! WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. eng i 90-8M0055683 311 225/250/250-300 Pro/300 Verado FourStroke EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.
Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.
• • • • Provides timely service for all Mercury Marine customers. Offers extended service hours and mobile service, when appropriate. Uses, displays, and stocks adequate inventory of genuine Mercury Precision Parts. Offers a clean, neat shop with well organized tools and service literature.
Conformity assessment module used for exhaust emissions: ☐B +C ☐B +E ☐B +F ☐G ☒H ☐ stage II of Directive ☐ Directive 97/68/EC 88/77/EC or engine type approved according to: Conformity assessment module used for noise emissions: ☐B +D ☐A ☐ Aa ☐G ☒H Other Community Directives applied: Safety of Machinery Directive 98/37/EC; Electromagnetic Compatibility Directive 2004/108/EC Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle ☐ z or sterndrive without inte
Essential requirements standards other normative document/ method technical file Please specify in more detail (* = mandatory standard) Annex 1.B—Exhaust Emissions B.1 engine identification ☐ ☐ ☒ B.2 exhaust emission requirements ☒* ☐ ☐ B.3 durability ☐ ☐ ☒ B.4 owner's manual ☒ ☐ ☐ ISO 8665: 1995 * EN ISO 8178‑1:1996 Annex 1.C—Noise Emissions C.1 Noise emission levels ☒* ☐ ☐ EN ISO 14509 C.
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WARRANTY INFORMATION Warranty Registration.................................................................. 1 Transfer of Warranty.................................................................... 2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada................................. 2 Outboard Limited Warranty.......................................................... 3 3 Year Limited Warranty Against Corrosion................................
Installation Installing Outboard..................................................................... 38 Propeller Selection..................................................................... 40 Transporting Trailering Boat/Outboard .......................................................... 41 Fuel and Oil Fuel Recommendations............................................................. 43 Low Permeation Fuel Hose Requirement .................................
Operation Prestarting Check List................................................................ 98 Operating in Freezing Temperatures......................................... 98 Operating in Saltwater or Polluted Water.................................. 99 Engine Break‑in Procedure........................................................ 99 Starting the Engine.................................................................... 99 Gear Shifting..................................................................
Storage Storage Preparation................................................................. 141 Protecting External Outboard Components............................. 142 Protecting Internal Engine Components.................................. 142 Gearcase................................................................................. 142 Positioning Outboard for Storage............................................ 143 Battery Storage........................................................................
WARRANTY INFORMATION Warranty Registration UNITED STATES AND CANADA To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the selling 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. A copy of the warranty registration should be provided to you by your selling dealer.
WARRANTY INFORMATION Transfer of Warranty UNITED STATES AND CANADA The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. 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.
WARRANTY INFORMATION To transfer the plan to the subsequent owner, contact Mercury Product Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
WARRANTY INFORMATION 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.
WARRANTY INFORMATION 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 remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.
WARRANTY INFORMATION 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,
WARRANTY INFORMATION For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty. DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED.
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 predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
WARRANTY INFORMATION Corrosion damage caused by stray electrical currents (onshore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited Outboard Warranty.
WARRANTY INFORMATION 5. Additional service work requested by customer other than that necessary to satisfy the warranty obligation. 6. Labor performed by other than an authorized dealer may be covered only under the 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). 7.
WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product. U.S.
WARRANTY INFORMATION d. Ignition coil and/or control module e. 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 c. Vacuum, temperature, check and time sensitive valves and switches d.
WARRANTY INFORMATION WHAT IS COVERED: Mercury Marine warrants the components of the emissions control systems (see the components listed in the Emission Control System Components) of its new, 2001 model year and later outboards, sold by a California dealer to retail customers residing in California, to be free from defects in material or workmanship, that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certific
WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
WARRANTY INFORMATION Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.
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.
WARRANTY INFORMATION 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 dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.
WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission 42538 The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines.
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 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 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.
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.
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.
GENERAL INFORMATION ! WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.
GENERAL INFORMATION 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 heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
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 the boat.
GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating.
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 • • • 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. 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.
GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.
GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 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.
GENERAL INFORMATION 2. Examples of poor ventilation while the boat is moving: a b 21628 a - Operating the boat with the trim angle of the bow too high b - Operating the boat with no forward hatches open (station wagon effect) 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. IMPORTANT: Check with your dealer before installing accessories.
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.
GENERAL INFORMATION Watch fallen skiers. 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 assist the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents.
GENERAL INFORMATION Models 225 250 Kilowatts 165 184 250 Pro 300 Pro 184 300 221 Full throttle RPM range 5800‑6400 Idle speed in neutral gear1. 550 RPM Number of cylinders 6 Piston displacement 2,598 cc (158.5 cid) Cylinder bore 82 mm (3.23 in.) Stroke 82 mm (3.23 in.) 221 Valve clearance (cold) Intake valve 0.150–0.270 mm (0.0059–0.0106 in.) Exhaust valve 0.350–0.470 mm (0.0137–0.0185 in.) Recommended spark plug NGK ILFR6G‑E Spark plug gap 0.8 mm (0.0315 in.
GENERAL INFORMATION Component Identification j i a h b g f d eng c e 28919 37 a - Rear cowl b - Lower cowl chaps c - Anti‑ventilation plate d - Gearcase e - Cooling water intake holes f - Spray plate g - Pedestal h - Engine flush i - Auxiliary tilt switch j - Top cowl
INSTALLATION Installing Outboard ! 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. Do not accelerate above idle speed in water that may contain underwater obstacles if the outboard is not attached to the transom correctly.
INSTALLATION MAXIMUM OUTBOARD MOUNTING HEIGHT The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76.2 cm (30 in.) for XL models, and 88.9 cm (35 in.) for XXL models. Mounting the outboard higher may cause damage to the gearcase components. 28929 Maximum Static Waterline The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE" mark on the idle relief grommet (located at the rear of the outboard) when the outboard is fully tilted in/ down.
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 with the boat normally loaded (refer to General Information ‑ Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed.
TRANSPORTING Trailering Boat/Outboard When transporting the boat on a trailer, the outboard should be positioned and/or supported in one of the following ways: 1. If the boat trailer provides sufficient ground clearance, the outboard may be tilted down to the vertical operating position with no additional support required. 28780 2.
TRANSPORTING 3. For maximum ground clearance, the outboard can be tilted to the full tilt position and supported using the outboards tilt support bracket and/or an accessory transom support device. 28779 Additional clearance may be required for railroad crossings, driveways and trailer bouncing. Refer to your local dealer for recommendations. IMPORTANT: Do not rely on the power trim/tilt system to maintain proper ground clearance for trailering.
FUEL AND OIL Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.
FUEL AND OIL These reformulated gasolines are acceptable for use in your Mercury Marine engine. GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.
FUEL AND OIL IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol‑blend fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place.
FUEL AND OIL Fuel Demand Valve (FDV) Requirement Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and the engine. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage. The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve.
FUEL AND OIL Since sealed fuel tanks are not openly vented, they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air. This is normal. REMOVING THE FUEL CAP b a - Fuel cap b - Manual vent screw c - Tab lock a c 46290 IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening. 1. Open the manual vent screw on top of the fuel cap. 2. Turn the fuel cap until it contacts the tab lock. 3.
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 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 AND OIL IMPORTANT: The use of non‑detergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives are not recommended. VERADO ENGINE OIL OIL CAPACITY: 7.0L (7.4 U.S. qt.) SAE 25W-50 +120 +100 +80 +60 +40 +20 0 F +49 +38 +27 +16 +4 -7 -18 7.0L C 29430 Checking and Adding Engine Oil IMPORTANT: Do not overfill.
FUEL AND OIL IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil level is correct as long as it appears in the operating range (cross hatched region). a 15730 a - Oil level operating range 6. If the oil level is below the operating range (cross hatched region), remove the oil filler cap and add approximately 500 ml (16 oz) of specified outboard motor oil. Allow a few minutes for the added oil to drain to the oil sump and recheck the dipstick.
