94/25/EC; std. ISO 8665, ISO 11547 Machinery Directive: 98/37/EC, EMC Directive: 89/336/EC; std. EN50081‑1, SAE J551 (CISPR Pub. 12), EN 50082‑1, IEC 61000 PT4‑2, IEC 61000 PT4‑3 Patrick C.
Thank You for your purchase of one of the finest outboards available. You have made a sound investment in boating pleasure. Your outboard has been manufactured by Mercury Marine, a world leader in marine technology and outboard manufacturing since 1939. These years of experience have been committed to the goal of producing the finest quality products.
Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment to service. Earning a Mercury Premier Service rating means a dealer: • Achieves a high 12 month service CSI (Customer Satisfaction Index) score for warranty service. • Possesses all necessary service tools, test equipment, manuals and parts books. • Employs at least one Certified or Master technician.
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TABLE OF CONTENTS Warranty Information Warranty Registration United States And Canada...................................1 Mercury Racing Demonstrator Policy.......................................................1 Transfer Of Warranty................................................................................2 Mercury Racing Division 2 Year Limited Warranty (OptiMax XS Series Outboards)................................................................................................
TABLE OF CONTENTS Fuel and Oil Avoiding Fuel Flow Restrictions.............................................................. 33 Fuel Requirements.................................................................................33 Oil Recommendation..............................................................................34 Filling Remote Oil Tank..........................................................................35 Filling Engine Mounted Oil Reservoir Tank...........................................
TABLE OF CONTENTS Submerged Power Package...................................................................55 Replacement Parts for Your Power Package.........................................55 EPA Emissions Regulations...................................................................55 Inspection And Maintenance Schedule..................................................56 Flushing the Cooling System (Powerhead)............................................58 Flushing the Cooling System (Lower Unit)........
TABLE OF CONTENTS Owner Service Assistance Local Repair Service...............................................................................85 Service Away From Home......................................................................85 Parts And Accessories Inquiries.............................................................85 Service Assistance.................................................................................85 Mercury Marine Service Offices.............................................
WARRANTY INFORMATION Warranty Registration United States And Canada Outside United States and Canada ‑ Check with your local distributor. 1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information. Mercury Marine Attn.
WARRANTY 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 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 (refer to 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, accide
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 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 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 Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products 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.
WARRANTY INFORMATION 7. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 8. 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. 9. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 10. Water in the starter motor. 11.
WARRANTY INFORMATION DURATION OF COVERAGE: This limited warranty provides coverage for the components of the emissions control systems of new, 2001 model year (and later) outboards, sold to retail customers in California for 4 years from either the date the product is first sold, or first put into service, whichever occurs first, or the accumulation of 250 hours of engine operation (as determined by the engines hour meter, if any).
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 General Information ‑ Specifications), operation of the product in a manner inconsistent with the recommended operation procedures, neglect, accident, submersion, improper installation (proper instal
WARRANTY INFORMATION 3. Ignition System a. Spark plugs b. Magneto or electronic ignition system c. Spark advance/retard system d. Ignition coil and/or control module e. Ignition wires 4. Lubrication System 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.
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 Star Label Outboards are labeled on the cowl with one of the following star labels. The Symbol for Cleaner Marine Engines Means: Cleaner Air and Water ‑ for a healthier lifestyle and environment. Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil than conventional carbureted two‑stroke engines, saving money and resources. Longer Emission Warranty ‑ Protects consumer for worry free operation.
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 Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U .S .
GENERAL INFORMATION ! WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start in neutral only protection device. ob00308 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.
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. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to 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 gear case or propeller. • Loss of power and directional control in heavy seas, strong current or high winds.
GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines. This includes the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
GENERAL INFORMATION WHILE BOAT IS STATIONARY a b ob00317 a - Running the engine when the boat is moored in a confined space. b - Mooring close to another boat that has its engine running. WHILE BOAT IS MOVING a b ob00318 a - Running the boat with the trim angle of the bow too high. b - Running the boat with no forward hatches open. Passenger Safety Message ‑ Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers.
GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. ob00312 ! WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over. Stay back from the front end of the deck and remain seated while the boat is in motion.
GENERAL INFORMATION 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 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.
