322 eng © 2022 Mercury Marine Scan for service and support information 25/30 EFI FourStroke 8M0186412 Operation Maintenance and Installation Manual
eng
Welcome You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation and Maintenance Manual contains specific instructions for using and maintaining your product.
Additional alerts provide information that requires special attention: NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard.
Mercury Marine products are designed and manufactured to comply with our own high quality standards, applicable industry standards and regulations, and certain emissions regulations. At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use.
eng iv
General Information Boater's Responsibilities..................................................................................... 1 Outboard Remote Control Models ..................................................................... 1 Exhaust Emissions............................................................................................. 1 Lanyard Stop Switch........................................................................................... 3 Protecting People in the Water....................
Fuel and Oil Low Permeation Fuel Hose Requirement ........................................................ 49 Fuel Demand Valve (FDV) Requirement.......................................................... 49 EPA Pressurized Portable Fuel Tank Requirements........................................ 49 Mercury Marine's Pressurized Portable Fuel Tank........................................... 49 Filling Fuel Tank...............................................................................................
Maintenance Cleaning Care................................................................................................... 85 EPA Emissions Regulations............................................................................. 87 Inspection and Maintenance Schedule............................................................. 88 Maintenance Schedule Decal Icons ................................................................ 89 Maintenance Schedule Decal...................................................
Maintenance Log Maintenance Log............................................................................................
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard. Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION ! WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS co co co co co co co co co co co co co co co co co co co co 41127 Engine exhaust gases contain harmful carbon monoxide.
GENERAL INFORMATION Although the occurrence is rare, on a calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide. 1. Examples of poor ventilation while the boat is stationary: a b 21626 a - Running the engine while the boat is moored in a confined space b - Mooring close to another boat that has its engine operating 2.
GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
GENERAL INFORMATION ! WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard. ! WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.
GENERAL INFORMATION Approach slowly and exercise extreme caution when boating in areas where people may be in the water. When a boat is moving and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury. WHILE THE BOAT IS STATIONARY ! WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
GENERAL INFORMATION ! WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms 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.
GENERAL INFORMATION ! WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. 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.
GENERAL INFORMATION 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 that could be struck by the outboard or the boat bottom. The most significant action you can take 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 the minimum planing speed, typically 24 to 40 km/h (15 to 25 mph).
GENERAL INFORMATION Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds. ! WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
GENERAL INFORMATION Safe Boating Recommendations To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses.
GENERAL INFORMATION • Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient. Use personal flotation devices. • Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.
GENERAL INFORMATION • When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. Report accidents. • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents.
GENERAL INFORMATION • At extremes, can cause the boat to porpoise Shifting weight to front (bow): • Improves ease of planing • Improves rough water ride • At extremes, can cause the boat to veer back and forth (bow steer) BOTTOM OF BOAT For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore and aft direction. • Hook: Exists when bottom is concave in fore and aft direction when viewed from the side.
GENERAL INFORMATION • High humidity For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating weather conditions. In most cases, recommended RPM can be achieved by changing to a lower pitch propeller. DETONATION Detonation in a 4‑cycle engine resembles the pinging heard in an automobile engine.
GENERAL INFORMATION If full‑throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause higher than normal wear and damage. After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch. • Warmer weather and greater humidity cause a loss of RPM.
GENERAL INFORMATION Model Year Production Code The serial number decal lists the year of manufacture as an alpha code. This code can be deciphered into a corresponding number using the following table. Model Number XXXXXXX Serial Number XXXXX XX XXXX XXX HP XXX KW XXX LB XXX KG XXX Mercury Marine Brunswick Corp.
