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Mercury 125 Optimax

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100% found this document useful (1 vote)

1K views163 pages

Mercury 125 Optimax

Uploaded by

hormiganegra431

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Name of engine manufacturer: Mercury Marine

Address: W6250 W. Pioneer Road, P.O. Box 1939

Town: Fond du Lac, WI

Post Code: 549361939

Country: USA

90-8M0077318 1112

Declaration of Conformity For Recreational Craft

Propulsion Engines with the Requirements of Directive
94/25/EC as amended by Directive 2003/44/EC

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Post Code: B2800

Country: Belgium

Name of Notified Body for exhaust emission assessment: Det

Norske Veritas AS
Address: Veritasveien 1
Town: Hovik

Post Code:
1322

Country:
Norway

ID Number: 0575

Name of Notified Body for noise emission assessment: Det Norske

Veritas AS
Address: Veritasveien 1
Town: Hovik

Post Code:
1322

Country:
Norway

ID Number: 0575

Conformity
assessment module
used for exhaust
emissions:

B+C B+D B+E B+F G

Conformity
assessment module
used for noise
emissions:

Other Community Directives applied: Safety of Machinery Directive

2006/42/EC; Electromagnetic Compatibility Directive 2004/108/EC

Description of Engines and Essential Requirements

eng

Engine Type

Fuel Type

Combustion Cycle

Outboard engine

Petrol

2 stroke

2013 Mercury Marine

Town: Verviers

75/90/115/115 Pro XS/125 OptiMax

Address: Parc Industriel de PetitRechain

Identification of Engines Covered by This Declaration of

Conformity

Name of engine family

Unique engine
identification
number(s) or engine
family code(s):
starting serial number

Module H
Certificate

1.5L OptiMax 75, 90, 115, 115

Pro XS, 125 hp, 80 Jet

0B228000

RCDH2 Rev 4

2.5L OptiMax 135, 150, 150

Pro XS, 175 hp

0B228000

RCDH2 Rev 4

3.0L OptiMax 200, 200 Pro XS,

0B228000
225 hp

RCDH2 Rev 4

Essential
requirements

Standards

Annex 1.BExhaust Emissions

B.1 engine
identification

B.2 exhaust
emission
requirements

B.3 durability

B.4 owner's
manual

ISO 8665: 2006

* EN ISO
81781:1996

Annex 1.CNoise Emissions

C.1 Noise
emission levels

EN ISO 14509

C.2 Owner's
manual

Owner's 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.

eng

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

Date and place of issue:

September 04, 2012
Fond du Lac, Wisconsin, USA

Welcome
You have selected one of the finest outboards available. It
incorporates numerous design features to ensure operating ease
and durability.
With proper care and maintenance, you will enjoy using this
product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read
this manual.
The Operation, Maintenance and Warranty Manual contains
specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready
reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely
hope your boating will be pleasant!
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 individual.
eng

iii

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.

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 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, and to change
specifications, designs, methods, or procedures without notice
and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Printed in the U.S.A.
2013, Mercury Marine
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with
Waves Logo, Kplanes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury
Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook,
SmartCraft, SportJet, Verado, VesselView, Zero Effort, Zeus,
and #1 On the Water are registered trademarks of Brunswick
Corporation. Mercury Product Protection is a registered service
mark of Brunswick Corporation.

eng

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 12month service Customer Satisfaction
Index (CSI) score for warranty service.
Possesses all of the necessary service tools, test
equipment, manuals, and parts books.
Employs at least one certified or master technician.
Provides timely service for all Mercury Marine customers.
Offers extended service hours and mobile service, when
appropriate.
Uses, displays, and stocks an adequate inventory of
genuine Mercury Precision Parts.
Offers a clean, neat shop with wellorganized tools and
service literature.

eng

WARRANTY INFORMATION
Warranty Registration United States and Canada....................... 1
Transfer of Warranty United States and Canada......................... 1
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
Warranty PolicyAustralia and New Zealand........................... 20

eng

vii

General Information
Boater's Responsibilities............................................................ 27
Before Operating Your Outboard............................................... 27
Boat Horsepower Capacity........................................................ 28
HighSpeed and HighPerformance Boat Operation................. 28
Propeller Selection..................................................................... 29
Outboard Remote Control Models ............................................ 32
Remote Steering Notice............................................................. 32
Lanyard Stop Switch.................................................................. 33
Protecting People in the Water.................................................. 37
Passenger Safety Message Pontoon Boats and Deck Boats
................................................................................................... 38
Wave and Wake Jumping.......................................................... 39
Impact with Underwater Hazards............................................... 40
Exhaust Emissions.................................................................... 42
Selecting Accessories for Your Outboard.................................. 44
Safe Boating Recommendations............................................... 44
Recording Serial Number.......................................................... 48
Specifications............................................................................. 48
Component Identification........................................................... 50
Transporting
Trailering Boat/Outboard .......................................................... 51

viii

eng

Fuel and Oil

Fuel Recommendations............................................................. 52
Fuel Requirements.................................................................... 54
Fuel Additives............................................................................ 54
Avoiding Fuel Flow Restriction.................................................. 54
Low Permeation Fuel Hose Requirement ................................. 54
EPA Pressurized Portable Fuel Tank Requirements................. 54
Fuel Demand Valve (FDV) Requirement................................... 55
Mercury Marine's Pressurized Portable Fuel Tank.................... 55
Oil Recommendation................................................................. 57
Filling Oil Injection System......................................................... 57
Filling Fuel Tank........................................................................ 59
Features and Controls
Remote Control Features.......................................................... 61
Warning System........................................................................ 62
Power Trim and Tilt.................................................................... 64
Trim Tab Adjustment................................................................. 68
Operation
Important Daily Inspection Before Each Use ............................ 70
Prestarting Check List................................................................ 70
Operating in Freezing Temperatures......................................... 71
Operating in Saltwater or Polluted Water.................................. 71
Operating at High Elevations..................................................... 72
Setting Trim Angle While Running Engine at Idle Speed.......... 72
Engine Breakin......................................................................... 72
Starting the Engine.................................................................... 73
Gear Shifting.............................................................................. 76
Stopping the Engine.................................................................. 77

eng

Maintenance
Outboard Care........................................................................... 78
EPA Emissions Regulations...................................................... 78
Inspection and Maintenance Schedule...................................... 79
Flushing the Cooling System .................................................... 82
Top Cowl Removal and Installation........................................... 83
Cleaning Care for Top Cowl...................................................... 84
Flywheel Cover Removal and Installation.................................. 84
Side Panel Removal and Installation......................................... 85
Fuel System............................................................................... 86
Steering Link Rod Fasteners..................................................... 89
Fuse Replacement..................................................................... 90
Corrosion Control Anode........................................................... 91
Battery Inspection ..................................................................... 92
Battery Information.................................................................... 92
Propellers................................................................................... 93
Spark Plug Inspection and Replacement................................... 97
Compressor Air Intake Filter...................................................... 99
Alternator Belt Inspection......................................................... 100
Lubrication Points.................................................................... 100
Checking Power Trim Fluid...................................................... 102
Gearcase Lubrication............................................................... 103
Storage
Storage Preparation................................................................. 106
Fuel System............................................................................. 106
Protecting Internal Engine Components.................................. 108
Protecting External Outboard Components............................. 108
Gearcase................................................................................. 109
Positioning Outboard for Storage............................................ 109
Battery Storage........................................................................ 109