GENERAL INFORMATION The boat should also be checked for any hull fractures, transom fractures, or water leaks. Operating a damaged outboard could cause additional damage to other parts of the outboard, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds. ! WARNING Avoid serious injury or death from loss of boat control. Continued boating with major impact damage can result in sudden outboard component failure with or without subsequent impacts.
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 Description Specifications Neutral Rev Limit Full Throttle RPM Range 1900 rpm 20 in. (Torque/Sport Master) 5500 – 6300 rpm 25 in. (Torque Master) 5500 – 6300 rpm 25 in. (Fleet Master) 5300 – 5800 rpm 30 in. (Fleet Master) 20 in. (Torque/ Master) 5300 – 5800 rpm Sport Overspeed Rev 25 in. (Torque Master) Limit 25 in. (Fleet Master) 30 in. Models 6300 rpm 6300 rpm 5950 rpm 5950 rpm Engine Displacement 3032 cc (185 cu. in.) Cylinder Bore 92.075 mm (3.625 in.) Stroke 76.
GENERAL INFORMATION NOTE: Where applicable, specifications are derived at sea level.
GENERAL INFORMATION Component Identification 2 1 250xs 3 13 4 12 11 5 10 6 9 7 8 1 - Top cowl 2 - Side cowl latches (both sides) 3 - Front cowl latch 4 - Auxiliary tilt switch 5 - Clamp/Swivel bracket 6 - Gearcase 7 - Cooling water intake (location dependent on gearcase) 8910 11 12 13 - 30 3540 Skeg Anode plate Anti‑ventilation plate Drive shaft housing Water pump indicator Bottom cowl
GENERAL INFORMATION Propeller Selection Propping the engine at the higher end of the RPM range may increase acceleration, but decrease top boat speed. Conversely, propping the engine at the lower end of the range may increase top boat speed but hinder acceleration. Mercury Marine recommends selecting 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).
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 Avoiding Fuel Flow Restrictions ! CAUTION Avoid engine damage. Adding components to the fuel supply system, such as filters, valves, fittings, etc., may restrict the fuel flow. This condition may cause the engine to stall at low speeds and create lean fuel conditions at high speeds, causing engine damage. Fuel Requirements Use a major brand of unleaded gasoline, preferably without alcohol. ! CAUTION Use of improper fuel can seriously damage your engine.
FUEL AND OIL FUEL CONTAINING ALCOHOL If the fuel 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 TC‑W3 Premium Plus Outboard Oil is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or varying grades of gasoline. IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3.
FUEL AND OIL NOTE: Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated. Filling Fuel Tank • • • • 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.
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. c c c b h a b a g f i a d e i d f f g e ob00329 a - Control handle ‑ forward, neutral, reverse. b - Neutral release lever c - Trim/tilt switch (if equipped). ‑ Refer to Features & Controls ‑ Power Trim and Tilt.
FEATURES AND CONTROLS Zero Effort Control Features a b c 4090 a - Throttle lever b - Trim switch c - Shift lever Warning System The warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or under the dash connected to the ignition key switch.
FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. Refer to the Troubleshooting section for specific information. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft product information. ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems.
FEATURES AND CONTROLS Problem Monitor Display Horn Guardian Activated Percentage of Full Engine Power Available <10 v = 0% <11.5 v = 50% Single Battery Voltage Beep...Continuous Out of Limits Beep when Guardian Engages Yes Yes 11.5 ‑ 16 v = 100% >16 v = 50 % >17 v = 0% Horn Failure No Yes Yes 95% Water In Fuel 4 Beeps...
FEATURES AND CONTROLS Upon reaching the rev limit, the Guardian System activates the warning horn. If the operator does not reduce engine speed within five seconds, the Guardian Systems reduces available engine power. To reset the Guardian System protection: 1. Completely reduce throttle for two to three seconds. 2. Re‑engage the throttle. If the engine does not respond, repeat step one. Power Trim And Tilt NOTE: Outboard position can be adjusted by pressing trim switch.
FEATURES AND CONTROLS Power Trim Operation With most boats, operating around the middle of the trim range will give satisfactory results. Trimming your outboard all the way in or out may improve performance, but cause some potential control hazards. ! WARNING Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel in either direction may result.
FEATURES AND CONTROLS ! WARNING Avoid possible injury or death. Always perform a water test to examine boat handling and steering after making any trim in limiting adjustments. Operating a boat with a full trim angle without the aid of a trim in limiting device may result in undesirable or unsafe steering conditions.
