Proper care and maintenance is an important part in keeping your Mercury Product operating at
peak efficiency for maximum performance and economy. The enclosed Owner's Registration
Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for
full details of your warranty coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and
full contact information are displayed.
Is your engine properly registered for warranty purpose?
www.marinepower.com. If necessary, please contact your local dealer.
Please
check
on
90-10237061 805
Welcome Aboard!
This outboard motor’s serial number plate contains in the lower corner left hand corner either the
CE mark alone or the CE mark accompanied by a notified body number. This outboard motor
manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park
Industriel, de Petit‑Rechain, Belgium complies with the requirements of the following directives
by meeting the associated standards, as amended:
If the CE mark is accompanied by a notified body number, the following Recreational Craft
Directive applies:
Recreational Craft Directive:
2003/44/EC amending 94/25/EC
Owner's manual (A.2.5)
ISO 10240
Handling characteristics (A.4)
ISO 8665
Outboard engine starting (A.5.1.4)
ISO 11547
Fuel tanks (A.5.2.2)
ISO 13591; ISO 8469
General steering system
ABYC P‑17
Exhaust emission requirements (B.2)
ISO 8178
Owner's manual (B.4)
ISO 8665
Noise emission levels (C.1)
ISO 14509
200/225/250/275 Verado (4-Stroke)
Declaration of Conformity
The notified body responsible for surveillance of the quality system under
Full Quality Assurance Module H of Directive 2003/44/EC is:
Det Norske Veritas
Notified Body Number: 0575
If the CE mark is not accompanied by a notified body number, the following Recreational Craft
Directive language applies:
Recreational Craft Directive:
94/25/EC
Owner's manual (A.2.5)
ISO 10240
Handling characteristics (A.4)
ISO 8665
Outboard engine starting (A.5.1.4)
ISO 11547
Fuel tanks (A.5.2.2)
ISO 13591; ISO 8469
i
© 2005 Mercury Marine
Norway
General steering system
ABYC P‑17
The following applies to all product covered by this manual:
Safety of Machinery Directive
98/37/EC
Principles of safety integration (1.1.2)
EN 292‑1; EN 292‑2; EN 1050
Noise (1.5.8)
ICOMIA 39/94
Vibration
ICOMIA 38/94
Electromagnetic Compatibility Directive 89/336/EC
Generic emission standard
EN 61000‑6‑3
Generic immunity standard
EN 61000‑6‑1
Vehicles, boats and internal combustion
engine driven devices ‑ radio disturbance SAE J551 (CISPR 12)
characteristics
Electrostatic discharge testing
EN 61000‑6‑2; EN 61000‑4‑2; EN
61000‑4‑3
This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe.
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Regulations and Product Safety Department, Mercury Marine,
Fond du Lac, WI USA
ii
TABLE OF CONTENTS
WARRANTY INFORMATION
Transfer Of Warranty.............................................................................................................................. 1
Warranty Registration United States And Canada................................................................................. 1
Warranty Registration Outside The United States And Canada............................................................. 1
FourStroke Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent
States, Middle-East and Africa............................................................................................................... 2
3 Year Limited Warranty Against Corrosion........................................................................................... 3
Warranty Coverage And Exclusions....................................................................................................... 5
General Information
Boater's Responsibilities......................................................................................................................... 7
Before Operating Your Outboard............................................................................................................ 7
Boat Horsepower Capacity..................................................................................................................... 7
High-Speed And High-Performance Boat Operation.............................................................................. 8
Outboard Remote Control Models ......................................................................................................... 8
Lanyard Stop Switch............................................................................................................................... 8
Protecting People In The Water.............................................................................................................. 9
Passenger Safety Message - Pontoon Boats And Deck Boats............................................................ 10
Wave And Wake Jumping.................................................................................................................... 11
Impact With Underwater Hazards......................................................................................................... 11
Exhaust Emissions............................................................................................................................... 12
Selecting Accessories For Your Outboard............................................................................................ 13
Safe Boating Suggestions.................................................................................................................... 14
Recording Serial Number..................................................................................................................... 14
200/225/250/275 Specifications - International..................................................................................... 15
Component Identification...................................................................................................................... 16
Installation
Installing Outboard................................................................................................................................ 17
Propeller Selection................................................................................................................................ 18
Transporting
Trailering Boat/Outboard ..................................................................................................................... 20
Fuel and Oil
Fuel Recommendations........................................................................................................................ 22
Filling Fuel Tank................................................................................................................................... 23
Engine Oil Recommendations.............................................................................................................. 23
Checking And Adding Engine Oil.......................................................................................................... 23
Features and Controls
Remote Control Features..................................................................................................................... 25
Warning System................................................................................................................................... 31
iii
TABLE OF CONTENTS
Power Trim and Tilt............................................................................................................................... 34
Operation
Pre-Starting Check List......................................................................................................................... 37
Operating In Freezing Temperatures.................................................................................................... 37
Operating In Salt Water Or Polluted Water........................................................................................... 37
Engine Break-in Procedure................................................................................................................... 37
Starting The Engine.............................................................................................................................. 37
Gear Shifting......................................................................................................................................... 49
Dual Helm Station Transfer.................................................................................................................. 50
Synchronizing Dual Engines................................................................................................................. 51
Stopping The Engine............................................................................................................................ 52
Remote Control Adjustments................................................................................................................ 52
Maintenance
Outboard Care...................................................................................................................................... 54
EPA Emissions..................................................................................................................................... 54
Inspection And Maintenance Schedule................................................................................................ 55
Flushing The Cooling System............................................................................................................... 56
Cowl Removal and Installation............................................................................................................. 56
Cleaning Care for Top and Bottom Cowls............................................................................................ 58
Battery Inspection ................................................................................................................................ 58
DTS Battery Specifications................................................................................................................... 59
Air Filter................................................................................................................................................ 60
Fuel System.......................................................................................................................................... 62
Corrosion Control Anode...................................................................................................................... 65
Propeller Replacement......................................................................................................................... 65
Spark Plug Inspection and Replacement.............................................................................................. 67
Fuses.................................................................................................................................................... 68
DTS Wiring System.............................................................................................................................. 69
Accessory Drive Belt Inspection........................................................................................................... 69
Checking Power Trim Fluid................................................................................................................... 70
Checking Power Steering Fluid............................................................................................................ 70
Changing Engine Oil ............................................................................................................................ 71
Gearcase Lubrication............................................................................................................................ 74
Storage
Storage Preparation.............................................................................................................................. 76
Protecting External Outboard Components.......................................................................................... 76
Protecting Internal Engine Components............................................................................................... 76
Gearcase.............................................................................................................................................. 77
Positioning Outboard For Storage........................................................................................................ 77
Battery Storage..................................................................................................................................... 77
Troubleshooting
Starter Motor Will Not Crank the Engine............................................................................................... 78
Engine Will Not Start............................................................................................................................. 78
Engine Starts But Will Not Shift Into Gear............................................................................................ 78
Engine Runs Erratically........................................................................................................................ 78
Performance Loss................................................................................................................................. 79
iv
TABLE OF CONTENTS
Battery Will Not Hold Charge................................................................................................................ 79
Owner Service Assistance
Local Repair Service.............................................................................................................................80
Service Away From Home....................................................................................................................80
Parts And Accessories Inquiries...........................................................................................................80
Service Assistance............................................................................................................................... 80
Mercury Marine Service Offices............................................................................................................80
v
vi
WARRANTY INFORMATION
Transfer Of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused
portion of the limited warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase
agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty
registration department. 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 920-929-5893
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.