eng

Owner Service Assistance

Local Repair Service................................................................ 110
Service Away from Home........................................................ 110
Parts and Accessories Inquiries.............................................. 110
Service Assistance.................................................................. 110
Ordering Literature................................................................... 113
Troubleshooting
Starter Motor Will Not Crank the Engine.................................. 115
Engine Will Not Start................................................................ 115
Engine Runs Erratically........................................................... 116
Performance Loss.................................................................... 116
Battery Will Not Hold Charge................................................... 116
Outboard Installation
Mercury Marine Validated Engine Mounting Hardware........... 117
Important Information............................................................... 118
Boat Horsepower Capacity...................................................... 118
Start in Gear Protection........................................................... 119
Selecting Accessories for Your Outboard................................ 119
Fuel System............................................................................. 119
Installation Specifications........................................................ 121
Lifting the Outboard................................................................. 122
Steering Cable Starboard Side Routed Cable....................... 123
Determining Recommended Outboard Mounting Height......... 125
Drilling Outboard Mounting Holes............................................ 126
Fastening the Outboard to the Transom.................................. 127
Electrical, Fuel Hose, Flush Hose, and Control Cables........... 133
Oil Injection SetUp.................................................................. 147
Trim In Pin............................................................................... 149

eng

Maintenance Log
Maintenance Log..................................................................... 151

xii

eng

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, email, 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 of Mercury Marine products sold in the United
States, should a safety recall notification under the Federal
Safety Act be required.
You may change your registered 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 Marines 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 +1 920 907 6663
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.

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.

eng

WARRANTY INFORMATION
To transfer the warranty to the subsequent owner, send or fax a
copy of the bill of sale or purchase agreement, new owners
name, address, and engine serial number to Mercury Marines
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 +1 920 907 6663
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.
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 noneligible applications.
The certified preowned engine plans are not transferable.
2

eng

WARRANTY INFORMATION
For help or assistance, contact Mercury Product Protection
Department at 18884275373 from 7:30 a.m. to 4:30 p.m. CST,
MondayFriday or email mpp_support@mercmarine.com.

Outboard Limited Warranty

UNITED STATES, CANADA, EUROPE, MIDDLE EAST,
AFRICA, 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.
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.

eng

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. 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.
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.

eng

WARRANTY INFORMATION
WHAT IS NOT COVERED: This limited warranty does not cover
routine maintenance items, tuneups, 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 wideopen 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 haulout, 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.

eng

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, SportJet, 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.

eng

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 touchup 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.

eng

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.

eng

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,
TriButylTinAdipate (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.

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 tuneups, 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. Haulout, 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.
eng

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 haulout, 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 emissionrelated
warranty covers all the components listed in the Emission
Control System Components.

Emission Control System Components

The EPA and California emissionrelated 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

WARRANTY INFORMATION
d. Ignition coil and/or control module
e. Ignition wires
4. Lubrication system (4Stroke 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 emissionrelated 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 nonemissionrelated 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). Emissionrelated
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

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, tuneups, 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 wideopen 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.

eng

WARRANTY INFORMATION
Expenses related to haulout, 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
nonMercury parts for nonwarranty maintenance or repairs will
not be grounds for disallowing other warranty work. The use of
addon (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 addon 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
19209295040.

eng

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
antismog 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 emissionrelated 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 emissionrelated 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.

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
19209295040.

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 3040 percent less gas and oil
than conventional carbureted twostroke engines, saving money
and resources.
Longer emission warranty protects consumer for worryfree
operation.
One Star Low Emission

22531

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
conventional carbureted twostroke engines.
These engines are equivalent to the U.S. EPA's
2006 standards for marine engines.
Two Stars Very Low Emission

42537

eng

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
standards have 20% lower emissions than One
Star Low Emission engines.

WARRANTY INFORMATION
Three Stars Ultra Low Emission

42538

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 20032008 exhaust
emission standards. Engines meeting these
standards have 65% lower emissions than One
Star Low Emission engines.
Four Stars Super Ultra Low Emission

42539

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
meeting these standards have 90% lower
emissions than One Star Low Emission engines.

Warranty PolicyAustralia and New Zealand

MERCURY/MARINER OUTBOARD LIMITED WARRANTY
AUSTRALIA AND NEW ZEALAND POLICY
This limited warranty is given by Marine Power International Pty
Ltd ACN 003 100 007 of 4171 Bessemer Drive, Dandenong
South, Victoria 3175 Australia (telephone (61) (3) 9791 5822)
email: merc_info@mercmarine.com.
What is Covered

Mercury Marine warrants its new products to be free of defects in

material and workmanship during the period described below.
The benefits to the consumer given by the warranty are in
addition to other rights and remedies of the consumer under a
law in relation to the goods or services to which the warranty
relates.

eng

WARRANTY INFORMATION
Guarantees Under Australian Consumer Law

Our goods come with guarantees that cannot be excluded under

the Australian Consumer Law. You are entitled to a replacement
or refund for a major failure and compensation for any other
reasonably foreseeable loss or damage. You are also entitled to
have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major
failure.
Warranty Period for Recreational Use

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. Unexpired warranty coverage
can be transferred to a subsequent recreational use customer
upon proper registration of the product.
Warranty Period for Commercial Use

Commercial users of these products receive warranty coverage

under this Limited Warranty 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. Unexpired warranty coverage cannot be
transferred either to or from a commercial use customer.

eng

WARRANTY INFORMATION
Conditions That Must Be Met to Obtain Warranty Coverage

Warranty coverage under this Limited Warranty 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 registered) 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.
What Mercury Will Do

Mercury Marine's sole and exclusive obligation under this

Limited 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 Marine product. Mercury Marine reserves the right
to improve or modify products from time to time without
assuming an obligation to modify products previously
manufactured.

eng

WARRANTY INFORMATION
How to Obtain Warranty Coverage Under This Limited Warranty

The customer must provide Mercury Marine 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 Marine dealer authorized
to service the product. A list of dealers and their contact details is
available at www.mercurymarine.com.au. If the purchaser cannot
deliver the product to such a dealer, written notice must be given
to Mercury Marine at the address shown above. Mercury Marine
will then arrange for the inspection and any covered repair. This
Limited Warranty will not cover the purchaser for all related
transportation charges and travel time. If the service provided is
not covered by this limited warranty, the purchaser shall pay for
all related labor and material and any other expenses associated
with that service, provided that a consumer will not be obligated
to pay where the service has been carried out to remedy a failure
of an acceptable quality guarantee which is binding on Mercury
Marine under the Australian Consumer Law. The purchaser shall
not, unless requested by Mercury Marine, ship the product or
parts of the product directly to Mercury Marine. Proof of
registered ownership must be presented to the dealer at the time
warranty service is requested in order to obtain coverage under
this Limited Warranty.

eng

WARRANTY INFORMATION
What is Not Covered

This limited warranty does not cover routine maintenance items,

tuneups, 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 wideopen
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 haulout, 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
Limited 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.

eng

WARRANTY INFORMATION
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. 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.
Expense of Claiming This Limited Warranty

This Limited Warranty does not cover any expenses you may
incur claiming the warranty.
DISCLAIMERS AND LIMITATIONS:
EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND
REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN
CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE
PRODUCTS
RELATE,
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 LIMITED WARRANTY.