FEATURES AND CONTROLS Power Tilt Operation (Single‑Ram Systems) To tilt the outboard, shut off the engine and press the trim/tilt switch or the auxiliary tilt switch to the up position. The outboard tilts up until the switch is released or it reaches the maximum tilt position. The hydraulic system is fully capable of supporting the outboard during normal tilting operation. However, if trailering the boat in the trim/tilt position, use an accessory outboard support device.
FEATURES AND CONTROLS Auxiliary Tilt Switch This switch can be used to tilt the outboard up or down using the power trim system. a or54-1 a - Auxiliary tilt switch Manual Tilt Operation If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be tilted manually. 1. Turn out the manual tilt release valve three turns (counter‑clockwise). This allows manual tilting of the outboard.
FEATURES AND CONTROLS 2. Tilt the outboard to the desired position and tighten the manual tilt release valve. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.
OPERATION Engine Break‑in ! CAUTION Severe damage to the engine can result by not complying with the engine break‑in proceedure. Engine damage may not be covered by the limited warranty. ! WARNING Avoid loss of boat control or an unsafe boat handling situation. Increasing trim under can place greater load on an engine and enhance breakin. At higher speeds, increasing trim under could produce a dangerous boat handling situation. It is the boat operator’s responsibility to always drive in a safe manner.
OPERATION Fuel tank vent cap open or fuel drain valve on. Fuel supply OK Lanyard stop switch in "RUN" position and cord connected. Remote control in neutral Top cowl latches secure. Make inspection checks listed in the Inspection and Maintenance Schedule. Refer to Maintenance section. Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures, keep the outboard tilted down at all times so the gearcase is submerged.
OPERATION Effects of Elevation and Weather on Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems. • Above sea level elevations • High temperature. • Low barometric pressure. • High humidity.
OPERATION Setting Trim Angle While Running Engine at Idle Speed Submerging the exhaust relief hole on the outboard can happen on some boats if you trim full in while running at idle speed, resulting in, exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim outboard up until exhaust relief hole is out of the water.
OPERATION Starting The Engine ! 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. INITIAL STARTING PROCEDURE NOTE: For initial start up of a new engine, or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled according to the following procedure. 1.
OPERATION 3. Squeeze the fuel line primer bulb several times until it feels firm. ob00349 4. Set the lanyard stop switch to the "RUN" position. Read the Lanyard Stop Switch safety explanation and warning in the General Information section. ob00350 5. Shift the outboard to the neutral position. N ob00351 6. Do not advance the neutral fast idle speed feature on the remote control for starting (if equipped).
OPERATION 7. Turn the ignition key to the "START" position. Release the key when the engine starts. If the engine fails to start in ten seconds, return the key to the "OFF" position, wait one second, and try again. ob00354 8. Check for water coming out of the water pump indicator hole. or55 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting. ! CAUTION Avoid possible engine damage.
OPERATION Gear Shifting IMPORTANT: Never shift into gear unless the engine is at idle. Never shift into reverse without the engine running. • Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear) and reverse. F N R ob00557 • • • When shifting, always stop at neutral position and allow the engine speed to return to idle. Always shift into gear with a quick motion. After shifting into gear, advance the lever further to increase speed.
MAINTENANCE Power Package Care ! WARNING Avoid equipment damage, serious injury or death from improper or neglected maintenance, repairs or inspections of the power package. If you are not familiar with proper maintenance or service procedures, have the work performed by an authorized Mercury Marine dealer.
MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture.
MAINTENANCE AFTER EACH SALTWATER OR POLLUTED WATER USE • • • • Flush all internal passages with fresh water. Wash the power package exterior (cowl, mid section, and gearcase) with fresh water. Flush the propeller and gearcase exhaust outlet with fresh water. Remove the cowl and wipe off any saltwater spray with a damp cloth. EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATER OR POLLUTED WATER USE • Spray the powerhead and all external, unpainted metal surfaces (except anodes) with Corrosion Guard.