FUEL AND OIL 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. 7. Push the dipstick back in all the way. 8. Reinstall the oil fill cap hand tight. 9. Reinstall top cowl.
FEATURES AND CONTROLS Panel Mount Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling back to increase speed. N R F 3413 2. Shift lock ‑ Pressing the shift lock allows the engine to shift.
FEATURES AND CONTROLS 3. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5152 4. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn indicates throttle only is engaged. Advance throttle to increase engine RPM.
FEATURES AND CONTROLS 5. Stop/start button ‑ Allows the boat operator to start or stop the engine without using the ignition key. The ignition key must be in the "ON" position to start the engine. 3414 6. Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch. a - Lanyard stop switch a 22964 7.
FEATURES AND CONTROLS 8. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to tension desired. a - + b a - Detent tension adjustment screw b - Control handle tension adjustment screw 5171 Single Handle Console Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle.
FEATURES AND CONTROLS 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5185 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the remote control handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to the desired tension. 4.
FEATURES AND CONTROLS 6. Select button ‑ Selects the System View on‑screen options and confirm data entries. Holding the select button for two seconds will pause the slide show if selected in Favorites. Holding the select button for three seconds will activate the reset data function (except when in the slide show function). Holding the select button for five seconds or more will bring up the Home page. 7. Neutral LED ‑ The neutral LED illuminates when engine is in neutral gear position.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Idle position is preferred when doing a helm transfer.
FEATURES AND CONTROLS 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine. b a ACTIVE THROTTLE ONLY a b ACTIVE STATION SELECT SYNC THROTTLE ONLY STAT ION SELECT 22753 a - Active light b - Throttle only/station select button 4. The "ACTIVE" light will switch off at the original helm.
FEATURES AND CONTROLS Slim Binnacle Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pushing back to increase speed. N F R 12871 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down.
FEATURES AND CONTROLS 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the remote control handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to the desired tension. 4.
FEATURES AND CONTROLS 8. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn will sound once and the neutral light will start flashing. The horn will sound twice when throttle only is engaged. Advance throttle to increase engine RPM.
FEATURES AND CONTROLS The helm transfer function allows the boat operator to select which helm is in control of engine operation. Pressing the throttle only/station select button two times allows engine control to be transferred to a new helm. When a helm transfer is initiated, the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm. Adjust the control handles to the desired throttle and gear position.
FEATURES AND CONTROLS Dual Handle Console Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling back to increase speed. N F R 3417 2.
FEATURES AND CONTROLS 4. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to the desired tension. a b a - Detent tension adjustment screw b - Control handle friction adjustment screw 28556 5. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear.
FEATURES AND CONTROLS 8. Neutral LEDs ‑ The neutral LEDs illuminate when engines are in neutral gear position. The lights will flash when in throttle only mode. NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the control handle. 9. Active LED ‑ The active LED illuminates to show the remote control is active and ready for use. 10. Sync LED ‑ The sync LED illuminates when the RPM of the two engines are being synchronized by the DTS system.
FEATURES AND CONTROLS Engine auto synchronization will automatically engage when engine speed is over 900 RPM for two seconds and remote control handles are positioned within 10% of each other. The "SYNC" light will turn on when the engines are synchronized. Auto synchronization will stay engaged up to 95% throttle opening. To disengage, move one or both control handles until they are more than 10% apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.
FEATURES AND CONTROLS NOTE: There is a 10 second time frame to complete a helm transfer. If the helm transfer is not completed, the action will be cancelled and a double beep will sound. Pressing the throttle only/station select button again will reinitiate a helm transfer. 1. Place active remote control lever to idle position. 2. Proceed to the inactive helm and position remote control lever to the idle position. 3. Press throttle only/station select button two times.
FEATURES AND CONTROLS Dual Handle Console Control with CAN Trackpad Features and Operation DUAL-HANDLE CONSOLE CONTROL WITH CAN TRACKPAD: FEATURES AND OPERATION 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear.
FEATURES AND CONTROLS 4. Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering. To activate, move the control handles into forward detent and press the button. Use the ‑ or + buttons to decrease or increase speed, up to a maximum of 1000 RPM.