GENERAL INFORMATION Component Identification POWER TRIM MODEL a n m l k b c j i h d e g f 74282 18 eng
GENERAL INFORMATION abcdefgh- eng Top cowl Tilt support lever Transom brackets Anti‑ventilation plate Primary cooling water intake Gearcase Secondary cooling water intake Manual tilt release valve (accessible through port transom bracket) 19 ijklmn- Oil drain screw Water pump indicator hole Auxiliary trim/tilt switch Port lower cowl Starboard lower cowl Cowl latch
GENERAL INFORMATION MANUAL GAS ASSIST TILT MODEL e d c b a f g q h p i o n m j l k 74388 20 eng
GENERAL INFORMATION abcdefg- Top cowl Manual start handle Shift lever Throttle grip Engine stop switch Throttle friction adjustment knob Lanyard stop switch (lanyard cord not shown) h - Steering friction adjustment lever eng 21 ijklmnopq- Tilt support lever Primary cooling water intake Gearcase Secondary cooling water intake Anti‑ventilation plate Oil drain screw Water pump indicator hole Lower cowls Cowl latch
GENERAL INFORMATION MANUAL TILT MODEL e d c b a f g t s h i r j k q p l m o n 74281 22 eng
GENERAL INFORMATION abcdefg- Top cowl Manual start handle Shift lever Throttle grip Engine stop switch Throttle friction adjustment knob Lanyard stop switch (lanyard cord not shown) h - Transom brackets i - Tilt lock lever j - Ignition key switch (electric start models) k - Tiller handle tilt lock lever l - Steering friction adjustment lever m - Primary cooling water intake n - Gearcase o - Secondary cooling water intake p - Anti‑ventilation plate q - Oil drain screw r - Water pump indicator hole s - Lowe
GENERAL INFORMATION Parameter Specification Gear ratio Gear lubricant type 2.17:1 Premium Gear Lubricant or SAE 80W‑90 API GL‑4 Gearcase lubricant capacity 460 ml (15.
INSTALLATION Installation Information BOAT HORSEPOWER CAPACITY ! WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating. Do not overpower or overload your boat.
INSTALLATION FUEL TANKS Portable Fuel Tank Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place. Permanent Fuel Tank Permanent fuel tanks should be installed in accordance with industry and federal safety standards, which include recommendations applicable to grounding, anti‑siphon protection, ventilation, etc.
INSTALLATION MERCURY MARINE VALIDATED ENGINE MOUNTING HARDWARE IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability issues that can lead to safety concerns. Follow all of the instructions relating to the outboard installation.
INSTALLATION Installing the Outboard INSTALLATION SPECIFICATIONS A B A 2763 a - Minimum transom opening b - Engine centerline for dual engines Minimum Transom Opening Single engine (remote) 48.3 cm (19 in.) Single engine (tiller) 76.2 cm (30 in.) Dual engines 101.6 cm (40 in.) Engine Centerline Minimum 66 cm (26 in.) LIFTING THE OUTBOARD Use the lifting eye located aft of the recoil starter to support the engine when installing the outboard.
INSTALLATION INSTALLING THE OUTBOARD ON THE TRANSOM (MANUAL TILT MODELS) ! WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. This product must be secured to the transom with the required mounting hardware.
INSTALLATION 2. Tighten the transom clamp bolts. 74492 3. Use a long drill bit to drill the two lower 8 mm (0.315 in.) holes through the transom, using the transom clamps as a template for the bolt hole pattern. a - Upper transom clamp hole b - Lower transom clamp hole a b 15949 4. Apply marine sealer to the shanks of the bolts. Do not apply marine sealer to the threads of the bolts. 5. Secure the engine to the transom with the mounting hardware supplied with the engine.
INSTALLATION INSTALLING THE OUTBOARD ON THE TRANSOM (POWER TRIM AND GAS ASSIST) ! WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. This product must be secured to the transom with the required mounting hardware.
INSTALLATION When first determining transom strength, use a dial torque wrench. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate. NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts.
INSTALLATION Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 3. Install the outboard so that the anti‑ventilation plate is in‑line or within 25 mm (1 in.) of the bottom of the boat. a a - Anti‑ventilation plate b - In‑line or within 25 mm (1 in.) b 8045 4. Apply marine sealer to shanks of bolts. Do not apply marine sealer to the threads of the bolts. 5.
INSTALLATION The outboard must be secured to the transom with the two transom bracket clamp screws and four 13 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of mounting holes and two bolts through the lower set of mounting slots. b c d a abcd- Bolt (4) Transom clamp bolt Washer (4) Locknut (4) 10175 Description Nm lb‑in. lb‑ft Outboard mounting locknuts and bolts 75 – 55 Remote Control Connections REMOTE WIRING HARNESS INSTALLATION 1.
