common sense can help prevent perso
84. t hook ob00369 INSTALLATION 1 2 Engage the front hook and push cowl back over the cowl seal Push cowl down and move the rear latch lever up to lock Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes 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 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 against movement Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals 69 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 stop engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in
85. ted octane rating of 9ORON Automotive gasolines that contain fuel injector cleaner are preferred for added internal engine cleanliness Leaded gasoline is acceptable in areas where unleaded gasoline is not available USING REFORMULATED OXYGENATED FUELS UNITED STATES ONLY This type of fuel is required in certain areas of the United States The two types of reformulated ingredients in these fuels are alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenates that is used in the gasoline refer to Alcohol in Gasoline These reformulated fuels are acceptable for use in the Mercury engine ALCOHOL IN GASOLINE We do not recommend the use of gasoline which contains alcohol because of the possible adverse effect the alcohol may have on the fuel system In general if only gasoline containing alcohol is available it must not contain more than 10 ethanol or 5 methanol and the addition of a water separating fuel filter is recommended If gasoline containing alcohol is used or if you suspect the presence of alcohol in your gasoline increase your inspection of the fuel system visually checking for fuel leaks or abnormalities Gasoline containing alcohol may cause the following problems to your outboard and fuel system e Corrosion of metal parts Deterioration of elastomers and plastic parts e Wear and damage of internal engine parts e Starting and operating difficulties e Vapor lock or fuel starvation Some of these adverse
86. teering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked A hydraulically locked steering cable will cause loss of steering control possibly resulting in serious injury or death e Steering Cable Grease Fitting If equipped Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting a Fitting b Steering cable end 83 MAINTENANCE 3 Lubricate the following with light weight oil e Steering Link Rod Pivot Points Lubricate points 0b00433 Checking Power Trim Fluid 1 Tilt outboard to the full up position and engage the tilt support lock 0b00434 2 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Precision Lubricants Power Trim amp Steering Fluid If not available use automotive ATF automatic transmission fluid 0b00435 Changing Engine Oil ENGINE OIL CAPACITY 3 0 Liter 3 U S Quarts OIL CHANGING PROCEDURE 1 Tilt the outboard up to the trailer position 84 MAINTENANCE 2 Turn the steering on the outboard so that the drain hole is facing downward Remove drain plug and drain engine oil into an appropriate container Lubricate the seal on the drain plug with oil and reinstall
87. tion 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 COVERAGE 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 You are responsible for presenting your outboard to a Mercury deale
88. ts 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 disallowing 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 13 WARRANTY INFORMATION b Turbocharger systems where applicable 3 Ignition System a Spark plugs Magneto or electronic ignition system Spark advance retard system Ignition coil and or control module Ignition wires 4 Lubrication System 4 Stroke engines excluded a Oil pump and internal parts 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 Vacuum temperature check and time sensitive valves and switches d Electronic controls papo DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES O
89. uld result in serious injury or death 3 Electric Start Models Turn the ignition key to on position OFF 0b00364 63 OPERATION To prevent getting an electrical shock do not touch any ignition component wiring or spark plug wire when starting or running the engine The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel Pull the starter rope to start the engine ob00365 64 MAINTENANCE Outboard Care To keep your outboard in the best operating condition it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury death or product failure Record maintenance performed in Maintenance Log at the back of this book Save all maintenance work orders and receipts SELECTING REPLACEMENT PARTS FOR Y
90. urn knob counterclockwise to loosen friction E z ERO tee E C 0b00341 a Loosen friction b Tighten friction Steering Friction Adjustment TILLER HANDLE MODELS Steering Friction Adjustment Adjust this lever to achieve the desired steering friction drag on the tiller handle Move lever to the left to tighten friction or move to the right to loosen friction NOTE To maintain proper adjustment the locknut located on top of the steering friction lever pivot shaft can be tightened 0b00342 a Tighten friction c Locknut b Loosen friction 51 FEATURES amp CONTROLS REMOTE STEERING MODELS Avoid possible serious injury or death from loss of boat control Maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle is released Steering Friction Adjustment Adjust this screw to achieve the desired steering friction drag on the steering wheel Turn screw clockwise to tighten friction or turn counterclockwise to loosen friction 0b00343 a Loosen friction b Tighten friction Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to
91. water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine 89 STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust corrosion and damage caused by freezing of trapped water The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage two months or longer 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 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 Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with following instructions e Portable Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel e Permanently Installed Fuel Tank Pour the required amount
92. with the boat normally loaded refer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed 0b00323 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations 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 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 PROPELLER REQUIREMENTS BIGFOOT MODELS Bigfoot models require the use of specially designed rubber hub propellers to reduce both instances and severity of gearcase clutch rattle The use of the other propellers although not detrimental to either performance or durability could result in clutch rattle 35 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 IMPORTANT Do not rely on the power trim tilt system or tilt support
93. y type inconvenience or loss of time or income are the owner s responsibility Use of other than Mercury Precision or Quicksilver parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 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 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard Water entering engine through the fuel intake air intake or exhaust system or submersion 10 WARRANTY INFORMATION 14 Failure of any parts caused by lack of cooling water which results from starting motor out of water foreign material blocking inlet holes motor being mounted too high or trimmed too far out 15 Use of fuels and lubricants which are not suitable for use with or on the product Refer to the Maintenance section 16 Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which

i If the outboard motor`s serial number plate contains the CE mark in

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