FEATURES AND CONTROLS 9. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines. a L RA UT NE b NEUTRAL - TROLL + SYNC c TRANSFER g 1 LEVER THROTTLE ONLY d f e abcdefg- DOCK 22133 Neutral LEDS Troll button Transfer button Dock button Throttle only 1 lever button Sync button 10.
FEATURES AND CONTROLS 11. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Neutral position is preferred when doing a station transfer.
FEATURES AND CONTROLS Synchronizing Helms Prior to Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash. The light blinks faster as the handles are nearing match position. Once the light stays on continuously, the handles are matched and the button can be pressed again to complete the transfer.
FEATURES AND CONTROLS Port Engine Center Engine Starboard Engine Control Handle Function Port engine throttle and shift = controlled by port control handle Running Off Running Running Off Off Port engine throttle and shift = controlled by port control handle Off Off Running Starboard engine throttle and shift = controlled by starboard control handle Off (ignition key switch turned on) Running Off (ignition key switch turned on) Center engine throttle and shift = neutral/idle unless both co
FEATURES AND CONTROLS Port Outer Engine Port Inner Engine Starboard Inner Engine Starboard Outer Engine Control Handle Function Port inner and outer engines throttle and shift = controlled by port control handle Running Running Off Running Running Off Off (ignition key switch Running turned on) Running Running Off (ignition key switch Running turned off) Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by starboard control handle Off Port
FEATURES AND CONTROLS Port Outer Engine Running Port Inner Engine Off Off (ignition key switch Running turned on) Starboard Inner Engine Off Starboard Outer Engine Running Off (ignition key switch turned on) Running Control Handle Function Port outer engine throttle and shift = controlled by port control handle Starboard outer engine throttle and shift = controlled by starboard control handle Port inner engine throttle and shift = controlled by port control handle Starboard inner engine throttle
FEATURES AND CONTROLS If a failure should occur while underway which causes the starboard outer engines into forced neutral/idle condition, the inner starboard engine will also be forced to neutral/idle. Operation to the inner engine can be restored by moving the starboard control handle back into neutral and then reengaging. If a failure should occur while underway which causes the port outer engines into forced neutral/idle condition, the inner port engine will also be forced to neutral/idle.
FEATURES AND CONTROLS 2. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn will sound once and the neutral light will start flashing. The horn will sound twice when throttle only is engaged. Advance throttle to increase engine RPM.
FEATURES AND CONTROLS 7. Sync LED ‑ The "SYNC" LED illuminates when the RPM of the engines are being synchronized by the DTS system. abcde- Neutral LEDS Select button Arrow trackpad Sync LED Throttle only/station select button f - Active LED a b NEUTRAL c SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT f d e 13854 SYNCHRONIZING ENGINES The auto synchronizing feature, when engaged, will automatically adjust all engine speeds to match the speed of the starboard engine.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Idle position is preferred when doing a helm transfer.
FEATURES AND CONTROLS 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine. b a ACTIVE THROTTLE ONLY STATION SELECT a b ACTIVE SYNC THROTTLE ONLY STAT ION SELECT 22753 a - Active light b - Throttle only/station select button 4. The "ACTIVE" light will switch off at the original helm.
FEATURES AND CONTROLS Port Engine Center Engine Starboard Engine Control Handle Function Port engine throttle and shift = controlled by port control handle Running Running Running Starboard engine throttle and shift = controlled by starboard control handle Center engine throttle = average of port and starboard engines Center engine shift = neutral unless both engines are in the same gear Running Running Off Port and center engine throttle and shift = controlled by port control handle Off Runnin
FEATURES AND CONTROLS If a failure should occur while underway which causes one of the outer engines into forced neutral/idle condition, the center engine will also be forced to neutral/idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral and then reengaging.
