90-8M0055669 311

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. This led to Mercury Marine's reputation for strict
quality control, excellence, durability, lasting performance,
and being the best at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use, and care of your outboard.

75/90/115/125 OptiMax
All of us at Mercury Marine took pride in building your
outboard and wish you many years of happy and safe
boating.
Again, thank you for your confidence in Mercury Marine.
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.
This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of
the design. Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine engine repair establishment or
© 2012 Mercury Marine

individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.

! WARNING
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth
defects or other reproductive harm.

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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.
The description and specifications contained herein were in
effect at the time this manual was approved for printing. Mercury
Marine, whose policy is one of continued improvement, reserves
the right to discontinue models at any time, to change
specifications, designs, methods, or procedures without notice
and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2010, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,
OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,
SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves
logo, and SmartCraft logo are all registered trademarks of
Brunswick Corporation. Mercury Product Protection logo is a
registered service mark of Brunswick Corporation.
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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 • 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.
Declaration of Conformity OptiMax ‑ For Recreational Craft
Propulsion Engines with the Requirements of Directive
94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Mercury Marine
Address: W6250 Pioneer Road P.O. Box 1939
Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Address: Parc Industriel de Petit‑Rechain
Town: Verviers Post Code: 4800 Country: Belgium

Name of Notified Body for exhaust emission assessment: Det Norske

Veritas AS
Address: Veritasveien 1
Post Code: Country:
Town: Hovik ID Number: 0575
1322 Norway

Name of Notified Body for noise emission assessment: Det Norske

Veritas AS
Address: Veritasveien 1
Post Code: Country:
Town: Hovik ID Number: 0575
1322 Norway

Conformity assessment
module used for exhaust ☐ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G ☒H
emissions:
Conformity assessment
module used for noise ☐A ☐ Aa ☐G ☒H
emissions:
Other Community Directives applied: Safety of Machinery Directive
98/37/EC; Electromagnetic Compatibility Directive 2004/108/EC

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Description of Engines and Essential Requirements
Engine Type Fuel Type Combustion Cycle
☒ Outboard engine ☒ Petrol ☒ 2 stroke

Identification of Engines Covered by This Declaration of

Conformity
Unique engine EC Module H
Name of engine family identification number: certificate
starting serial number number
1.5L OptiMax 75, 80, 90, 115,
1B227000 RCD‑H‑2
125 hp
2.5L OptiMax 135, 150, 175 hp 1B227000 RCD‑H‑2
3.0L OptiMax 200, 225 hp 1B227000 RCD‑H‑2

other Please specify in

Essential normative technical more detail
standards
requirements document/ file (* = mandatory
method standard)
Annex 1.B—Exhaust Emissions
B.1 engine
☐ ☐ ☒
identification
B.2 exhaust
* EN ISO
emission ☒* ☐ ☐
8178‑1:1996
requirements
B.3 durability ☐ ☐ ☒
B.4 owner's
☒ ☐ ☐ ISO 8665: 1995
manual
Annex 1.C—Noise Emissions
C.1 Noise emission
☒* ☐ ☐ EN ISO 14509
levels
C.2 Owner's
☐ ☒ ☐ Owner's manual
manual

This declaration of conformity is issued under the sole responsibility of the

manufacturer. I declare on behalf of the engine manufacturer that the engines
mentioned preceding complies with all applicable essential requirements in
the way specified.

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 Name / function:
Mark D. Schwabero, President, Mercury
Outboard

Date and place of issue:July 24, 2008

Fond du Lac, Wisconsin, USA

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vi eng
 WARRANTY INFORMATION

Warranty Registration.................................................................. 1
Transfer of Warranty.................................................................... 2
Transfer of Mercury Product Protection (Extended Service
Coverage) Plan United States and Canada................................. 2
Outboard Limited Warranty.......................................................... 3
3 Year Limited Warranty Against Corrosion................................ 7
Warranty Coverage and Exclusions.......................................... 11
U.S. EPA Emissions Limited Warranty...................................... 13
Emission Control System Components..................................... 13
California Emissions Limited Warranty...................................... 14
California Air Resources Board Explanation of Your California
Emission Control Warranty Statement....................................... 18
Emission Certification Star Label............................................... 19

General Information

Boater's Responsibilities............................................................ 21
Before Operating Your Outboard............................................... 21
Boat Horsepower Capacity........................................................ 22
High‑Speed and High‑Performance Boat Operation................. 22
Propeller Selection..................................................................... 23
Outboard Remote Control Models ............................................ 26
Remote Steering Notice............................................................. 26
Lanyard Stop Switch.................................................................. 27
Protecting People in the Water.................................................. 31
Passenger Safety Message ‑ Pontoon Boats and Deck Boats
................................................................................................... 32
Wave and Wake Jumping.......................................................... 33
Impact with Underwater Hazards............................................... 34
Exhaust Emissions.................................................................... 36
Selecting Accessories for Your Outboard.................................. 38
Safe Boating Suggestions......................................................... 38
Recording Serial Number.......................................................... 40
Specifications............................................................................. 41
Component Identification........................................................... 42

eng vii
 Transporting

Trailering Boat/Outboard .......................................................... 43

Fuel and Oil

Fuel Recommendations............................................................. 44
Fuel Requirements.................................................................... 46
Fuel Additives............................................................................ 46
Avoiding Fuel Flow Restriction.................................................. 46
Low Permeation Fuel Hose Requirement ................................. 46
EPA Pressurized Portable Fuel Tank Requirements................. 46
Fuel Demand Valve (FDV) Requirement................................... 47
Mercury Marine's Pressurized Portable Fuel Tank.................... 47
Oil Recommendation................................................................. 49
Filling Oil Injection System......................................................... 49
Filling Fuel Tank........................................................................ 51

Features and Controls

Remote Control Features.......................................................... 53

Warning System........................................................................ 54
Power Trim and Tilt.................................................................... 57
Trim Tab Adjustment................................................................. 61

Operation

Pre‑Starting Check List.............................................................. 62

Operating in Freezing Temperatures......................................... 62
Operating in Saltwater or Polluted Water.................................. 63
Operating at High Elevations..................................................... 63
Setting Trim Angle While Running Engine at Idle Speed.......... 64
Engine Break‑In Procedure....................................................... 64
Starting the Engine.................................................................... 65
Gear Shifting.............................................................................. 68
Stopping the Engine.................................................................. 69

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 Maintenance

Outboard Care........................................................................... 70
EPA Emissions Regulations...................................................... 70
Inspection and Maintenance Schedule...................................... 71
Flushing the Cooling System .................................................... 74
Top Cowl Removal and Installation........................................... 75
Cleaning Care for Top Cowl...................................................... 75
Flywheel Cover Removal and Installation.................................. 75
Side Panel Removal and Installation......................................... 76
Fuel System............................................................................... 77
Steering Link Rod Fasteners..................................................... 80
Fuse Replacement..................................................................... 81
Corrosion Control Anode........................................................... 82
Battery Inspection ..................................................................... 83
Battery Information.................................................................... 83
Propellers................................................................................... 84
Spark Plug Inspection and Replacement................................... 88
Compressor Air Intake Filter...................................................... 89
Alternator Belt Inspection........................................................... 90
Lubrication Points...................................................................... 90
Checking Power Trim Fluid........................................................ 92
Gearcase Lubrication................................................................. 93

Storage

Storage Preparation................................................................... 96
Fuel System............................................................................... 96
Protecting Internal Engine Components.................................... 98
Protecting External Outboard Components............................... 98
Gearcase................................................................................... 99
Positioning Outboard for Storage.............................................. 99
Battery Storage.......................................................................... 99

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 Troubleshooting

Starter Motor Will Not Crank the Engine.................................. 100

Engine Will Not Start................................................................ 100
Engine Runs Erratically........................................................... 101
Performance Loss.................................................................... 101
Battery Will Not Hold Charge................................................... 101

Owner Service Assistance

Local Repair Service................................................................ 102

Service Away from Home........................................................ 102
Parts and Accessories Inquiries.............................................. 102
Service Assistance.................................................................. 102
Mercury Marine Service Offices............................................... 103

Outboard Installation

Important Information............................................................... 105

Boat Horsepower Capacity...................................................... 105
Start in Gear Protection........................................................... 106
Selecting Accessories for Your Outboard................................ 106
Fuel System............................................................................. 106
Installation Specifications........................................................ 108
Lifting the Outboard................................................................. 109
Steering Cable ‑ Starboard Side Routed Cable....................... 110
Determining Recommended Outboard Mounting Height......... 112
Drilling Outboard Mounting Holes............................................ 113
Fastening the Outboard to the Transom.................................. 114
Electrical, Fuel Hose, Flush Hose and Control Cables............ 118
Oil Injection Set‑Up.................................................................. 131
Trim In Pin............................................................................... 133

Maintenance Log

Maintenance Log..................................................................... 135

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 WARRANTY INFORMATION
Warranty Registration
UNITED STATES AND CANADA
To be eligible for warranty coverage, the product must be
registered with Mercury Marine.
At the time of sale, the selling dealer should complete the
warranty registration and immediately submit it to Mercury
Marine via MercNET, e‑mail, or mail. Upon receipt of this
warranty registration, Mercury Marine will record the registration.
A copy of the warranty registration should be provided to you by
your selling dealer.
NOTE: Registration lists must be maintained by Mercury Marine
and any dealer on marine products sold in the United States,
should a safety recall notification under the Federal Safety Act
be required.
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 Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax +1 920 929 5893
OUTSIDE UNITED STATES AND CANADA
For products purchased outside the United States and Canada,
contact the distributor in your country, or the Marine Power
Service Center closest to you.

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 WARRANTY INFORMATION
Transfer of Warranty
UNITED STATES AND CANADA
The limited warranty is transferable to a subsequent purchaser,
but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial
applications.
To transfer the warranty to the subsequent owner, send or fax a
copy of the bill of sale or purchase agreement, new owner’s
name, address, and engine serial number to Mercury Marine’s
warranty registration department. In the United States and
Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax +1 920 929 5893
Upon processing the transfer of warranty, Mercury Marine will
record the new owner's information.
There is no charge for this service.
OUTSIDE THE UNITED STATES AND CANADA
For products purchased outside the United States and Canada,
contact the distributor in your country, or the Marine Power
Service Center closest to you.

Transfer of Mercury Product Protection (Extended

Service Coverage) Plan United States and Canada
The remaining coverage period of the Product Protection Plan is
transferable to the subsequent purchaser of the engine within
thirty (30) days from the date of sale. Contracts not transferred
within thirty (30) days of the subsequent purchase will no longer
be valid and the product will no longer be eligible for coverage
under the terms of the contract.

2 eng
 WARRANTY INFORMATION
To transfer the plan to the subsequent owner, contact Mercury
Product Protection or an authorized dealer to receive a Request
for Transfer form. Submit to Mercury Product Protection a
receipt/bill of sale, a completed Request of Transfer form, and a
check payable to Mercury Marine in the amount of $50.00 (per
engine) to cover the transfer fee.
Plan coverage is not transferable from one product to another
product or for non‑eligible applications.
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@mercmarine.com.

Outboard Limited Warranty

UNITED STATES, CANADA, EUROPE, MIDDLE EAST,
AFICA, AND THE CONFEDERATION OF INDEPENDENT
STATES
WHAT IS COVERED: Mercury Marine warrants its new products
to be free of defects in material and workmanship during the
period described below.

eng 3
 WARRANTY INFORMATION
DURATION OF COVERAGE: This Limited Warranty provides
coverage for three (3) years from the date the product is first sold
to a recreational use retail purchaser, or the date on which the
product is first put into service, whichever occurs first.
Commercial users of these products receive warranty coverage
of one (1) year from the date of first retail sale, or one (1) year
from the date on which the product was first put into service,
whichever occurs first. Commercial use is defined as any work or
employment related use of the product, or any use of the product
which generates income, for any part of the warranty period,
even if the product is only occasionally used for such purposes.
The repair or replacement of parts, or the performance of service
under this warranty, does not extend the life of this warranty
beyond its original expiration date. Unexpired warranty coverage
can be transferred from one recreational use customer to a
subsequent recreational use customer upon proper reregistration
of the product. Unexpired warranty coverage cannot be
transferred either to or from a commercial use customer.
Warranty coverage may be terminated for used repossessed
product; or product purchased at auction, from a salvage yard, or
from an insurance company.
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. Inaccurate
warranty registration information regarding recreational use, or
subsequent change of use from recreational to commercial
(unless properly reregistered) may void the warranty at the sole
discretion of Mercury Marine. Routine maintenance outlined in
the Operation and Maintenance Manual must be timely
performed in order to maintain warranty coverage. Mercury
Marine reserves the right to make warranty coverage contingent
upon proof of proper maintenance.

