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.
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 Filling Fuel Tank................................................................................................................................................... 26 FEATURES & CONTROLS Remote Control Features..................................................................................................................................... 27 Warning System - Electric Start Models...........................................................................................................
TABLE OF CONTENTS Protecting Internal Engine Components............................................................................................................... 71 Gearcase.............................................................................................................................................................. 71 Positioning Outboard For Storage........................................................................................................................ 71 Battery Storage.
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 4. In some countries, the Marine Power Service Center will issue you a permanent (plastic) Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor/dealer. If you receive a plastic Warranty Registration Card, you may discard the Purchaser's Copy that you received from the distributor/dealer when you purchased the product. Ask your distributor/ dealer if this plastic card program applies to you.
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 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 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 Corrosion damage caused by stray electrical currents (on-shore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
WARRANTY INFORMATION 6. Labor performed by other than an authorized dealer may be covered only under following circumstances: When performed on emergency basis (providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility). 7.
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 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 ! WARNING Should the operator fall out of the boat, the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both ends of the stop switch lanyard to the stop switch and the operator. ! WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.
GENERAL INFORMATION BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. 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 by the outboard.
GENERAL INFORMATION 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. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat. ! WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible.
GENERAL INFORMATION • 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. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles.
GENERAL INFORMATION 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 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. Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Use flotation devices.
GENERAL INFORMATION Serial Number XXXXXXXX a b c XXXX XXXX MAX RPM H P L B K W K G e d XX abc- Serial number Model year Model designation de- 3066 Year manufactured Certified Europe Insignia (as applicable) 40 Sea Pro/Marathon - 30/40 HP Specifications Models Horsepower Kilowatts Full Throttle RPM Range Pleasure Models 30 40 30 40 22.4 29.
GENERAL INFORMATION Component Identification n m a o b p j c l i d q h s e f r g abcdefghij- k Top cowl Water pump indicator hole Auxiliary tilt switch Driveshaft housing Anti-ventilation plate Trim tab Gearcase Transom brackets Steering friction adjustment (non-tiller handle models) Tilt lock lever 3067 klmnopqrs- 18 Secondary cooling water intake Shallow water drive lever (non-power trim) Shift handle Throttle friction adjustment knob Lanyard stop switch Steering friction adjustment lev
GENERAL INFORMATION 40 SeaPro/Marathon Component Identification p t q g f e h i d j c k b s o r l a n m 3920 abcdefghij- Trim tab Anti-ventilation plate Driveshaft housing Bottom cowl Water pump indicator hole Top cowl Shift handle Throttle friction adjustment Tilt support pin Shallow water drive/trailering lever - manual tilt system 19 klmnopqrst- Transom bracket Primary cooling water intake Gearcase Secondary cooling water intake Tilt lever - gas assisted type tilt system Primer Starter
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. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.
INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information - Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed.
TRANSPORTING Trailering Boat/Outboard 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.
TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidently pushed-in, thus, allowing fuel or vapor to escape.
FUEL & OIL Gasoline Recommendations UNITED STATES AND CANADA Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 87. Mid-grade automotive gasolines that contain fuel injector cleaner are preferred for added internal engine cleanliness. Leaded gasoline is not recommended. INTERNATIONAL Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 90RON.
FUEL & OIL GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal.) gas 11.5 liters (3 gal.) gas 23 liters (6 gal.) gas 50:1 (2%) 89 ml (3 fl. oz.) oil 237 ml (8 fl. oz.) oil 473 ml (16 fl. oz.) oil MODELS WITHOUT OIL INJECTION Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel. After the break-in fuel mixture is used up, use a 50:1 (2%) gasoline/oil mixture. Follow the table for mixing ratios. GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal.) gas 11.
FUEL & OIL Capacity Oil tank 1.5 liters (50.5 fl. oz.) Fluid Type Mercury or Quicksilver Premium TC-W3 2-cycle oil Filling Fuel Tank ! WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill fuel tanks outdoors away from heat, sparks, and open flames. Remove portable fuel tanks from boat to refill them. Always stop engine before refilling tanks.