FEATURES AND CONTROLS Port Outer Engine Port Inner Engine Off (ignition key switch Running turned off) Running Running Running Off Off (ignition key switch Running turned on) Starboard Inner Engine Starboard Outer Engine Control Handle Function Running Running Port inner engine throttle and shift = controlled by starboard control handle Running Off (ignition key switch turned off) Starboard inner engine throttle and shift = controlled by port control handle Off Running Off (ignition key s
FEATURES AND CONTROLS Turning off the port outer engine while underway will cause the port inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the port outer engine ignition key to the on position and moving the port control handle back into neutral position and then reengaging. The inner engine speed and gear shift will then be controlled by the port control handle.
FEATURES AND CONTROLS 2. Neutral lights ‑ The neutral lights illuminate when the engine is in neutral gear position. The lights will flash when the engine is in throttle only mode. NOTE: Gear position is determined by the position of the shift actuator on the engine, not the position of the control handle. 3. Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering.
FEATURES AND CONTROLS 7. 1 lever button ‑ Pressing the "1 LEVER" button initiates single lever mode. Single lever mode enables the throttle and shift functions of both engines to be controlled by the port control handle. To turn off single lever mode, shift the engine into neutral and press the "1 LEVER" button. 8. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines.
FEATURES AND CONTROLS 10. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Neutral position is preferred when doing a station transfer.
FEATURES AND CONTROLS Synchronizing Helms Prior to Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash. The light blinks faster as the handles are nearing match position. Once the light stays on continuously, the handles are matched and the button can be pressed again to complete the transfer.
FEATURES AND CONTROLS It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present. For visual display of the specific engine functions and additional engine data, refer to SmartCraft Product information, following. A few of the noncritical conditions indicated by the intermittent short beeps for six seconds can be corrected by the operator.
FEATURES AND CONTROLS The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems. Power Trim and Tilt The 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 trimming down.
FEATURES AND 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 the outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, this being an awareness of some potential control hazards. Consider the following lists carefully: 1.
FEATURES AND CONTROLS TILTING TO FULL UP POSITION Tilt at Helm NOTE: The trim/tilt switch will remain active for 15 minutes after the ignition key switch has been turned off. 1. If the ignition key switch has been turned off for over 15 minutes, turn it to the "ON" position. 2. Press the trim/tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position.
FEATURES AND CONTROLS MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. 28497 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve.
FEATURES AND CONTROLS 2. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. 3. Operate the engine at slow speed only. With the outboard tilted past 20° trim limit, the warning horn will sound and engine speed will be automatically limited to approximately 2000 RPM. The outboard must be tilted (trimmed) down below the maximum trim range to allow operation above 2000 RPM.
OPERATION Prestarting Check List • • • • • • • • • • Operator knows safe navigation, boating, and operating procedures. An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). A ring type life buoy or buoyant cushion designed to be thrown to a person in the water. Know your boats' maximum load capacity. Look at the boat capacity plate. Fuel supply OK.
OPERATION Operating in Saltwater or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water. This will prevent a buildup of deposits from clogging the water passages. Refer to Maintenance ‑ Flushing the Cooling System. 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.
OPERATION 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. 1. Make sure the cooling water intake is submerged. 28928 2. Check the engine oil level. 27780 3. Open fuel tank vent on manual venting type tanks. 19748 NOTE: The engine will not start unless the lanyard is set to the "RUN" position.
OPERATION 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to neutral (N) position. N F N R F R 3413 3417 NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON" position for approximately one minute. This operates the fuel lift pump.
OPERATION 6. Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking. Turn the key to "START" position again until engine starts. A CC ON A RT ST F A CC ON OF A RT ST F OF 3485 7. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.
OPERATION • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). N R F 3427 • • When shifting, always stop at neutral position and allow the engine speed to return to idle. Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position. 3428 • Advance the control lever to further increase speed.
OPERATION • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). N R F 3417 • • When shifting, always stop at neutral position and allow the engine speed to return to idle. Advance the control lever to further increase speed. Stopping the Engine IMPORTANT: Turning key to the "START" position while the engine is running will result in engine shut down, while leaving the DTS system active.
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. Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.
MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION a THIS ENGINE CONFORMS TO CALIFORNIA AND U.S.
