! WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. i 90-10128081 1008 200/225/250/3.0 Liter 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.
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TABLE OF CONTENTS Warranty Information Transfer of Warranty....................................................................1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan............................................................................1 Warranty Registration United States and Canada.......................2 Outboard Limited Warranty..........................................................3 3 Year Limited Warranty Against Corrosion................................
TABLE OF CONTENTS Fuel and Oil Fuel Recommendations.............................................................32 Oil Recommendation.................................................................33 Fuel Requirements for Engine Break‑in..................................... 34 Avoiding Fuel Flow Restriction..................................................34 Low Permeation Fuel Hose Requirement .................................34 Filling Remote Oil Tank......................................................
TABLE OF CONTENTS Maintenance Outboard Care...........................................................................53 EPA Regulations........................................................................ 53 EPA Emissions..........................................................................54 Inspection and Maintenance Schedule......................................54 Flushing the Cooling System.....................................................56 Top Cowl Removal and Installation..................
TABLE OF CONTENTS Owner Service Assistance Local Repair Service.................................................................. 79 Service Away from Home..........................................................79 Parts and Accessories Inquiries................................................79 Service Assistance....................................................................79 Mercury Marine Service Offices.................................................
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 Plan coverage is not transferable from one product to another product or for non‑eligible applications. The Certified Pre‑Owned engine plans are not transferable. For help or assistance, contact Mercury Product Protection Department at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST, Monday ‑ Friday or email mpp_support@mercurymarine.com. Warranty Registration United States and Canada Outside United States and Canada ‑ Check with your local distributor. 1.
WARRANTY INFORMATION 3. Upon processing the warranty registration, Mercury Marine will send registration verification by mail to the purchaser of the product. If this registration verification is not received within 30 days, please contact your selling dealer immediately. Warranty coverage is not effective until your product is registered with Mercury Marine. Outboard Limited Warranty Outside the United States and Canada ‑ Check with your local distributor.
WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
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 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 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 WHAT IS NOT COVERED: This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by customer); products used in a commercial application.
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 2. Factory installed jet drive units ‑ Specific parts excluded from the warranty are: the jet drive impeller and jet drive liner damaged by impact or wear, and water damaged driveshaft bearings as a result of improper maintenance. 3. Damage caused by neglect, lack of maintenance, accident, abnormal operation, or improper installation or service. 4.
WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 13. Water entering engine through the fuel intake, air intake, or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high, or trimmed too far out. 15. Use of fuels and lubricants which are not suitable for use with or on the product.
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 When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer. SELECTING THE CORRECT PROPELLER An accurate tachometer for measuring engine speed is important in choosing the correct propeller.
GENERAL INFORMATION Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. The first number represents the diameter of the propeller and the second number represents the pitch. For example, 14x19 represents a propeller with a 14 inch diameter and 19 inches of pitch.
GENERAL INFORMATION • Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200 • Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200 • Upgrading from a 3‑blade propeller to a 4‑blade propeller will generally decrease full throttle RPM by 50 to 100 IMPORTANT: Avoid damage to the engine. Never use a propeller which allows the engine to exceed the recommended full throttle RPM range when under normal full throttle operation.
GENERAL INFORMATION ! WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 26779 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
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 Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller. • Loss of power and directional control in heavy seas, strong current or high winds.
GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. 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.
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 ! WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide. GOOD VENTILATION Ventilate passenger area, open side curtains or forward hatches to remove fumes.
GENERAL INFORMATION WHILE BOAT IS MOVING a b 21628 a - Running the boat with the trim angle of the bow too high b - Running the boat with no forward hatches open Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. 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 Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is complete loss of the boat.
GENERAL INFORMATION Models 200 3.0 Liter 225 Cylinder bore 92.1 mm (3.626 in.) Stroke 76.2 mm (3.000 in.) Recommended spark plug Champion QL77CC1. Spark plug gap 0.90 mm (0.035 in.) Gear ratio 1.75:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity 798 ml (27 fl oz) Battery rating 250 630 marine cranking amps (MCA) or 490 cold cranking amps (CCA) or 80 ampere hours (Ah) Charging system output 60 A 1.