4 eng
 WARRANTY INFORMATION
WHAT MERCURY WILL DO: Mercury's sole and exclusive
obligation under this warranty is limited to, at our option,
repairing a defective part, replacing such part or parts with new
or Mercury Marine certified remanufactured parts, or refunding
the purchase price of the Mercury product. Mercury reserves the
right to improve or modify products from time to time without
assuming an obligation to modify products previously
manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer
must provide Mercury with a reasonable opportunity to repair,
and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for
inspection to a Mercury dealer authorized to service the product.
If purchaser cannot deliver the product to such a dealer, written
notice must be given to Mercury. We will then arrange for the
inspection and any covered repair. Purchaser, in that case, shall
pay for all related transportation charges and/or travel time. If the
service provided is not covered by this warranty, purchaser shall
pay for all related labor and material, and any other expenses
associated with that service. Purchaser shall not, unless
requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested
in order to obtain coverage.

eng 5
 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,
submersion, improper installation (proper installation
specifications and techniques are set forth in the installation
instructions for the product), improper service, use of an
accessory or part not manufactured or sold by us, jet pump
impellers and liners, operation with fuels, oils or lubricants which
are not suitable for use with the product (see the Operation and
Maintenance Manual), alteration or removal of parts, water
entering the engine through the fuel intake, air intake or exhaust
system, or damage to the product from insufficient cooling water
caused by blockage of the cooling system by a foreign body,
running the engine out of water, mounting the engine too high on
the transom, or running the boat with the engine trimmed out too
far. Use of the product for racing or other competitive activity, or
operating with a racing type lower unit, at any point, even by a
prior owner of the product, voids the warranty.
Expenses related to haul‑out, launch, towing, storage, telephone,
rental, inconvenience, slip fees, insurance coverage, loan
payments, loss of time, loss of income, or any other type of
incidental or consequential damages are not covered by this
warranty. Also, expenses associated with the removal and/or
replacement of boat partitions or material caused by boat design
for access to the product are not covered by this warranty.
No individual or entity, including Mercury Marine authorized
dealers, has been given authority by Mercury Marine to make
any affirmation, representation or warranty regarding the
product, other than those contained in this limited warranty, and
if made, shall not be enforceable against Mercury Marine.

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 WARRANTY INFORMATION
For additional information regarding events and circumstances
covered by this warranty, and those that are not, see the
Warranty Coverage section of the Operation and Maintenance
Manual, incorporated by reference into this warranty.
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. 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. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO
COUNTRY.

3 Year Limited Warranty Against Corrosion

WHAT IS COVERED: Mercury Marine warrants that each new
Mercury, Mariner, Mercury Racing, Sport Jet, M2 Jet Drive,
Tracker by Mercury Marine Outboard, Mercury MerCruiser
Inboard or Sterndrive Engine (Product) will not be rendered
inoperative as a direct result of corrosion for the period of time
described below.
DURATION OF COVERAGE: This limited corrosion warranty
provides coverage for three (3) years from either the date the
product is first sold, or the date on which the product is first put
into service, whichever occurs first. The repair or replacement of
parts, or the performance of service under this warranty, does
not extend the life of this warranty beyond its original expiration
date. Unexpired warranty coverage can be transferred to
subsequent (noncommercial use) purchaser upon proper
reregistration of the product.

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 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. Corrosion
prevention devices specified in the Operation and Maintenance
Manual must be in use on the boat, and routine maintenance
outlined in the Operation and Maintenance Manual must be
timely performed (including, without limitation, the replacement of
sacrificial anodes, use of specified lubricants, and touch‑up of
nicks and scratches) in order to maintain warranty coverage.
Mercury Marine reserves the right to make warranty coverage
contingent upon proof of proper maintenance.
WHAT MERCURY WILL DO: Mercury's sole and exclusive
obligation under this warranty is limited to, at our option,
repairing a corroded part, replacing such part or parts with new
or Mercury Marine certified remanufactured parts, or refunding
the purchase price of the Mercury product. Mercury reserves the
right to improve or modify products from time to time without
assuming an obligation to modify products previously
manufactured.

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 WARRANTY INFORMATION
HOW TO OBTAIN WARRANTY COVERAGE: The customer
must provide Mercury with a reasonable opportunity to repair,
and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for
inspection to a Mercury dealer authorized to service the product.
If purchaser cannot deliver the product to such a dealer, written
notice must be given to Mercury. We will then arrange for the
inspection and any covered repair. Purchaser, in that case, shall
pay for all related transportation charges and/or travel time. If the
service provided is not covered by this warranty, purchaser shall
pay for all related labor and material, and any other expenses
associated with that service. Purchaser shall not, unless
requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested
in order to obtain coverage.
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.
Commercial use is defined as any work or employment related
use of the product, or any use of the product which generates
income, for any part of the warranty period, even if the product is
only occasionally used for such purposes.

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 WARRANTY INFORMATION
Corrosion damage caused by stray electrical currents (onshore
power connections, nearby boats, submerged metal) is not
covered by this corrosion warranty and should be protected
against by the use of a corrosion protection system, such as the
Mercury Precision Parts or Quicksilver MerCathode system
and/or Galvanic Isolator. Corrosion damage caused by improper
application of copper base antifouling paints is also not covered
by this limited warranty. If antifouling protection is required,
Tri‑Butyl‑Tin‑Adipate (TBTA) base antifouling paints are
recommended on Outboard and MerCruiser boating applications.
In areas where TBTA base paints are prohibited by law, copper
base paints can be used on the hull and transom. Do not apply
paint to the outboard or MerCruiser product. In addition, care
must be taken to avoid an electrical interconnection between the
warranted product and the paint. For MerCruiser product, an
unpainted gap of at least 38 mm (1.5 in.) should be left around
the transom assembly. Refer to the Operation and Maintenance
Manual for additional details.
For additional information regarding events and circumstances
covered by this warranty, and those that are not, see the
Warranty Coverage section of the Operation and Maintenance
Manual, incorporated by reference into this warranty.
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. 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. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO
COUNTRY.

10 eng
 WARRANTY INFORMATION
Warranty Coverage and Exclusions
The purpose of this section is to help eliminate some of the more
common misunderstandings regarding warranty coverage. The
following information explains some of the types of services that
are not covered by warranty. The provisions set forth following
have been incorporated by reference into the Three Year Limited
Warranty Against Corrosion Failure, the International Limited
Outboard Warranty, and the United States and Canada Limited
Outboard Warranty.
Keep in mind that warranty covers repairs that are needed within
the warranty period because of defects in material and
workmanship. Installation errors, accidents, normal wear, and a
variety of other causes that affect the product are not covered.
Warranty is limited to defects in material or workmanship, but
only when the consumer sale is made in the country to which
distribution is authorized by us.
Should you have any questions concerning warranty coverage,
contact your authorized dealer. They will be pleased to answer
any questions that you may have.
GENERAL EXCLUSIONS FROM WARRANTY
1. Minor adjustments and tune‑ups, including checking,
cleaning, or adjusting spark plugs, ignition components,
carburetor settings, filters, belts, controls, and checking
lubrication made in connection with normal services.
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. Haul‑out, launch, towing charges, removal and/or
replacement of boat partitions or material because of boat
design for necessary access to the product, all related
transportation charges and/or travel time, etc. Reasonable
access must be provided to the product for warranty service.
Customer must deliver product to an authorized dealer.

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 WARRANTY INFORMATION
5. Additional service work requested by customer other than
that necessary to satisfy the warranty obligation.
6. Labor performed by other than an authorized dealer may be
covered only under the following circumstances: when
performed on emergency basis (providing there are no
authorized dealers in the area who can perform the work
required or have no facilities to haul‑out, etc., and prior
factory approval has been given to have the work performed
at this facility).
7. All incidental and/or consequential damages (storage
charges, telephone or rental charges of any type,
inconvenience or loss of time or income) are the owner's
responsibility.
8. Use of other than Mercury Precision or Quicksilver parts
when making warranty repairs.
9. Oils, lubricants, or fluids changed as a matter of normal
maintenance is customer's responsibility unless loss or
contamination of same is caused by product failure that
would be eligible for warranty consideration.
10. Participating in or preparing for racing or other competitive
activity or operating with a racing type lower unit.
11. Engine noise does not necessarily indicate a serious engine
problem. If diagnosis indicates a serious internal engine
condition which could result in a failure, condition
responsible for noise should be corrected under the
warranty.
12. Lower unit and/or propeller damage caused by striking a
submerged object is considered a marine hazard.
13. 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. Refer to the Maintenance section.

12 eng
 WARRANTY INFORMATION
16. Our limited warranty does not apply to any damage to our
products caused by the installation or use of parts and
accessories which are not manufactured or sold by us.
Failures which are not related to the use of those parts or
accessories are covered under warranty if they otherwise
meet the terms of the limited warranty for that product.

U.S. EPA Emissions Limited Warranty

Consistent with the obligations created by 40 CFR Part 1045,
Subpart B, Mercury Marine provides a five year or 175 hours of
engine use, whichever occurs first, to the retail customer, that
the engine is designed, built, and equipped so as to conform at
the time of sale with applicable regulations under section 213 of
the Clean Air Act, and that the engine is free from defects in
materials and workmanship which cause the engine to fail to
conform with applicable regulations. This emission‑related
warranty covers all the components listed in the Emission
Control System Components.

Emission Control System Components

The EPA and Califormia emission‑related warranty covers all the
following list of components:
COMPONENTS OF THE EMISSIONS CONTROL SYSTEM:
1. Fuel metering system
a. Carburetor and internal parts (and/or pressure regulator
or fuel injection system)
b. Cold start enrichment system
c. Intake valves
2. Air induction system
a. Intake manifold
b. Turbocharger or supercharger systems (where
applicable)
3. Ignition system
a. Spark plugs
b. Magneto or electronic ignition system
c. Spark advance/retard system

eng 13
 WARRANTY INFORMATION
d. Ignition coil and/or control module
e. Ignition wires
4. Lubrication system (4‑Stroke engines excluded)
a. Oil pump and internal parts
b. Oil injectors
c. Oil meter
5. Exhaust system
a. Exhaust manifold
b. Exhaust valves
6. Miscellaneous items used in above systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or
devices, and mounting hardware
b. Pulleys, belts, and idlers
c. Vacuum, temperature, check and time sensitive valves
and switches
d. Electronic controls
The emission‑related warranty does not cover components
whose failure would not increase an engine's emissions on any
regulated pollutant.

California Emissions Limited Warranty

The California Air Resources Board has promulgated air
emission regulations for outboard engines. The regulations apply
to all outboard engines sold to retail consumers in California, and
which were manufactured for the 2001 model year and later.
Mercury Marine, in compliance with those regulations, provides
this limited warranty for the emission control systems (see the
components listed in the Emission Control System
Components), and further warrants that the outboard engine
was designed, built, and equipped to conform with all applicable
regulations adopted by the California Air Resources Board
pursuant to its authority in Chapters 1 and 2, Part 5, Division 26
of the Health and Safety Code. For information regarding the
limited warranty for the nonemission‑related components of the
outboard, please see the limited warranty statement for your
outboard.

14 eng
 WARRANTY INFORMATION
WHAT IS COVERED: Mercury Marine warrants the components
of the emissions control systems (see the components listed in
the Emission Control System Components) of its new, 2001
model year and later outboards, sold by a California dealer to
retail customers residing in California, to be free from defects in
material or workmanship, that cause the failure of a warranted
part to be identical in all material respects to that part as
described in the application of Mercury Marine for certification
from the California Air Resources Board, for the period of time,
and under the conditions, identified below. The cost to diagnose
a warranty failure is covered under the warranty (if the warranty
claim is approved). Damage to other engine components caused
by the failure of a warranted part will also be repaired under
warranty.
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 four (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 engine's hour meter, if any). Emission‑related
normal maintenance items such as spark plugs and filters, that
are on the warranted parts list, are warranted up to their first
required replacement interval only. Refer to Emission Control
System Components and Maintenance Schedule. The repair or
replacement of parts, or the performance of service under this
warranty, does not extend the life of this warranty beyond its
original expiration date. Unexpired warranty coverage can be
transferred to a subsequent purchaser. (See instructions on
transfer of warranty.)

eng 15
 WARRANTY INFORMATION
HOW TO OBTAIN WARRANTY COVERAGE: The customer
must provide Mercury with a reasonable opportunity to repair
and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for
inspection to a Mercury dealer authorized to service the product.
If purchaser cannot deliver the product to such a dealer, please
notify Mercury Marine and Mercury will then arrange for the
inspection and any covered repair. Purchaser, in that case, shall
pay for all related transportation charges and/or travel time. If the
service provided is not covered by this warranty, purchaser shall
pay for all related labor and material, and any other expenses
associated with that service. Purchaser shall not, unless
requested by Mercury, ship the product or parts of the product
directly to Mercury.
WHAT MERCURY WILL DO: Mercury Marine's sole and
exclusive obligation under this warranty is limited to, at our
expense and at our option, repairing or replacing defective parts
with new or Mercury Marine certified remanufactured parts, or
refunding the purchase price of the Mercury product. Mercury
reserves the right to improve or modify products from time to
time without assuming an obligation to modify products
previously manufactured.
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 installation specifications and techniques are set forth in
the installation instructions for the product), improper service, jet
pump impellers and liners, operation with fuels, oils, or lubricants
which are not suitable for use with the product (see Fuel and
Oil), alteration or removal of parts.

16 eng
 WARRANTY INFORMATION
Expenses related to haul‑out, launch, towing, storage, telephone,
rental, inconvenience, slip fees, insurance coverage, loan
payments, loss of time, loss of income, or any other type of
incidental or consequential damages are not covered by this
warranty. Also, expenses associated with the removal and/or
replacement of boat partitions or material caused by boat design
for access to the product are not covered by this warranty.
Nonwarranty maintenance, replacement, or repair of emission
control devices and systems may be performed by any marine
engine repair establishment or individual. The use of
non‑Mercury parts for nonwarranty maintenance or repairs will
not be grounds for disallowing other warranty work. The use of
add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13
of the California Code of Regulations) or modified parts not
exempted by the California Air Resources Board may be
grounds for disallowing a warranty claim, at the discretion of
Mercury Marine. Failures of warranted parts caused by the use
of a nonexempted add‑on or modified part will not be covered.
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. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO
COUNTRY.