MAINTENANCE • • • • • • Check that lanyard stop switch stops the engine. Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retorque the outboard mounting fasteners to 75 Nm (55 lb‑ft). Visually inspect the fuel system for deterioration or leaks. Check steering system for binding or loose components. Visually check power steering fittings and hoses for leaks or signs of damage.
MAINTENANCE • • • Check power steering fluid. See Checking Power Steering Fluid. Inspect battery. See Battery Inspection. Saltwater usage: Remove and inspect spark plugs for corrosion and replace spark plugs as necessary. Apply a thin coating of Anti‑Seize Compound only on threads of spark plug prior to installation. See Spark Plug Inspection and Replacement. Tube Ref No. 81 • • • • • • • Description Anti-Seize Compound Where Used Part No.
MAINTENANCE • Replace accessory drive belt. See Accessory Drive Belt Inspection.1. BEFORE PERIODS OF STORAGE • 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. NOTE: The outboard can be tilted or in the vertical operating position during flushing. 1.
MAINTENANCE 5. When flushing is complete, turn off water and disconnect the water hose. 6. Install the flushing connector to the fitting on the bottom cowl. Tighten the connector securely. Cowl Removal and Installation COWL REMOVAL IMPORTANT: Most maintenance points are accessible by removing the top cowl only. 1. Pull up on the top cowl lock latch. 28946 2. Pull top cowl forward and lift off. 3. Pull lower cowl release latch up. 4. Remove rear cowl towards aft of outboard. 28770 COWL INSTALLATION 1.
MAINTENANCE 2. Lock cowl in place by pulling lower cowl latch down. 29591 3. Place top cowl into position over engine, front first. Ensure cowl fits properly into the rubber seal. 4. The top cowl will lock into place when downward pressure is applied to the back side of cowl. Ensure cowl is securely fastened by pulling up on back of cowl. Cleaning Care for Top and Bottom Cowls IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches.
MAINTENANCE Cleaning Care for the Powerhead (Saltwater Use) If the outboard is operated in saltwater, remove the top cowl and flywheel cover. Inspect the powerhead and powerhead components for salt build‑up. Wash off any salt build‑up from the powerhead and powerhead components with fresh water. Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry.
MAINTENANCE Verado Engine Battery Specifications IMPORTANT: Verado engines require a 12 volt AGM (absorbed glass mat) marine starting battery that meets the minimum ratings. For best performance, Mercury Marine does not recommend using the more common flooded (wet cell) or gel cell type lead acid batteries for starting Verado engines. Each Verado engine must be equipped with its own starting battery.
MAINTENANCE When connecting the engine battery, hex nuts must be used to secure the battery leads to the battery posts. Tighten the hex nuts to the specified torque. ! WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections. Description Nm lb‑in. Hex nuts 13.
MAINTENANCE Air Filter The air filter assembly is a serviceable item and can be cleaned with warm soap water if required. AIR FILTER REMOVAL AND CLEANING 1. Loosen air filter clamp screw. 2. Remove crankcase ventilation hose. a b c d a - Crankcase ventilation hose b - Fuel system module (FSM) purge valve hose c - Filter assembly d - Clamp screw 3664 3. Remove air filter assembly and disconnect fuel system module (FSM) purge valve hose by rotating the air filter assembly and pulling on hose. 3665 4.
MAINTENANCE Tube Ref No. Description 4 Stroke 10W30 Outboard Oil 110 Where Used Part No. Air filter element 92-858045K01 AIR FILTER INSTALLATION 1. Install fuel system module (FSM) purge valve hose to air filter assembly. 3665 2. Install crankcase ventilation hose. 3. Install air filter assembly and tighten clamp screw securely.
MAINTENANCE Fuel System ! WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any spilled fuel immediately. IMPORTANT: Use an approved container to collect and store fuel.
MAINTENANCE ! CAUTION Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and skin from pressurized fuel and vapors. 3. Place a rag or towel around the valve. Release the fuel pressure by pushing in on the valve stem.
MAINTENANCE 4. Slide the filter holder up to release it from the bracket. Hoses and wire harness can remain attached to filter holder. a b 29644 a - Fuel filter b - Filter holder 5. Use the fuel filter removal/installation tool or the shaft of a screwdriver between the lugs on the filter cap and unscrew the fuel filter.