FEATURES & 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 i d d f abcdefghi- f g e e ob00329 Control handle - forward, neutral, reverse. Neutral release lever Trim/tilt switch (if equipped). - Refer to Features & Controls - Power Trim and Tilt.
FEATURES & CONTROLS WARNING SYSTEM OPERATION The warning horn will emit a continuous beep. This will alert the operator and help identify the following listed situations. Warning System Function Sound Description Engine Over Temperature Continuous Engine Over Heat Low Oil Level Continuous Low Oil Level ENGINE OVERHEAT If the engine overheats, immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
FEATURES & CONTROLS 3104 ENGINE OVERHEAT If the engine overheats, the warning horn will sound and the warning system will automatically limit the engine speed to 2500 RPM. Immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. ob00331 If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check the cooling water intake holes for obstruction.
FEATURES & CONTROLS Manual Tilt System TILT LOCK LEVER The tilt lock lever is used to engage the reverse lock mechanism, and prevent the outboard from lifting out of the water when operating in reverse gear due to reverse propeller thrust. The tilt lock lever can be placed in two positions as follows. Release Position - Placing the tilt lock lever up in the release position will allow you to tilt up the outboard.
FEATURES & CONTROLS a b c ob00615 abc- Release position Lock position Tilt support pin Lowering To Run Position 1. Raise outboard slightly and pull out the tilt support pin. Lower the outboard. 2. Move the tilt lock lever down to the lock position. SHALLOW WATER OPERATION The shallow water drive feature on the outboard allows you to position the outboard at a higher tilt angle to prevent hitting bottom.
FEATURES & CONTROLS a c b ab- d Release position Lock position cd- ob00616 Knob Shallow water drive bracket 4. Take hold of the top cowl grip and raise outboard to enable the shallow water drive bracket to swing down. 5. Lower the outboard to rest on the shallow water drive bracket. 6. Move the tilt lock lever down to the lock position. Releasing Outboard From Shallow Water Drive Position 1. Push the tilt lock lever up to the release position. 2.
FEATURES & CONTROLS a b c ob00613 abc- Too much angle (stern down - bow up) Not enough angle (stern up - bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom can: • Lower the bow. • Result in quicker planing off, especially with a heavy load or a stern heavy boat. • Generally improve the ride in choppy water.
FEATURES & CONTROLS ! WARNING Before operating, the outboard must be locked in its lock/run position. Failure to lock the outboard in its lock/ run position could result in the outboard tilting up out of the water during deceleration or while operating in reverse, resulting in possible loss of boat control. Loss of boat control can result in serious injury, death, or boat damage. Basic Tilting Operation Move tilt lock lever to the tilt position.
FEATURES & CONTROLS a a- ob00611 Tilt support pin Operating Angle Adjustment The transom brackets have five holes for adjusting the operating angle (forward stop movement) of the outboard. Tilt stops are installed for adjustment in the first hole. Use tilt pin provided for adjustments in the remaining four holes. Remove tilt pin when using the tilt stops.
FEATURES & CONTROLS a b c ob00613 ab- Too much angle (bow up) - adjust in. Not enough angle (bow down) - adjust out. c- Angle adjusted properly (bow slightly up). NOTE: The outboard should be locked against the tilt stops or tilt pin during operation by setting the tilt lock lever to the lock/run position. Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom can: • Lower the bow.
FEATURES & CONTROLS a b c ab- Trim switch Tilt range of travel c- ob00663 Trim range of travel 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.
FEATURES & CONTROLS ! WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. • 2. In rare circumstances, the owner may decide to limit the trim in.
FEATURES & CONTROLS a a- ob00666 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. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range.
FEATURES & CONTROLS a a- b Tighten friction b- 3073 Loosen friction REMOTE STEERING MODELS Steering Friction Adjustment - Adjust this screw to achieve the desired steering friction (drag) on the steering wheel. Turn screw clockwise to tighten friction or turn counterclockwise to loosen friction. a b ob00623 a- Loosen friction b- Tighten friction Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction.