INSTALLATION 3. Route the harness along the top and forward sides of the intake runner, and secure the harness with cable ties in three locations. a b c 74441 a - 14‑pin connector b - Cable ties c - Remote harness THROTTLE CABLE INSTALLATION - RC MODELS Install cables into the remote control following the instructions provided with the remote control. 1. Move the remote control handle from neutral into forward and advance the handle to full speed position.
INSTALLATION 3. Adjust the throttle cable barrel so that when the barrel is installed into the barrel support bracket, no play can be felt when lightly pushing the throttle cam with a finger. c d b a e f 74479 abcdef- Throttle actuating lever Cotter pin Plastic washer Throttle cam (no play can be felt when lightly pushing) Throttle cable barrel Barrel support bracket 4. Slowly return the remote control handle back to the neutral detent position. 5.
INSTALLATION c. Make a center mark ("c"), midway between marks "a" and "b". Align the cable end guide with this center mark when connecting the cable to the engine. a b c 6098 2. 3. 4. Ensure that both the outboard engine and the remote control are in neutral. Install the shift cable onto the shift actuating lever. Secure the connection with a plastic washer and cotter pin.
INSTALLATION a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the cable end accordingly. b. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the cable end accordingly. Repeat steps a through c. c. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the cable end accordingly. Repeat steps a through c. 6.
INSTALLATION Description Nm lb‑in. lb‑ft Captive screw (7) 8.5 75 – 9. Use cable ties to secure the throttle, shift, and battery cables to the boat harness, to prevent contact with the steering components. 74478 Steering Control Connections STEERING BRACKET, STEERING CABLE INSTALLATION 1. Install the steering bracket with two washers and two 30 x 80 mm bolts. Tighten the steering bracket bolts to the specified torque. Description Nm lb‑in. lb‑ft Steering bracket bolt 30 – 22 2.
INSTALLATION 4. Insert the steering cable into the tilt tube and secure with the steering cable nut. Tighten the steering cable nut to the specified torque. b c a 59494 a - Steering cable nut b - Steering bracket bolt and washer (2) c - Steering cable seal Description Nm lb‑in. lb‑ft Steering cable nut 47.5 – 35 STEERING LINK ROD FASTENERS ! WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.
INSTALLATION 1. Install the steering link rod onto the steering bracket aft threaded hole. 59496 2. Assemble the steering link rod onto the steering bracket with the screw, two washers, spacer, and a locknut. Do not tighten the screw or locknut.
INSTALLATION 3. Install the loose end of the steering link onto the steering cable and secure with a washer and locknut. Tighten the locknut securely and then back the nut off 1/4 turn. a - Washer b - Locknut a b 59499 4. Tighten the link rod screw to the specified torque. 5. Secure the link rod screw so it does not loosen and tighten the locknut to the specified torque. b a 59500 a - Link rod screw b - Locknut Description Nm lb‑in. lb‑ft Link rod screw 27.1 – 20 Locknut 27.
INSTALLATION SINGLE OUTBOARD a - Red sleeve ‑ positive (+) b - Black sleeve ‑ negative (–) c - Cranking battery a b c 15496 DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries.
INSTALLATION Installing the Propeller ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and activate the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Shift the outboard to neutral (N) position. 2.
INSTALLATION 5. Place a block of wood between the gearcase and the propeller and torque the propeller nut to specification. NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut further to align it with the hole in the propeller shaft. 6. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. 28353 28351 Description Nm lb‑in.
TRANSPORTING Aquatic Invasive Species (AIS) STOP AQUATIC HITCHHIKERS!™ Be A Good Steward. Clean. Drain. Dry. 68805 For additional information, visit StopAquaticHitchhikers.org. AIS and their spread can detrimentally impact the boating experience and the future of the boating lifestyle.
TRANSPORTING If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing. 74512 IMPORTANT: Do not rely on the power tilt system or the tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailering.
TRANSPORTING • An upright position 74336 Upright position • On the port side. The port side lower cowl has two bumpers to help reduce damage to the cowl when the engine is stored laying down. Storing the engine on the port side will prevent oil from draining out of the crankcase into the cylinders or crankcase ventilation system. 74337 Port side lower cowl bumpers • Horizontal, with the front of the engine facing up (tiller handle facing up).
FUEL AND OIL Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.