MAINTENANCE Filter Draining 1. Tip the filter holder to drain any fluid into an approved container. a 29648 a - Filter holder Filter Installation 1. Lubricate the O‑ring seals with oil. 2. Install the filter and tighten securely.
MAINTENANCE 3. Place the filter holder mounting tabs into the slots on the bracket and push down on the filter holder to slide the mounting tabs into the lock position.
MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition key to the run position, forcing fuel into the filter. Corrosion Control Anodes The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion.
MAINTENANCE 2. Straighten the bent tabs on the propeller nut retainer. 26900 3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. 29592 4. Pull propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5.
MAINTENANCE 6. Flo‑Torq II drive hub propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c e d f 26941 a - Propeller nut b - Propeller nut retainer c - Thrust hub d - Propeller e - Replaceable drive sleeve f - Forward thrust hub 7. Place a block of wood between the gearcase and the propeller and torque to specifications. Description Nm Propeller nut 75 lb‑in. lb‑ft 55 8.
MAINTENANCE Propeller Replacement ‑ 31.75 mm (1‑1/4 in.) Diameter Propeller Shaft ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Shift outboard to neutral position. 2.
MAINTENANCE 5. Heavy‑duty propeller hub ‑ Install the propeller hub, propeller, washer, Belleville washer, washer, and propeller nut onto the shaft. a b c d e f 44856 abcdef- Propeller nut Washer Belleville washer Washer Propeller Propeller hub 6. Place a block of wood between the gearcase and propeller and tighten the propeller nut to the specified torque. 2691 Description Nm Propeller nut 75 lb‑in. lb‑ft 55 Spark Plug Inspection and Replacement 1. Remove top and rear cowlings.
MAINTENANCE 2. Disconnect the six wiring harness connectors from pencil coil connections. 3. Remove mounting bolts, using a twisting motion, and pull pencil coils from spark plugs. a b a - Wiring harness connector b - Pencil coil c - Bolt c 3658 4. Remove the spark plugs to inspect. Replace spark plug if electrode is worn, threads of seal area are corroded, or the insulator is rough, cracked, broken, blistered, or fouled. 28438 5. Set the spark plug gap to specifications.
MAINTENANCE 8. 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. Description Nm Spark plug 27 lb. in. lb. ft. 20 9. Push pencil coils into place over the spark plugs using a twisting motion. 10. Secure coils with retained bolts. Torque to specifications. Description Bolts Nm lb. in. 8 71 lb. ft. 11. Connect the six wiring harness connectors to pencil coil connections.
MAINTENANCE Remove the cover from the fuse holder. Remove the suspected blown fuse and look at the silver band inside the fuse. If band is broken, replace the fuse. Replace the fuse with a new fuse with the same amp rating. a b e c d j abcdefghij- eng f g 20 20 20 20 20 20 20 2 h i 29663 Fuse puller Fuse holder Good fuse Blown fuse Electronic control module and purge valve "ECM" ‑ 20 amp fuse Ignition coils "IGN.
MAINTENANCE DTS Wiring System ! WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. • • • Verify the harnesses are not routed near sharp edges, hot surfaces, or moving parts.
MAINTENANCE 4. Remove the power trim fill cap. The fill cap only requires 1/4 turn to remove. a b abcd- c Tilt support lever Power trim fill cap Tilt support bracket Pedestal d 29312 5. The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF). Tube Ref No. 114 Description Power Trim and Steering Fluid Where Used Part No.
MAINTENANCE Checking Power Steering Fluid Remove power steering cover and fill cap to check fluid level. The fluid level should be slightly below the bottom of the fill hole. Use SAE 0W‑30 synthetic power steering fluid, if needed. b a c 29315 a - Power steering cover b - Fill cap c - Fill/full level Tube Ref No. 138 Description Where Used Part No.