MAINTENANCE • Remove engine deposits with Power Tune Engine Cleaner. EVERY 100 HOURS OR ONCE A YEAR, WHICHEVER OCCURS FIRST • • Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).1. Use QuicKleen in fuel. EVERY 100 HOURS OF OPERATION • Inspect Carbon Fiber reeds for chipping or cracks. EVERY 200 HOURS OR ONCE EVERY TWO YEARS, WHICHEVER OCCURS FIRST • • Replace water separating fuel filter. Check the spark plug gap and replace if necessary.
MAINTENANCE Flushing the Cooling System (Lower Unit) ! WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. c b a d d a - Fleet Master and Torque Master gearcase b - Sport Master gearcase or37-1 c - Water hose d - Flushing attachments 1. Remove the propeller. Refer to Propeller Replacement. 2. Fleet Master and Torque Master gearcases – Install the appropriate flushing attachment so the rubber cups fit tightly over the strut intake holes.
MAINTENANCE Top Cowl Removal and Installation REMOVAL Release the front and side cowl latches. Lift the top cowl from the outboard. or38 INSTALLATION Position the top cowl over the engine. Make sure the bottom rubber seal fits properly and lock the front and side latches. Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Follow cleaning and waxing procedure.
MAINTENANCE Fuel System FUEL SYSTEM SERVICE INFORMATION ! 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 any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle.
MAINTENANCE Removal a b c or39-1 a - O‑ring seals b - Filter c - Raised bosses 1. Disconnect the link rod. 2. Use the shaft of a screwdriver between the filter cap bosses and unscrew the filter. Installation 1. Lubricate the o‑ring seals with oil. 2. Install the fuel filter and tighten securely. 3. Reconnect the link rod. IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm, forcing fuel into the filter.
MAINTENANCE DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on. Draining the water from the fuel filter chamber is required. 1. Pull the drain hose off the right side fitting. Hold open end of the hose over a container. 2. Loosen drain screw and drain the fuel filter chamber. NOTE: If little or no liquid drains from the hose, loosen the red filter to vent the chamber. 3.
MAINTENANCE ! WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ! WARNING Avoid equipment damage, serious injury or death. Visually inspect all steering attachment components for wear, lubricate all attachment hardware, and check for proper torque tightness in accordance with the inspection and maintenance schedule.
MAINTENANCE Description Nm Special washer head bolt 27 lb. in. lb. ft. 20 Fuses IMPORTANT: Always carry spare 5 and 20 amp fuses. The electrical wiring circuits on the engine are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. 1. Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. 2.
MAINTENANCE Corrosion Control Anode ! CAUTION Avoid corrosion damage. Mercury Marine recommends using anodes sold through Mercury Precision Parts only. Some other manufacturers of aluminum anodes use alloys that are insufficiently pure to adequately protect critical drive components for the duration of the anodes' expected life. Anodes help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of other metals.
MAINTENANCE Spark Plug Inspection and Replacement ! WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots. 1. Remove the spark plug leads. Twist the rubber boots slightly and pull off. ob00375 2. Remove the spark plugs to inspect.
MAINTENANCE 1. 2. 3. 4. Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.
MAINTENANCE NOTE: If propeller is seized to the shaft and cannot be removed, consult your authorized Mercury Marine dealer. 1. Shift outboard to neutral. N ob00351 2. Remove the spark plug leads to prevent the engine from starting. ob00375 3. Straighten the bent tabs on the propeller nut retainer (if applicable). 4. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. ob00377 5.
MAINTENANCE ! CAUTION Avoid engine damage. Prop the engine so engine speed is limited to the required full throttle rpm range. An under‑propped engine may occasionally initiate the rev limiter. This may result in internal powerhead damage. Applications using 19 spline propeller shafts require the Heavy‑Duty Propeller Hub kit, included with most Mercury Racing propellers. Before installing the propeller: 1. Set the remote control into the neutral position. 2.
MAINTENANCE Tube Ref No. 94 Description Where Used Anti-Corrosion Grease Propeller shaft splines Part No. 92-802867A 1 3. Place a block of wood between the gearcase and propeller and torque the propeller nut. or119 Description Nm Propeller nut 75 lb. in. 4. Place the safety stop switch into the "RUN" position. 71 lb. ft.
MAINTENANCE Lubrication Points 34 94 95 95 95 5517 Tube Ref. No. 34 Description Special Lubricant 101 Where Used Part Number Trim Rod Ball Ends 92‑802865A1 Prop Shaft 95 Swivel Bracket 2‑4‑C with Teflon Tilt Support Lever 92‑802859A1 Tilt Tube NOTE: Turn the ball ends to work the lubricant into the ball sockets.