For products purchased outside the United States and Canada, contact the distributor in your country,
or the Marine Power Service Center closest to you.
Warranty Registration United States And Canada
Outside United States and Canada ‑ Check with your local distributor.
1.
You may change your address at any time, including at time of warranty claim, by calling Mercury
Marine or sending a letter or fax with your name, old address, new address, and engine serial
number to Mercury Marine’s warranty registration department. Your dealer can also process this
change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax 920-929-5893
NOTE: Registration lists must be maintained by Mercury Marine and any dealer on marine products
sold in the United States, should a safety recall notification under the Federal Safety Act be required.
2.
To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the
time of sale, the dealer should complete the warranty registration and immediately submit it to
Mercury Marine via MercNET, E‑mail, or mail. Upon receipt of this warranty registration, Mercury
Marine will record the registration.
3.
Upon processing the warranty registration, Mercury Marine will send registration verification by
mail to the purchaser of the product. If this registration verification is not received within 30 days,
please contact your selling dealer immediately. Warranty coverage is not effective until your
product is registered with Mercury Marine.
Warranty Registration Outside The United States And Canada
1.
It is important that your selling dealer fills out the Warranty Registration Card completely and mails
it to the distributor or Marine Power Service Center responsible for administering the warranty
registration/claim program for your area.
2.
The Warranty Registration Card identifies your name and address, product model and serial
numbers, date of sale, type of use and the selling distributor's/dealer's code number, name and
address. The distributor/dealer also certifies that you are the original purchaser and user of the
product.
1
WARRANTY INFORMATION
3.
A copy of the Warranty Registration Card, designated as the Purchaser's Copy, MUST be given
to you immediately after the card has been completely filled out by the selling distributor/dealer.
This card represents your factory registration identification, and should be retained by you for
future use when required. Should you ever require warranty service on this product, your dealer
may ask you for the Warranty Registration Card to verify date of purchase and to use the
information on the card to prepare the warranty claim forms.
4.
In some countries, the Marine Power Service Center will issue you a permanent (plastic) Warranty
Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration
Card from your distributor/dealer. If you receive a plastic Warranty Registration Card, you may
discard the Purchaser's Copy that you received from the distributor/dealer when you purchased
the product. Ask your distributor/dealer if this plastic card program applies to you.
IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law.
It is our desire to have ALL products registered at the factory should it ever be necessary to contact
you. Make sure your dealer/distributor fills out the warranty registration card immediately and sends the
factory copy to the Marine Power International Service Center for your area.
5.
For further information concerning the Warranty Registration Card and its relationship to Warranty
Claim processing, refer to the International Warranty.
FourStroke Outboard Limited Warranty United States, Canada,
Europe, Confederation of Independent States, Middle‑East and
Africa
Outside the United States, Canada, Europe, Confederation of Independent States, Middle‑East and
Africa ‑ check with your local distributor.
WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet 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 in 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 re–registration of the product. Unexpired warrant
coverage cannot be transferred either to or from a commercial use customer.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty
coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine
to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine
specified pre–delivery inspection process is completed and documented. Warranty coverage becomes
available upon proper registration of the product by the authorized dealer. 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 future warranty coverage contingent on 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.
2
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 routine maintenance items, tune ups,
adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear
ratio that does not allow the engine to run in its recommended wide open throttle RPM range (see the
Operation and Maintenance Manual), operation of the product in a manner inconsistent with the
recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident,
submersion, improper installation (proper installation specifications and techniques are set forth in the
installation instructions for the product), improper service, use of an accessory or part not manufactured
or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable
for use with the product (see the Operation and Maintenance Manual), alteration or removal of parts, or
water entering the engine through the fuel intake, air intake or exhaust system, or damage to the product
from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the
engine out of water, mounting the engine too high on the transom, or running the boat with the engine
trimmed out too far.. Use of the product for racing or other competitive activity, or operating with a racing
type lower unit, at any point, even by a prior owner of the product, voids the warranty.
Expenses related to haul out, launch, towing, storage, telephone, rental, inconvenience, slip fees,
insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or
consequential damages are not covered by this warranty. Also, expenses associated with the removal
and/or replacement of boat partitions or material caused by boat design for access to the product are
not covered by this warranty.
No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury
Marine to make any affirmation, representation or warranty regarding the product, other than those
contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
For additional information regarding events and circumstances covered by this warranty, and those that
are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by
reference into this warranty.
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT
THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE
LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO
NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS
IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS
WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND
COUNTRY TO COUNTRY.
3 Year Limited Warranty Against Corrosion
WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport
Jet, M2 Jet Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser Inboard or Sterndrive
Engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time
described below.