FUEL AND OIL • The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage. • When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening. • The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal.
FUEL AND OIL Filling Fuel Tank ! WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill the fuel tanks outdoors away from heat, sparks, and open flames. Remove the portable fuel tanks from the boat to fill them. Always stop the engine before filling the tanks. Do not completely fill the fuel tanks.
FUEL AND OIL Methanol and Ethanol Fuel Blends IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).
FUEL AND OIL IMPORTANT: Nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), full synthetic oils, low quality oils, and oils that contain solid additives are not recommended.
FEATURES AND CONTROLS Tiller Handle Features • A decal on the tiller handle provides a quick reference for starting the engine. • Throttle grip friction knob ‑ Turn the friction knob to set and maintain the throttle at desired speed. Turn the knob clockwise to increase the friction or turn the knob counterclockwise to decrease the friction.
FEATURES AND CONTROLS • Tiller handle adjustment knob ‑ Turn the adjustment knob to raise or lower the tiller handle in its operating position. a b a - Tiller lock release lever b - Tiller handle adjustment knob 74496 a. Adjustment knob at the lowest setting. 74497 b. Adjustment knob at the highest setting. 74498 • Tiller handle yaw ‑ The tiller handle yaw allows the operator to change the angle of the handle up to 18° left or right of center. Each increment demarcation is 6°. a.
FEATURES AND CONTROLS b. Loosen the 15 mm nut so it is almost completely off. b a - Clamp screw nut b - Rubber boot a 74499 c. Loosen the 6 mm Allen socket head pivot screw. 63259 6 mm Allen socket head pivot screw d. Lift the clamp with your fingers and rotate the tiller handle to the desired angle.
FEATURES AND CONTROLS e. Tighten the clamp screw nut to the specified torque and install the rubber boot. Description Nm lb‑in. lb‑ft Clamp screw nut 50 – 36.8 f. Tighten the 6 mm Allen socket head pivot screw to the specified torque. Description Nm lb‑in. lb‑ft 6 mm Allen socket head pivot screw 24 – 17.7 • Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch. NOTE: A spare lanyard stop switch clip is stored on the tiller handle.
FEATURES AND CONTROLS • Throttle grip ‑ Controls the engine speed. Align the throttle grip with the idle mark on the tiller handle when starting or shifting into or out of gear. Twist the throttle grip to increase the engine speed. 63086 • Power tilt switch (if equipped) ‑ Tiller handle models equipped with power tilt have a switch located on the underside of the tiller handle. Press the switch to raise (UP) or lower (DN) the engine.
FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. Consult your dealer for a description of the functions and operations of other remote controls. a a b c abcd- d c c 58240 Trim switch Ignition key switch—OFF, ON, START Throttle only button Lanyard stop switch • Trim switch ‑ Used to trim the drive during operation or to raise the drive for trailering, launching, beaching, or shallow water operation.
FEATURES AND CONTROLS Tiller Handle Models with Manual Gas Assist Tilt ! WARNING Operating the engine without engaging the tilt lock lever can cause serious injury or death. The outboard can tilt upwards when decelerating or operating in reverse, causing loss of boat control. Always lock the outboard in its run position before operating. Models equipped with a gas assisted tilt system allow the operator to lock the outboard at any tilt position, from full down to full up.
FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating the boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle. Operate the outboard at slow speed while tilted up for shallow water operation. Keep the cooling water intake holes submerged in the water, and continue to check for water discharge from the water pump indicator hole. 74513 TILTING OUTBOARD TO FULL UP POSITION 1. Stop the engine. Move the lock lever to the free position.
FEATURES AND CONTROLS 2. Move the lock lever to the lock position. 9703 OPERATING ANGLE ADJUSTMENT The transom brackets have four holes for adjusting the vertical operating angle (forward stop movement) of the outboard. Use the tilt pin for adjustments in the four holes. a - Transom bracket holes b - Tilt pin FREE LOCK b a 10290 Adjust the operating angle of the outboard so that the outboard runs perpendicular to the water when the boat is at full speed.
FEATURES AND CONTROLS Arrange passengers and the load in the boat so the weight is distributed evenly. a b c 74515 a - Too much angle (bow up) ‑ adjust in b - Not enough angle (bow down) ‑ adjust out c - Angle adjusted properly (bow slightly up) NOTE: The outboard should be locked against the tilt pin during operation, by setting the tilt lock lever to the lock position. Consider the following items carefully when adjusting the operating angle of your outboard.