If you have any questions regarding your warranty rights and

responsibilities, you should contact Mercury Marine at
1‑920‑929‑5040.

eng 17
 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. Mercury Marine must warrant the emission
control system on your outboard engine for the periods of time
listed below, provided there has been no abuse, neglect, or
improper maintenance of your outboard engine.
Your emission control system may include parts such as the
carburetor or fuel injection system, the ignition system, and
catalytic converter. Also included may be hoses, belts,
connectors, and other emission‑related assemblies.
Where a warrantable condition exists, Mercury Marine will repair
your outboard engine at no cost to you, including diagnosis,
parts, and labor.
MANUFACTURER'S WARRANTY COVERAGE: Select emission
control parts from model year 2001 and later outboard engines
are warranted for four (4) years, or for 250 hours of use,
whichever occurs first. However, warranty coverage based on
the hourly period is only permitted for outboard engines and
personal watercraft equipped with appropriate hour meters or
their equivalent. If any emission‑related part on your engine is
defective under warranty, the part will be repaired or replaced by
Mercury Marine.
OWNER'S WARRANTY RESPONSIBILITIES: As the outboard
engine owner, you are responsible for the performance of the
required maintenance listed in the Maintenance section.
Mercury Marine recommends that you retain all receipts covering
maintenance on your outboard engine, but Mercury Marine
cannot deny warranty solely for the lack of receipts or your
failure to ensure the performance of all scheduled maintenance.

18 eng
 WARRANTY INFORMATION
As the outboard engine owner, you should, however, be aware
that Mercury Marine may deny you warranty coverage if your
outboard engine or a part has failed due to abuse, neglect,
improper maintenance, or unapproved modifications.
You are responsible for presenting your outboard to a Mercury
dealer authorized to service the product as soon as a problem
exists. The warranty repairs will be completed in a reasonable
amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, you should contact Mercury Marine at
1‑920‑929‑5040.

Emission Certification Star Label

Outboards are labeled on the cowl with one of the following star
labels.
The symbol for a cleaner marine engine 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.
One Star ‑ Low Emission
The One Star label identifies engines that meet
the Air Resources Board's 2001 exhaust
emissions standards. Engines meeting these
standards have 75% lower emissions than
22531
conventional carbureted two‑stroke engines.
These engines are equivalent to the U.S. EPA's
2006 standards for marine engines.
Two Stars ‑ Very Low Emission
The Two Star label identifies engines that meet
the Air Resources Board's Personal Watercraft
and Outboard marine engine 2004 exhaust
emissions standards. Engines meeting these
42537 standards have 20% lower emissions than One
Star ‑ Low Emission engines.

eng 19
WARRANTY INFORMATION
Three Stars ‑ Ultra Low Emission
The Three Star label identifies engines that meet
the Air Resources Board's Personal Watercraft
and Outboard marine engine 2008 exhaust
emissions standards or the Sterndrive and
Inboard marine engine 2003‑2008 exhaust
42538
emission standards. Engines meeting these
standards have 65% lower emissions than One
Star ‑ Low Emission engines.
Four Stars ‑ Super Ultra Low Emission
The Four Star label identifies engines that meet
the Air Resources Board's Sterndrive and Inboard
marine engine 2009 exhaust emission standards.
Personal Watercraft and Outboard marine engines
may also comply with these standards. Engines
42539
meeting these standards have 90% lower
emissions than One Star ‑ Low Emission engines.

20 eng
 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.

Before Operating Your Outboard

Read this manual carefully. Learn how to operate your outboard
properly. If you have any questions, contact your dealer.
Safety and operating information that is practiced, along with
using good common sense, can help prevent personal injury and
product damage.
This manual as well as safety labels posted on the outboard use
the following safety alerts to draw your attention to special safety
instructions that should be followed.

! DANGER
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.

! WARNING
Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.

NOTICE
Indicates a situation which, if not avoided, could result in
engine or major component failure.

eng 21
 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. 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. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777

High‑Speed and High‑Performance Boat Operation

If your outboard is to be used on a high‑speed or
high‑performance boat with which you are unfamiliar, we
recommend that you never operate it at its high speed capability
without first requesting an initial orientation and familiarization
demonstration ride with your dealer or an operator experienced
with your boat/outboard combination. For additional information,
obtain a copy of our Hi‑Performance Boat Operation booklet
from your dealer, distributor, or Mercury Marine.

22 eng
 GENERAL INFORMATION
Propeller Selection
The propeller on your outboard is one of the most important
components in the propulsion system. An improper propeller
choice can significantly affect the performance of your boat and
could result in damage to the outboard engine.
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.
Choose a propeller for your boating application that will allow the
engine to operate within the specified full throttle operating
range. When operating the boat at full throttle under normal load
conditions, the engine RPM should be in the upper half of the
recommended full throttle RPM range. Refer to Specifications.
If engine RPM is above that range, select a propeller of
increased pitch in order to reduce engine RPM. If engine RPM is
below the recommended range, select a propeller of reduced
pitch to increase engine RPM.
IMPORTANT: To ensure proper fit, and performance, Mercury
Marine recommends the use of Mercury or Quicksilver branded
propellers and mounting hardware.

eng 23
 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.
a

22669
b

a - Diameter
b - Pitch ‑ Travel during one revolution

The following are some propeller basics that will help you
determine the correct propeller for your boating application.
Diameter ‑ The diameter is the distance across the imaginary
circle that is made when the propeller rotates. The correct
diameter for each propeller has been predetermined for the
design of your outboard. However, when more than one
diameter is available for the same pitch, use a larger diameter for
heavy boat applications and a smaller diameter for lighter
applications.
Pitch ‑ The pitch is the theoretical distance, in inches, that a
propeller travels forward during one revolution. Pitch can be
thought of similar to gears in a car. The lower the gear, the faster
the car will accelerate, but with lower overall top speed.
Likewise, a lower pitch propeller will accelerate quickly, but
top‑end speed will be reduced. The higher the propeller pitch the
faster the boat will usually go; though typically slowing
acceleration.

24 eng
 GENERAL INFORMATION
Determining the Correct Pitch size ‑ First, check the full
throttle RPM under normal load condition. If the full throttle RPM
is within the recommended range, select a replacement or
upgrade propeller with the same pitch as the current propeller.
• 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.
PROPELLER MATERIAL
Most propellers manufactured by Mercury Marine are made from
either aluminum or stainless steel. Aluminum is suitable for
general purpose use and is standard equipment on many new
boats. Stainless steel is over five times more durable than
aluminum and typically provides performance gains in
acceleration and top end speed due to design efficiencies.
Stainless steel propellers also come in a larger variety of sizes
and styles that allow you to dial in the ultimate performance for
your boat.
3 BLADE VS. 4 BLADE
Available in many sizes of both aluminum and stainless, 3 and
4‑blade propellers have unique performance characteristics. In
general, 3‑blade propellers offer good all around performance
and higher top speed than 4‑blade propellers. However, 4‑blade
propellers are usually faster to plane and more efficient at
cruising speeds, but lack the top end speed of a 3‑blade
propeller.

eng 25
 GENERAL INFORMATION
Outboard Remote Control Models
The remote control connected to your outboard must be
equipped with a start in neutral only protection device. This
prevents the engine from starting when the shift is actuated in
any position other than neutral.

! 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.

26 eng
 GENERAL INFORMATION
! 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.

a - Self‑locking nuts

a
a 27740

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.

eng 27
 GENERAL INFORMATION
The lanyard is a cord usually 122–152 cm (4–5 feet) in length
when stretched out, with an element on one end made to be
inserted into the switch and a snap on the other end for attaching
to the operator. The lanyard is coiled to make its at‑rest condition
as short as possible to minimize the likelihood of lanyard
entanglement with nearby objects. Its stretched‑out length is
made to minimize the likelihood of accidental activation should
the operator choose to move around in an area close to the
normal operator's position. If it is desired to have a shorter
lanyard, wrap the lanyard around the operator's wrist or leg, or
tie a knot in the lanyard.

a b

21629

a - Lanyard cord
b - Lanyard stop switch

Read the following Safety Information before proceeding.

28 eng
 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.
Falling overboard and accidental ejections are more likely to
occur in certain types of boats such as low sided inflatables,
bass boats, high performance boats, and light, sensitive handling
fishing boats operated by a hand tiller. Falling overboard and
accidental ejections are also likely to occur as a result of poor
operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting
on elevated fishing boat decks, operating at planing speeds in
shallow or obstacle infested waters, releasing your grip on a
steering wheel or tiller handle that is pulling in one direction,
drinking alcohol or consuming drugs, or daring high speed boat
maneuvers.
While activation of the lanyard stop switch will stop the engine
immediately, a boat will continue to coast for some distance
depending upon the velocity and degree of any turn at shut
down. However, the boat will not complete a full circle. While the
boat is coasting, it can cause injury to anyone in the boat's path
as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on
proper starting and operating procedures should they be
required to operate the engine in an emergency (e.g. if the
operator is accidentally ejected).

! WARNING
If the operator falls out of the boat, stop the engine immediately
to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the
stop switch using a lanyard.

eng 29
 GENERAL INFORMATION
! WARNING
Avoid serious injury or death from deceleration forces resulting
from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first
disconnecting the stop switch lanyard from the operator.

Accidental or unintended activation of the switch during normal

operation is also a possibility. 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.
• Loss of control when docking.
KEEP THE LANYARD STOP SWITCH AND LANYARD
CORD IN GOOD OPERATING CONDITION
Before each use, check to ensure the lanyard stop switch works
properly. Start the engine and stop it by pulling the lanyard cord.
If the engine does not stop, have the switch repaired before
operating the boat.
Before each use, visually inspect the lanyard cord to ensure it is
in good working condition and that there are no breaks, cuts, or
wear to the cord. Check that the clips on the ends of the cord are
in good condition. Replace any damaged or worn lanyard cords.

30 eng
 GENERAL INFORMATION
Protecting People in the Water
WHILE YOU ARE CRUISING
It is very difficult for a person standing or floating in the water to
take quick action to avoid a boat heading in his/her direction,
even at slow speed.

21604

Always slow down and exercise extreme caution any time you
are boating in an area where there might be people in the water.
Whenever a boat is moving (coasting) and the outboard gear
shift is in neutral position, there is sufficient force by the water on
the propeller to cause the propeller to rotate. This neutral
propeller rotation can cause serious injury.
WHILE BOAT IS STATIONARY

! WARNING
A spinning propeller, a moving boat, or any solid device
attached to the boat can cause serious injury or death to
swimmers. Stop the engine immediately whenever anyone in
the water is near your boat.

Shift outboard into neutral and shut off the engine before
allowing people to swim or be in the water near your boat.

eng 31
 GENERAL INFORMATION
Passenger Safety Message ‑ Pontoon Boats and
Deck Boats
Whenever the boat is in motion, observe the location of all
passengers. Do not allow any passengers to stand or use seats
other than those designated for traveling faster than idle speed.
A sudden reduction in boat speed, such as plunging into a large
wave or wake, a sudden throttle reduction, or a sharp change of
boat direction, could throw them over the front of the boat.
Falling over the front of the boat between the two pontoons will
position them to be run over by the outboard.
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.

26782

! WARNING
Sitting or standing in an area of the boat not designed for
passengers at speeds above idle can cause serious injury or
death. Stay back from the front end of deck boats or raised
platforms and remain seated while the boat is in motion.

32 eng
 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. 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 reenters
the water.

26784

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.

eng 33
 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. This will bring the boat to a nearly instantaneous stop
and can send the occupants flying forward. The boat may also
steer sharply to one side.

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. Under these
conditions, boat speed should be kept to a minimum planing
speed of 24 to 40 km/h (15 to 25 MPH).

26785

Striking a floating or underwater object could result in an infinite

number of situations. Some of these situations could result in the
following:
• Part of the outboard or the entire outboard could break loose
and fly into the boat.

34 eng
 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. Boat speed should be kept to a minimum planing
speed when driving in waters known to have underwater
obstacles.
After striking a submerged object, stop the engine as soon as
possible and inspect it for any broken or loose parts. If damage
is present or suspected, the outboard should be taken to an
authorized dealer for a thorough inspection and necessary
repair.
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
Operating a boat or engine with impact damage can result in
product damage, serious injury, or death. If the vessel
experiences any form of impact, have an authorized Mercury
Marine dealer inspect and repair the vessel or power package.

eng 35
 GENERAL INFORMATION
Exhaust Emissions
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide (CO) is a deadly gas that is present in the
exhaust fumes of all internal combustion engines, including the
engines that propel boats, and the generators that power boat
accessories. By itself, CO is odorless, colorless, and tasteless,
but if you can smell or taste engine exhaust, you are inhaling
CO.
Early symptoms of carbon monoxide poisoning, which are similar
to the symptoms of seasickness and intoxication, include
headache, dizziness, drowsiness, and nausea.

! WARNING
Inhaling engine exhaust gases can result in carbon monoxide
poisoning, which can lead to unconsciousness, brain damage,
or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep
the boat well‑ventilated while at rest or underway.

STAY CLEAR OF EXHAUST AREAS

41127

Engine exhaust gases contain harmful carbon monoxide. Avoid

areas of concentrated engine exhaust gases. When engines are
running, keep swimmers away from the boat, and do not sit, lie,
or stand on swim platforms or boarding ladders. While underway,
do not allow passengers to be positioned immediately behind the
boat (platform dragging, teak/body surfing). This dangerous
practice not only places a person in an area of high engine
exhaust concentration, but also subjects them to the possibility of
injury from the boat propeller.