TRANSFER OF WARRANTYAUSTRALIA AND NEW

ZEALAND POLICY
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 owners
name, address, and hull identification number (HIN) to Mercury
Marines Warranty Registration Department. In Australia and
New Zealand, mail to:

eng

WARRANTY INFORMATION
Mercury Marine
Attn: Warranty Registration Department
Brunswick Asia Pacific Group
Private Bag 1420
Dandenong South, Victoria 3164
Australia

Upon processing the transfer of warranty, Mercury Marine will

send registration verification to the new owner of the product by
mail. There is no charge for this service.
You may change your address at any time, including at the time
of the warranty claim, by calling Mercury Marine or sending a
letter or fax with your name, old address, new address, and hull
identification number (HIN) to Mercury Marines Warranty
Registration Department.

eng

GENERAL INFORMATION
Boater's Responsibilities
The operator (driver) is responsible for the correct and safe
operation of the boat and the safety of its occupants and general
public. It is strongly recommended that each operator read and
understand this entire manual before operating the outboard.
Be sure that 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

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

HighSpeed and HighPerformance Boat Operation

If your outboard is to be used on a highspeed or
highperformance 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 HiPerformance Boat Operation booklet
from your dealer, distributor, or Mercury Marine.

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

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

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
topend speed will be reduced. The higher the propeller pitch the
faster the boat will usually go; though typically slowing
acceleration.
30

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 3blade propeller to a 4blade 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
4blade propellers have unique performance characteristics. In
general, 3blade propellers offer good all around performance
and higher top speed than 4blade propellers. However, 4blade
propellers are usually faster to plane and more efficient at
cruising speeds, but lack the top end speed of a 3blade
propeller.

eng

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
neutralsafetyprotection device.

26838

Remote Steering Notice

The steering link rod that connects the steering cable to the
engine must be fastened utilizing selflocking nuts. These
selflocking nuts must never be replaced with common nuts
(nonlocking) as they will work loose and vibrate off, freeing the
link rod to disengage.

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 - Selflocking nuts

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

GENERAL INFORMATION
The lanyard is a cord usually 122152 cm (45 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 atrest condition
as short as possible to minimize the likelihood of lanyard
entanglement with nearby objects. Its stretchedout 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.

21629

a - Lanyard cord
b - Lanyard stop switch
Read the following Safety Information before proceeding.

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 (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

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.

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

eng

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.

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 enters
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

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.

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

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 wellventilated 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.
42

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:

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

GENERAL INFORMATION
2. Examples of poor ventilation while the boat is moving:

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 Recommendations

To safely enjoy the waterways, familiarize yourself with local and
all other governmental boating regulations and restrictions and
consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
We recommend that all powerboat operators complete a
boating safety course. In the U.S., the U.S. Coast Guard
Auxiliary, the Power Squadron, the Red Cross, and your
state or provincial boating law enforcement agency provide
courses. For more information in the U.S., call the Boat U.S.
Foundation at 1800336BOAT (2628).
Perform safety checks and required maintenance.
44

eng

GENERAL INFORMATION

Follow a regular schedule and ensure that all repairs are

properly made.

Check safety equipment onboard.

Here are some suggestions of the types of safety equipment
to carry when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and
whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench
First aid kit and instructions
Waterproof storage containers
Spare operating equipment, batteries, bulbs, and fuses
Compass and map or chart of the area
Personal flotation device (one per person onboard)
Watch for signs of weather change and avoid foul weather
and roughsea boating.
Tell someone where you are going and when you expect to
return.
Passenger boarding.
Stop the engine whenever passengers are boarding,
unloading, or are near the back (stern) of the boat. Shifting
the drive unit into neutral is not sufficient.
Use personal flotation devices.

eng

GENERAL INFORMATION

Federal law requires that there be a U.S. Coast

Guardapproved life jacket (personal flotation device),
correctly sized and readily accessible for every person
onboard, plus a throwable cushion or ring. We strongly
advise that everyone wear a life jacket at all times while in
the boat.

Prepare other boat operators.

Instruct at least one person onboard in the basics of starting
and operating the engine and boat handling in case the
driver becomes disabled or falls overboard.
Do not overload your boat.
Most boats are rated and certified for maximum load
(weight) capacities (refer to your boat's capacity plate).
Know your boat's operating and loading limitations. Know if
your boat will float if it is full of water. When in doubt, contact
your authorized Mercury Marine dealer or the boat
manufacturer.
Ensure that 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 backs of
seats, gunwales, transom, bow, decks, raised fishing seats,
and any rotating fishing seat. Passengers should not sit or
ride anywhere that sudden 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. Ensure that all passengers have a proper seat
and are in it before any boat movement.
Never operate a boat while under the influence of alcohol or
drugs. It is the law.
Alcohol or drugs can impair your judgment and greatly
reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
Be alert.

eng

GENERAL INFORMATION

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 the boat is above idle or planing
transition speed. Watch out for others, the water, and your
wake.

Never drive your boat directly behind a water skier.

Your boat traveling at 40 km/h (25 mph) will overtake a
fallen skier who is 61 m (200 ft) in front of you in five
seconds.
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 attend to 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.

eng

GENERAL INFORMATION
Recording Serial Number
It is important to record this number for future reference. The
serial number is located on the outboard as shown.
Model Number
-

XXXXXXX

Serial Number

XXXXXXL
XX
XXXX XXX
HP XXX KW XXX
LB XXX KG XXX
H
Me
P rc ury Marine
Brunswick Corp.
L in Japan
Made

23884

abcd-

Serial number
Model designation
Year manufactured
Certified Europe Insignia (as applicable)

Specifications
Models

115/115 Pro
XS

125

Horsepower

115

125

55.2

66.2

84.6

91.3

Kilowatts
Full throttle
RPM range
Idle speed in
forward gear

50005750 RPM
625675 RPM

Number of
cylinders

Piston
displacement

1523.5 cc (92.9 in)

Cylinder bore

92.11 mm (3.63 in.)