FEATURES AND CONTROLS • Increase clearance over submerged objects or a shallow bottom • Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller) • In excess, cause boat porpoising (bouncing) or propeller ventilation Tiller Handle Models with Manual Tilt BASIC TILTING OPERATION The tilt feature allows the operator to tilt the outboard to a higher tilt angle for operation in shallow water or tilt the outboard to the full up position.
FEATURES AND CONTROLS LOWERING OUTBOARD DOWN TO RUN POSITION Position the tilt lever in the release position. Raise the outboard slightly, to release it from its locked position, and gently lower it. SHALLOW WATER OPERATION The shallow water drive position on the outboard allows the outboard to be positioned at a higher tilt angle, to prevent hitting bottom. IMPORTANT: Before tilting the outboard into the shallow water drive position, reduce the engine speed to idle and shift the engine into forward gear.
FEATURES AND CONTROLS Arrange the passengers and load in the boat so the weight is distributed evenly. a b c 74517 a - Too much angle (stern down ‑ bow up) b - Not enough angle (stern up ‑ bow down) c - Angle adjusted properly (bow slightly up) Consider the following items carefully, when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom can: • Lower the bow. • Result in quicker planing off, especially with a heavy load or a stern heavy boat.
FEATURES AND CONTROLS • In excess, cause boat porpoising (bouncing) or propeller ventilation Power Trim and Tilt (if Equipped) Power trim allows the operator to easily adjust the position of the outboard by pressing the trim switch. Trim generally refers to the adjustment of the outboard within the first 20° range of travel. This is the range used while operating a boat on plane. Moving the outboard in closer to the boat transom is called trimming in or down.
FEATURES AND CONTROLS ! WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully. 1. Trimming in or down can: • Lower the bow. • Result in quicker planing off, especially with a heavy load or a stern heavy boat. • Generally improve the ride in choppy water.
FEATURES AND CONTROLS 1. Engage the tilt support lever by rotating the lever down. 2. Lower the outboard to rest on the tilt support lever. 3. Disengage the tilt support lever, by slightly tilting up the outboard and releasing the tilt support bracket. Lower the outboard. 9703 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
FEATURES AND CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. 74338 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. 1. Reduce the engine speed below 2000 RPM. 2. Tilt the outboard up. Make sure all the water intake holes stay submerged at all times. 3. Operate the engine at slow speed only.
FEATURES AND CONTROLS Function Sensor (ECT or MAP) error Warning Horn Description Rev Limit Intermittent short beep Engine speed will be limited. Consult your dealer for assistance. 2800 RPM ENGINE OVERHEAT If the engine overheats, immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
FEATURES AND CONTROLS • Tilting the outboard out beyond a vertical position • Cavitation of the propeller due to rough water or obstruction in the boat hull When the engine overspeed limiter is activated, the engine timing will be momentarily retarded to decrease the engine speed. Excessive overspeed (above 6300 RPM) will result in cutout of the cylinders to prevent operation above this limit. Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction.
OPERATION Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 1. For the first two hours of operation, run the engine at varied throttle settings up to 4500 RPM or three‑quarter throttle. Changes in throttle should be gradual and extended time at idle should be avoided. 2.
OPERATION 2. Check the engine oil level. 73881 NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 3. Make sure the cooling water intake is submerged. 26837 Starting the Engine ‑ Remote Control Models Before starting, read the Prestarting Check List, Prestarting Instructions, and Engine Break‑in Procedure in this section. 1.
OPERATION 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. 27348 3. Set the lanyard stop switch to the RUN position. Refer to General Information ‑ Lanyard Stop Switch. 19791 4. Verify the remote control handle is in the neutral position. N 63103 IMPORTANT: Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery.
OPERATION 5. Turn the ignition key to the START position and start the engine. If the engine fails to start in ten seconds, wait 30 seconds and try again. If the engine begins to stall, use the throttle‑only feature and advance the throttle. Do not exceed 2000 RPM. 19804 6. Check for a steady stream of water flowing out of the water pump indicator. 73883 IMPORTANT: If no water is coming out of the water pump indicator, stop the engine and check the cooling water intake for obstruction.