GENERAL INFORMATION Component Identification g a b c h d e i f j a - Top cowl b - Bottom cowl c - Water pump indicator hole d - Driveshaft housing e - Anti‑ventilation plate fghij- 30 29304 Anode plate Auxiliary tilt switch Transom brackets Gearcase Cooling water intake holes
TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing.
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 RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R +M)/2 minimum.
FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).
FUEL AND OIL IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. Severe engine damage may result from use of an inferior oil.
FUEL AND OIL IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air leak will prevent oil flow to the engine. 2723 Filling Engine Mounted Oil Reservoir Tank NOTE: Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated. 1. Remove the top cowl. 2. Loosen the fill cap on the engine oil reservoir tank.
FUEL AND OIL Always stop engine before refilling tanks. Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled.
FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control.
FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch. b a 27755 a - Horn inside remote control b - Horn connected to ignition key switch WARNING HORN SIGNALS When the key switch is turned to the "ON" position, the horn will turn on for a moment as a test to show the horn is working.
FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling System Continuous Problem 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. If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check water intake holes for obstruction.
FEATURES AND CONTROLS If Guardian System has been activated, reduce throttle speed. The horn will turn off when throttle speed is within the allowable limit. Consult your dealer for assistance. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption, and engine operating hours.
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 your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.
FEATURES AND CONTROLS ! WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner. • In rare circumstances, the owner may decide to limit the trim in.
FEATURES AND CONTROLS 3. Disengage the tilt support lever, by raising the outboard off the support lever and rotating the lever down. Lower the outboard. a b 27778 a - Tilt support lever b - Knob MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. 1.
FEATURES AND CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. a 27779 a - Auxiliary tilt switch SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. 1. Reduce engine speed below 2000 RPM. 2. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. 3. Operate the engine at slow speed only.
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 the boat's maximum load capacity. Look at the boat capacity plate. Fuel supply OK. Oil supply (oil injection) 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 Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full‑in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim the outboard up until the exhaust relief hole is out of the water. The outboard should be lowered for accelerating from a standing start or from idle speed.
OPERATION b. Change engine speed approximately every two minutes, and avoid continuous operation at idle speed for more than ten minutes. Short bursts of full throttle for periods up to ten seconds are acceptable. c. Avoid trimming the outboard out (up) beyond a vertical trim position during operation. NOTE: It is the driver's responsibility to always drive in a safe manner. Improper trim angle of the outboard when driving at the proper speed can be difficult and dangerous.
OPERATION 2. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. 27348 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to the neutral ("N") position. N 26838 6.
OPERATION b. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. c. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. Turn the ignition key switch to the "ON" position again for three seconds. Continue this procedure until the fuel line primer bulb stays firm. 7. Do not advance the throttle‑only feature on the remote control for starting. 27242 8. Turn the ignition key to "START" position.
OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. This condition will cause the engine to overheat. Have the outboard checked by your dealer. Operating the engine while overheated will cause engine damage. 19805 Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle.
OPERATION Stopping the Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position.
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 EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. a b c EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines. Refer to Owner's Manual for required maintenance.
MAINTENANCE • • • • 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). Check steering system for binding or loose components. Visually check steering link rod fasteners for proper tightness. See Steering Link Rod Fasteners. Check propeller blades for damage. AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water.
MAINTENANCE • • Check control cable adjustments.1. Check tightness of bolts, nuts, and other fasteners. EVERY 300 HOURS OF USE OR THREE YEARS • Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).1. • Inspect the poppet valve assembly for deterioration of the rubber diaphragm. Replace the rubber diaphragm if necessary. BEFORE PERIODS OF STORAGE • Refer to storage procedure. See Storage section.