Piston stroke

76.2 mm (3.0 in.)

Recommended
spark plug

IZFR5J

Spark plug gap

0.80 mm (0.030 in.)

eng

GENERAL INFORMATION
Models
Gear ratio

90
2.33:1

125

2.07:1

Recommended
gasoline

Refer to Fuel and Oil

Recommended
oil

Refer to Fuel and Oil

Oil tank
capacity

4.72 liter (5 US qt)

Gearcase
lubricant
capacity

665 ml (22.5 fl oz)

Battery rating

1000 marine cranking amps (MCA) or 800 cold cranking

amps (CCA)

Charging
system output

60 A

Emission
control system

Electronic engine control (EC)

Sound at
drivers ear
(ICOMIA 3994)
dBA

eng

115/115 Pro
XS

82.0

GENERAL INFORMATION
Component Identification
b

abcde-

fg-

i
h

d
f

hij-

Top cowl
Auxiliary tilt switch
Transom brackets
Gearcase
Cooling water
intake holes
Trim tab
Antiventilation
plate
Driveshaft housing
Water pump
indicator hole
Bottom cowl

e
29461

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

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
two 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.
52

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 alcoholfree 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, alcoholblend
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

FUEL AND OIL

Fuel Requirements
Do not use premixed gas and oil in this engine. The engine
automatically receives extra oil during engine breakin. Use a
fresh supply of the recommended gasoline during engine
breakin and after engine breakin.

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 B115 or Type A115,
defined as not exceeding 15/gm/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) requires 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:

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
c

46273

a - Fuel demand valve installed

in the fuel hose between the
fuel tank and primer bulb
b - Manual release
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 twoway 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

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 builtin 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 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

a - Fuel cap
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 builtin 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.
56

eng

FUEL AND OIL

4. Follow Filling Fuel Tank instructions for fueling.

Oil Recommendation
Recommended Oil

OptiMax Oil or Premium Plus 2Cycle TCW 3

Outboard Oil

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

recommended for your engine. If Mercury OptiMax/DFI or
Quicksilver DFI 2Cycle Engine Oil is not available, we
recommend using Mercury or Quicksilver TCW3 Premium Plus
2Cycle 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
a - Cowl cover
b - Oil filler cap

eng

37147

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.

a
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.

a
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.

eng

FUEL AND OIL

Oil tank

Capacity

Fluid Type

4.72 liters (5 US qt)

OptiMax/DFI 2Cycle 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 the fuel tanks outdoors away from heat, sparks, and open
flames.
Remove portable fuel tanks from the boat to refill them.
Always stop engine engine before filling the tanks.

eng

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.

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
a
b

i
i

a
d
e

f
26800

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

FEATURES AND CONTROLS

Warning System
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 indicate the horn is working.
There are two types of warning horns to alert the operator of an
active problem within the engines operating system.
1. Continuous six second beep: Indicates a critical engine
condition. Depending on the condition, the Engine Guardian
system may engage and protect the engine by limiting its
power. You should return to port immediately and contact
your servicing dealer.
2. Intermittent short beeps for six seconds: Indicates a
noncritical engine condition. This condition does not require
immediate attention. You may continue using your boat,
however, depending on the nature of the problem, the
engines power may be limited by the Engine Guardian
system (see Engine Guardian System following) to protect
the engine. You should contact your servicing dealer at your
earliest convenience.
It is important to note that in either of the above scenarios, the
horn will only sound one time. If you key the engine off and
restart it, the horn will sound again, one time, if the fault is still
present. For visual display of the specific engine functions and
additional engine data, refer to SmartCraft Product information,
following.
A few of the noncritical conditions indicated by the intermittent
short beeps for six seconds can be corrected by the operator.
These operator correctable conditions are as follows:
Water in the engine mounted fuel filter. Refer to
Maintenance Water Separating Fuel Filter.
Cooling system (water pressure or engine temperature)
problem. Stop the engine and check the water intake holes
in the lower unit for obstruction.
Low engine oil level. Refer to Fuel and Oil Checking and
Adding Engine Oil.
62

eng

FEATURES AND CONTROLS

ENGINE GUARDIAN SYSTEM
The Engine Guardian system monitors the critical sensors on the
engine for any early indications of problems. Engine Guardian is
functional whenever your engine is operating, so you never have
to be concerned about whether or not you are protected. The
system will respond to a problem by sounding the warning horn
for six seconds and/or reducing engine power in order to provide
engine protection.
If Engine Guardian has been activated, reduce the engine
speed. The problem will need to be identified and corrected. The
system must be reset before the engine will operate at higher
speeds. Moving the throttle lever back to the idle position will
reset the Engine Guardian system. If the Engine Guardian
system has determined the reset has not corrected the problem,
Engine Guardian will remain activated, limiting the throttle. The
problem must be identified and corrected before Engine
Guardian will allow the engine to reach a normal operating RPM.
OVERSPEED REV LIMIT
The overspeed rev limit is set at an RPM greater than the
operating range. In the event that the engine is operated at an
RPM greater than or equal to the overspeed limit, the PCM does
not allow the engine to maintain the power requested by the
operator. Refer to Specifications to determine this engines
RPM limit.
Upon reaching the beginning of the rev limit, Engine Guardian
will cutout the ignition to specific cylinders. If the operator does
not reduce engine speed, Engine Guardian will cutout the
ignition to all the cylinders. There is no audible warning while
Engine Guardian overspeed limit is active.
To reset the Engine Guardian protection:
1. Completely reduce the throttle for three seconds.
2. Engage the throttle. If the engine does not respond, repeat
step one.

eng

FEATURES AND CONTROLS

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.

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 - Trim switch
b - Tilt range of
travel
c - Trim range of
travel

b
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.
64

eng

FEATURES AND CONTROLS

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.
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 righthand 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.

eng

FEATURES AND CONTROLS

! WARNING
Operating the boat at high speeds with the outboard trimmed
too far under can create excessive bow steer, resulting in the
operator losing control of the boat. Install the trim limit pin in a
position that prevents excessive trim under and operate the
boat in a safe manner.
In rare circumstances, the owner may decide to limit the
trim in. 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.
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 righthand 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 the 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.

eng

FEATURES AND CONTROLS

3. Disengage the tilt support lever by raising the outboard off
the support lever and rotating the lever down. Lower the
outboard.

a - Tilt support lever

b - Knob

b
27778

MANUAL TILTING
If the outboard cannot be tilted using the power trim/tilt switch,
the outboard can be manually tilted.
NOTE: The manual tilt release valve must be tightened before
operating the outboard to prevent the outboard from tilting up
during reverse operation.
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.
eng

FEATURES AND CONTROLS

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

27779

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 antiventilation
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.

eng

FEATURES AND CONTROLS

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. Tighten bolt and retest.

eng

OPERATION
Important Daily Inspection Before Each Use
Any outboard mounted on the boat must have the mounting
hardware inspected and checked to ensure that the hardware
has not become loose. A decal on the transom bracket reminds
the owner to check the fasteners securing the outboard to the
transom before each use.