36 eng
 GENERAL INFORMATION
GOOD VENTILATION
Ventilate the passenger area, open side curtains or forward
hatches to remove fumes.
Example of desired air flow through the boat:

21622

POOR VENTILATION
Under certain running and/or wind conditions, permanently
enclosed or canvas enclosed cabins or cockpits with insufficient
ventilation may draw in carbon monoxide. Install one or more
carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers
and passengers in an open area of a stationary boat that
contains, or is near, a running engine may be exposed to a
hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:

a
b

21626

a - Operating the engine when the boat is moored in a

confined space
b - Mooring close to another boat that has its engine
operating

eng 37
 GENERAL INFORMATION
2. Examples of poor ventilation while the boat is moving:
a b

21628

a - Operating the boat with the trim angle of the bow too high
b - Operating the boat with no forward hatches open (station
wagon effect)

Selecting Accessories for Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have
been specifically designed and tested for your outboard. These
accessories are available from Mercury Marine dealers.
IMPORTANT: Check with your dealer before installing
accessories. The misuse of approved accessories or the use of
nonapproved accessories can damage the product.
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. Have an approved personal flotation
device of suitable size for each person aboard (it is the law) and
have it readily accessible.
Do not overload your boat. Most boats are rated and certified for
maximum load (weight) capacities (refer to your boat capacity
plate). If in doubt, contact your dealer or the boat's manufacturer.
Perform safety checks and required maintenance. Follow a
regular schedule and ensure that all repairs are properly made.

38 eng
 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. Do not allow
anyone to sit or ride on any part of the boat that was not
intended for such use. This includes the back of seats,
gunwales, transom, bow, decks, raised fishing seats, any
rotating fishing seat; or anywhere that an unexpected
acceleration, sudden stopping, unexpected loss of boat control,
or sudden boat movement could cause a person to be thrown
overboard or into the boat.
Never be under the influence of alcohol or drugs while boating (it
is the law). Alcohol or drug use impairs your judgment and
greatly reduces your ability to react quickly.
Prepare other boat operators. Instruct at least one other person
onboard in the basics of starting and operating the outboard, and
boat handling, in case the driver becomes disabled or falls
overboard.
Passenger boarding. Stop the engine whenever passengers are
boarding, unloading, or are near the back (stern) of the boat.
Just shifting the outboard into neutral is not sufficient.
Be alert. The operator of the boat is responsible by law to
maintain a proper lookout by sight and hearing. The operator
must have an unobstructed view particularly to the front. No
passengers, load, or fishing seats should block the operator's
view when operating the boat above idle speed.
Never drive your boat directly behind a water‑skier in case the
skier falls. As an example, your boat traveling at 40 km/h
(25 MPH) will overtake a fallen skier 61 m (200 ft) in front of you
in 5 seconds.

eng 39
 GENERAL INFORMATION
Watch fallen skiers. When using your boat for waterskiing or
similar activities, always keep a fallen or down skier on the
operator's side of the boat while returning to assist the skier. The
operator should always have the down skier in sight and never
back up to the skier or anyone in the water.
Report accidents. Boat operators are required by law to file a
Boating Accident Report with their state boating law enforcement
agency when their boat is involved in certain boating accidents.
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. Seek further assistance from local
law enforcement.

Recording Serial Number

It is important to record this number for future reference. The
serial number is located on the outboard as shown.

a Serial Number
XXXXXXXX
b
XXXX
MAX
RP M
H K
P W
L K
B G

c
d
XX
23884

a- Serial number
b- Model designation
c- Year manufactured
d- Certified Europe Insignia (as applicable)

40 eng
 GENERAL INFORMATION
Specifications
115/115 Pro
Models 75 90 125
XS
Horsepower 75 90 115 125
Kilowatts 55.2 66.2 84.6 91.3
Full throttle
5000–5750 RPM
RPM range
Idle speed in
625–675 RPM
forward gear
Number of
3
cylinders
Piston
1523.5 cc (92.9 in³)
displacement
Cylinder bore 92.11 mm (3.63 in.)
Piston stroke 76.2 mm (3.0 in.)
Recommended
IZFR5J
spark plug
Spark plug gap 0.80 mm (0.030 in.)
Gear ratio 2.33:1 2.07:1
Recommended
Refer to Fuel and Oil
gasoline
Recommended
Refer to Fuel and Oil
oil
Oil tank
4.72 liter (5 US qt)
capacity
Gearcase
lubricant 665 ml (22.5 fl oz)
capacity
1000 marine cranking amps (MCA) or 800 cold cranking
Battery rating
amps (CCA)
Charging
60 A
system output
Emission
Electronic engine control (EC)
control system

eng 41
 GENERAL INFORMATION
115/115 Pro
Models 75 90 125
XS
Sound at
drivers ear
82.0
(ICOMIA 39‑94)
dBA

Component Identification
b a- Top cowl
a b- Auxiliary tilt switch
c- Transom brackets
j d- Gearcase
e- Cooling water
intake holes
f- Trim tab
i g- Anti‑ventilation
plate
h h- Driveshaft housing
c
i- Water pump
g indicator hole
d j- Bottom cowl

f
e
29461

42 eng
 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.

28419

IMPORTANT: Do not rely on the power trim/tilt system or tilt

support lever to maintain proper ground clearance for trailering.
The outboard tilt support lever is not intended to support the
outboard for trailering.
Shift the outboard to forward gear. This prevents the propeller
from spinning freely.

eng 43
 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. Premium gasoline (92 [R+M]/2 Octane) is
also acceptable. Do not use leaded gasoline.
Outside USA and Canada ‑ having a posted pump Octane
Rating of 90 RON minimum. Premium gasoline (98 RON) is also
acceptable. If unleaded gasoline is not available, use a major
brand of leaded gasoline.
USING REFORMULATED (OXYGENATED) GASOLINES
(USA ONLY)
This type of gasoline is required in certain areas of the USA. The
2 types of oxygenates used in these fuels are alcohol (ethanol)
or ether (MTBE or ETBE). If ethanol is the oxygenate that is
used in the gasoline in your area, refer to Gasolines Containing
Alcohol.
These reformulated gasolines are acceptable for use in your
Mercury Marine engine.
GASOLINES CONTAINING ALCOHOL
If the gasoline in your area contains either methanol (methyl
alcohol) or ethanol (ethyl alcohol), you should be aware of
certain adverse effects that can occur. These adverse effects are
more severe with methanol. Increasing the percentage of alcohol
in the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol
in the gasoline can absorb moisture from the air, resulting in a
separation of the water/alcohol from the gasoline in the fuel tank.

44 eng
 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). Be aware that gasolines containing alcohol may cause
increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through rubber fuel lines
• Starting and operating difficulties

! WARNING
Fuel leakage is a fire or explosion hazard, which can cause
serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or
corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine
operation.

Because of possible adverse effects of alcohol in gasoline, it is

recommended that only alcohol‑free gasoline be used where
possible. If only fuel containing alcohol is available, or if the
presence of alcohol is unknown, increased inspection frequency
for leaks and abnormalities is required.
IMPORTANT: When operating a Mercury Marine engine on
gasoline containing alcohol, storage of gasoline in the fuel tank
for long periods should be avoided. Long periods of storage,
common to boats, create unique problems. In cars, alcohol‑blend
fuels normally are consumed before they can absorb enough
moisture to cause trouble, but boats often sit idle long enough for
phase separation to take place. In addition, internal corrosion
may take place during storage if alcohol has washed protective
oil films from internal components.

eng 45
 FUEL AND OIL
Fuel Requirements
Do not use premixed gas and oil in this engine. The engine
automatically receives extra oil during engine break‑in. Use a
fresh supply of the recommended gasoline during engine
break‑in and after engine break‑in.

Fuel Additives
To minimize carbon deposit buildup in the engine, it is
recommended to add Mercury or Quicksilver Quickleen Engine
Treatment additive to the engine's fuel at each tank fill
throughout the boating season. Use additive as directed on
container.

Avoiding Fuel Flow Restriction

IMPORTANT: Adding components to the fuel supply system
(filters, valves, fittings, etc.) may restrict the fuel flow. This may
cause engine stalling at low speed, and/or a lean fuel condition
at high RPM that could cause engine damage.

Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered
for sale in the United States.
• The Environmental Protection Agency (EPA) requires that
any outboard manufactured after January 1, 2009 must use
low permeation fuel hose for the primary fuel hose
connecting the fuel tank to the outboard.
• Low permeation hose is USCG Type B1‑15 or Type A1‑15,
defined as not exceeding 15/gm²/24 h with CE 10 fuel at
23 °C as specified in SAE J 1527 ‑ marine fuel hose.

EPA Pressurized Portable Fuel Tank

Requirements
The Environmental Protection Agency (EPA) will require portable
fuel systems that are produced after January 1, 2011 for use with
outboard engines to remain fully sealed (pressurized) up to
34.4 kPa (5.0 psi). These tanks may contain the following:

46 eng
 FUEL AND OIL
• An air inlet that opens to allow air to enter as the fuel is
drawn out of the tank.
• An air outlet that opens (vents) to the atmosphere if
pressure exceeds 34.4 kPa (5.0 psi).

Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve
is required to be installed in the fuel hose between the fuel tank
and primer bulb. The fuel demand valve prevents pressurized
fuel from entering the engine and causing a fuel system overflow
or possible fuel spillage.
The fuel demand valve has a manual release. The manual
release can be used (pushed in) to open (bypass) the valve in
case of a fuel blockage in the valve.

b a - Fuel demand valve ‑ installed

a in the fuel hose between the
fuel tank and primer bulb
c b - Manual release
46273
c - Vent/water drain holes

Mercury Marine's Pressurized Portable Fuel Tank

Mercury Marine has created a new portable pressurized fuel tank
that meets the preceding EPA requirements. These fuel tanks
are available as an accessory or are provided with certain
portable outboard models.
SPECIAL FEATURES OF THE PORTABLE FUEL TANK
• The fuel tank has a two‑way valve which allows air to enter
the tank as the fuel is drawn to the engine, and also opens
to vent to the atmosphere if internal pressure in the tank
exceeds 34.4 kPa (5.0 psi). A hissing noise may be heard
as the tank vents to the atmosphere. This is normal.
• The fuel tank includes a fuel demand valve that prevents
pressurized fuel from entering the engine and causing a fuel
system overflow or possible fuel spillage.

eng 47
 FUEL AND OIL
• When installing the fuel tank cap, turn the cap to the right
until you hear a click. This signals that the fuel cap is fully
seated. A built‑in device prevents overtightening.
• The fuel tank has a manual vent screw which should be
closed for transportation and open for operation and cap
removal.
Since sealed fuel tanks are not openly vented, they will expand
and contract as the fuel expands and contracts during heating
and cooling cycles of the outside air. This is normal.
REMOVING THE FUEL CAP

b a - Fuel cap
a
b - Manual vent screw
c - Tab lock

c
46290
IMPORTANT: Contents may be under pressure. Rotate the fuel
cap 1/4 turn to relieve pressure before opening.
1. Open the manual vent screw on top of the fuel cap.
2. Turn the fuel cap until it contacts the tab lock.
3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to
relieve the pressure.
4. Press down on the tab lock again and remove the cap.
DIRECTIONS FOR USING THE PRESSURIZED PORTABLE
FUEL TANK
1. When installing the fuel tank cap, turn the cap to the right
until you hear a click. This signals that the fuel cap is fully
seated. A built‑in device prevents overtightening.
2. Open the manual vent screw on top of the cap for operation
and cap removal. Close the manual vent screw for
transportation.
3. For fuel hoses that have quick disconnects, disconnect the
fuel line from the engine or fuel tank when not in use.

48 eng
 FUEL AND OIL
4. Follow Filling Fuel Tank instructions for refueling.

Oil Recommendation
Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle
Recommended Oil
Engine Oil

Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is

recommended for your engine. If Mercury OptiMax/DFI or
Quicksilver DFI 2‑Cycle Engine Oil is not available, we
recommend using Mercury or Quicksilver TC‑W3 Premium Plus
2‑Cycle Oil. Severe engine damage may result from use of an
inferior oil.

Filling Oil Injection System

1. Place the outboard in a vertical operating position.
2. Remove the cowl cover.
3. Remove the oil filler cap.

b 37147

a - Cowl cover
b - Oil filler cap

eng 49
 FUEL AND OIL
4. Oil filler caps with a dipstick ‑ Check the oil level on the
dipstick. The first set of holes indicates 0.94 liters (1 US qt)
low. The second set of holes indicates 1.89 liters (2 US qt)
low. The third set of holes indicates 2.83 liters (3 US qt) low.

b
c 37143

a - Add 0.94 liters (1 US qt)

b - Add 1.89 liters (2 US qt)
c - Add 2.83 liters (3 US qt)

5. Oil filler caps with a chain ‑ Check the oil level on the chain.
The first ball marker indicates 0.94 liters (1 US qt) low. The
second ball marker indicates 1.89 liters (2 US qt) low.

b
37146

a - Add 0.94 liters (1 US qt)

b - Add 1.89 liters (2 US qt)

6. Slowly fill the oil tank with the specified oil. Do not overfill.
Add only enough oil to bring the oil level up to the bottom of
the fill neck.

50 eng
 FUEL AND OIL
Capacity Fluid Type
Oil tank 4.72 liters (5 US qt) OptiMax/DFI 2‑Cycle Engine Oil

29465

7. Install the oil filler cap and tighten securely. Install the cowl
cover.

29466

Filling Fuel Tank

! WARNING
Avoid serious injury or death from a gasoline fire or explosion.
Use caution when filling fuel tanks. Always stop the engine and
do not smoke or allow open flames or sparks in the area while
filling fuel tanks.

Fill fuel tanks outdoors away from heat, sparks, and open
flames.
Remove portable fuel tanks from boat to refill them.
Always stop engine before refilling tanks.

eng 51
 FUEL AND OIL
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.