MAINTENANCE Top Cowl Removal and Installation REMOVAL 1. Pull out the front cowl latch. 28431 2. Lift front of cowl to clear front latch and push toward the rear to clear rear hooks. 3. Lift top cowl to remove. INSTALLATION 1. Lower top cowl into position over engine. 2. Move the cowl toward the rear to align rear hooks. After rear hooks have engaged, move cowl toward front and push down front of cowl. 3. Push in latch to secure top cowl.
MAINTENANCE Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well‑ventilated area. Inspect any completed service work for sign of fuel leakage.
MAINTENANCE d. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten securely by hand. Reconnect the wire to the filter. IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter.
MAINTENANCE Description Nm Special washer head bolt 27 20 Nylon insert locknut "d" 27 20 Nylon insert locknut "c" lb. in. lb. ft. Tighten until seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and self‑locking nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with special washer head bolt and self‑locking nylon insert locknut.
MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. a b d c 5 20 20 20 e f 3381 abcdef- Good fuse Blown fuse SmartCraft data bus circuit ‑ 5 amp fuse Accessories ‑ 20 amp fuse Ignition coil circuit ‑ 20 amp fuse Electric fuel pump/ECM driver power/oil pump circuit ‑ 20 amp fuse Corrosion Control Anode Your outboard has corrosion control anodes at different locations.
MAINTENANCE The gearcase has two corrosion control anodes, one on each side. A third anode is installed on the bottom of the transom bracket assembly. a b 27844 a - Anode (2) on each side of gearcase b - Anode on transom bracket assembly Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2.
MAINTENANCE 1. Shift outboard to neutral (N) position. N 26838 IMPORTANT: Refer to Spark Plug Inspection and Replacement for removing spark plug leads. 2. Remove spark plug leads to prevent engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer.
MAINTENANCE 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 26901 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref No. Description Where Used Part No.
MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c d e a - Propeller nut b - Propeller nut retainer c - Rear thrust hub f 26908 d - Continuity washer e - Propeller f - Forward thrust washer 8. 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.
MAINTENANCE 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots. 1. Remove the spark plug leads. Twist the rubber boots slightly and pull off. 26899 2.
MAINTENANCE 3. Set the spark plug gap to specifications. 27848 Spark Plug Gap Spark plug 0.90 mm (0.035 in.) 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten to the specified value. Description Nm Spark plug 27 lb. in. lb. ft. 20 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Ref No. 34 Description Special Lubricant 101 Where Used Part No.
MAINTENANCE Tube Ref No. Description Where Used Part No. 94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1 95 2-4-C with Teflon Propeller shaft 92-802859A 1 • Propeller Shaft ‑ refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 26902 3.
MAINTENANCE • Alternator Belt Tensioner Pivot Shaft ‑ Lubricate through fitting. 29300 • Swivel Bracket ‑ Lubricate through fitting. • Tilt Support Lever ‑ Lubricate through fitting. a b 27873 b - Tilt support lever a - Swivel Bracket • Tilt tube ‑ Lubricate through fitting. 27874 ! WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant.
MAINTENANCE • Steering Cable Grease Fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. a b 27875 a - Fitting b - Steering cable end 4. Lubricate the following with light weight oil. • Steering Link Rod Pivot Points ‑ Lubricate pivot points. 27876 Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lever.
MAINTENANCE 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 28460 Tube Ref No. 114 Description Power Trim and Steering Fluid Where Used Part No. Power trim system 92-858074K01 Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
MAINTENANCE 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. 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 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. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.
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 Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Protecting Internal Engine Components NOTE: Make sure the fuel system has been prepared for storage. Refer to Fuel System, preceding. 1. Remove the spark plugs. Add approximately 30 ml (1 oz.) of engine oil or inject a five second spray of storage seal into each spark plug hole.
STORAGE Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance ‑ Gearcase Lubrication). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. 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.
TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure. • Wiring or electrical connection faulty. • Starter motor solenoid or slave solenoid failure. Engine Will Not Start POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Incorrect starting procedure.
TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • 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 on built in fuel tank. d. Fuel line is kinked or pinched. e. Injector plugged. • Fuel pump failure. • Ignition system component failure.
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 • • • 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.com Mercury Marine W6250 W. Pioneer Road P.O.
OWNER SERVICE ASSISTANCE Asia, Singapore Telephone 5466160 Fax 5467789 Mercury Marine Singapore 72 Loyang Way Singapore, 508762 81
OUTBOARD INSTALLATION Important Information BEFORE STARTING THE ENGINE NOTICE Lack of oil pressure in the system can cause severe internal engine damage during start‑up. Prime the oil injection pump on new or rebuilt engines or after performing maintenance on the oiling system. Refer to Priming the Oil Injection Pump for instructions. FUEL REQUIREMENTS Do not use pre‑mixed gas and oil in this engine. The engine automatically receives extra oil during engine break‑in.
OUTBOARD INSTALLATION 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.
OUTBOARD INSTALLATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories. Fuel Tanks PORTABLE FUEL TANK Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place.
OUTBOARD INSTALLATION Installation Specifications a a b 18552 a - Minimum transom opening b - Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33‑3/8 in.) Dual engine 151.8 cm (59‑3/4 in.) Lifting the Outboard ! WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death.
OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. a 24290 a - Lifting eye 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine for removal/ installation. 2756 Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate O‑ring seal and entire cable end.
OUTBOARD INSTALLATION Tube Ref No. 95 Description 2-4-C with Teflon Where Used Part No. O-ring seal and entire cable end 92-802859A 1 2. Insert steering cable into tilt tube. 3725 3. Torque nut to specification. 3727 Description Nm Nut 47.5 lb. in. lb. ft. 35 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
OUTBOARD INSTALLATION ! WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures. ! WARNING Worn, loose, or seized steering components can lead to loss of boat control.
OUTBOARD INSTALLATION 3. Torque the head bolt, then the locknut to specifications. Description Nm lb. in. lb. ft. Tighten locknut until it seats, then loosen ¼ turn.
OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) e 60.9 cm (24 in.) b c 58.4 cm (23 in.) 56.0 cm (22 in.) a 53.3 cm (21 in.) 50.8 cm (20 in.) e d 48.2 cm (19 in.
OUTBOARD INSTALLATION NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions. Exhaust restrictions will result in poor performance at idle. 2. Add 12.7 cm (5 in.) for XL models to the listed outboard mounting heights. 3. The mounting height of the outboard must not exceed 63.
OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. b a a c a - Drill guide holes b - Transom drilling fixture 2757 c - Transom centerline Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2. Drill four 13.5 mm (17/32 in.) mounting holes.
OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name 10‑8M0033366 Transom bolt 11‑826711‑17 Description 1/2‑20 x 5.00 in. long (3.25 in. thread) Nylon insert locknut 1/2‑20 12‑28421 Washer ‑ Inner 0.516 in. ID x 1.50 in. OD 12‑54012 Washer ‑ Outer 0.53 in. ID x 0.87 in. OD Available Transom Mounting Bolts Part Number Part Name Description 10‑67755005 Transom bolt 1/2‑20 x 2.50 in.
OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate. The boat transom must be strengthened or the load carrying area increased.
OUTBOARD INSTALLATION 1. Apply marine sealer to shanks of bolts, not the threads. 2. Fasten the outboard with the correct mounting hardware. Tighten locknuts to the specified torque. NOTE: For more accurate torque, whenever possible, turn/tighten the mounting locknuts rather than turn the mounting bolts. a e b d c abcde- 3729 Flat washer (4) 1/2 in. diameter bolt (4) Shank of bolt Flat washer (4) Locknut (4) Description Nm Outboard mounting locknuts and bolts 75 95 lb. in. lb. ft.
OUTBOARD INSTALLATION Electrical, Hoses, Control Cables, and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl. Connect remote harness to the 14 pin connector on the engine harness.
OUTBOARD INSTALLATION Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. 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.
OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. a b a b c (-) (-) d d 15497 a - Red sleeve ‑ Positive (+) b - Black sleeve ‑ Negative (–) c - Ground cable d - Cranking battery HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate fuel line/fuel tank pickup for each engine.
OUTBOARD INSTALLATION This outboard has a speedometer water pick‑up located in the leading edge of the gearcase. If you want to use this water pickup for the speedometer, disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl. Install the coupler provided with the outboard on the end of the tubing. Make the water pressure gauge hose connection to the tubing as shown.
OUTBOARD INSTALLATION Locating the Center Point of the Shift Cable IMPORTANT: Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustment of the shift cable. 1. Mark the forward position as follows: a. Move the remote control handle from neutral into forward and advance the handle to the full speed position. Ensure that the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the handle back to the neutral detent position.
OUTBOARD INSTALLATION 3. Mark the center on the shift cable midway between the forward and reverse marks. a 4361 a - Center mark 4. Align the cable end guide against this center mark when installing the cable to the engine. 5. Position the remote control and outboard into neutral position. 6. Slide the anchor pin forward until resistance is felt, then slide the anchor pin toward the rear until resistance is felt. 7. Center the anchor pin between these resistance points.
OUTBOARD INSTALLATION 2. Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder. 3. Secure the shift cable to the anchor pin with the retainer clip. a c b a - Cable barrel b - Shift cable retainer 28749 c - Retainer clip 4. Check the shift cable adjustments as follows: a. Shift the remote control to forward while turning the propeller shaft.
OUTBOARD INSTALLATION 2. Attach the throttle cable to the throttle lever. Secure with a washer and locknut. Tighten the locknut to the specified value. a b 2678 a - Nylon washer b - Locknut Description Nm Throttle cable locknut "b" lb. in. lb. ft. Tighten then loosen 1/4 turn. 3. Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw against the stop. c a b 28751 a - Barrel sleeve b - Cable barrel c - Idle stop screw 4.
OUTBOARD INSTALLATION c. Place a thin piece of paper between the idle adjustment screw and the idle stop. The adjustment is correct when the paper can be removed without tearing, but has some drag on it. IMPORTANT: The idle stop screw must be touching the stop. b a 2680 a - Idle stop screw b - Idle stop d. Readjust the cable barrel if necessary. 5. Lock the barrel holder in place with the cable latch.
OUTBOARD INSTALLATION 2. Place the neoprene wrap around the wiring, hoses, and control cables, and place into the lower half of the front clamp. a b 29073 a - Neoprene wrap b - Lower half of the front clamp 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties. a b 29074 a - Top half of the front clamp b - Cable ties 4. Secure the front clamp into the bottom cowl with the retainer and two screws.
OUTBOARD INSTALLATION 5. Reinstall the cowl seal. a 29075 a - Retainer Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: 1. Squeeze the fuel line primer bulb until it feels firm. 2. Turn the key switch to the "ON" position for three seconds. This operates the electric fuel pump. 3.
OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1. Fill the remote oil tank with the recommended oil. Refer to Oil Recommendation. Tighten the fill cap securely. a 2683 a - Fill cap 2. Remove the cap and fill the engine oil tank with oil. Reinstall the fill cap and tighten securely.
OUTBOARD INSTALLATION PRIMING OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose or internal passages. a b 24291 a - Oil injection pump b - Oil supply hose IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump. Otherwise, the fuel pump will run without fuel during the priming process and may be damaged. 1. Fill the fuel system. a. Connect the fuel hose. b.
OUTBOARD INSTALLATION d. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. 26846 e. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. f. Turn the ignition key switch to the "ON" position again for three seconds. g. Continue this procedure until the fuel primer bulb stays firm. 2. Turn the ignition key switch to the "ON" position. 3.
OUTBOARD INSTALLATION Trim In Pin ! WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner. Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to be trimmed further in or under.
OUTBOARD INSTALLATION The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired. A non‑stainless steel shipping bolt should not be used in this application other than on a temporary basis.
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
