Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage. Details of your nearest dealer can be found on www.marinepower.com where country maps and full contact information are displayed. Is your engine properly registered for warranty purpose? www.
General steering system ABYC P‑17 The following applies to all product covered by this manual: Safety of Machinery Directive 98/37/EC Principles of safety integration (1.1.2) EN 292‑1; EN 292‑2; EN 1050 Noise (1.5.
TABLE OF CONTENTS WARRANTY INFORMATION Transfer Of Warranty.............................................................................................................................. 1 Warranty Registration United States And Canada................................................................................. 1 Warranty Registration Outside The United States And Canada.............................................................
TABLE OF CONTENTS Power Trim and Tilt............................................................................................................................... 34 Operation Pre-Starting Check List......................................................................................................................... 37 Operating In Freezing Temperatures.................................................................................................... 37 Operating In Salt Water Or Polluted Water......
TABLE OF CONTENTS Battery Will Not Hold Charge................................................................................................................ 79 Owner Service Assistance Local Repair Service.............................................................................................................................80 Service Away From Home....................................................................................................................80 Parts And Accessories Inquiries....
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WARRANTY INFORMATION Transfer Of Warranty The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. 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 3. A copy of the Warranty Registration Card, designated as the Purchaser's Copy, MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer. This card represents your factory registration identification, and should be retained by you for future use when required.
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 DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU.
WARRANTY INFORMATION 10. Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit. 11. Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty. 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 13.
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person on board is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION U.S.
GENERAL INFORMATION Read the following Safety Information before proceeding. 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 Whenever a boat is moving (coasting) and the outboard gear shift is in neutral position, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury. WHILE BOAT IS STATIONARY ! WARNING Stop your engine immediately whenever anyone in the water is near your boat.
GENERAL INFORMATION ob00313 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water. ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction.
GENERAL INFORMATION ob00315 ! WARNING To avoid serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater obstacle maintain a top speed no greater than minimum planing speed. Striking a floating or underwater object could result in an infinite number of situations. Some of these situations could result in the following: • Part of the outboard or the entire outboard could break loose and fly into the boat.
GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. ob00316 Example of desired air flow through the boat POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
GENERAL INFORMATION ! WARNING Check with your dealer before installation of accessories. The misuse of acceptable accessories or the use of unacceptable accessories can result in serious injury, death, or product failure. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
GENERAL INFORMATION a Serial Number OTXXXXXX b 20XX XXXX H P L B e MAX RPM K W K G c d XX ob01322 abc- Serial number Model year Model designation de- Year manufactured Certified Europe Insignia (as applicable) 200/225/250/275 Specifications ‑ International Models 200/225/250/275 Horsepower 200/225/250/275 Kilowatts 149/168/186/205 Full Throttle RPM Range 5800‑6400 Idle Speed in Neutral Gear1. 550 RPM Number of Cylinders 6 Piston Displacement 2,598 cc (158.
GENERAL INFORMATION Models 200/225/250/275 Engine Oil Capacity With Oil Filter Replacement 7.0 liters (7.4 qt) 1000 Marine Cranking Amps (MCA), 800 Cold Cranking AMPS (CCA) or 180 Ampere Hour (Ah) Battery Rating Sound at Drivers Ear (ICOMIA 39‑94) 4‑Stroke 79.
INSTALLATION Installing Outboard ! WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. IMPORTANT: For optimum boat performance and detailed engine installation instructions, refer to the outboard installation manual, supplied with the outboard.
INSTALLATION ob01312 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. If waterline is above "MAX STATIC WATERLINE" mark, adjust boat load forward or increase (raise) outboard mounting height to correctly place mark above waterline.
INSTALLATION Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.
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. 2.
TRANSPORTING ob01267 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. The power trim/tilt system is not intended to support the outboard for trailering. Shift the outboard to forward gear. This prevents the propeller from spinning freely when boat is trailered.
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 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 3. Remove the top cowl. Refer to Maintenance ‑ Cowl Removal And Installation. 4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way. 5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region). IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region).
FEATURES AND CONTROLS Remote Control Features PANEL MOUNT FEATURES d c e b - + f h a 3409 g abcd- Lanyard/lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch. Control handle – Forward (F), Neutral (N), Reverse (R). Shift lock ‑ Refer to Operation ‑ Gear Shifting. Trim/tilt switch ‑ Refer to Power Trim and Tilt. e- fgh- 25 Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear.