51985

Decal on the transom bracket

Prestarting 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 ringtype 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.

eng

OPERATION
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 the 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.

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.

eng

OPERATION
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.

Setting Trim Angle While Running Engine at Idle

Speed
The exhaust relief hole on the outboard may become submerged
if the outboard is trimmed fullin 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 Breakin
IMPORTANT: Failure to follow the engine breakin procedures
can result in poor performance throughout the life of the engine
and can cause engine damage. Always follow breakin
procedures.
Breakin Procedure
Vary throttle settings during breakin. Use the following suggestions.
First Hour

Allow the engine to warmup for 3060 seconds.

eng

OPERATION
Breakin Procedure

Do not idle for more than five minutes.

Run the engine the majority of the time between 40005400 RPM
(approximately threequarter throttle).

Short bursts of wideopen throttle for 10 seconds or less are acceptable.

Change the engine speed approximately every two minutes.

Avoid trimming the outboard out (up) beyond a vertical trim position
during operation.

Avoid using a hydraulic jack plate to raise the engine during the breakin
cycle.

Next Three Hours: Change the engine speed every 10 minutes.

Starting the Engine

Before starting, read the prestarting check list, special operating
instructions, and engine breakin 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.
1. Lower the outboard to the vertical operating position. Make
sure all cooling water intake holes are submerged.

26837

eng

OPERATION
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

5. Shift outboard to neutral ("N") position.

26838

eng

OPERATION
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

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.

eng

OPERATION
IMPORTANT: If no water is coming out of the water pump
indicator hole, stop the 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 the outboard into gear unless the engine speed
is at idle.
Do not shift the 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 the outboard into gear with a quick motion.
After shifting the outboard into gear, advance the lever
further to increase speed.

27237

eng

OPERATION
Stopping the Engine
Reduce engine speed and shift outboard to neutral position. Turn
ignition key to "OFF" position.

26843

eng

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.

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
INFORMATION

THIS ENGINE CONFORMS TO

CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS

b
c

IDLE SPEED (in gear):

d
e
abcdefghij-

hp
kw

FAMILY:

HC+NOx:FEL:

g/kWh

CO FEL:

g/kWh

SPARK PLUG:
GAP:

LOW PERM/HIGH PERM:

f
g
h
i
j

43210

Idle speed
Engine horsepower
Piston displacement
Engine power kilowatts
Date of manufacture
Family number
Regulated emission limit for the engine family
Regulated emission limit for the engine family
Recommended spark plug and gap
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

PRIOR TO EVERY USE
Check that the lanyard stop switch stops the engine.
Check the steering system for binding or loose components.
eng

MAINTENANCE

Verify the outboard is securely attached to the boat transom.

If the outboard or any of its fasteners are loose, tighten them
to the specified torque. When checking to verify the
outboard is securely fastened, 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 or lift
plate/setback bracket.
Description

lbin.

lbft

Outboard mounting locknuts and

bolts standard boat transom

Outboard mounting locknuts and

bolts metal lift plates and setback
brackets

122

Check the propeller blades for damage.

Inspect all hoses, clamps, fittings, tubing, sealing gaskets,
and mounting hardware for wear.

AFTER EACH SALTWATER OR POLLUTED WATER USE

Flush all internal passages with fresh water.
Wash the power package exterior (cowl, midsection, and
gearcase) with fresh water.
Flush the propeller and gearcase exhaust outlet with fresh
water.
Remove the cowl and wipe off any saltwater spray with a
damp cloth.
EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATER
OR POLLUTED WATER USE
Spray the powerhead and all external, unpainted metal
surfaces (except anodes) with Corrosion Guard.
Tube
Ref No.
120

Description
Corrosion
Guard

Where Used

Part No.

Powerhead and all external,

unpainted metal surfaces
(except anodes)

92-802878 55

eng

MAINTENANCE
EVERY 25 HOURS OR EVERY 30 DAYS, WHICHEVER
OCCURS FIRST
Verify the front and side cowl latches are tight. Tighten them
if necessary.
Inspect the fuel and oil systems for deterioration or leaks.
Inspect the hydraulic steering hoses for deterioration or
leaks.
Inspect the steering link rod fasteners for wear. Lubricate all
of the specified components. Check all attachment hardware
to ensure proper torque.
Check the level and condition of the gearcase lubricant.
Check the alternator belt tension.
EVERY 50 HOURS OR ONCE A YEAR, WHICHEVER
OCCURS FIRST
Lubricate all of the lubrication points listed in the manual.
Lubricate the splines on the driveshaft.1.

Lubricate the length of driveshaft with Extreme Grease.

Tube
Ref No.

Description
Extreme
Grease

Where Used

Part No.

Length of driveshaft

8M0071842

Lubricate the splines on the propeller shaft.

Drain and replace the gearcase lubricant.
Inspect all belts, pulleys, and idler pulleys for deterioration.
Check the fuel pressure. 1.
Check the control cable adjustments.
Inspect the battery.
Check the corrosion control anodes.
Check the tightness of all fasteners.
Check the power trim fluid.
Use Quicksilver products to remove engine deposits. See
your dealer for an explanation of which products to use.

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

eng

MAINTENANCE
EVERY 100 HOURS OR ONCE A YEAR, WHICHEVER
OCCURS FIRST
Tighten the fasteners that secure the outboard to the boat
transom to the specified torque.1.

Description

lbin.

lbft

Outboard mounting locknuts and

bolts standard boat transom

Outboard mounting locknuts and

bolts metal lift plates and setback
brackets

122

Replace the water pump impeller (more often if overheating

occurs or reduced water pressure is noted).1.
Replace the spark plugs after the first 100 hours or first
year. After that, inspect the spark plugs every 100 hours or
once yearly. Replace the spark plugs as needed.
Replace the water separating fuel filter.
Use Quickleen in the fuel.
Verify that the cowl seals are intact and not damaged.
Check that the internal cowl sound reduction foam (if
equipped) is intact and not deteriorating.
Ensure that the intake silencer (if equipped) is in place.
Ensure 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 100 HOURS OF OPERATION

Inspect the carbon fiber reeds for chipping or cracks.
BEFORE PERIODS OF STORAGE
Refer to 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.
82

eng

MAINTENANCE
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 three 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.

22703

a - Hose adapter
b - Sealing washer
c - Cover

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

eng

MAINTENANCE
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 nonabrasive
soap. Use a soft, clean cloth when washing.
3. Dry thoroughly with a soft, clean cloth.
4. Wax the surface using a nonabrasive automotive polish
(polish designed for clear coat finishes). Remove the applied
wax by hand using a soft, clean cloth.