3
WARRANTY INFORMATION
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 (non‑commercial use) purchaser upon proper re‑registration of the product.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty
coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine
to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine
specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes
available upon proper registration of the product by the authorized dealer. Corrosion prevention devices
specified in the Operation and Maintenance Manual must be in use on the boat, and routine maintenance
outlined in the Operation and Maintenance Manual must be timely performed (including without limitation
the replacement of sacrificial anodes, use of specified lubricants, and touch‑up of nicks and scratches)
in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage
contingent upon proof of proper maintenance.
WHAT MERCURY WILL DO: Mercury's sole and exclusive obligation under this warranty is limited to,
at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine certified
re‑manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the
right to improve or modify products from time to time without assuming an obligation to modify products
previously manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable
opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall
be made by delivering the product for inspection to a Mercury dealer authorized to service the product.
If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We
will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related
transportation charges and/or travel time. If the service provided is not covered by this warranty,
purchaser shall pay for all related labor and material, and any other expenses associated with that
service. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly
to Mercury. Proof of registered ownership must be presented to the dealer at the time warranty service
is requested in order to obtain coverage.
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.
Corrosion damage caused by stray electrical currents (on‑shore power connections, nearby boats,
submerged metal) is not covered by this corrosion warranty and should be protected against by the use
of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system
and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling
paints is also not covered by this limited warranty. If anti‑fouling protection is required,
Tri‑Butyl‑Tin‑Adipate (TBTA) base anti‑fouling 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.
4
WARRANTY INFORMATION
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT
THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE
LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO
NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS
IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. 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.
Warranty Coverage And Exclusions
The purpose of this section is to help eliminate some of the more common misunderstandings regarding
warranty coverage. The following information explains some of the types of services that are not covered
by warranty. The provisions set forth following have been incorporated by reference into the Three Year
Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United
States and Canada Limited Outboard Warranty.
Keep in mind that warranty covers repairs that are needed within the warranty period because of defects
in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes
that affect the product are not covered.
Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in
the country to which distribution is authorized by us.
Should you have any questions concerning warranty coverage, contact your authorized dealer. They will
be pleased to answer any questions that you may have.
GENERAL EXCLUSIONS FROM WARRANTY
1.
Minor adjustments and tune‑ups, including checking, cleaning or adjusting spark plugs, ignition
components, carburetor settings, filters, belts, controls, and checking lubrication made in
connection with normal services.
2.
Factory installed jet drive units ‑ Specific parts excluded from the warranty are: The jet drive
impeller and jet drive liner damaged by impact or wear, and water damaged drive shaft bearings
as a result of improper maintenance.
3.
Damage caused by neglect, lack of maintenance, accident, abnormal operation or improper
installation or service.
4.
Haul out, launch, towing charges, removal and/or replacement of boat partitions or material
because of boat design for necessary access to the product, all related transportation charges
and/or travel time, etc. Reasonable access must be provided to the product for warranty service.
Customer must deliver product to an authorized dealer.
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 following
circumstances: When performed on emergency basis (providing there are no authorized dealers
in the area who can perform the work required or have no facilities to haul out, etc., and prior
factory approval has been given to have the work performed at this facility).
7.
All incidental and/or consequential damages (storage charges, telephone or rental charges of any
type, inconvenience or loss of time or income) are the owner's responsibility.
8.
Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.
9.
Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility
unless loss or contamination of same is caused by product failure that would be eligible for
warranty consideration.
5
WARRANTY INFORMATION
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.
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.
6
GENERAL INFORMATION
Boater's Responsibilities
The operator (driver) is responsible for the correct and safe operation of the boat and safety of its
occupants and general public. It is strongly recommended that each operator (driver) read and
understand this entire manual before operating the outboard.
Be sure at least one additional person on board is instructed in the basics of starting and operating the
outboard and boat handling in case the driver is unable to operate the boat.
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
DANGER ‑ indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury.
! WARNING
WARNING ‑ indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury.
! CAUTION
CAUTION ‑ indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury or property damage. It may also be used to alert against unsafe practices.
Boat Horsepower Capacity
! WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1) cause loss of boat
control 2) place too much weight at the transom altering the designed flotation characteristics of the
boat or 3) cause the boat to break apart particularly around the transom area. Overpowering a boat
can result in serious injury, death or boat damage.
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.
7
GENERAL INFORMATION
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS)
XXX
MAXIMUM WEIGHT
CAPACITY
XXX
ob00306
High‑Speed And High‑Performance Boat Operation
If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar,
we recommend that you never operate it at its high speed capability without first requesting an initial
orientation and familiarization demonstration ride with your dealer or an operator experienced with your
boat/outboard combination. For additional information, obtain a copy of our Hi‑Performance Boat
Operation booklet from your dealer, distributor, or Mercury Marine.
ob00307
Outboard Remote Control Models
The outboard must be equipped with a Mercury remote control designed for digital throttle and shift.
Start‑in‑gear protection is provided by the remote control system.
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.
The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when stretched out, with
an element on one end made to be inserted into the switch and a snap on the other end for attaching to
the operator. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the
likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the
likelihood of accidental activation should the operator choose to move around in an area close to the
normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the
operator's wrist or leg, or tie a knot in the lanyard.
a
b
ob00310
a-
Lanyard cord
b-
8
Lanyard stop switch
GENERAL INFORMATION
Read the following Safety Information before proceeding.
Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the
operator moves far enough away from the operator's position to activate the switch. This would occur if
the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's
position. Falling overboard and accidental ejections are more likely to occur in certain types of boats
such as low sided inflatables, bass boats, high performance boats, and light, sensitive handling fishing
boats operated by a hand tiller. Falling overboard and accidental ejections are also likely to occur as a
result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds,
standing at planing speeds, sitting on elevated fishing boat decks, operating at planing speeds in shallow
or obstacle infested waters, releasing your grip on a steering wheel or tiller handle that is pulling in one
direction, drinking alcohol or consuming drugs, or daring high speed boat maneuvers.
While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast
for some distance depending upon the velocity and degree of any turn at shut down. However, the boat
will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path
as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting and operating procedures
should they be required to operate the engine in an emergency (e.g. if the operator is accidentally
ejected).