MAINTENANCE ! WARNING Avoid serious injury or death. The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to the steering cable when fully extended could cause the steering cable to become hydraulically locked, causing loss of steering control. 95 95 95 Tube Ref. No.
MAINTENANCE 3. If necessary, remove the yellow fill cap and add Power Trim and Steering Fluid until the level in the reservoir reaches the "MIN" level mark. It is acceptable to fill the reservoir beyond the "MIN" level mark, but do not overfill past the "MAX" level mark. 11 4 15033 Tube Ref No. 114 Description Power Trim and Steering Fluid Where Used Part No. Trim pump reservoir 92-802880A 1 4. Trim the outboard down to bleed air out of the system. The fluid level may drop.
MAINTENANCE Checking Power Trim Fluid (Three‑Ram Trim Systems) 1. Tilt outboard to the full up position and engage the tilt support lock. 114 a or47-1 a - Tilt support lock Tube Ref. No. 114 Description Power Trim and Steering Fluid Where Used Part Number Fill hole 92‑802880A1 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add fluid if required.
MAINTENANCE Gearcase Lubricant CHECKING/REFILLING GEARCASE LUBRICANT c d c d b a f e a - SportMaster gearcase (vertical operating position) b - Fleet/Torque Master gearcase (vertical operating position) c - Vent hole Tube Ref. No. 87 Description 87 or49-1 d - Vent plug and sealing washer e - Fill/drain hole f - Fill/drain plug Where Used Part Number High Performance Gear Lube Fill/Drain Hole 92‑802854A1 1. 2. 3. 4. 5. 6. Place the outboard in a vertical operating position.
MAINTENANCE 7. Remove lubricant tube and reinstall cleaned (lower) 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).
STORAGE NOTE: If little or no liquid drains from the hose, loosen the red filter to vent the chamber. a c b ob01352 a - Drain screw b - Drain hose c - Right side fitting 4. Re‑tighten drain screw and re‑attach hose. 5. Pull the drain hose off the left side fitting. Hold the open end of the hose over a container and loosen drain screw and drain the float chamber. Re‑tighten drain screw and re‑attach hose.
STORAGE 6. Premix the following in a container: • 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant. • 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer. 7. Remove the fuel filter. Refer to Maintenance ‑ Fuel System. 8. Pour mixture into the fuel filter opening. 9. Reinstall the fuel filter. 10. Prime the fuel system as outlined in the Operation ‑ Starting the Engine. 11. Place the outboard in water or use the flushing attachment for circulating cooling water.
STORAGE Positioning Outboard For Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. ! CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. Battery Storage • • • • Follow the battery manufacturer's instructions for storage and recharging. Remove the battery from the boat and check water level.
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. Battery not fully charged.
TROUBLESHOOTING • • • 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. Threaded connection of an air hose is loose. Fuel pump failure. Ignition system component failure. Performance Loss POSSIBLE CAUSES • • • • • • • Throttle not opening fully. Damaged propeller or improper propeller size. Boat overloaded or load improperly distributed. Excessive water in bilge. Boat bottom is dirty or damaged. Warning horn failure.
TROUBLESHOOTING • High engine temperature or low block water pressure. • Cooling system clogged. • Incorrect transom height (water pickups not getting adequate water supply). Warning Horn Activates (No Power Loss) POSSIBLE CAUSES • • Warning horn activates on start up. This is normal operation. Water is detected in the water‑separating fuel filter. Refer to Maintenance for procedures on removing water from the filter.
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 Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone Fax (920) 929‑5040 (920) 929‑5893 Mercury Marine W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 United States (Mercury Racing) Telephone Fax (920) 924‑2088 (920) 924‑2096 Mercury Racing N7480 County Rd.
OWNER SERVICE ASSISTANCE Europe, Middle East, Africa Telephone Fax Marine Power - Europe, Inc. Parc Industriel de Petit-Rechain B-4800 (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Verviers, Belgium Mexico, Central America, South America, Caribbean Telephone Fax (954) 744‑3513 (954) 744‑3535 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 U.S.A.
OWNER SERVICE ASSISTANCE OUTSIDE THE UNITED STATES AND CANADA Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature.
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