Flywheel Cover Removal and Installation

REMOVAL
Lift the cover off the three mounting pins.

eng

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
a - Flywheel cover
b - Mounting pins
c - Tabs

Side Panel Removal and Installation

REMOVAL
Pull the side panel off the three mounting pins.

eng

23754

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

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 wellventilated 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

Use fuel filter tool 91896661, or the shaft of a screwdriver,

between the lugs on the filter cap and unscrew the filter.

a
b

29594

a - Filter
b - Orings
Fuel Filter Removal/Installation Tool

91896661

Aids in the removal and

installation of the fuel filter cap
assembly.
24896

eng

MAINTENANCE
Installation

1. Lubricate the Oring seals with oil.

2. Install the fuel filter and tighten securely.
3. Squeeze the primer bulb until firm and inspect for fuel
leakage at the filter.

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.

23743

a - Drain hose
b - Right side fitting
c - Drain screw
3. Tighten the drain screw and attach the hose.
IMPORTANT: Visually inspect for fuel leakage from the drain
screw by squeezing the primer bulb until firm, forcing fuel into the
chamber.
88

eng

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 10849838) and selflocking nylon
insert locknuts ("c" and "d" Part Number 11826709113). 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
c

27843

d
abcd-

eng

Special washer head bolt (10849838)

Flat washer (2)
Nylon insert locknut (11826709113)
Nylon insert locknut (11826709113)

Description

lbin.

lbft

Special washer head bolt

Nylon insert locknut "d"

MAINTENANCE
Description
Nylon insert locknut "c"

lbin.

lbft

Tighten until it seats, then back off 1/4

turn

Assemble steering link rod to steering cable with two flat

washers and selflocking 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 selflocking nylon insert locknut. First torque bolt, then
torque locknut to specifications.

Fuse Replacement
IMPORTANT: Always carry spare 5 and 20amp 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

MAINTENANCE
Open the fuse holder and look at the silver colored band inside
the fuse. If the band is broken, replace the fuse. Replace fuse
with a new fuse with the same rating.

b
c
20

g
f

2
5

e
23793

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

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.

27844

a - Anode (2) on
each side of
gearcase
b - Anode on
transom bracket
assembly

Battery Inspection
The battery should be inspected at periodic intervals to ensure
proper engine starting capability.
IMPORTANT: Read the safety and maintenance instructions
which accompany your battery.
1. Turn off the engine before servicing the battery.
2. 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.
92

eng

MAINTENANCE

Do not use deepcycle 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.
Description

lbin.

Hex nuts

13.5

120

lbft

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

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

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 antiventilation 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

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 Extreme Grease or 24C with
PTFE.

26902

Tube
Ref No.

Description
Extreme
Grease

eng

Where Used

Part No.

Propeller shaft

8M0071842

MAINTENANCE
Tube
Ref No.

Description
2-4-C with
PTFE

Where Used

Part No.

Propeller shaft

92-802859A 1

NOTE: The FloTorq 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. FloTorq III drive hub propellers Install the forward thrust
hub, replaceable drive sleeve, propeller, thrust hub,
propeller nut retainer, and propeller nut onto the shaft.

b
abcdef-

3223

Propeller nut
Propeller nut retainer
Rear thrust hub
Propeller
Replaceable drive sleeve
Forward thrust hub

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

Torque the propeller nut to specification.
Description

lbin.

lbft

Propeller nut

eng

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 that 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 by twisting the rubber boots
while pulling them off the spark plugs.

26899

2. Remove the spark plugs. Replace the spark plug if the

electrode is worn; the insulator is rough, cracked, broken, or
blistered; or if the precious metal is not visible on the spark
plug electrode.

eng

MAINTENANCE
IMPORTANT: The color of the plug may not accurately reflect
its condition. To accurately diagnose a faulty plug, inspect the
precious metal on the plug's electrode. If no precious metal is
visible, replace the plug.

a
9381

a - Precious metal
3. Set the spark plug gap. Refer to Specifications.

27848

a. All of the spark plugs should have the gap checked and
corrected as necessary before installation.
b. Measure the gap with a feeler gauge or pin gauge. Never
use a wedgetype gap checking tool to inspect or to
adjust the gap.
c. If an adjustment is necessary, do not pry or apply any
force on the center electrode. This is critical with any type
of spark plug that has a wear surface, such as platinum
or iridium added to either the ground electrode or the
center electrode.

eng

MAINTENANCE
d. When it is necessary to widen the gap, use a tool that
only pulls back on the ground electrode without touching
the center electrode, the porcelain, or the wear portion of
the ground electrode.
e. When it is necessary to close the gap, gently tap the plug
ground electrode on a hard surface.
4. Before installing spark plugs, clean off any dirt on the spark
plug seats. Install the plugs fingertight and then tighten an
additional 1/4 turn or tighten to the specified torque.
Description

lbin.

lbft

Spark plug

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
a
29476

INSTALLATION
1. Install filter into cover.
2. Fasten filter cover with three screws.

eng

MAINTENANCE
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.
Inspect the alternator belt and have it replaced by an authorized
dealer if any of the following conditions are found.
Cracks or deterioration in the rubber portion of the belt.
Belt surfaces rough or uneven.
Signs of wear on edges or outer surfaces of belt.

29477

Lubrication Points
1. Lubricate the following with Extreme Grease or 24C with
PTFE.
Tube
Ref No.

Description

Where Used

Part No.

Extreme
Grease

Propeller shaft

8M0071842

2-4-C with
PTFE

Propeller shaft

92-802859A 1

100

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 24C with PTFE.

Tube
Ref No.
95

Description
2-4-C with
PTFE

Where Used

Part No.

Swivel bracket, tilt support

lever, tilt tube, steering cable
grease fitting

92-802859A 1

Swivel bracket Lubricate through fitting.

Tilt support lever Lubricate through fitting.

a - Swivel bracket
b - Tilt support lever

b
27873

Tilt tube Lubricate through fitting.

29478

Steering cable grease fitting (if equipped) Rotate

steering wheel to fully retract the steering cable end into
the outboard tilt tube. Lubricate through fitting.

eng

101

MAINTENANCE
! 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 - 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

102

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 automatic
transmission fluid (ATF).
Tube
Ref No.
114

Description
Power Trim
and Steering
Fluid

Where Used

Part No.

Power trim reservoir

92-858074K01

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

103

MAINTENANCE
3. Remove vent plugs and fill/drain plug and drain lubricant.
a - Vent plugs
b - Fill/drain plug

a
b
26977

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 665 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.

104

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.

c
b

d
27001

abcde-

Front vent plug

Front vent hole
Rear vent hole
Rear vent plug
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

105

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 US qt) of gasoline. Pour this mixture
into fuel tank.

106

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

c
b
23751

5. Tighten the drain screw and attach 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

b
c
23752

8. Tighten the drain screw and attach 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

107

STORAGE
10. Remove the fuel filter. See Maintenance Fuel System for
procedure.
11. Pour this mixture into the fuel filter opening. Install 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

9144357Q 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. Install the spark plugs.