! WARNING
Should the operator fall out of the boat, the possibility of serious injury or death from being run over
by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both
ends of the stop switch lanyard to the stop switch and the operator.
! WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop
switch activation. 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.
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.
ob00311
Always slow down and exercise extreme caution any time you are boating in an area where there might
be people in the water.
9
GENERAL INFORMATION
Whenever a boat is moving (coasting) and the outboard gear shift is in neutral position, there is sufficient
force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can
cause serious injury.
WHILE BOAT IS STATIONARY
! WARNING
Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the
person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or
any solid device rigidly attached to a moving boat or gearcase.
Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near
your boat.
Passenger Safety Message ‑ Pontoon Boats And Deck Boats
Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to
stand or use seats other than those designated for traveling faster than idle speed. 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.
ob00312
! WARNING
Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run
over. Stay back from the front end of the deck and remain seated while the boat is in motion.
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.
10
GENERAL INFORMATION
ob00313
Wave And Wake Jumping
Operating recreational boats over waves and wake is a natural part of boating. However, when this
activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain
hazards arise, particularly when the boat re‑enters the water.
ob00314
The primary concern is the boat changing direction while in the midst of the jump. In such case the landing
may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause
occupants to be thrown out of their seats, or out of the boat.
! WARNING
Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a
wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake
or wave jump occurs, get low and hang on to a boat hand hold.
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).
11
GENERAL INFORMATION
ob00315
! WARNING
To avoid serious injury or death from all or part of an outboard coming into the boat after striking a
floating or underwater obstacle maintain a top speed no greater than minimum planing speed.
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.
•
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
Avoid serious injury or death from loss of boat control. Continued boating with major impact damage
can result in sudden outboard component failure with or without subsequent impacts. Have the
outboard thoroughly inspected and any necessary repairs made.
Exhaust Emissions
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide is present in the exhaust fumes of all internal combustion engines. This includes the
outboards, sterndrives and inboard engines that propel boats, as well as the generators that power
various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or
intoxication, include headache, dizziness, drowsiness, and nausea.
! WARNING
Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon
monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death.
12
GENERAL INFORMATION
GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches to remove fumes.
ob00316
Example of desired air flow through the boat
POOR VENTILATION
Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or
cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide
detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an enclosed area of
a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon
monoxide.
WHILE BOAT IS STATIONARY
a
b
ob00317
a-
Running the engine when the boat is
moored in a confined space
b-
Mooring close to another boat that has its
engine running
WHILE BOAT IS MOVING
a
b
ob00318
a-
Running the boat with the trim angle of
the bow too high
b-
Running the boat with no forward
hatches open
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.
13
GENERAL INFORMATION
! WARNING
Check with your dealer before installation of accessories. The misuse of acceptable accessories or
the use of unacceptable accessories can result in serious injury, death, or product failure.
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with
your outboard or outboard operating system. Acquire and read the installation, operation, and
maintenance manuals for all your selected accessories.
Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating
regulations and restrictions, and consider the following suggestions.
Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard
(it is the law) and have it readily accessible.
Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer
to your boat capacity plate). If in doubt, contact your dealer or the boats manufacturer.
Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs
are properly made.
Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating
safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power
Squadron, 3) The Red Cross and 4) your state boating law enforcement agency. Inquiries may be made
to the Boating Hotline, 1‑800‑368‑5647 or the Boat U.S. Foundation information number
1‑800‑336‑BOAT.
Make sure everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the
boat that was not intended for such use. This includes the back of seats, gunwales, transom, bow, decks,
raised fishing seats, any rotating fishing seat; or anywhere that an unexpected acceleration, sudden
stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown
overboard or into the boat.
Never be under the influence of alcohol or drugs while boating (it is the law). Alcohol or drug use impairs
your judgment and greatly reduces your ability to react quickly.
Prepare other boat operators. Instruct at least one other person on board in the basics of starting and
operating the outboard, and boat handling, in case the driver becomes disabled or falls overboard.
Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the
back (stern) of the boat. Just shifting the outboard into neutral is not sufficient.
Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing.
The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing
seats should block the operators view when operating the boat above idle speed.
Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat
traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft.) in front of you in 5 seconds.
Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or
down skier on the operator's side of the boat while returning to assist the skier. The operator should
always have the down skier in sight and never back up to the skier or anyone in the water.
Report accidents. Boat operators are required by law to file a Boating Accident Report with their state
boating law enforcement agency when their boat is involved in certain boating accidents. A boating
accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury
requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the
damage value exceeds $500.00 or 4) there is complete loss of the boat. Seek further assistance from
local law enforcement.
Recording Serial Number
It is important to record this number for future reference. The serial number is located on the outboard
as shown.
14
GENERAL INFORMATION
a
Serial Number
OTXXXXXX
b
20XX
XXXX
H
P
L
B
e
MAX
RPM
K
W
K
G
c
d
XX
ob01322
abc-
Serial number
Model year
Model designation
de-
Year manufactured
Certified Europe Insignia (as applicable)
200/225/250/275 Specifications ‑ International
Models
200/225/250/275
Horsepower
200/225/250/275
Kilowatts
149/168/186/205
Full Throttle RPM Range
5800‑6400
Idle Speed in Neutral Gear1.
550 RPM
Number of Cylinders
6
Piston Displacement
2,598 cc (158.5 cid)
Cylinder Bore
82 mm (3.23 in.)
Stroke
82 mm (3.23 in.)
Recommended Spark Plug
NGK ILFR6G
Spark Plug Gap
0.8 mm (0.0315 in.)
Spark Plug Hex Size
16 mm
Gear Ratio
1.85:1
Recommended Gasoline
Refer to Fuel & Oil
Recommended Oil
Refer to Fuel & Oil
Right Hand Rotation Gearcase
Lubricant Capacity
970 ml (32.8 fl. oz.)
Left Hand Rotation Gearcase
Lubricant Capacity
900 ml (30.4 fl. oz.)