52 eng
 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
a a
b
b h
g
f i
a i
g
d d
f f
e 26800
e

a - Control handle ‑ forward, neutral, reverse

b - Neutral release lever
c - Trim/tilt switch (if equipped) ‑ Refer to Features and
Controls ‑ Power Trim and Tilt
d - Lanyard stop switch ‑ Refer to General Information ‑
Lanyard Stop Switch
e - Lanyard ‑ Refer to General Information ‑ Lanyard Stop
Switch
f - Throttle friction adjustment ‑ Console controls require
cover removal for adjustment
g - Ignition key switch ‑ "OFF," "ON," START"
h - Fast idle lever ‑ Refer to Operation ‑ Starting the Engine
i - Throttle only button ‑ Refer to Operation ‑ Starting the
Engine

eng 53
 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.

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.
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. For visual display of the
specific engine functions and for additional engine data, refer to
SmartCraft Product information, following.
Warning Horn
Function Sound Description
Start up One beep Normal system test.
Low oil Four beeps Oil level is low in the oil tank. Refill the oil
every 2 tank. Refer to Fuel and Oil.
minutes
Water in fuel Four beeps Water in the fuel filter chamber reached the
every 2 full level. Water can be removed from the
minutes chamber. Refer to Maintenance ‑ Fuel
System for water removal.

54 eng
 FEATURES AND CONTROLS
Warning Horn
Function Sound Description
Cooling Continuous Engine Guardian System is activated.
system Power limit will vary with level of overheat.
problem 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.
Oil level is Continuous Engine Guardian System is activated.
critically low Power limit will allow a fast idle. The oil level
is critically low in the oil tank. Refill the oil
tank. Refer to Fuel and Oil.
Oil pump Continuous Engine Guardian System is activated.
failure Power limit will allow a fast idle. The
warning horn is activated if the oil pump
should ever stop functioning electrically. No
lubricating oil is being supplied to the
engine.
Engine Continuous The warning horn is activated any time
overspeed engine speed exceeds the maximum
allowable RPM. The system will limit the
engine speed to within the allowable range.
Engine overspeed indicates a condition that
should be corrected. Overspeed could be
caused by incorrect propeller pitch, engine
height, trim angle, etc.
Sensor out of Continuous Engine Guardian System is activated.
range Power limit may activate at full throttle
speed.
Intermittent Engine Guardian System is activated.
beep Power limit may restrict engine speed to
idle.
Engine One beep Engine is not reaching correct temperature
running cold at while operating below 1000 RPM. Have
slow speed your dealer check the engine.

eng 55
 FEATURES AND CONTROLS
ENGINE GUARDIAN SYSTEM
The Engine Guardian System monitors the critical sensors on
the engine for any early indications of problems. The system will
respond to a problem by emitting a continuous beep and/or
reducing engine power in order to provide engine protection.
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.
The SmartCraft instrument package will also aid in Engine
Guardian diagnostics. The SmartCraft instrument package will
display critical engine alarm data and potential problems.

56 eng
 FEATURES AND CONTROLS
Power Trim and Tilt
Your outboard has a trim/tilt control called power trim. This
enables the operator to easily adjust the position of the outboard
by pressing the trim switch. Moving the outboard in closer to the
boat transom is called trimming in or down. Moving the outboard
further away from the boat transom is called trimming out or up.
The term trim generally refers to the adjustment of the outboard
within the first 20° range of travel. This is the range used while
operating your boat on plane. The term tilt is generally used
when referring to adjusting the outboard further up out of the
water. With the engine turned off, the outboard can be tilted out
of the water. At low idle speed, the outboard can also be tilted up
past the trim range to permit, for example, shallow water
operation.
a
a - Trim switch
b - Tilt range of
travel
c - Trim range of
b travel
c 27761

POWER TRIM OPERATION

NOTE: When traveling at slow speeds, a slight drop in engine
RPM may be noticed on occasion when engaging power trim.
This condition is normal and has no adverse affect on the
outboard.
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.

eng 57
 FEATURES AND CONTROLS
The most significant control hazard is a pull or torque that can be
felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so that the propeller
shaft is not parallel to the water surface.

! WARNING
Trimming the outboard beyond a neutral steering condition
may result in a pull on the steering wheel or tiller handle and
loss of boat control. Maintain control of the boat if trimming
beyond a neutral steering condition.

Consider the following lists carefully.

1. Trimming in or down 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.
• Increase steering torque or pull to the right (with the
normal right‑hand rotation propeller).
• In excess, can lower the bow of some boats to a point
where they begin to plow with their bow in the water while
on plane. This can result in an unexpected turn in either
direction (called bow steering or oversteering) if any turn
is attempted, or if a significant wave is encountered.

! 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. This can be accomplished by purchasing a
stainless steel tilt pin from your dealer and inserting it in
whatever adjustment hole in the transom brackets is
desired. The nonstainless steel shipping bolt should not
be used in this application.

58 eng
 FEATURES AND CONTROLS
2. Trimming out or up can:
• Lift the bow higher out of the water.
• Generally increase top speed.
• Increase clearance over submerged objects or a shallow
bottom.
• Increase steering torque or pull to the left at a normal
installation height (with the normal right‑hand rotation
propeller).
• In excess, can cause boat porpoising (bouncing) or
propeller ventilation.
• Cause engine overheating if any cooling water intake
holes are above the waterline.
TILTING OPERATION
To tilt outboard, shut off the engine and press the trim/tilt switch
or auxiliary tilt switch to the up position. The outboard will tilt up
until the switch is released or it reaches its maximum tilt position.
1. Engage the tilt support lever by rotating the knob to bring the
support lever upward.
2. Lower the outboard to rest on the tilt support lever.
3. Disengage the tilt support lever by raising the outboard off
the support lever and rotating the lever down. Lower the
outboard.

a - Tilt support lever

b - Knob
a

b
27778

MANUAL TILTING
If the outboard cannot be tilted using the power trim/tilt switch,
the outboard can be manually tilted.

eng 59
 FEATURES AND CONTROLS
NOTE: The manual tilt release valve must be tightened before
operating the outboard to prevent the outboard from tilting up
during reverse operation.
Turn out the manual tilt release valve three turns
counterclockwise. This allows manual tilting of the outboard. Tilt
the outboard to the desired position and tighten the manual tilt
release valve.

22362

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.
AUXILIARY TILT SWITCH
The auxiliary tilt switch can be used to tilt the outboard up or
down using the power trim system.

a - Auxiliary tilt switch

a
27779

60 eng
 FEATURES AND CONTROLS
Trim Tab Adjustment
Propeller steering torque will cause your boat to pull in one
direction. This steering torque is a normal thing that results from
your outboard not being trimmed so the propeller shaft is parallel
to the water surface. The trim tab can help compensate for this
steering torque in many cases and can be adjusted within limits
to reduce any unequal steering effort.

26816

NOTE: Trim tab adjustment will have little effect reducing

steering torque if the outboard is installed with the anti‑ventilation
plate approximately 50 mm (2 inches) or more above the boat
bottom.
Operate your boat at normal cruising speed, trimmed to the
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.

eng 61
 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.
• Arrange passengers and load in the boat so the weight is
distributed evenly and everyone is seated in a proper seat.
• Tell someone where you are going and when you expect to
return.
• It is illegal to operate a boat while under the influence of
alcohol or drugs.
• Know the waters and area you will be boating; tides,
currents, sand bars, rocks, and other hazards.
• Make inspection checks listed in Maintenance ‑ Inspection
and Maintenance Schedule.

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. This prevents
the trapped water in the gearcase from freezing and causing
possible damage to the water pump and other components.
If there is a chance of ice forming on the water, the outboard
should be removed and drained completely of water. If ice
should form at the water level inside the outboard driveshaft
housing, it will block water flow to the engine causing possible
damage.

62 eng
 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.
Wash the outboard exterior and flush out the exhaust outlet of
the propeller and gearcase with fresh water after each use. Each
month, spray Mercury Precision or Quicksilver Corrosion Guard
on external metal surfaces. Do not spray on corrosion control
anodes as this will reduce the effectiveness of the anodes.

Operating at High Elevations

Your engine automatically compensates for high elevation
changes. A different pitch propeller may help reduce some
normal performance loss resulting from reduced oxygen in the
air. Consult your dealer.

eng 63
 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.

28423

Engine Break‑In Procedure

IMPORTANT: Failure to follow the engine break‑in procedures
can result in poor performance throughout the life of the engine
and can cause engine damage. Always follow break‑in
procedures.
GASOLINE/OIL BREAK-IN MIXTURE
NOTE: Do not use premixed gas and oil during break‑in. Use
straight gasoline during engine break‑in and after engine
break‑in.
The engine break‑in procedure for an OptiMax outboard is
important to ensure proper performance and maximum life from
the engine. The following break‑in procedure allows the internal
engine parts to wear‑in evenly. Incorrect engine break‑in can
shorten the engine life.

64 eng
 OPERATION
The engine automatically receives extra oil during the first hours
of operation. For most boaters this extra oil mode will be
complete in about ten hours.
BREAK-IN PROCEDURE
1. For the first hour of operation, allow the engine to warm up
for 30–60 seconds.
a. Run the engine at varied throttle settings, the majority of
the time between 3000 and 4500 RPM or three‑quarter
throttle.
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
high speed can be difficult and dangerous. The purpose of
specifying trim angle is to help guide the operator in determining
how to put the proper load on the engine. They are intended to
be guidelines and do not suggest or require unsafe boat
operation.
2. For the next three hours of operation, change engine speed
every ten minutes.

Starting the Engine

Before starting, read the pre‑starting check list, special operating
instructions, and engine break‑in procedure in the Operation
Section.

NOTICE
Without sufficient cooling water, the engine, the water pump,
and other components will overheat and suffer damage.
Provide a sufficient supply of water to the water inlets during
operation.

eng 65
 OPERATION
1. Lower the outboard to the vertical operating position. Make
sure all cooling water intake holes are submerged.

26837

2. Open the fuel tank vent screw, located in the 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 "RUN" position. Refer to

General Information ‑ Lanyard Stop Switch.

19791

66 eng
 OPERATION
5. Shift outboard to neutral ("N") position.

26838

6. For the initial start of a new engine, or for an engine that ran
out of fuel or was drained of fuel, the fuel system should be
filled as follows:
a. Squeeze the fuel line primer bulb until it feels firm.
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 neutral fast idle speed feature on the
remote control for starting.

27242

8. Turn the ignition key to "START" position. Release the key

when engine starts. If engine fails to start in 10 seconds,
return the key to "OFF" position, wait one second and try
again.

19804

eng 67
 OPERATION
NOTE: The electronic starting system will automatically prime
(choke) the engine and increase idle speed for starting.
9. Check for a steady stream of water flowing out of the water
pump indicator hole.
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.
• Do not shift outboard into reverse when the engine is not
running.
• Your outboard has three gear shift positions to provide
operation: Forward (F), Neutral (N), and Reverse (R).
• When shifting, always stop at neutral position and allow the
engine speed to return to idle.
• Always shift outboard into gear with a quick motion.

68 eng
 OPERATION
• After shifting outboard into gear, advance the lever further to
increase speed.
N
F R

27237

Stopping the Engine

Reduce engine speed and shift outboard to neutral position. Turn
ignition key to "OFF" position.

26843

eng 69
 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.
SELECTING REPLACEMENT PARTS FOR YOUR
OUTBOARD
We recommend using original Mercury Precision or Quicksilver
replacement parts and Genuine Lubricants.

EPA Emissions Regulations

All new outboards manufactured by Mercury Marine 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. This certification is
contingent on certain adjustments set to factory standards. For
this reason, the factory procedure for servicing the product must
be strictly followed and, wherever practicable, returned to the
original intent of the design. Maintenance, replacement, or repair
of the emission control devices and systems may be performed
by any marine spark ignition (SI) engine repair establishment or
individual.

70 eng
 MAINTENANCE
EMISSION CERTIFICATION LABEL
An emission certification label, showing emission levels and
engine specifications directly related to emissions, is placed on
the engine at the time of manufacture.
EMISSION CONTROL
a INFORMATION
f
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA

b
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, g
SPECIFICATIONS, AND ADJUSTMENTS

c IDLE SPEED (in gear): FAMILY:

h
hp L HC+NOx:FEL: g/kWh

d kw
SPARK PLUG:
CO FEL: g/kWh
i
GAP:
e LOW PERM/HIGH PERM: j
43210

a- Idle speed
b- Engine horsepower
c- Piston displacement
d- Engine power ‑ kilowatts
e- Date of manufacture
f- Family number
g- Regulated emission limit for the engine family
h- Regulated emission limit for the engine family
i- Recommended spark plug and gap
j- Percent of fuel line permeation

OWNER RESPONSIBILITY
The owner/operator is required to have routine engine
maintenance performed to maintain emission levels within
prescribed certification standards.
The owner/operator is not to modify the engine in any manner
that would alter the horsepower or allow emission levels to
exceed their predetermined factory specifications.