OPERATION 1. Open the fuel tank vent screw on the manual venting type tanks. b a - Fuel cap b - Manual vent screw c - Tab lock a c 46290 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after the engine has warmed up. 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. 27348 3. Insert the lanyard clip into the stop switch. This is the operating position.
OPERATION 4. Verify the shift handle is in the neutral (N) position. F N R 74495 5. Verify the throttle grip is set to the idle position. 63086 6. Manual starting models ‑ Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until the engine starts. IMPORTANT: Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery.
OPERATION 8. Flooded engine ‑ If the engine will not start, advance the throttle grip slightly and attempt to start the engine. After the engine has started, immediately reduce the throttle speed to idle. 9. Check for a steady stream of water flowing out of the water pump indicator. 73883 IMPORTANT: If no water is coming out of the water pump indicator, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.
OPERATION • Tiller handle models ‑ Three gear shift positions provide boat operation: forward (F), neutral (N), and reverse (R). When shifting, always stop at the neutral position and allow the engine speed to return to idle. N F R 74495 • Remote control models ‑ Three gear shift positions provide boat operation: forward (F), neutral (N), and reverse (R). When shifting, always stop at the neutral position and allow the engine speed to return to idle.
OPERATION • Tiller handle models ‑ Reduce the engine speed, and shift the outboard to neutral. Push in the engine stop button or turn the ignition key OFF. 74501 Emergency Starting Procedure If the starter system fails, use the tools provided with the engine to remove the recoil assembly (manual start models) or the flywheel cover (electric start models), and then use the provided emergency starter rope to start the engine. Read the following procedure before attempting to remove the recoil assembly.
OPERATION b. Lift the neutral interlock cable out of the clip on the recoil housing. a a b a 74069 a - Screws with washers (3) b - Clip securing neutral interlock cable c. Pull and lift the neutral interlock cable to disengage it from the recoil housing. d. Remove the neutral interlock cable tension spring and the interlock cable from the recoil housing. a b 74504 a - Neutral interlock cable tension spring b - Neutral interlock cable ‑ pull and lift e. Carefully remove the recoil starter assembly.
OPERATION a. Remove the three screws with washers securing the flywheel cover to the top of the engine. a a b a - Screws with washers (3) b - Flywheel cover a 74314 b. Remove the flywheel cover from the engine. 3. Shift the outboard into neutral. 4. Ensure that the lanyard stop switch is in the RUN position. 5. Electric start models ‑ Ensure that the key switch is in the ON position. ! WARNING The exposed moving flywheel can cause serious injury.
OPERATION 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 the trapped water in the 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.
MAINTENANCE Cleaning Care 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. Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.
MAINTENANCE Routine cleaning of the remote control external surfaces is recommended to prevent a buildup of salt and other environmental debris. Use a cloth towel which has a sufficient amount of fresh water to dissolve and remove salt or mineral deposits. When water marks cannot be removed with a damp cloth, mix a 50/50 solution of warm water and isopropyl alcohol to clean the remote control. Do not use acetone, mineral spirits, turpentine type solvents, or ammonia based cleaning products.
MAINTENANCE Description Corrosion Guard Where Used Part No. External metal surfaces of the powerhead and powerhead components. 92-802878 55 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 set to factory standards.
MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Inspection and Maintenance Schedule Refer to the table below for proper inspections and maintenance intervals. After each use of the outboard be sure to: • Wash the power package exterior with fresh water. For precaution information, refer to Cleaning Care.
MAINTENANCE Dealer Item 3 Year or 300 Hour Maintenance Replace the spark plugs. Refer to Spark Plug Inspection and Replacement. Inspect the timing belt. X Inspect the wire harness connectors. X Check the remote control cable adjustment, if equipped. X Check the power trim fluid level, if equipped. X Inspect the engine mounts. X Replace the water pump impeller. NOTE: Replace the water pump impeller more often, if overheating occurs or reduced water pressure is noted.
MAINTENANCE Maintenance Schedule Decal 74462 Top Cowl Removal and Installation TOP COWL REMOVAL 1. Unlock the cowl latch located at the rear of the engine by lifting the latch up. 2. Lift up on the rear of the cowl and disengage the front hook. 74510 TOP COWL INSTALLATION 1. Engage the front hook and push the top cowl onto the lower cowl. 2. Push the cowl latch down to lock the cowl in place.