1. With engine fully warmed up.
15
GENERAL INFORMATION
Models
200/225/250/275
Engine Oil Capacity With Oil
Filter Replacement
7.0 liters (7.4 qt)
1000 Marine Cranking Amps (MCA), 800 Cold
Cranking AMPS (CCA) or 180 Ampere Hour
(Ah)
Battery Rating
Sound at Drivers Ear (ICOMIA
39‑94)
4‑Stroke
79.6
Component Identification
j
i
a
h
b
g
f
c
e
d
abcde-
ob01302
Rear cowl
Lower cowl chaps
Anti‑ventilation plate
Gearcase
Cooling water intake holes
fghij-
16
Spray plate
Pedestal
Engine flush
Auxiliary tilt switch
Top cowl
INSTALLATION
Installing Outboard
! WARNING
Before operation, the outboard must be correctly installed with the required mounting hardware as
shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing
serious injury, death, or property damage.
IMPORTANT: For optimum boat performance and detailed engine installation instructions, refer to the
outboard installation manual, supplied with the outboard.
We strongly recommend that your dealer install your outboard and related accessories to ensure proper
installation and good performance. If you install the outboard yourself, follow instructions in the Outboard
Installation Manual which is provided with the outboard.
The outboard must be secured to the boat transom with the four 12.7 mm (1/2 in.) diameter mounting
bolts, locknuts and washers provided. Install two bolts through the upper set of mounting holes and two
bolts through the lower set of mounting slots.
ob01306
MAXIMUM OUTBOARD MOUNTING HEIGHT
The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76.2 cm (30 in.) for
XL models and 88.9 cm (35 in.) for XXL models. Mounting the outboard higher may cause damage to
the gearcase components.
17
INSTALLATION
ob01312
Maximum Static Waterline
The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE" mark on the idle
relief grommet (located at the rear of the outboard) when the outboard is fully tilted in/down. If waterline
is above "MAX STATIC WATERLINE" mark, adjust boat load forward or increase (raise) outboard
mounting height to correctly place mark above waterline.
MAX STATIC
WATERLINE
4224
Propeller Selection
For best all around performance from your outboard/boat combination, select a propeller that allows the
engine to operate in the upper half of the recommended full throttle RPM range with the boat normally
loaded (refer to General Information ‑ Specifications). This RPM range allows for better acceleration
while maintaining maximum boat speed.
ob00323
If changing conditions cause the RPM to drop below the recommended range, such as warmer, more
humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a
propeller change or cleaning may be required to maintain performance and ensure the outboards
durability.
18
INSTALLATION
Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a
balanced‑steering condition (steering effort equal in both directions) without causing the propeller to
break loose.
19
TRANSPORTING
Trailering Boat/Outboard
When transporting the boat on a trailer, the outboard should be positioned and/or supported in one of
the following ways:
1.
If the boat trailer provides sufficient ground clearance, the outboard may be tilted down to the
vertical operating position with no additional support required.
2.
If additional ground clearance is required, the outboard should be tilted up and supported using
the outboard's tilt support bracket (trailering position) and/or an accessory transom support
device. Refer to Features and Controls ‑ Tilting Operation.
ob01268
ob01307
3.
For maximum ground clearance, the outboard can be tilted to the full tilt position and supported
using the outboards tilt support bracket and/or an accessory transom support device.
20
TRANSPORTING
ob01267
Additional clearance may be required for railroad crossings, driveways and trailer bouncing. Refer to
your local dealer for recommendations.
IMPORTANT: Do not rely on the power trim/tilt system to maintain proper ground clearance for trailering.
The power trim/tilt system is not intended to support the outboard for trailering.
Shift the outboard to forward gear. This prevents the propeller from spinning freely when boat is trailered.
21
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 ‑ Model 275: Having a posted pump Octane Rating of 92 (R+M)/2 Octane is required
for best performance. Having a posted pump Octane Rating of 87 (R+M)/2 minimum is acceptable,
however performance losses may occur. Do NOT use leaded gasoline.
Outside USA and Canada ‑ Model 275: Having a posted pump Octane Rating of 96 RON is required for
best performance. Having a posted pump Octane Rating of 90 RON minimum is acceptable, however
performance losses may occur. If unleaded gasoline is not available, use a major brand of leaded
gasoline.
USA and Canada ‑ Models 200/225/250: 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 ‑ Models 200/225/250: Having a posted pump Octane Rating of 90 RON
minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a
major brand of leaded gasoline.
USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)
This type of gasoline is required in certain areas of the USA. The 2 types of oxygenates used in these
fuels are Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the
gasoline in your area, refer to Gasolines Containing Alcohol.
These Reformulated Gasolines are acceptable for use in your Mercury Marine engine.
GASOLINES CONTAINING ALCOHOL
If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you
should be aware of certain adverse effects that can occur. These adverse effects are more severe with
methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from
the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank.
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
FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system can be a fire and
explosion hazard which can cause serious bodily injury or death. Careful periodic inspection of entire
fuel system is mandatory, particularly after storage. All fuel components should be inspected for
leakage, softening, hardening, swelling or corrosion. Any sign of leakage or deterioration requires
replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol‑free
gasoline be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol
is unknown, increased inspection frequency for leaks and abnormalities is required.
22
FUEL AND OIL
IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of
gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats,
create unique problems. In cars, alcohol‑blend fuels normally are consumed before they can absorb
enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place.
In addition, internal corrosion may take place during storage if alcohol has washed protective oil films
from internal components.
Filling Fuel Tank
! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and do not
smoke or allow open flames or sparks in the area while filling fuel tanks.
Fill fuel tanks outdoors away from heat, sparks, and open flames.
Remove portable fuel tanks from boat to refill them.
Always stop engine before refilling tanks.
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.
PORTABLE FUEL TANK PLACEMENT IN THE BOAT
Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating
conditions.
Engine Oil Recommendations
Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 multi‑viscosity 4‑Stroke Outboard
Oil is recommended for general, all‑temperature use. If the recommended Mercury or Quicksilver NMMA
FC‑W certified oil is not available, a major brand of NMMA FC‑W certified 4‑Stroke Outboard Oil of similar
viscosity may be used.
IMPORTANT: The use of non‑detergent oils, multi‑viscosity oils (other than Mercury or Quicksilver
NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils or
oils that contain solid additives are not recommended.