FEATURES & CONTROLS MODELS WITH POWER TRIM Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left and right and note the direction the boat turns more easily. If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and retest.
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 boats maximum load capacity. Look at the boat capacity plate. • Fuel supply OK. • Oil supply (oil injection) OK.
OPERATION Engine Break-in Procedure - Vary the throttle setting during the first hour of operation. During the first hour of operation, avoid remaining at constant speed for more than two minutes and avoid sustained wide open throttle. MODELS WITHOUT OIL INJECTION Engine Break-in Fuel Mixture - Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel. After the break-in fuel mixture is used up, use a 50:1 (2%) gasoline/oil mixture.
OPERATION ob00350 6. Shift outboard to neutral (N) position. N ob00351 7. Models without power trim - Position the tilt lock lever down to the lock position. a b ob00625 ! WARNING Models without power trim - Before operating, the outboard must be locked in its tilt position. Failure to lock the outboard in its tilt position could result in the outboard lifting out of the water when operating in reverse, resulting in possible loss of boat control.
OPERATION ob00354 10. Starting Flooded Engine - Advance the fast idle lever or throttle only feature to the maximum position. Without activating primer, crank engine for 10 seconds. Wait 30 seconds and repeat until engine starts. Immediately start to reduce engine speed after engine starts. 11. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.
OPERATION ob00348 3. Connect the fuel line to the outboard. 3074 4. Squeeze the fuel line primer bulb several times until it feels firm. 5. Set the lanyard stop switch to "RUN" position. Refer to General Information - Lanyard Stop Switch. ob00349 ob00350 6. Shift outboard to neutral (N) position. N N 3107 ob00351 7. Position the tilt lock lever to the lock position.
OPERATION a b ob00625 a b ob00333 a8. Reverse/tilt position b- Lock/run position Tiller handle models - Move throttle grip to "START" position. 0%100 START START 3075 9. Remote control models - Move on/off switch to the on position. 3026 NOTE: Manual starting models - For initial start of a new engine or first start after a prolonged storage, primer lines may have air in them. In this case, push in the primer bulb several times until fluid can be felt and then the normal 4 to 6 rapid primes.
OPERATION 3076 a. Pull the starter rope slowly until starter engages, then pull rapidly to crank the engine. b. Allow rope to return slowly. Repeat until engine starts. If engine begins to stall, re-prime until engine is running. 3072 11. Electric starting models - Turn ignition key to the "START" position and start the engine. If engine is cold, push in on key to choke engine. If engine fails to start in 10 seconds, wait 30 seconds and try again.
OPERATION Gear Shifting IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). F N R R N 3108 ob00557 • F Remote Control Models - When shifting, always stop at neutral position and allow the engine speed to return to idle. ob00308 • Tiller Handle Models - Reduce engine speed to idle before shifting.
OPERATION ob00361 Emergency Starting - Electric Start Models If the starter system fails, use the spare starter rope (provided) and follow procedure. ! WARNING When using emergency starter rope to start engine, the start in gear protection device is inoperative. Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear. Sudden unexpected acceleration could result in serious injury or death. 1. Shift outboard to neutral (N) position. N N 3107 ob00351 2.
OPERATION 3097 ! WARNING To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine. ! WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine. Do not attempt to reinstall the flywheel cover or top cowl when engine is running. 5.
OPERATION Emergency Starting - Manual Start Models If the starter system fails, use the spare starter rope (provided) and follow procedure. ! WARNING When using emergency starter rope to start engine, the start in gear protection device is inoperative. Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear. Sudden unexpected acceleration could result in serious injury or death. 1. Shift outboard to neutral (N) position. N N 3107 ob00351 2.
OPERATION 3085 ! WARNING To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine. ! WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine. Do not attempt to reinstall the rewind starter assembly or top cowl when engine is running. 5. Remote control models - Move on/off switch to the on position. 6.