MAINTENANCE IMPORTANT: The pump method is preferred to remove engine oil from XXL models. If the drain method is used, an oil drain funnel must be used to divert oil from the lower splash plate and into the container. 1. Tilt the outboard out/up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump. 2. Place the outboard in a vertical position. 3.
MAINTENANCE 4. Loosen the drain plug/seal washer. Install the oil drain funnel over the drain plug/seal washer. a - Drain plug/seal washer b - Oil drain funnel b a 28778 Oil Drain Funnel 91‑892866A01 Diverts draining engine oil from contacting the anti‑splash and anti‑cavitation plates. 4993 5. Remove drain plug/seal washer and drain the engine oil into a container. 6. Reinstall the drain plug/seal washer.
MAINTENANCE 3. Unscrew the old filter by using an oil filter wrench tool and turning the filter counterclockwise. a a - Oil filter 29662 Oil Filter Wrench 91‑889277 Aids in the removal of the oil filter. 5221 4. Clean the oil filter mounting base. 5. Apply a film of clean oil to the filter gasket. Do not use grease. 6. Screw the new filter on until the gasket contacts the base, then tighten the filter another 3/4 to 1 turn.
MAINTENANCE OIL FILLING 1. Remove the oil fill cap and add the recommended oil to the midpoint of the operating range (midpoint of cross hatched region). Adding approximately 7 liter (7.4 US qt) will bring the oil level to midpoint of the cross hatched region. 29681 2. Reinstall the oil fill cap. 3. With the outboard in water or a cooling water flush hose connected, idle the engine for five minutes to check for leaks at the oil filter. 4. Stop the engine and check the oil level.
MAINTENANCE 122 MM (4.8 IN.) DIAMETER GEARCASE Draining Gearcase 1. Place outboard in a vertical operating position. 2. Remove propeller. Refer to Propeller Replacement. 3. Place drain pan below outboard. 4. Remove vent plug and fill/drain plug and drain lubricant. b a 22692 a - Vent plug b - Fill/drain plug Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 970 ml (32.8 fl oz). Gearcase Lubricant Recommendation Mercury or Quicksilver High Performance Gear Lubricant.
MAINTENANCE 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. a b 22693 a - Vent hole b - Fill 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. 137 MM (5.4 IN.) DIAMETER GEARCASE Draining Gearcase 1. Place outboard in a vertical operating position.
MAINTENANCE 4. Remove vent plug and fill/drain plug and drain lubricant. a - Vent plug b - Fill/drain plug a b 45900 Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 850 ml (28.7 fl oz). Gearcase Lubricant Recommendation Mercury or Quicksilver High Performance Gear Lubricant. Checking Lubricant Level and Refilling Gearcase 1. Place outboard in a vertical operating position. 2. Remove vent plug/sealing washer. 3. Remove fill/drain plug.
MAINTENANCE 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
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 Tube Ref No. 124 Description Where Used Part No. Fuel System Treatment and Stabilizer Fuel tank 92-8M0047932 Protecting External Outboard Components • • Touch up any paint nicks. See your dealer for touch‑up paint. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. 120 Description Corrosion Guard Where Used Part No.
STORAGE Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of the outboard. NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position. Battery Storage • • • • eng Follow the battery manufacturer's instructions for storage and recharging.
TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 5 amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Shift actuator failure. "Gear Shift Diff" error message shown on System View. Refer to Maintenance section. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure. • Wiring or electrical connection faulty.
TROUBLESHOOTING 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. 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.
TROUBLESHOOTING • • • Excessive use of electrical accessories. Defective rectifier, alternator, or voltage regulator. Open circuit in the alternator output wire (fused link).
OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Service Away from Home If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer.
OWNER SERVICE ASSISTANCE • • • • • Your name and address Daytime telephone number Model and serial number of your outboard The name and address of your dealership Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada Telephone English ‑ (920) 929‑5040 Français ‑ (905) 636‑4751 Fax English ‑ (920) 929‑5893 Français ‑ (905) 636‑1704 Website www.mercurymarine.
OWNER SERVICE ASSISTANCE Asia, Singapore eng Telephone (65) 65466160 Fax (65) 65467789 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore, 508944 149
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