4-STROKE ENGINE OIL
OIL CAPACITY: 7.0L (7.4 U.S. qt.)
SAE 25W-40
+49
+38
+27
+16
+4
-7
-18
+120
+100
+80
+60
+40
+20
0
C
F
7.0L
37
-8
9
1
53
5-
00
1
3435
Checking And Adding Engine Oil
IMPORTANT: Do not overfill. Tilt outboard out/up past vertical for approximately one minute to allow
trapped oil to drain back to the oil sump. Tilt outboard to vertical (not tilted) position when checking engine
oil. For accurate readings, check oil only when engine is cold or after engine has not run for at least an
hour.
1.
Before starting (cold engine) tilt outboard out/up past vertical to allow trapped oil to drain back to
the oil sump. Allow outboard to remain tilted for approximately one minute.
2.
Tilt outboard to vertical operating position.
23
FUEL AND OIL
3.
Remove the top cowl. Refer to Maintenance ‑ Cowl Removal And Installation.
4.
Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the
way.
5.
Pull the dipstick back out again and observe the oil level. Oil should be in the operating range
(cross hatched region).
IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil
level is correct as long as it appears in the operating range (cross hatched region).
a
a6.
15730
Oil level operating range
If the oil level is below the operating range (cross hatched region), remove the oil filler cap and
add approximately 500 ml (16 oz.) of specified outboard motor oil. Allow a few minutes for the
added oil to drain to the oil sump and recheck the dipstick. Repeat the process until oil level is on
the operating range (cross hatched region). Do not try to fill to the upper end of the operation
range (cross hatched region).
ob01250
IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color
to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the
engine checked by your dealer.
7.
Push the dipstick back in all the way.
8.
Reinstall the oil fill cap hand tight.
9.
Reinstall top cowl.
24
FEATURES AND CONTROLS
Remote Control Features
PANEL MOUNT FEATURES
d
c
e
b
-
+
f
h
a
3409
g
abcd-
Lanyard/lanyard stop switch ‑ Refer to
General Information ‑ Lanyard Stop
Switch.
Control handle – Forward (F), Neutral
(N), Reverse (R).
Shift lock ‑ Refer to Operation ‑ Gear
Shifting.
Trim/tilt switch ‑ Refer to Power Trim
and Tilt.
e-
fgh-
25
Throttle only button ‑ Allows the boat
operator to increase engine RPM for
warm‑up, without shifting the engine into
gear.
Stop/start button ‑ Allows the boat
operator to start or stop the engine
without using the ignition key.
Detent tension adjustment ‑ Refer to
Operation ‑ Remote Control
Adjustments.
Control handle friction adjustment
screw ‑ Refer to Operation ‑ Remote
Control Adjustments.
FEATURES AND CONTROLS
CONSOLE MOUNT FEATURES - SINGLE ENGINE
b
d
e
-
a
+
h
c
abcde-
f
g
Control handle ‑ Forward (F), Neutral
(N), Reverse (R).
Trim/tilt switch ‑ Refer to Power Trim
and Tilt.
Active light ‑ Illuminated when remote
control is active and ready.
Neutral light ‑ Illuminated when engine
is in neutral gear position. Blinks when
engine is in throttle only mode.
Select key ‑ Used to select System
View on‑screen options, if equipped.
Refer to System View Operation
Manual for screen options.
3410
f-
g-
hi-
26
i
Arrow trackpad ‑ Used to scroll through
System View displays, if equipped. Refer
to System View Operation Manual for
screen options.
Throttle only/station select key ‑ Allows
the boat operator to increase engine
RPM for warm‑up, without shifting the
engine into gear. Allows the boat
operator to select which station will be
used for dual helm applications. Refer to
Operation ‑ Starting The Engine.
Detent tension adjustment ‑ Refer to
Operation ‑ Remote Control
Adjustments.
Control handle friction adjustment
screw ‑ Refer to Operation ‑ Remote
Control Adjustments.
FEATURES AND CONTROLS
CONSOLE MOUNT FEATURES - DUAL ENGINE
b
d
i
a
SYNC
ACTIVE
f
THROTTLE
ONLY
STATION SELECT
c
h
bcde-
+
j
e
a-
-
Trim/tilt switch ‑ Refer to Power Trim
and Tilt.
Control handles ‑ Forward (F), Neutral
(N), Reverse (R).
Active light ‑ Illuminated when remote
control is active and ready to use.
Neutral light ‑ Illuminated when engine
is in neutral gear position. Blinks when
engine is in throttle only mode.
Select key ‑ Used to select System
View on‑screen options, if equipped.
Refer to System View Operation
Manual for screen options.
g
f-
gh-
ij-
27
3411
Arrow trackpad ‑ Used to scroll through
System View displays, if equipped. Refer
to System View Operation Manual for
screen options.
Sync light ‑ Illuminated when the auto
synchronizing feature is engaged. Refer
to Operation ‑ Starting The Engine.
Throttle only/station select key ‑ Allows
the boat operator to increase engine
RPM for warm‑up, without shifting the
engine into gear. Allows the boat
operator to select which station will be
used for dual helm applications. Refer to
Operation ‑ Starting The Engine.
Detent tension adjustment ‑ Refer to
Operation ‑ Remote Control
Adjustments.
Control handle friction adjustment
screw ‑ Refer to Operation ‑ Remote
Control Adjustments.
FEATURES AND CONTROLS
SLIM BINNACLE CONSOLE MOUNT FEATURES - SINGLE ENGINE
b
a
d
+
e
g
START
STOP
c
abcd-
f
Control handle ‑ Forward (F), Neutral
(N), Reverse (R).
Trim/tilt switch ‑ Refer to Power Trim
and Tilt.
Active light ‑ Illuminated when remote
control is active and ready.
Neutral light ‑ Illuminated when engine
is in neutral gear position. Blinks when
engine is in throttle only mode.
ef-
gh-
28
h
14637
Start/stop button ‑ Allows the boat
operator to start or stop the engine
without using the ignition key.
Throttle only/station select key ‑ Allows
the boat operator to increase engine
RPM for warm‑up, without shifting the
engine into gear. Allows the boat
operator to select which station will be
used for dual helm applications. Refer to
Operation ‑ Starting The Engine.