MAINTENANCE Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages. ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and activate the lanyard stop switch to prevent the engine from starting.
MAINTENANCE 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 27259 3. Start the engine and run it at idle speed in neutral shift position. IMPORTANT: Do not run the engine above idle when flushing. 4.
MAINTENANCE The trim tab is an anode. a - Trim tab a 10236 Additional anodes are located on the transom bracket, lower engine mount, and swivel bracket. The number and location of the anodes depends on the model. • Manual tilt models have three additional anodes. b a c 74439 Manual tilt model a - Anode on lower engine mount b - Anode on swivel bracket c - Anode on transom bracket • Power trim models have five additional anodes.
MAINTENANCE Engine Oil CHECKING AND ADDING ENGINE OIL IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. NOTE: Under certain conditions, the operating temperature of 4‑stroke outboard engines may not get hot enough to evaporate the normal fuel and moisture that accumulate in the crankcase. These conditions include operating at idle for long periods, repeated short trips, slow speed or quick stop‑and‑go operation, and operating in cooler climates.
MAINTENANCE 4. Push the dipstick back in all the way. Install the oil fill cap hand‑tight. OIL CHANGE KITS Mercury Marine offers convenient oil change kits for several outboard models ranging from 9.9 hp to 150 hp. These kits contain a new filter, oil, and any additional parts required for a complete oil change. The kits are available in both Mercury Marine and Quicksilver brands. Refer to the following chart for details. Mercury P/N Quicksilver P/N 9.
MAINTENANCE 3. Remove the oil filter by turning the filter counterclockwise. a b c 74049 a - Oil filter b - Oil filter drain c - Cap 4. Clean the mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Install the new filter. When the gasket contacts the base, tighten the filter an additional 3/4 to 1 turn. 5. Remove the drain hose, and place the cap on the end of the oil filter drain fitting. 6. Wipe up any spilled oil. DRAINING THE ENGINE OIL 1.
MAINTENANCE 5. Inspect the drain plug seal and replace it if it is damaged. Lubricate the seal on the drain plug with oil and install. Tighten to the specified torque. 4537 74050 Description Nm lb‑in. lb‑ft Drain plug 24.0 – 17.7 FILLING THE CRANKCASE WITH OIL IMPORTANT: Do not try to fill the oil level to the top of the operating range (upper hole). The oil level is correct as long as it appears in the operating range between the upper and lower hole. 1.
MAINTENANCE 3. Install the oil fill cap. b a c 73882 a - Oil fill cap b - Dipstick c - Oil level operating range 4. With cooling water properly supplied, idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. Fuel System FUEL SYSTEM PRECAUTIONS ! WARNING Fuel is flammable and explosive. Ensure that the key switch is OFF and the lanyard is positioned so that the engine cannot start.
MAINTENANCE DRAINING WATER FROM THE FUEL FILTER Check the fuel filter for water accumulation or sediment. If water is in the fuel, drain the water. If the filter appears to be contaminated, remove and replace. 1. Read Fuel System Precautions, preceding. 2. Inspect the water‑separating fuel filter. If water is present, the red ring inside the filter assembly should float at the water level. 3.
MAINTENANCE FUEL FILTER REPLACEMENT Filter Removal 1. Pull the filter assembly—including the rubber mount—off of the mounting bracket on the engine, and swing the assembly over the edge of the engine cowl. a Fuel filter assembly installed on engine a - Mounting bracket b - Rubber mount b 74507 2. Pull the rubber mount downward, to remove it from the filter assembly. 3. Remove the sight bowl from the filter housing. a a - Filter housing b - Rubber mount c - Sight bowl b c 74508 4.
MAINTENANCE IMPORTANT: The filter is secured and sealed to the filter housing with an O‑ring. The O‑ring may remain on the filter housing. The O‑ring should be removed before installing the fuel filter.
MAINTENANCE 1. Install the fuel filter O‑ring seal into the fuel filter. Verify the O‑ring does not have any folds or kinks. 63114 2. Lubricate the O‑ring with clean engine oil. 3. Push the fuel filter element onto the filter housing. Verify the filter is completely installed by pushing on the filter in the locations shown in the following illustration. 63115 4. Install the sight bowl O‑ring seal onto the sight bowl and place the red ring into the sight bowl. 5.