FEATURES AND CONTROLS CONSOLE MOUNT FEATURES - SINGLE ENGINE b d e - a + h c abcde- f g Control handle ‑ Forward (F), Neutral (N), Reverse (R). Trim/tilt switch ‑ Refer to Power Trim and Tilt. Active light ‑ Illuminated when remote control is active and ready. Neutral light ‑ Illuminated when engine is in neutral gear position. Blinks when engine is in throttle only mode. Select key ‑ Used to select System View on‑screen options, if equipped.
FEATURES AND CONTROLS CONSOLE MOUNT FEATURES - DUAL ENGINE b d i a SYNC ACTIVE f THROTTLE ONLY STATION SELECT c h bcde- + j e a- - Trim/tilt switch ‑ Refer to Power Trim and Tilt. Control handles ‑ Forward (F), Neutral (N), Reverse (R). Active light ‑ Illuminated when remote control is active and ready to use. Neutral light ‑ Illuminated when engine is in neutral gear position. Blinks when engine is in throttle only mode. Select key ‑ Used to select System View on‑screen options, if equipped.
FEATURES AND CONTROLS SLIM BINNACLE CONSOLE MOUNT FEATURES - SINGLE ENGINE b a d + e g START STOP c abcd- f Control handle ‑ Forward (F), Neutral (N), Reverse (R). Trim/tilt switch ‑ Refer to Power Trim and Tilt. Active light ‑ Illuminated when remote control is active and ready. Neutral light ‑ Illuminated when engine is in neutral gear position. Blinks when engine is in throttle only mode.
FEATURES AND CONTROLS SHADOW MODE REMOTE CONTROL FEATURES b a d e NEUTRAL i + f SELECT SYNC ACTIVE THROTTLE ONLY j STATION SELECT c g h abcde- 14642 Trim/tilt switch ‑ Refer to Power Trim and Tilt. Control handle ‑ Forward (F), Neutral (N), Reverse (R). Active light ‑ Illuminated when remote control is active and ready. Neutral light ‑ Illuminated when engine is in neutral gear position. Blinks when engine is in throttle only mode.
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 Off Running Running Off Port and center engine throttle and shift = controlled by port control handl
FEATURES AND CONTROLS Port Engine Off Center Engine Off Off (ignition key switch turned on) Running Starboard Engine Control Handle Function Running Starboard engine throttle and shift = controlled by starboard control handle Off (ignition key switch turned on) Center engine throttle and shift = neutral/idle unless both control handles are in the same gear Turning off one of the outer engines while underway will cause the center engine to go into forced neutral/ idle.
FEATURES AND CONTROLS Warning Horn Function Sound Description Low battery Four beeps every 2 minutes Battery charging unable to keep up with demand. Raise engine speed, to increase charge, or shut down accessories, to reduce demand. Cooling system problem Continuous Engine Guardian System is activated. Power limit will vary with level of overheat. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
FEATURES AND CONTROLS Warning Horn Function Sound Description Engine overspeed Continuous The warning horn is activated any time the engine speed exceeds the maximum allowable RPM. The system will limit the engine speed to within the allowable range. Engine overspeed indicates a condition that should be corrected. Overspeed could be caused by incorrect propeller pitch, engine height, trim angle, tilt angle (shallow water operation) etc.
FEATURES AND CONTROLS 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. Moving the outboard further away from the boat transom is called trimming out or trimming up. The term trim generally refers to the adjustment of the outboard within the first 20° range of travel.
FEATURES AND CONTROLS • Lift the bow higher out of the water. • Generally increase top speed. • Increase clearance over submerged objects or a shallow bottom. • In excess can cause boat porpoising (bouncing) or propeller ventilation. • Cause engine overheating if any cooling water intake holes are above the water line. 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.
FEATURES AND CONTROLS ob01143 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. 1. Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.
OPERATION Pre‑Starting 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 ! CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. 1. Make sure the cooling water intake is submerged. ob01310 2. Check the engine oil level. 3. Open fuel tank vent on manual venting type tanks. ob00667 ob00348 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. 4.
OPERATION N R F 3413 NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote control handle. 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. ACC ON ART ST F ACC ON OF ART ST F OF 3485 7.
OPERATION 3416 1. Move the control handle into neutral position. 2. Depress shift lock button, press and hold the throttle only button while moving the control handle ahead to the forward detent. The horn sound indicates that throttle only is engaged. 3. Advance the control handle to increase engine RPM. Engine RPM is limited to prevent engine damage. 4. To disengage, return the control handle back to neutral position.
OPERATION ob00348 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 5. Shift outboard to neutral (N) position. ob00350 N R F 3417 6. 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.