Inspection and Maintenance Schedule

BEFORE EACH USE
• Check that the lanyard stop switch stops the engine.
• Visually inspect the fuel system for deterioration or leaks.

eng 71
 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 the specified
torque. When looking for signs of looseness, look for loss of
outboard transom bracket material or paint caused by
movement between the outboard mounting fasteners and
the outboard transom brackets. Also look for signs of
movement between the outboard transom brackets and the
boat transom (lift plate/setback bracket).
Description Nm lb‑in. lb‑ft
Outboard mounting locknuts and
75 55
bolts ‑ standard boat transom
Outboard mounting locknuts and
bolts ‑ metal lift plates and setback 122 90
brackets

• 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. See Flushing the Cooling System.
• Wash off all salt deposits and flush out the exhaust outlet of
the propeller and gearcase with fresh water if operating in
saltwater.
EVERY 100 HOURS OF USE OR ONCE YEARLY,
WHICHEVER OCCURS FIRST
• Lubricate all lubrication points. Lubricate more frequently
when used in saltwater. See Lubrication Points.
• Replace spark plugs at first 100 hours or first year. After
that, inspect spark plugs every 100 hours or once yearly.
Replace spark plugs as needed. See Spark Plug Inspection
and Replacement.
• Replace fuel filter. See Fuel System.

72 eng
 MAINTENANCE
• Replace compressor air intake filter. See Compressor Air
Intake Filter.
• Inspect alternator belt. See Alternator Belt Inspection.
• Retorque the outboard mounting fasteners that fasten the
outboard to the boat transom. Tighten the fasteners to the
specified torque.1.
Description Nm lb‑in. lb‑ft
Outboard mounting locknuts and
75 55
bolts ‑ standard boat transom
Outboard mounting locknuts and
bolts ‑ metal lift plates and setback 122 90
brackets

• Check corrosion control anodes. Check more frequently

when used in saltwater. See Corrosion Control Anode.
• Drain and replace gearcase lubricant. See Gearcase
Lubrication.
• Check power trim fluid. See Checking Power Trim Fluid.
• Inspect battery. See Battery Inspection.
• Check control cable adjustments.1.
• Lubricate splines on the driveshaft and shift shaft.1.
• Check tightness of bolts, nuts, and other fasteners.
• Check cowl seals to make sure seals are intact and not
damaged.
• Check internal cowl sound reduction foam (if equipped) to
make sure foam is intact and not damaged.
• Check that the intake silencer (if equipped) is in place.
• Check that the idle relief muffler (if equipped) is in place.
• Check for loose hose clamps and rubber boots (if equipped)
on the air intake assembly.
EVERY 300 HOURS OF USE OR THREE YEARS
• Replace water pump impeller (more often if overheating
occurs or reduced water pressure is noted).1.

1. These items should be serviced by an authorized dealer.

eng 73
 MAINTENANCE
• Replace the in‑line oil filter that is located in the oil hose
between the oil tank and the oil injection pump.1.
BEFORE PERIODS OF STORAGE
• Refer to storage procedure. See Storage section.

Flushing the Cooling System

Flush the internal water passages of the outboard with fresh
water after each use in salt, polluted, or muddy water. This will
help prevent a buildup of deposits from clogging the internal
water passages.
NOTE: The engine can be stopped, or running at idle speed in
neutral, when flushing the cooling system. Do not flush the
engine using a water source that exceeds 310 kPa (45 psi).
1. Unscrew the cover from the end of the hose adapter.
2. Attach a water hose to the hose adapter.
3. Turn on the water and flush the cooling system for a
minimum of 3 minutes.
IMPORTANT: Do not run engine above idle speed when
flushing.
4. Turn off the water and remove the water hose from the hose
adapter. Reinstall the cover into the hose adapter.

a b

c
22703

a - Hose adapter
b - Sealing washer
c - Cover

74 eng
 MAINTENANCE
Top Cowl Removal and Installation
REMOVAL
1. Unlock the rear latch by pushing lever up.
2. Lift rear of cowl and disengage front hook.

29468

INSTALLATION
1. Engage the front hook and push cowl back over the cowl
seal.
2. Push cowl down and move the rear latch lever down to lock.

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 the cleaning and waxing
procedure.
CLEANING AND WAXING PROCEDURE
1. Before washing, rinse the top cowl with clean water to
remove the dirt and dust that may scratch the surface.
2. Wash the top cowl with clean water and a mild non‑abrasive
soap. Use a soft clean cloth when washing.
3. Dry thoroughly with a soft clean cloth.
4. Wax the surface using a non‑abrasive automotive polish
(polish designed for clear coat finishes). Remove the applied
wax by hand using a clean soft cloth.

Flywheel Cover Removal and Installation

REMOVAL
Lift the cover off the three mounting pins.

eng 75
 MAINTENANCE
INSTALLATION
Position the cover onto the three mounting pins. Insert the tabs
into the slots in the side panel and push the cover down onto the
mounting pins.

a
b

c
23754

a - Flywheel cover
b - Mounting pins
c - Tabs

Side Panel Removal and Installation

REMOVAL
Pull the side panel off the three mounting pins.

76 eng
 MAINTENANCE
INSTALLATION
Position the side panel onto the three mounting pins. Insert the
tabs on the flywheel cover into the upper slots and push the side
panel onto the mounting pins.

b
c

23765

a - Side panel
b - Upper slots
c - Mounting pins

Fuel System
! WARNING
Fuel is flammable and explosive. Ensure that the key switch is
off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in
the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for
leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.

eng 77
 MAINTENANCE
Before servicing any part of the fuel system, stop the 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.
FUEL LINE INSPECTION
Visually inspect the fuel line and primer bulb for cracks, swelling,
leaks, hardness, or other signs of deterioration or damage. If any
of these conditions are found, the fuel line or primer bulb must be
replaced.
FUEL FILTER REPLACEMENT
Removal
1. Use fuel filter tool 91‑896661 or use the shaft of a
screwdriver between the lugs on the filter cap and unscrew
the filter.

29594

a - Filter
b - O‑rings

Installation
1. Lubricate the O‑ring seals with oil.
2. Install the fuel filter and tighten securely.
IMPORTANT: Visually inspect for fuel leakage from the filter
while squeezing the primer bulb until firm, forcing fuel into the
filter.

78 eng
 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 the open
end of the hose over a container.
2. Use a 1/8 in. hex wrench and loosen the drain screw and
drain the fuel filter chamber.

b
c
a

23743

a - Drain hose
b - Right side fitting
c - Drain screw

3. Retighten the drain screw and reattach the hose.

IMPORTANT: Visually inspect for fuel leakage from the drain
screw by squeezing the primer bulb until firm, forcing fuel into the
chamber.

eng 79
 MAINTENANCE
Steering Link Rod Fasteners
IMPORTANT: The steering link rod that connects the steering
cable to the engine must be fastened using a special washer
head bolt ("a" ‑ Part Number 10‑849838) and self‑locking nylon
insert locknuts ("c" and "d" ‑ Part Number 11‑826709113). These
locknuts must never be replaced with common nuts (nonlocking)
as they will work loose and vibrate off, freeing the link rod to
disengage.

! 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.

a
b

27843
d

a- Special washer head bolt (10‑849838)

b- Flat washer (2)
c- Nylon insert locknut (11‑826709113)
d- Nylon insert locknut (11‑826709113)

Description Nm lb‑in. lb‑ft

Special washer head bolt 27 20
Nylon insert locknut "d" 27 20

80 eng
 MAINTENANCE
Description Nm lb‑in. lb‑ft
Tighten until it seats, then back off 1/4
Nylon insert locknut "c"
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. First torque bolt, then
torque locknut to specifications.

Fuse Replacement
IMPORTANT: Always carry spare 5 and 20 amp fuses.
The electrical wiring circuits on the outboard 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.

eng 81
 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

c
15
h
20

20 20

g d

f 2

e
23793

a - Good fuse
b - Blown fuse
c - 14 pin remote control harness/cowl trim switch/main power
relay ‑ 15 amp fuse
d - Ignition coil circuit ‑ 20 amp fuse
e - SmartCraft data bus circuit ‑ 5 amp fuse
f - Diagnostics terminal ‑ 2 amp fuse
g - Spare fuse ‑ 20 amp fuse
h - Fuel injectors/direct injectors/oil pump/PCM ‑ 20 amp fuse

Corrosion Control Anode

Your outboard has corrosion control anodes at different
locations. An anode helps protect the outboard against galvanic
corrosion by sacrificing its metal to be slowly corroded instead of
the outboard metals.

82 eng
 MAINTENANCE
Each anode requires periodic inspection, especially in saltwater
which will accelerate the erosion. To maintain this corrosion
protection, always replace the anode before it is completely
eroded. Never paint or apply a protective coating on the anode
as this will reduce effectiveness of the anode.
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
a - Anode (2) on
each side of
gearcase
b - Anode on
transom bracket
b assembly
27844

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. Ensure the battery is secure against movement.
3. Battery cable terminals should be clean, tight, and correctly
installed. Positive to positive and negative to negative.
4. Ensure the battery is equipped with a nonconductive shield
to prevent accidental shorting of battery terminals.

Battery Information
! WARNING
Failure to properly secure the battery leads can result in a loss
of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure
the battery leads to the battery posts with hex nuts to avoid
loose connections.

eng 83
 MAINTENANCE
• Do not use deep cycle batteries. Engines must use a marine
starting battery with 1000 MCA, 800 CCA or 180 Ah.
• When connecting engine battery, hex nuts must be used to
secure battery leads to battery posts. Torque nuts to
specification.
Description Nm lb. in. lb. ft.
Hex nuts 13.5 120

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.)

DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387

Place decal on or near battery box for future service

reference. 5/16” and 3/8” hex nuts supplied for wing
nut replacement. Metric hex nuts not supplied.
3486

Propellers
REMOVAL
IMPORTANT: Propellers used on this product require the
Mercury Marine Flo‑Torq III type hub or equivalent.

84 eng
 MAINTENANCE
! WARNING
Rotating propellers can cause serious injury or death. Never
operate the boat out of the water with a propeller installed.
Before installing or removing a propeller, place the drive unit in
neutral and engage the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the
propeller blade and the anti‑ventilation plate.

1. Shift the outboard to the neutral ("N") position.

26838

IMPORTANT: Refer to Spark Plug Inspection and Replacement

for removing spark plug leads.
2. Remove the spark plug leads to prevent the engine from
starting.

26899

3. Straighten the bent tabs on the propeller nut retainer.

26900

eng 85
 MAINTENANCE
4. Place a block of wood between the gearcase and propeller
and remove the propeller nut.

26901

5. Pull the propeller straight off the shaft. If the propeller is

seized to the shaft and cannot be removed, have the
propeller removed by an authorized dealer.
INSTALLATION
IMPORTANT: To prevent the propeller hub from corroding and
seizing to the propeller shaft (especially in saltwater), 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.
1. Coat the propeller shaft with Quicksilver or Mercury
Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with
PTFE.

26902

Tube
Description Where Used Part No.
Ref No.
Anti-Corrosion
94 Propeller shaft 92-802867Q 1
Grease

86 eng
 MAINTENANCE
Tube
Description Where Used Part No.
Ref No.
2-4-C with
95 Propeller shaft 92-802859A 1
PTFE

NOTE: The Flo‑Torq lll propeller drive hubs are designed to

have a small amount of free play when installed. This free play
allows the propeller to slide back and forth on the rear thrust
hub (up to 3.17 mm [1/8 in.]) and rotate up to 10 degrees.
2. Flo‑Torq III drive hub propellers ‑ Install the forward thrust
hub, replaceable drive sleeve, propeller, thrust hub,
propeller nut retainer, and propeller nut onto the shaft.

a b c d e f 3223

a- Propeller nut
b- Propeller nut retainer
c- Rear thrust hub
d- Propeller
e- Replaceable drive sleeve
f- Forward thrust hub

3. Place a block of wood between the gearcase and propeller.

Torque the propeller nut to specification.
Description Nm lb. in. lb. ft.
Propeller nut 75 55

eng 87
 MAINTENANCE
4. Secure the 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. Remove the spark plugs to inspect. Replace spark plug if

electrode is worn or the insulator is rough, cracked, broken,
blistered, or fouled.

26946

88 eng
 MAINTENANCE
3. Set the spark plug gap to specifications.

26947

Spark Plug
Spark plug gap 0.80 mm (0.030 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 lb. in. lb. ft.
Spark plug 27 20

Compressor Air Intake Filter

The filter should be changed every 100 hours of operation, or
once a season.
IMPORTANT: Never run the engine without the air filter.
REMOVAL
1. Remove three screws and filter cover from engine.
2. Remove filter from the cover.

a - Cover
b - Filter
b

29476

INSTALLATION
1. Install filter into cover.

eng 89
 MAINTENANCE
2. Fasten filter cover with three screws.

Alternator Belt Inspection

! WARNING
Inspecting the belts with the engine running may cause serious
injury or death. Turn off the engine and remove the ignition key
before adjusting tension or inspecting belts.

1. Inspect the alternator belt and have it replaced by an

authorized dealer if any of the following conditions are
found.
a. Cracks or deterioration in the rubber portion of the belt.
b. Belt surfaces rough or uneven.
c. Signs of wear on edges or outer surfaces of belt.

29477

Lubrication Points
1. Lubricate the following with Quicksilver or Mercury Precision
Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.

Tube
Description Where Used Part No.
Ref No.
Anti-Corrosion
94 Propeller shaft 92-802867Q 1
Grease
2-4-C with
95 Propeller shaft 92-802859A 1
PTFE

90 eng
 MAINTENANCE
• 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

2. Lubricate the following with Quicksilver or Mercury Precision

Lubricants 2‑4‑C with PTFE or Special Lubricant 101.

Tube
Description Where Used Part No.
Ref No.
Swivel bracket, tilt support
Special
34 lever, tilt tube, steering cable 92-802865Q02
Lubricant 101
grease fitting
Swivel bracket, tilt support
2-4-C with
95 lever, tilt tube, steering cable 92-802859A 1
PTFE
grease fitting

• Swivel bracket ‑ Lubricate through fitting.

• Tilt support lever ‑ Lubricate through fitting.

a - Swivel bracket
b - Tilt support lever
a
b
27873

• Tilt tube ‑ Lubricate through fitting.