Detent tension adjustment ‑ Refer to
Operation ‑ Remote Control
Adjustments.
Control handle friction adjustment
screw ‑ Refer to Operation ‑ Remote
Control Adjustments.
FEATURES AND CONTROLS
SHADOW MODE REMOTE CONTROL FEATURES
b
a
d
e
NEUTRAL
i
+
f
SELECT
SYNC
ACTIVE
THROTTLE
ONLY
j
STATION SELECT
c
g
h
abcde-
14642
Trim/tilt switch ‑ Refer to Power Trim
and Tilt.
Control handle ‑ Forward (F), Neutral
(N), Reverse (R).
Active light ‑ Illuminated when remote
control is active and ready.
Neutral light ‑ Illuminated when engine
is in neutral gear position. Blinks when
engine is in throttle only mode.
Select key ‑ Used to select System
View on‑screen options, if equipped.
Refer to System View Operation
Manual for screen options.
f-
gh-
ij-
Arrow trackpad ‑ Used to scroll through
System View displays, if equipped. Refer
to System View Operation Manual for
screen options.
Sync light ‑ Illuminated when the auto
synchroning feature is engaged. Refer to
Operation ‑ Starting The Engine.
Throttle only/station select key ‑ Allows
the boat operator to increase engine
RPM for warm‑up, without shifting the
engine into gear. Allows the boat
operator to select which station will be
used for dual helm applications. Refer to
Operation ‑ Starting The Engine.
Detent tension adjustment ‑ Refer to
Operation ‑ Remote Control
Adjustments.
Control handle friction adjustment
screw ‑ Refer to Operation ‑ Remote
Control Adjustments.
Throttle and Shift Operation
Movement of the handles on the remote control allows the boat operator to control the engine throttle
speed and gear shift positions of all three engines.
The throttle and shift function is dependant on what engines are running. Refer to the following table.
29
FEATURES AND CONTROLS
Port Engine
Center Engine
Starboard Engine
Control Handle
Function
Port engine throttle
and shift = controlled
by port control
handle
Running
Running
Running
Starboard engine
throttle and shift =
controlled by
starboard control
handle
Center engine
throttle = average of
port and starboard
engines
Center engine shift =
neutral unless both
engines are in the
same gear
Running
Off
Running
Running
Off
Port and center
engine throttle and
shift = controlled by
port control handle
Running
Starboard and
center engine
throttle and shift =
controlled by
starboard control
handle
Port engine throttle
and shift = controlled
by port control
handle
Running
Running
Off
Off
Running
Starboard engine
throttle and shift =
controlled by
starboard control
handle
Port engine throttle
and shift = controlled
by port control
handle
Off
30
FEATURES AND CONTROLS
Port Engine
Off
Center Engine
Off
Off (ignition key
switch turned on)
Running
Starboard Engine
Control Handle
Function
Running
Starboard engine
throttle and shift =
controlled by
starboard control
handle
Off (ignition key
switch turned on)
Center engine
throttle and shift =
neutral/idle unless
both control handles
are in the same gear
Turning off one of the outer engines while underway will cause the center engine to go into forced neutral/
idle. Operation to the center engine can be restored by moving the control handle of the functioning outer
engine back into neutral position and then re‑engaging. The center engine speed and gear shift will then
be controlled by the functioning outer engine.
Turning off the center engine while underway will have no effect on the operation of the outer engines.
If a failure should occur while underway which causes one of the outer engines into forced neutral/idle
condition, the center engine will also be forced to neutral/idle. Operation to the center engine can be
restored by moving the control handle of the functioning outer engine back into neutral and then
re‑engaging.
Operation of the shift and throttle is controlled by the movement of the control handles. Push the control
handles forward from the neutral to the first detent for forward gear. Continue pushing the control handles
forward to increase speed. Pull the control handles back from neutral to the first detent for reverse gear.
Continue pulling back to increase speed.
Warning System
WARNING HORN SIGNALS
When the key switch is turned to the "ON" position, the horn (located on the command module harness)
will turn on for a moment as a test to indicate the horn is working.
The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator
and help identify the following listed situations. For visual display of the specific engine functions and for
additional engine data, refer to SmartCraft Product information, following.
Warning Horn
Function
Sound
Description
Start up
Single beep
Normal system test
Water in fuel
Four beeps every 2
minutes
Water in engine mounted
fuel filter. Refer to
Maintenance ‑ Water
Separating Fuel Filter.
31
FEATURES AND CONTROLS
Warning Horn
Function
Sound
Description
Low battery
Four beeps every 2
minutes
Battery charging unable to
keep up with demand.
Raise engine speed, to
increase charge, or shut
down accessories, to
reduce demand.
Cooling system problem
Continuous
Engine Guardian System
is activated. Power limit
will vary with level of
overheat. Shift outboard
into neutral and check for
a steady stream of water
coming out of the water
pump indicator hole. If no
water is coming out of the
water pump indicator hole
or flow is intermittent, stop
engine and check water
intake holes for
obstruction.
Oil pressure low
Continuous
Engine Guardian System
is activated. Power limit
will vary depending on
available oil pressure.
Stop engine and check oil
dipstick. Add oil if
necessary. Refer to Fuel
and Oil ‑ Checking and
Adding Engine Oil.
32
FEATURES AND CONTROLS
Warning Horn
Function
Sound
Description
Engine overspeed
Continuous
The warning horn is
activated any time the
engine speed exceeds the
maximum allowable RPM.
The system will limit the
engine speed to within the
allowable range. Engine
overspeed indicates a
condition that should be
corrected. Overspeed
could be caused by
incorrect propeller pitch,
engine height, trim angle,
tilt angle (shallow water
operation) etc.
Engine communication/
Remote control failure
Intermittent beep
Engine Guardian System
is activated. Power limit
will restrict engine speed
to idle.
Single beep (engine
running)
May be a problem with
one of the engine
functions. Have your
dealer check the engine
soon.
Continuous
Engine Guardian System
is activated. Power limit
will restrict engine speed
to either idle or 75%,
depending on fault.