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 Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. • Remote control models - Visually check steering link rod fasteners for proper tightness. See Steering Link Rod Fasteners. • Check propeller blades for damage.
MAINTENANCE ob01604 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 3. Start the engine and run it at idle speed in neutral shift position. ob00570 IMPORTANT: Do not run engine above idle when flushing. 4.
MAINTENANCE ob00369 INSTALLATION 1. Engage the front hook and push cowl back over the cowl seal. 2. Push cowl down and move the rear latch lever up to lock. 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. Add water as necessary to keep the battery full. 3.
MAINTENANCE a b c d 3933 a b c d ob01406 ab- Cover Filter element cd- O-ring Sight bowl Installation 1. Push the filter element (with open end toward cover) into the cover. 2. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the cover. IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter.
MAINTENANCE a b c d 3933 ab2. Cover Filter cd- O-ring seal Sight bowl Wash sight bow and filter in cleaning solvent. 3806 Carburetor Fuel Bowl ! 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. 1. Loosen main jet plug on side of carburetor 1 turn to drain fuel. 2. Dispose of fuel properly.
MAINTENANCE CARBURETOR ADJUSTMENTS Slow Speed Mixture Adjustment 1. Before starting engine, turn the slow speed mixture screw in until it is lightly seated then back it out 1-1/4 turns. 3951 2. With boat tied securely to dock, start engine and allow it to warm up. 3. Shift the outboard into forward gear while maintaining idle speed. R 0%100 START START N 3075 3108 F 4. Turn the slow speed mixture screw slowly in until the engine starts to misfire or stall due to a lean mixture.
MAINTENANCE High Speed Mixture Adjustment The carburetor is equipped with a standard size high speed fixed jet that is replaceable for operation at higher elevations. See an authorized dealer. Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes.
MAINTENANCE b d c e a abcde- 3086 Special washer head bolt (10-856680) Nylon insert locknut (11-826709113) Spacer Flat washers Nylon insert locknut (11-826709113) Description Nm Special washer head bolt 27 20 Nylon insert locknut "b" 27 20 Nylon insert locknut "e" lb. in. lb. ft. Tighten until seats, then back off 1/4 turn Fuse Replacement - Electric Start Models IMPORTANT: Always carry spare SFE 20 AMP fuses. The electric starting circuit is protected from overload by an SFE 20 AMP fuse.
MAINTENANCE a b c 3087 ab- Good band Broken band c- Fuse holder 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 N N 3107 ob00351 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the propeller nut retainer. 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 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.
MAINTENANCE IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed. 7. Flo-Torq I Drive Hub Propellers - Install forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft. b a d c ab8.
MAINTENANCE ob00375 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap to specification. ob00423 ob00424 Spark Plug Spark plug gap 4. 1.0 mm (0.040 in.) Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger tight, and then tighten 1/4 turn or torque to specifications. Description Nm Spark plug 27 lb. in. lb. ft.
MAINTENANCE 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. • Swivel Bracket - Lubricate through fitting. ob00635 • Tilt Tube - Lubricate through fitting. • Co-Pilot Shaft (Tiller Handle Models) - Lubricate through fitting. Move the steering friction lever back and forth while lubricating. b a a a- Tilt Tube b- 3089 Co-pilot shaft • Lubricate threads of transom clamp screws (if equipped).
MAINTENANCE ! WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. a b 3092 a3. Fitting b- Steering cable end Lubricate the following with light weight oil.
MAINTENANCE Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gearcase checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gearcase.
MAINTENANCE a b c ob00440 ab3. Vent hole Vent plug c- Fill/drain plug Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
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 ! 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. Recharge if necessary. • Store the battery in a cool, dry place.
TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models - Blown 20 Amp fuse in the starting circuit. Refer to Maintenance section. • 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 or starter solenoid failure.
TROUBLESHOOTING • 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. • Worn out or inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator.
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.