29478

eng 91
 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.

! 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.

a b a - Fitting
b - Steering cable end

29479

3. Lubricate the following with lightweight oil.

• Steering link rod pivot points ‑ Lubricate pivot points.

29480

Checking Power Trim Fluid

1. Tilt outboard to the full up position and engage the tilt
support lever.

27877

92 eng
 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 and Steering
Fluid. If not available, use automotive (ATF) automatic
transmission fluid.

Tube
Description Where Used Part No.
Ref No.
Power Trim
114 and Steering Power trim reservoir 92-858074K01
Fluid

27884

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.
Examine the drained gearcase lubricant for metal particles. A
small amount of metal particles indicates normal gear wear. An
excessive amount of metal filings or larger particles (chips) may
indicate abnormal gear wear and should be checked by an
authorized dealer.
DRAINING GEARCASE
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.

eng 93
 MAINTENANCE
3. Remove vent plugs and fill/drain plug and drain lubricant.

a - Vent plugs
b - Fill/drain plug

b
26977

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 666 ml (22.5 fl oz).
GEARCASE LUBRICANT RECOMMENDATION
Mercury or Quicksilver Premium or High Performance Gear
Lubricant.
CHECKING LUBRICANT LEVEL AND FILLING GEARCASE
1. Place outboard in a vertical operating position.
2. Remove the front vent plug and rear vent plug.

94 eng
 MAINTENANCE
3. Remove fill/drain plug. Place lubricant tube into the fill/drain
plug hole and add lubricant until it appears at the front vent
hole. At this time install the front vent plug and sealing
washer.

b a d

27001 e

a- Front vent plug

b- Front vent hole
c- Rear vent hole
d- Rear vent plug
e- Fill/drain plug

4. Continue adding lubricant until it appears at the rear vent

hole.
5. Stop adding lubricant. Install the rear vent plug and sealing
washer before removing lubricant tube.
6. 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.

eng 95
 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.
Provide a sufficient supply of water to the water inlets during
operation.

Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol)
can cause a formation of acid during storage and can damage
the fuel system. If the gasoline being used contains alcohol, it is
advisable to drain as much of the remaining gasoline as possible
from the fuel tank, remote fuel line, and engine fuel system.
The most effective method of storage preparation is to add the
recommended amount of Mercury Precision Fuel Stabilizer and
Mercury Precision Quickleen products as described on the
containers to the fuel tank before the last operation of the boat.
Adding fuel stabilizer will help prevent the formation of varnish
and gum in the gasoline. The Mercury Precision Quickleen
product will help clean and lubricate the fuel injectors.
1. Portable Fuel Tank ‑ Pour the required amount of gasoline
stabilizer and Quickleen (follow instructions on containers)
into fuel tank. Tip fuel tank back and forth to mix stabilizer
and Quickleen with the fuel.
2. Permanently Installed Fuel Tank ‑ Pour the required amount
of gasoline stabilizer and Quickleen (follow instructions on
containers) into a separate container and mix with
approximately 1 liter (1 quart) of gasoline. Pour this mixture
into fuel tank.

96 eng
 STORAGE
3. Pull the drain hose off the right side fitting. Hold the open
end of the hose over a container.
4. Loosen drain screw and drain the fuel filter chamber.

a - Drain screw
b - Drain hose
c - Right side fitting

a c
b
23751

5. Retighten the drain screw and reattach the hose.

6. Pull the drain hose off the left side fitting. Hold the open end
of the hose over a container.
7. Loosen the drain screw and drain the float chamber.

a - Left side fitting

b - Drain screw
c - Drain hose

a b
c
23752

8. Retighten the drain screw and reattach the hose.

9. Premix the following in a container:
a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision
Quickleen lubricant.
b. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel
Stabilizer.

eng 97
 STORAGE
10. Remove the fuel filter. See Maintenance ‑ Fuel System for
procedure.
11. Pour this mixture into the fuel filter opening. Reinstall the
fuel filter.
12. Prime the fuel system. See Operation ‑ Starting The
Engine.
13. Place the outboard in water or use the flush hose or flushing
device or for circulating cooling water. Start the engine and
run at idle speed for five minutes to allow the treated fuel to
fill the fuel system.
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.
IMPORTANT: Refer to Spark Plug Inspection and
Replacement for correct procedure for removing spark plug
leads.
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.
2. Rotate the flywheel manually several times to distribute the
oil or storage seal in the cylinders.
3. Reinstall spark plugs.

Protecting External Outboard Components

• Lubricate all outboard components listed in Maintenance ‑
Inspection and Maintenance Schedule.

98 eng
 STORAGE
• Touch up any paint nicks. See your dealer for touch‑up
paint.
• Spray Quicksilver or Mercury Precision Lubricants Corrosion
Guard on external metal surfaces (except corrosion control
anodes).

Tube
Description Where Used Part No.
Ref No.
Corrosion
120 External metal surfaces 92-802878 55
Guard

Gearcase
• Drain and refill the gearcase lubricant (refer to Gearcase
Lubrication).

Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to
drain out of the outboard.

NOTICE
Storing the outboard in a tilted position can damage the
outboard. Water trapped in the cooling passages or rain water
collected in the propeller exhaust outlet in the gearcase can
freeze. Store the outboard in the full down position.

Battery Storage
• 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.
• Periodically check the water level and recharge the battery
during storage.

eng 99
 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.
• Incorrect starting procedure. Refer to Operation section.
• Old or contaminated fuel.
• Fuel is not reaching the engine.
• Fuel tank is empty.
• Fuel tank vent not open or restricted.
• Fuel line is disconnected or kinked.
• Primer bulb not squeezed.
• Primer bulb check valve is faulty.
• Fuel filter is obstructed. Refer to Maintenance section.
• Fuel pump failure.
• Fuel tank filter obstructed.
• Open 20 amp fuse. Check fuses, refer to Maintenance
section.
• Threaded connection of an air hose is loose.
• Ignition system component failure.
• Spark plugs fouled or defective. Refer to Maintenance
section.

100 eng
 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 antisiphon 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 fully open.
• Damaged propeller or improper propeller size.
• Boat overloaded or load improperly distributed.
• Excessive water in bilge.
• Boat bottom is dirty or damaged.

Battery Will Not Hold Charge

POSSIBLE CAUSES
• Battery connections are loose or corroded.
• Low electrolyte level in battery.
• Worn out or inefficient battery.
• Excessive use of electrical accessories.
• Defective rectifier, alternator, or voltage regulator.
• Open circuit in the alternator output wire (fused link).

eng 101
 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. Refer to the
Yellow Pages of the telephone directory. If, for any reason, you
cannot obtain service, contact the nearest Mercury Marine
Service Office.

Parts and Accessories Inquiries

All inquiries concerning genuine replacement parts and
accessories should be directed to your local authorized dealer.
The dealer has the necessary information to order parts and
accessories for you. When inquiring on parts and accessories,
the dealer requires the model and serial number to order the
correct parts.

Service Assistance
Your satisfaction with your outboard product is very important to
your dealer and to us. If you ever have a problem, question or
concern about your outboard product, contact your dealer or any
authorized Mercury Marine dealership. If additional assistance is
required, take these steps.
1. Talk with the dealership's sales manager or service
manager. If this has already been done, then contact the
owner of the dealership.
2. Should you have a question, concern, or problem that
cannot be resolved by your dealership, please contact
Mercury Marine Service Office for assistance. Mercury
Marine will work with you and your dealership to resolve all
problems.
The following information will be needed by the service office:

102 eng
 OWNER SERVICE ASSISTANCE
• Your name and address
• Daytime telephone number
• Model and serial number of your outboard
• The name and address of your dealership
• Nature of problem

Mercury Marine Service Offices

For assistance, call, fax, or write. Please include your daytime
telephone number with mail and fax correspondence.
United States, Canada
English ‑ (920) 929‑5040 Mercury Marine
Telephone
Français ‑ (905) 636‑4751 W6250 W. Pioneer Road
English ‑ (920) 929‑5893 P.O. Box 1939
Fax Fond du Lac, WI 54936-1939
Français ‑ (905) 636‑1704
Website www.mercurymarine.com

Australia, Pacific
Telephone (61) (3) 9791‑5822 Brunswick Asia Pacific Group
41–71 Bessemer Drive
Fax (61) (3) 9706‑7228 Dandenong South, Victoria 3175
Australia

Europe, Middle East, Africa

Telephone (32) (87) 32 • 32 • 11 Brunswick Marine Europe
Parc Industriel de Petit-Rechain
Fax (32) (87) 31 • 19 • 65 B-4800 Verviers,
Belgium

Mexico, Central America, South America, Caribbean

Telephone (954) 744‑3500 Mercury Marine
11650 Interchange Circle North
Fax (954) 744‑3535 Miramar, FL 33025
U.S.A.

Japan
Telephone 072‑233‑8888 Kisaka Co., Ltd.
4-130 Kannabecho Sakai-shi Sakai-ku
Fax 072‑233‑8833 5900984 Osaka,
Japan

eng 103
 OWNER SERVICE ASSISTANCE
Asia, Singapore
Telephone (65) 65466160 Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
Fax (65) 65467789 29 Loyang Drive
Singapore, 508944

104 eng
 OUTBOARD INSTALLATION
Important Information
Rigging boats, which includes proper engine installation, has
become more complex over the years. As a result, we
recommend our engines be installed only by Mercury authorized
dealers. If you intend to disregard this recommendation and
install the engine yourself, please make sure to read and comply
with these instructions. Failure to comply with these installation
instructions could lead to serious injury or death.

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. 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. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777

eng 105
 OUTBOARD INSTALLATION
Start in Gear Protection
! 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.

The remote control connected to the outboard must be equipped

with a start in neutral only protection device. This prevents the
engine from starting in gear.

Selecting Accessories for Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have
been specifically designed and tested for this outboard.
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 System
AVOIDING FUEL FLOW RESTRICTION
IMPORTANT: Adding components to the fuel supply system
(filters, valves, fittings, etc.) may restrict the fuel flow. This may
cause engine stalling at low speed, and/or a lean fuel condition
at high RPM that could cause engine damage.
ELECTRIC FUEL PUMP
The fuel pressure must not exceed 28 kPa (4 psi). If necessary,
install a pressure regulator.
LOW PERMEATION FUEL HOSE REQUIREMENT
Required for outboards manufactured for sale, sold, or offered
for sale in the United States.
• The Environmental Protection Agency (EPA) requires that
any outboard manufactured after January 1, 2009 must use
low permeation fuel hose for the primary fuel hose
connecting the fuel tank to the outboard.

106 eng
 OUTBOARD INSTALLATION
• Low permeation hose is USCG Type B1‑15 or Type A1‑15,
defined as not exceeding 15/gm²/24 h with CE 10 fuel at
23 °C as specified in SAE J 1527 ‑ marine fuel hose.
EPA PRESSURIZED PORTABLE FUEL TANK
REQUIREMENTS
The Environmental Protection Agency (EPA) will require portable
fuel systems that are produced after January 1, 2011 for use with
outboard engines to remain fully sealed (pressurized) up to
34.4 kPa (5.0 psi). These tanks may contain the following:
• An air inlet that opens to allow air to enter as the fuel is
drawn out of the tank.
• An air outlet that opens (vents) to the atmosphere if
pressure exceeds 34.4 kPa (5.0 psi).
FUEL DEMAND VALVE (FDV) REQUIREMENT
Whenever a pressurized fuel tank is used, a fuel demand valve
is required to be installed in the fuel hose between the fuel tank
and primer bulb. The fuel demand valve prevents pressurized
fuel from entering the engine and causing a fuel system overflow
or possible fuel spillage.
The fuel demand valve has a manual release. The manual
release can be used (pushed in) to open (bypass) the valve in
case of a fuel blockage in the valve.

b a - Fuel demand valve ‑ installed

a in the fuel hose between the
fuel tank and primer bulb
c b - Manual release
46273
c - Vent/water drain holes

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.

eng 107
 OUTBOARD INSTALLATION
Permanent Fuel Tank
Permanent fuel tanks should be installed in accordance with
industry and federal safety standards, which include
recommendations applicable to grounding, anti‑siphon
protection, ventilation, etc.
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. Turn the key switch back to the "OFF" position and squeeze
the primer bulb again until it feels firm.
4. Turn the key switch to the "ON" position again for three
seconds.
5. Continue this procedure until the fuel line primer bulb stays
firm.

Installation Specifications
a
a b

18552

a - Minimum transom opening

b - Engine centerline for dual engine ‑ 66.0 cm (26 in.)

108 eng
 OUTBOARD INSTALLATION
Minimum Transom Opening
Single engine 84.2 cm (33 in.)
Dual engine 149.9 cm (59 in.)

Lifting the Outboard

! WARNING
Improperly supporting an engine during lifting can result in the
engine falling, causing serious injury or death. Before lifting the
engine, verify that the lifting ring is threaded into the flywheel
for a minimum of five turns and that the hoist has the correct
lifting capacity for the engine weight.

To lift the outboard:

1. Remove the cowl from the outboard.
2. Thread the lifting eye into the flywheel hub for a minimum of
five turns.

15363

Lifting Eye 91‑90455‑‑1

Threads into the flywheel to
remove the powerhead
assembly from the driveshaft
2756 housing, or to lift entire engine
for removal/installation.

3. Connect a hoist to the lifting eye.

4. Lift the outboard and place it on the boat transom.

eng 109
 OUTBOARD INSTALLATION
Steering Cable ‑ Starboard Side Routed Cable
1. Lubricate O‑ring seal and entire cable end.