MAINTENANCE 6. Align the notch in the rubber mount with the rib on the filter housing, and install the rubber mount. b a - Notch in rubber mount b - Rib on filter housing a 74509 7. Install the filter assembly onto the mounting bracket. 8. Connect the fuel line to the engine and prime the engine fuel system. Inspect the fuel filter area for fuel leaks. Repair as needed. Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
MAINTENANCE GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 460 ml (15.6 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High‑Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position. 2. Remove the vent plug. 3. Remove the drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
MAINTENANCE Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 10189 2. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Description Where Used Part No. Extreme Grease Swivel bracket, tilt tube, transom clamp screws, steering cable grease fitting 8M0071842 2-4-C with PTFE Swivel bracket, tilt tube, transom clamp screws, steering cable grease fitting 92-802859A 1 • Swivel bracket ‑ Lubricate through fitting.
MAINTENANCE • Tilt tube ‑ Lubricate through fittings. 15915 Tilt tube grease fittings (manual tilt model shown, others similar) • Lubricate threads on the transom clamp screws (if equipped). 15914 • Steering cable grease fitting (if equipped) ‑ Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting.
MAINTENANCE WARNING ! Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. 3. Lubricate the steering link rod pivot points (if equipped) with lightweight oil. 59491 Propeller Replacement PROPELLER REMOVAL ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
MAINTENANCE 2. Shift the outboard into neutral (N). F N R 74495 Tiller handle models N 63103 Remote control models 3. Straighten the cotter pin, and pull it out using a pair of pliers. 4. Place a block of wood between the gearcase and the propeller to prevent rotation, and remove the propeller nut.
MAINTENANCE 5. Pull the propeller straight off the shaft. b d a c 31926 abcd- Cotter pin Nut Rear thrust washer Front thrust hub IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. PROPELLER INSTALLATION ! WARNING Rotating propellers can cause serious injury or death.
MAINTENANCE 3. Place a block of wood between the gearcase and the propeller to prevent rotation and tighten the propeller nut. Tighten the propeller nut to specified torque, and secure the nut to the shaft with a cotter pin. NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut further to align it with the hole.
MAINTENANCE Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots. 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs for inspection.
MAINTENANCE Description Nm lb‑in. lb‑ft Spark plug 18.0 159.
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). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
STORAGE • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Description Corrosion Guard Where Used Part No. External metal surfaces 92-802878 55 Protecting Internal Engine Components • Remove the spark plugs and add approximately 30 ml (1 oz) of engine oil or inject a five second spray of storage seal inside of each cylinder.
TROUBLESHOOTING Fuse Replacement LOCATION OF FUSES The engine fuses are located at the top of the port side of the engine, near the front. 73868 FUSE IDENTIFICATION AND REPLACEMENT IMPORTANT: Both fuse housings have a space for a spare fuse. Always carry spare fuses. The voltage regulator circuit and the electric starting circuit are protected from overload by 20‑amp and 15‑amp fuses, respectively. If a fuse opens, try to locate and correct the cause of the overload.
TROUBLESHOOTING Remove the fuse and examine the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace the fuse with a new fuse of the same rating. a b Identifying an open fuse a - Good fuse b - Open (blown) fuse 28619 Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Blown fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position.
TROUBLESHOOTING • Ignition system component failure. • Wiring or electrical connection faulty. • Spark plugs fouled or defective. Refer to Maintenance section. Engine Runs Erratically POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section. b.
TROUBLESHOOTING Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the 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.
OWNER SERVICE ASSISTANCE Service Assistance LOCAL REPAIR SERVICE If you need service for your Mercury‑outboard‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package.
OWNER SERVICE ASSISTANCE RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1. Talk with the dealership's sales manager or service manager. 2. If your question, concern, or problem cannot be resolved by your dealership, please contact the Mercury Marine Service Office for assistance.
OWNER SERVICE ASSISTANCE Mexico, Central America, South America, Caribbean Telephone +1 954 744 3500 Fax +1 954 744 3535 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 U.S.A.
OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total . . . . . . . . . . Total Due 122 .
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