OPERATION ACTIVE THROTTLE ONLY STATION SELECT 3418 Warming up engine Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. ACTIVE THROTTLE ONLY STATION SELECT 3419 1. Move the control handle into neutral position. 2. Press and hold the throttle only/station select button while moving the control handle ahead to the forward detent. 3.
OPERATION ob01310 2. Check the engine oil level. ob00667 3. Open fuel tank vent on manual venting type tanks. ob00348 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 5. Shift outboard to neutral (N) position.
OPERATION 6. 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. Return the key to "START" position and try again. Repeat the procedure for the second engine. ACC ON ART ST F OF ART ST F ACC ON OF 3485 7.
OPERATION SLIM BINNACLE - SINGLE ENGINE STARTING PROCEDURE Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in Procedure in the Operation Section. ! CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. 1. Make sure the cooling water intake is submerged. 2.
OPERATION N R F 3417 NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote control panel. 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. ACC ON ART ST F ACC ON OF ART ST F OF 3485 7.
OPERATION Warming up engine Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. NEUTRAL START STOP 12204 1. Move the control handle into neutral position. 2. Depress shift lock button, press and hold the throttle only/station select button while moving the control handle ahead to the forward detent. 3. Hold in the button until the horn sounds twice and the neutral light starts flashing.
OPERATION ob00667 3. Open fuel tank vent on manual venting type tanks. ob00348 NOTE: The engines will not start unless the lanyard is set to the "RUN" position. 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 5. Shift outboards to neutral (N) position. ob00350 N R F 3417 6. Turn each ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting.
OPERATION NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT 14657 Warming up engines Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engines into gear. NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT 14658 1. Move the control handles into neutral position. 2. Press and hold the throttle only/station select button while moving the control handles ahead to the forward detent. 3.
OPERATION 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. DTS CONSOLE MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running.
OPERATION The active light is illuminated at the remote control station that is in control of the engine. ! 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 station transfer.
OPERATION ACTIVE SYNC THROTTLE ONLY STATION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%. 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. This will allow the use of the power trim/tilt from the remote control handle.
OPERATION 4. Turn screw towards "+" to increase friction or towards "–" to decrease friction. 5. Reinstall cover.
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.
MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Inspection And Maintenance Schedule BEFORE EACH USE • Check engine oil level. See Fuel & Oil ‑ Checking and Adding Engine Oil. • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom.
MAINTENANCE • Check power trim fluid. See Checking Power Trim Fluid. • Replace high pressure in‑line fuel filter1. • Replace spark plugs at first 300 hours or three years. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and Replacement. • Replace accessory drive belt. See Accessory Drive Belt Inspection.1. BEFORE PERIODS OF STORAGE • Refer to Storage procedure. See Storage section.
MAINTENANCE 1. Pull up on the top cowl lock latch. 2. Pull top cowl forward and lift off. 3. Pull lower cowl release latch up. 4. Remove rear cowl towards aft of outboard. ob01324 ob01257 COWL INSTALLATION 1. Position lower cowl from aft side of outboard. Make sure it fits properly in the rubber seal. 2. Lock cowl in place by pulling lower cowl latch down.
MAINTENANCE ob01671 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. Always wet the surface before cleaning.
MAINTENANCE DTS Battery Specifications IMPORTANT: Do not use deep cycle batteries for the main engine starting battery. IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations.
MAINTENANCE NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating. 13.5Nm (120 lbs. in.) DO NOT USE WING NUTS. IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements. 37-895387 Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement.
MAINTENANCE 3665 4. Wash air filter assembly in warm soap water. 5. Dry filter assembly with compressed air. 6. Apply 4‑Cycle Outboard Oil on rag or towel and lightly pad air filter element. Wipe off excess oil. Air filter element should be moist to the touch. Tube Ref No. 110 Description 4 Stroke 10W30 Outboard Oil Where Used Part No. Air filter element 92-802833Q1 AIR FILTER INSTALLATION 1. Install Fuel System Module (FSM) purge valve hose to air filter assembly. 3665 2.
MAINTENANCE a b c d ab- 3664 Crankcase ventilation hose Fuel System Module (FSM) purge valve hose cd- Filter assembly Clamp screw Fuel System ! WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system. IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately.
MAINTENANCE 3470 ! CAUTION Fuel vapor vent system is under pressure. Cover valve assembly with a rag or towel to prevent fuel or fuel vapor spray. Relieve pressure slowly. 3. Place rag or towel around valve, release pressure by pushing core of valve end in. 4. Unscrew the filter in a counterclockwise direction to remove.