95

3724

Tube
Description Where Used Part No.
Ref No.
2-4-C with O-ring seal and entire cable
95 92-802859A 1
PTFE end
2. Insert steering cable into tilt tube.

3725

110 eng
 OUTBOARD INSTALLATION
3. Torque nut to specification.

3727

Description Nm lb‑in. lb‑ft

Nut 47.5 35

eng 111
 OUTBOARD INSTALLATION
Determining Recommended Outboard Mounting
Height
63.5 cm
(25 in.)

60.9 cm
(24 in.)
e c b
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.)

10 20 30 40 50 60 70 80

f 18562

a - The solid line is recommended to determine the outboard

mounting height
b - The broken lines represent the extremes of known
successful outboard mounting height dimensions
c - This line may be preferred to determine outboard
mounting height dimension, if maximum speed is the only
objective
d - This line may be preferred to determine outboard
mounting height dimension for dual outboard installation
e - Outboard mounting height (height of outboard mounting
brackets from bottom of boat transom). For heights over
56.0 cm (22 in.), a propeller that is designed for surfacing
operation is usually preferred.
f - Maximum boat speed (MPH) anticipated

112 eng
 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 63.5 cm (25 in.)
for L models, 76 cm (30 in.) for XL models. Mounting the outboard higher
may cause damage to the gearcase components.

Increasing the mounting height will usually:

• Reduce steering torque
• Increase top speed
• Increase boat stability
• Cause propeller to break loose during planing

Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read
Determining Recommended Outboard Mounting Height and
install outboard to the nearest recommended mounting height.
1. Mark four mounting holes on the transom using the transom
drilling fixture.

b a - Drill guide holes

b - Transom drilling fixture
c - Transom centerline
a

c 2757

eng 113
 OUTBOARD INSTALLATION
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.

3973

Fastening the Outboard to the Transom

MOUNTING BOLTS
Outboard Transom Mounting Hardware ‑ Supplied with Outboard
Part Number Part Name Description
½‑20 x 4.50 in. long (2.25 in.
10‑67755‑1 Outboard mounting bolt
thread)
11‑826711‑17 Nylon insert locknut ½‑20
12‑28421 Flat washer 1‑1/2 in. diameter
12‑54012 Flat washer 7/8 in. diameter

Available Outboard Mounting Bolts

Part Number Description
10‑67755005 ½‑20 x 2.50 in. long (1.25 in. thread)
10‑67755006 ½‑20 x 3.50 in. long (1.25 in. thread)
10‑814259 ½‑20 x 4.00 in. long (2.25 in. thread)
10‑67755‑1 ½‑20 x 4.50 in. long (2.25 in. thread)

114 eng
 OUTBOARD INSTALLATION
Available Outboard Mounting Bolts
Part Number Description
10‑8M0033366 ½‑20 x 5.00 in. long (3.25 in. thread)
10‑67755‑003 ½‑20 x 5.50 in. long (3.25 in. thread)
10‑67755‑2 ½‑20 x 6.50 in. long (2.75 in. thread)
10‑8M0028080 ½‑20 x 7.50 in. long (2.75 in. thread)
10‑8M0032860 ½‑20 x 8.00 in. long (2.75 in. thread)

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.

b 18961

a - Transom yielding under bolt torque

b - Transom cracking under bolt torque

eng 115
 OUTBOARD INSTALLATION
Use a dial torque wrench to determine transom strength. If the
bolt or nut continues to turn without the torque reading on the
dial increasing, it is an indication that the transom is yielding. The
load area can be increased by using a larger washer or a
transom reinforcement plate.

33962

a - Large transom washer

b - Transom reinforcement plate

1. Apply marine sealer to the shanks of the bolts, not to the

threads.
2. Fasten the outboard with the correct mounting hardware.
Tighten the locknuts to the specified torque.
IMPORTANT: Ensure a minimum of two full threads of the
mounting bolts extend beyond the locknut after tightening. The
locknut must be drawn tight while still engaging the bolt threads
and not contacting the shank of the bolt.

116 eng
 OUTBOARD INSTALLATION
NOTE: For more accurate torque, tighten the mounting locknuts
rather than the outboard mounting bolts.

d
c
a

e
b
c

d a

40952

a- 1/2 in. diameter outboard mounting bolt (4)

b- 7/8 in. flat washer (4)
c- Nylon insert locknut (4)
d- 1‑1/2 in. flat washer (4)
e- Marine sealer ‑ apply to the shank of the bolts, not the
threads

Description Nm lb‑in. lb‑ft

Outboard mounting locknuts and
75 55
bolts ‑ standard boat transom
Outboard mounting locknuts and
bolts ‑ metal lift plates and setback 122 90
brackets

eng 117
 OUTBOARD INSTALLATION
Electrical, Fuel Hose, Flush Hose and Control
Cables
FRONT COWL GROMMET
NOTE: Sufficient slack must exist in wiring, battery cables, and
hoses that are routed between the grommet and engine
attachment points to relieve stress and prevent hoses from being
kinked or pinched.
1. Pull up the cowl seal. Remove the access cover from the
bottom cowl.

23714

a - Access cover
b - Screws

2. Insert the lower alignment pin on the grommet into the hole
in the lower cover. Ensure the lettered side of the grommet
is facing out.
3. Route the hoses, wiring, and cables through the correct
opening in the grommet, as shown.

118 eng
 OUTBOARD INSTALLATION
4. Install the flush hose after removing the knockouts. Refer to
Flush Hose Routing.

b
f g
h
e F

TH
SH B
i
d
W j
c k 23638

a- Flush hose
b- Grommet
c- Remote boat harness
d- Shift cable
e- Throttle cable
f- Fuel hose
g- Upper alignment pin
h- SmartCraft harness or additional harness opening
i- Water pressure tube
j- Battery cables
k- Lower alignment pin

5. Reinstall the access cover with two bolts. Reattach the cowl
seal.

eng 119
 OUTBOARD INSTALLATION
6. Attach two cable ties around the grommet tube.

a
23639

a - Cable tie

FLUSH HOSE ROUTING

If desired, the flush hose can be routed outside the cowling as
follows:
1. Using a needle‑nose pliers, break out the semi‑circular
knockouts in the access cover and lower cover. Smooth the
edges of the knockout with sandpaper or a small knife.
2. Route the flush hose through this opening.

23642

a - Knockout
b - Flush hose

120 eng
 OUTBOARD INSTALLATION
REMOTE BOAT HARNESS
Route the remote boat harness through the grommet. Connect
the remote harness to the 14 pin connector on the engine
harness.

23699

a - Remote 14 pin boat harness

BATTERY INFORMATION

! WARNING
Failure to properly secure the battery leads can result in a loss
of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure
the battery leads to the battery posts with hex nuts to avoid
loose connections.

• Do not use deep‑cycle batteries. Engines must use a marine

starting battery with 1000 MCA, 800 CCA, or 180 Ah.
• When connecting the engine battery, hex nuts must be used
to secure battery leads to battery posts. Torque nuts to
specification.

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 OUTBOARD INSTALLATION
Description Nm lb‑in. lb‑ft
Hex nuts 13.5 120

IMPORTANT: Battery cable size and length is critical. Refer to

engine installation manual for size requirements.
The decal needs to be placed on or near the battery box for
future service reference. One 5/16 in. and one 3/8 in. hex nut is
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.)

DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387

Place decal on or near battery box for future service

reference. 5/16” and 3/8” hex nuts supplied for wing
nut replacement. Metric hex nuts not supplied.
3486

BATTERY CABLE CONNECTIONS

Single Outboard

a a - Red sleeve ‑
Positive (+)
(+) b - Black sleeve ‑
Negative (–)
c - Cranking battery
b c

(-) 15496

122 eng
 OUTBOARD INSTALLATION
Dual Outboards
Connect a common ground cable (wire size same as engine
battery cables) between negative (–) terminals on starting
batteries.

b
a (-)
d

b
c (-)
d

15497

a- Red sleeve ‑ Positive (+)

b- Black sleeve ‑ Negative (–)
c- Ground cable
d- Cranking battery

eng 123
 OUTBOARD INSTALLATION
SMARTCRAFT HARNESS CONNECTION
If SmartCraft gauges are being used with the outboard, route the
SmartCraft wiring harness through the grommet and connect it to
the SmartCraft harness connector on the engine.

23700

a - SmartCraft harness connector

WATER PRESSURE TUBE CONNECTION

If a water connection to the engine is required for a water
pressure gauge, make the connection as follows:

124 eng
 OUTBOARD INSTALLATION
1. The water pressure tube is coiled and attached on the side
of the engine. Cut the cable tie and route the water pressure
tube out through the grommet.

23702

a - Water pressure tube

eng 125
 OUTBOARD INSTALLATION
2. Remove the plug from the coupler and make the connection.
A barb fitting (22‑859731) can be installed for larger
diameter hose connection.

c b
23708

a - Plug
b - Coupler
c - Barb fitting (22‑859731)

FUEL HOSE CONNECTION

Remote Fuel Hose Size
Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with
separate fuel hose/fuel tank pickup for each engine.

126 eng
 OUTBOARD INSTALLATION
Fuel Hose Connection
Fasten the remote fuel hose to the fitting with a hose clamp.

a b

23709

a - Hose clamp
b - Remote fuel hose

SHIFT CABLE INSTALLATION

NOTE: Install the shift cable to the engine first. The shift cable is
the first cable to move when the remote control handle is moved
out of neutral.
Install cables into the remote control following the instructions
provided with the remote control.
1. Position remote control into neutral.

26838

2. Shift outboard into neutral.

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 OUTBOARD INSTALLATION
3. Measure the distance between pin and center of barrel
pocket.

c
b

23720
F N R

a - Distance between pin and center of lower hole

b - Pin
c - Barrel pocket

128 eng
 OUTBOARD INSTALLATION
4. Push in on the shift cable end until resistance is felt. Adjust
the cable barrel to attain distance measured in Step 3.

b
a

23721

a - Shift cable end

b - Cable barrel

5. Place the cable barrel into the pocket. Fasten the cable with
locknut and flat washer.

b
a c

7736

a - Cable barrel
b - Locknut
c - Flat washer

6. Check shift cable adjustments as follows:

a. Shift the remote control into forward. The propeller shaft
should be locked in gear. If not, adjust the barrel closer to
the cable end.

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 OUTBOARD INSTALLATION
b. Shift the remote control into neutral. The propeller shaft
should turn freely without drag. If not, adjust the barrel
away from the cable end. Repeat steps a and b.
c. Shift the remote control into reverse while turning
propeller. The propeller shaft should be locked in gear. If
not, adjust the barrel away from the cable end. Repeat
steps a through c.
d. Shift the remote control back to neutral. The propeller
shaft should turn freely without drag. If not, adjust the
barrel closer to the cable end. Repeat steps a through d.
THROTTLE CABLE INSTALLATION
Install cables into the remote control following the instructions
provided with the remote control.
1. Position remote control into neutral.

26838

2. Install the throttle cable to the throttle arm with a flat washer
and locknut. Tighten the locknut, then back off the locknut
1/4 turn.
3. Adjust the cable barrel so that the installed throttle cable will
hold the throttle arm against the idle stop.
4. Place the cable barrel into the barrel retainer.

130 eng
 OUTBOARD INSTALLATION
5. Lock the retainer and cables in place with the cable latch.

d
a b
e

15317

a- Flat washer
b- Locknut
c- Barrel retainer
d- Cable barrel
e- Cable latch

Oil Injection Set‑Up

FILLING OIL INJECTION SYSTEM
1. Fill the oil tank with the specified oil. Refer to Filling Oil
Injection System. Add only enough oil to bring the oil level
up to the bottom of the fill neck.

29465

eng 131
 OUTBOARD INSTALLATION
All Models Capacity Fluid Type
Oil tank 4.72 liters (5 qt.) Optimax/DFI 2‑Cycle Engine Oil

PRIMING THE OIL INJECTION PUMP

Before starting 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 - Oil injection pump

b - Oil supply hose
a

7912
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.
Prime the oil injection pump as follows:
1. Fill the engine fuel tank with fuel.
NOTE: Use the primer bulb located in the fuel hose to the
engine to draw fuel from the tank to fill the engine fuel system.
2. Position the fuel hose primer bulb so that the arrow on the
side of the bulb is pointing up. Squeeze the fuel hose primer
bulb until it feels firm.

27348

132 eng
 OUTBOARD INSTALLATION
3. Turn the ignition key switch to the "ON" position.

26846

4. Within the first 10 seconds after the key switch has been
turned on, move the remote control handle from neutral into
forward gear 3 to 5 times. This will automatically start the
priming process.
NOTE: It may take a few minutes for the pump to complete the
priming process.
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. This greater trim under
capability is desirable to improve acceleration, reduce the angle
and time spent in a bow high boat during planing off, and in
some cases, may be necessary to plane off a boat with aft
livewells, given the variety of available propellers and height
range of engine installations.

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 OUTBOARD INSTALLATION
However, once on plane, the engine should be trimmed to a
more intermediate position to avoid a bow‑down planing
condition called plowing. Plowing can cause bow steering or
oversteering and inefficiently consumes horsepower.

a - Tilt pin (not included with engine)

2688

Stainless Steel Tilt Pin 17‑49930A 1

Limits the down trim angle of the
power trim equipped engines, or
aids in determining the trim out
angle on non‑power trim
2749 engines.

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 nonstainless steel shipping bolt should not
be used in this application other than on a temporary basis.

134 eng
 MAINTENANCE LOG
Maintenance Log
Record all maintenance performed on your outboard here. Be
sure to save all work orders and receipts.
Date Maintenance Performed Engine Hours

eng 135