Protecting External Outboard Components

Lubricate all outboard components listed in Maintenance

Inspection and Maintenance Schedule.
108

eng

STORAGE

Touch up any paint nicks. See your dealer for touchup

paint.
Spray Quicksilver or Mercury Precision Lubricants Corrosion
Guard on external metal surfaces (except corrosion control
anodes).

Tube
Ref No.
120

Description
Corrosion
Guard

Where Used

Part No.

External metal surfaces

92-802878 55

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

eng

Follow the battery manufacturer's instructions for storage

and charging.
Remove the battery from the boat and check water level.
Charge if necessary.
Store the battery in a cool, dry place.
Periodically check the water level and charge the battery
during storage.

109

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 about parts and
accessories, the dealer requires the model and serial number to
order the correct parts.

Service Assistance
LOCAL REPAIR SERVICE
If you need service for your Mercuryoutboardpowered boat,
take it to your authorized dealer. Only authorized dealers
specialize in Mercury products and have factorytrained
mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your
engine.
NOTE: Quicksilver parts and accessories are engineered and
built by Mercury Marine specifically for your power package.

110

eng

OWNER SERVICE ASSISTANCE

SERVICE AWAY FROM HOME
If you are away from your local dealer and the need arises for
service, contact the nearest authorized dealer. If, for any reason,
you cannot obtain service, contact the nearest Regional Service
Center. Outside the United States and Canada, contact the
nearest Marine Power International Service Center.
STOLEN POWER PACKAGE
If your power package is stolen, immediately advise the local
authorities and Mercury Marine of the model and serial numbers
and to whom the recovery is to be reported. This information is
maintained in a database at Mercury Marine to aid authorities
and dealers in the recovery of stolen power packages.
ATTENTION REQUIRED AFTER SUBMERSION
1. Before recovery, contact an authorized Mercury dealer.
2. After recovery, immediate service by an authorized Mercury
dealer is required to reduce the possibility of serious engine
damage.
REPLACEMENT SERVICE PARTS

! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel
system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or
explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When
servicing the electrical and fuel systems, properly install and
tighten all components.
Marine engines are expected to operate at or near full throttle for
most of their lives. They are also expected to operate in both
fresh and saltwater environments. These conditions require
numerous special parts.

eng

111

OWNER SERVICE ASSISTANCE

PARTS AND ACCESSORIES INQUIRIES
Direct any inquiries concerning Quicksilver replacement parts
and accessories to your local authorized dealer. The dealer has
the necessary information to order parts and accessories for you
if they are not in stock. Only authorized dealers can purchase
genuine Quicksilver parts and accessories from the factory.
Mercury Marine does not sell to unauthorized dealers or retail
customers. When inquiring about parts and accessories, the
dealer requires the engine model and serial numbers to order
the correct parts.
RESOLVING A PROBLEM
Satisfaction with your Mercury product is important to your dealer
and to us. If you ever have a problem, question or concern about
your power package, contact your dealer or any authorized
Mercury dealership. If you need additional assistance:
1. Talk with the dealership's sales manager or service
manager. Contact the owner of the dealership if the sales
manager and service manager have been unable to resolve
the problem.
2. If your question, concern, or problem cannot be resolved by
your dealership, please contact the 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 Customer
Service:
Your name and address
Your daytime telephone number
The model and serial numbers of your power package
The name and address of your dealership
The nature of the problem
CONTACT INFORMATION FOR MERCURY MARINE
CUSTOMER SERVICE
For assistance, call, fax, or write to the geographic office in your
area. Please include your daytime telephone number with mail
and fax correspondence.
112

eng

OWNER SERVICE ASSISTANCE

United States, Canada
Telephone

English +1 920 929 5040

Franais +1 905 636 4751

Fax

English +1 920 929 5893

Franais +1 905 636 1704

Website

www.mercurymarine.com

Mercury Marine
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939

Australia, Pacific
Telephone

+61 3 9791 5822

Fax

+61 3 9706 7228

Brunswick Asia Pacific Group

4171 Bessemer Drive
Dandenong South, Victoria 3175
Australia

Europe, Middle East, Africa

Telephone

+32 87 32 32 11

Fax

+32 87 31 19 65

Brunswick Marine Europe

Parc Industriel de Petit-Rechain
B-4800 Verviers,
Belgium

Mexico, Central America, South America, Caribbean

Telephone

+1 954 744 3500

Fax

+1 954 744 3535

Mercury Marine
11650 Interchange Circle North
Miramar, FL 33025
U.S.A.

Japan
Telephone

+81 72 233 8888

Fax

+81 72 233 8833

Kisaka Co., Ltd.

4130 Kannabecho, Sakaiku
Sakaishi, Osaka 5900984, Japan

Asia, Singapore
Telephone

+65 65466160

Fax

+65 65467789

Brunswick Asia Pacific Group

T/A Mercury Marine Singapore Pte Ltd
29 Loyang Drive
Singapore, 508944

Ordering Literature
Before ordering literature, have the following information about
your power package available:

eng

113

OWNER SERVICE ASSISTANCE

Model

Serial Number

Horsepower

Year

UNITED STATES AND CANADA

For additional literature for your Mercury Marine power package,
contact your nearest Mercury Marine dealer or contact:
Mercury Marine
Telephone

Fax

Mail

(920) 9295110
(USA only)

(920) 9294894
(USA only)

Mercury Marine
Attn: Publications Department
P.O. Box 1939
Fond du Lac, WI 54935-1939

OUTSIDE THE UNITED STATES AND CANADA

Contact your nearest Mercury Marine authorized service center
to order additional literature that is available for your particular
power package.
Submit the following
order form with payment
to:

Mercury Marine
Attn: Publications Department
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939

Ship To: (Copy this form and print or typeThis is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country
Quantity

Item Stock Number

114

Price

Total

Total Due

eng

TROUBLESHOOTING
Starter Motor Will Not Crank the Engine
POSSIBLE CAUSES
Blown 20amp 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 20amp 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.

eng

115

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 builtin 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).
116

eng

OUTBOARD INSTALLATION
Mercury Marine Validated Engine Mounting
Hardware
IMPORTANT: Mercury Marine provides validated fasteners and
installation instructions, including torque specifications, with all of
our outboards so they can be properly secured to boat transoms.
Improper installation of the outboard can cause performance and
reliability issues that can lead to safety concerns. Follow all of
the instructions relating to the outboard installation. DO NOT
mount any other accessory onto the boat with the fasteners
provided with the outboard. For example, do not mount a tow
sport bars or boarding ladders onto the boat using the mounting
hardware included with the outboard. Installing other products
onto the boat that utilize the outboard mounting hardware will
compromise the ability of that hardware to properly and safely
secure the outboard to the transom.
Outboards that require validated mounting hardware will have
the following decal on the transom clamp.