MAINTENANCE ob01253 Filter Draining 1. Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter holder. 2. Tip the filter holder to drain any fluid into an approved container. ob01263 Filter Installation 1. Position filter holder onto bracket and secure filter holder in place. 2. Lubricate the sealing ring on the filter with oil. 3. Install the filter and tighten securely by hand.
MAINTENANCE ob01258 Corrosion Control Anode 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 salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded.
MAINTENANCE ob01672 4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Tube Ref No. 6. Description Where Used Part No.
MAINTENANCE ob00422 Spark Plug Inspection and Replacement 1. Remove top and rear cowlings. Refer to Cowl Removal and Installation. 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 c 3658 ab4. Wiring harness connector Pencil coil c- Bolt Remove the spark plugs to inspect.
MAINTENANCE Tube Ref No. Description Anti-Seize Compound 81 Where Used Part No. Spark plug threads 92-881091K1 7. Clean area of spark plug seat. 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 9. lb. in. lb. ft. 20 Push pencil coils into place over the spark plugs using a twisting motion. 10. Secure coils with retained bolts.
MAINTENANCE 2. Remove the plastic cover from the fuse holder. 3. Remove fuse puller from fuse holder. 4. Remove suspected blown fuse to determine if the silver colored band is broken. 5. Replace fuse with a new fuse of the same amperage rating. ob01252 b a c 20 20 20 20 20 20 d 20 e abc- ob01259 Electronic Control Module and purge valve "ECM" ‑ 20 amp fuse Ignition coils "IGN.
MAINTENANCE • Belt surfaces roughened. • Signs of wear on edges or outer surfaces of belt. Checking Power Trim Fluid 1. Tilt outboard to the full up position. 2. Rotate the tilt support bracket down. 3. Lower outboard until tilt support bracket rests on pedestal. 4. Remove the power trim fill cap. The fill cap only requires 1/4 turn to remove. b a c d ob01526 ab5. Tilt support lever Power trim fill cap Tilt support bracket Pedestal The fluid level should be approximately 25 mm (1 in.
MAINTENANCE b a c ob01527 ab- Power steering cover Fill cap Tube Ref No. 138 c- Description Fill/full level Where Used Synthetic Power Steering Fluid SAE 0W-30 Part No. Power steering system 92-858002K01 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 7.0 liters (7.4 quarts). PUMP METHOD IMPORTANT: Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump.
MAINTENANCE Crankcase Oil Pump 91‑90265A 5 Aids in the removal of engine oil without draining the crankcase. 11591 DRAIN METHOD 1. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump. 2. Place the outboard in a vertical position. 3. Place appropriate container under engine oil sump plug. Drain plug/seal washer is located beneath the splash plate (port side of outboard). 4. Loosen the drain plug/seal washer.
MAINTENANCE CHANGING OIL FILTER IMPORTANT: To reduce or prevent oil spillage when removing the oil filter ensure that the outboard is upright (not tilted) and the engine is cold or has not run for at least one hour. 1. Remove the top cowl. 2. Place a rag or towel below the oil filter to absorb any spilled oil. 3. Unscrew old filter by using oil filter wrench tool and turning the filter counterclockwise. ob01251 Oil Filter Wrench 91‑802653Q02 Assists in removal of oil filter. 5221 4.
MAINTENANCE ob01250 2. Reinstall oil fill cap. 3. With outboard in water or cooling water flush hose connected, idle engine for five minutes to check for leaks at the oil filter. 4. Stop engine and check oil level. Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
MAINTENANCE 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. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. a b a a- Vent hole ob01530 b- Fill hole IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant.
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).
STORAGE Tube Ref No. 119 Description Storage Seal Rust Inhibitor Where Used Part No. Spark plug holes 92-802878Q5 6 • Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal throughout the cylinders. • Reinstall spark plugs and pencil coils. Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance ‑ Gearcase Lubrication).
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 Performance Loss POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Throttle not opening fully. • Damaged propeller or improper propeller size. • Incorrect engine timing, adjustment, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery.
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 Australia, Pacific Telephone (61) (3) 9791‑5822 Fax (61) (3) 9793‑5880 Mercury Marine Australia 132-140 Frankston Road Dandenong, Victoria 3164 Australia Europe, Middle East, Africa Telephone (32) (87) 32 • 32 • 11 Fax (32) (87) 31 • 19 • 65 Marine Power - Europe, Inc.