51965

eng

117

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

118

eng

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
neutralsafetyprotection 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.

eng

119

OUTBOARD INSTALLATION

Low permeation hose is USCG Type B115 or Type A115,

defined as not exceeding 15/gm/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) requires 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
c

46273

a - Fuel demand valve installed

in the fuel hose between the
fuel tank and primer bulb
b - Manual release
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.

120

eng

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, antisiphon
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

18552

a - Minimum transom opening

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

eng

121

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

91904551
Threads into the flywheel to
remove the powerhead
assembly from the driveshaft
housing, or to lift entire engine
for removal/installation.

2756

3. Connect a hoist to the lifting eye.

4. Lift the outboard and place it on the boat transom.
122

eng

OUTBOARD INSTALLATION
Steering Cable Starboard Side Routed Cable
1. Lubricate the Oring seal and the entire cable end.

3724

Tube
Ref No.
95

Description
2-4-C with
PTFE

Where Used

Part No.

O-ring seal and entire cable

end

92-802859A 1

2. Insert the steering cable into the tilt tube.

3725

eng

123

OUTBOARD INSTALLATION
3. Tighten the nut to the specified torque.

3727

Description

lbin.

lbft

Nut

47.5

124

eng

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

60.9 cm
(24 in.)

58.4 cm
(23 in.)
56.0 cm
(22 in.)

53.3 cm
(21 in.)
50.8 cm
(20 in.)

48.2 cm
(19 in.)

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

eng

125

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.

Add 12.7 cm (5 in.) for XL models to the listed outboard mounting

heights.

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.

a - Drill guide holes

b - Transom drilling fixture
c - Transom centerline

2757

126

eng

OUTBOARD INSTALLATION
Transom Drilling Fixture

9198234A2

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
8M0033366

Part Name

Description

Outboard mounting bolt 20 x 5.00 in. long (3.25 in. thread)

82671117

Nylon insert locknut

28421

Flat washer

1.50 in. diameter

54012

Flat washer

0.875 in. diameter

Available Outboard Mounting Bolts

eng

Part Number

Description

67755005

20 x 2.50 in. long (1.25 in. thread)

67755006

20 x 3.50 in. long (1.25 in. thread)

814259

20 x 4.00 in. long (2.25 in. thread)

677551

20 x 4.50 in. long (2.25 in. thread)

8M0033366

20 x 5.00 in. long (3.25 in. thread)

127

OUTBOARD INSTALLATION
Available Outboard Mounting Bolts
Part Number

Description

67755003

20 x 5.50 in. long (3.25 in. thread)

677552

20 x 6.50 in. long (2.75 in. thread)

8M0028080

20 x 7.50 in. long (2.75 in. thread)

8M0032860

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 lbft) 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.

18961

a
a - Transom yielding under bolt torque
b - Transom cracking under bolt torque

128

eng

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.

a
b

33962

a - Large transom washer

b - Transom reinforcement plate

eng

129

OUTBOARD INSTALLATION
FASTENING THE OUTBOARD TO THE TRANSOM
IMPORTANT: The transom mounting surface must be flat within
3.17 mm (0.125 in.). No step in the transom mounting surface is
allowed. The inside transom mounting bolt washer surface must
be flat within 3.17 mm (0.125 in.).

51817

a - Step (not allowed)

b - Gap between transom clamp and boat transom (not
allowed)

130

eng

OUTBOARD INSTALLATION
IMPORTANT: Clearance must be maintained between the
vessel transom and the outboard transom bracket relief radius
area. Failure to maintain clearance may damage the transom
bracket and cause the transom bracket to fail. Adjustments to the
position of the Mercury Marine transom drilling fixture may be
required to ensure proper clearance of the transom bracket relief
radius area.

51867

Installation

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 that 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.

eng

131

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

d
c

b
c
a

40952

abcde-

0.500 in. diameter outboard mounting bolt (4)

0.875 in. flat washer (4)
Nylon insert locknut (4)
1.500 in. flat washer (4)
Marine sealer apply to the shank of the bolts, not the
threads

Description

lbin.

lbft

Outboard mounting locknuts and

bolts standard boat transom

Outboard mounting locknuts and

bolts metal lift plates and setback
brackets

122

132

eng

OUTBOARD INSTALLATION
A decal on the transom bracket reminds the owner to check the
fasteners securing the outboard to the transom before each use.

51985

Decal on the transom bracket

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.

eng

133

OUTBOARD INSTALLATION
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.

134

eng

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

F
TH
SH

c
abcdefghijk-

23638

Flush hose
Grommet
Remote boat harness
Not used
Throttle cable
Fuel hose
Upper alignment pin
SmartCraft harness or additional harness opening
Water pressure tube
Battery cables
Lower alignment pin

5. Install the access cover with two screws. Tighten the screws
to the specified torque.

eng

Description

lbin.

lbft

Access cover screws

7.3

135

OUTBOARD INSTALLATION
6. Attach two cable ties around the grommet tube. Reattach
the cowl seal.

a
23639

a - Cable tie

FLUSH HOSE ROUTING

If desired, the flush hose can be routed outside the cowling as
follows:
1. Using a needlenose pliers, break out the semicircular
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.

a
b

23642

a - Knockout
b - Flush hose
136

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.

eng

Do not use deepcycle 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.

137

OUTBOARD INSTALLATION
Description

lbin.

lbft

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 - Red sleeve
positive (+)
b - Black sleeve
negative ()
c - Cranking battery

a
(+)

(-)

15496

138

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
15497

abcd-

eng

Red sleeve positive (+)

Black sleeve negative ()
Ground cable
Cranking battery

139

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:

140

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

141

OUTBOARD INSTALLATION
2. Remove the plug from the coupler and make the connection.
A barb fitting (22859731) can be installed for larger
diameter hose connection.

a
c

23708

a - Plug
b - Coupler
c - Barb fitting (22859731)

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.

142

eng

OUTBOARD INSTALLATION
Fuel Hose Connection

Fasten the remote fuel hose to the fitting with a hose clamp.

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.

eng

143

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

F N R

23720

a - Distance between pin and center of lower hole

b - Pin
c - Barrel pocket

144

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.

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

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.
eng

145

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.

146

eng

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

d
a

15317

abcde-

Flat washer
Locknut
Barrel retainer
Cable barrel
Cable latch

Oil Injection SetUp

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

147

OUTBOARD INSTALLATION
All Models
Oil tank

Capacity

Fluid Type

4.72 liters (5 US qt)

OptiMax/DFI 2Cycle 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
b

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

148

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 35 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.

eng

149

OUTBOARD INSTALLATION
However, once on plane, the engine should be trimmed to a
more intermediate position to avoid a bowdown 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

1749930A 1
Limits the down trim angle of the
power trim equipped engines, or
aids in determining the trim out
angle on nonpower trim
engines.

2749

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.

150

eng

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

eng

Maintenance Performed

151

Engine Hours

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