Sensor/Actuator out of
range
ENGINE GUARDIAN SYSTEM
The Engine Guardian System monitors the critical sensors on the engine for any early indications of
problems. The system will respond to a problem by emitting a continuous beep and/or reducing engine
power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The problem will need to be identified
and corrected, if possible. 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 system.
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, oil pressure, water
pressure, 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.
33
FEATURES AND CONTROLS
Power Trim and Tilt
The 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 trimming down. Moving the outboard further away from the boat transom is called
trimming out or trimming 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 the boat on plane. The term tilt is generally
used when referring to adjusting the outboard further up out of the water. With the engine not running
and the key switch in the "ON" position, the outboard can be tilted out of the water. At low idle speed
(2000 RPM and below), the outboard can also be tilted up past the trim range to permit shallow water
operation.
a
b
c
ab-
Trim switch
Tilt range of travel
c-
ob01303
Trim range of travel
POWER TRIM OPERATION
With most boats, operating around the middle of the trim range will give satisfactory results. However,
to take full advantage of the trimming capability there may be times when you choose to trim the outboard
all the way in or out. Along with an improvement in some performance aspects comes a greater
responsibility for the operator, this being an awareness of some potential control hazards.
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.
•
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 over‑steering) if any turn is attempted, or if a significant wave is
encountered.
! WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as
boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when
on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel.
2.
Trimming Out or Up can:
34
FEATURES AND CONTROLS
•
Lift the bow higher out of the water.
•
Generally increase top speed.
•
Increase clearance over submerged objects or a shallow bottom.
•
In excess can cause boat porpoising (bouncing) or propeller ventilation.
•
Cause engine overheating if any cooling water intake holes are above the water line.
TILTING TO FULL UP POSITION
Tilt At Helm
NOTE: The trim/tilt switch will remain active for 15 minutes after the ignition key switch has been turned
off.
1.
If the ignition key switch has been turned off for over 15 minutes, turn it to the "ON" position.
2.
Press the trim/tilt switch to the up position. The outboard will tilt up until the switch is released or
it reaches its maximum tilt position.
Tilt At Engine
The cowl mounted auxiliary tilt switch can be used to tilt the outboard with the key switch in the "OFF"
position.
Tilt Support Lever
1.
Rotate the tilt support lever down.
2.
Lower outboard until tilt support bracket rests on the pedestal.
3.
Disengage the tilt support bracket, by raising the outboard up and rotating the tilt support lever
up. Lower the outboard.
b
a
ob01305
a-
Tilt support lever
b-
Tilt support bracket
MANUAL TILTING
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
35
FEATURES AND CONTROLS
ob01143
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the
outboard from tilting up during reverse operation.
1.
Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the
outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve.
AUXILIARY TILT SWITCH
The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.
ob01309
SHALLOW WATER OPERATION
When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range
to prevent hitting bottom.
1.
Reduce engine speed below 2000 RPM.
2.
Tilt outboard up. Make sure all the water intake holes stay submerged at all times.
3.
Operate the engine at slow speed only. With the outboard tilted past 20° trim limit, the warning
horn will sound and engine speed will be automatically limited to approximately 2000 RPM. The
outboard must be tilted (trimmed) down below the maximum trim range to allow operation above
2000 RPM.
36
OPERATION
Pre‑Starting Check List
•
Operator knows safe navigation, boating, and operating procedures.
•
An approved personal flotation device of suitable size for each person aboard and readily
accessible (it is the law).
•
A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.
•
Know your boats maximum load capacity. Look at the boat capacity plate.
•
Fuel supply OK.
•
Arrange passengers and load in the boat so the weight is distributed evenly and everyone is
seated in a proper seat.
•
Tell someone where you are going and when you expect to return.
•
It is illegal to operate a boat while under the influence of alcohol or drugs.
•
Know the waters and area you will be boating; tides, currents, sand bars, rocks, and other hazards.
•
Make inspection checks listed in Maintenance ‑ Inspection and Maintenance Schedule.
Operating In Freezing Temperatures
When using your outboard or having your outboard moored in freezing or near freezing temperatures,
keep the outboard tilted down at all times so the gearcase is submerged. This prevents trapped water
in 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 Salt Water 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.
Engine Break‑in Procedure
! CAUTION
Severe damage to the engine can result by not complying with the Engine Break‑in Procedure.
1.
For the first two hours of operation, run the engine at varied throttle settings up to 4500 RPM or
at three‑quarter throttle, and at full throttle for approximately one minute every ten minutes.
2.
For the next eight hours of operation, avoid continuous operation at full throttle for more than five
minutes at a time.
Starting The Engine
PANEL MOUNT - SINGLE ENGINE STARTING PROCEDURE
Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in
Procedure in the Operation Section.
37
OPERATION
! CAUTION
Never start or operate your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or
overheating of the engine.
1.
Make sure the cooling water intake is submerged.
ob01310
2.
Check the engine oil level.
3.
Open fuel tank vent on manual venting type tanks.
ob00667
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN" position.
4.
Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop
Switch.
ob00350
5.
Shift outboard to neutral (N) position.
38
OPERATION
N
R
F
3413
NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote
control handle.
6.
Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic
starting system will automatically crank the engine for starting. If the engine fails to start, the
engine will stop cranking. Turn the key to "START" position again until engine starts.
ACC ON
ART
ST
F ACC ON
OF
ART
ST
F
OF
3485
7.
Start/stop button ‑ Turn the ignition key to "ON" position and press start/stop button and release.
The electronic starting system will automatically crank the engine for starting. If the engine fails
to start, the engine will stop cranking. Press start/stop button and release again until engine starts.
3414
Warming up engine
Throttle Only Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without
shifting the engine into gear.
39
OPERATION
3416
1.
Move the control handle into neutral position.
2.
Depress shift lock button, press and hold the throttle only button while moving the control handle
ahead to the forward detent. The horn sound indicates that throttle only is engaged.
3.
Advance the control handle to increase engine RPM. Engine RPM is limited to prevent engine
damage.
4.
To disengage, return the control handle back to neutral position.
CONSOLE MOUNT - SINGLE ENGINE STARTING PROCEDURE
Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in
Procedure in the Operation Section.
! CAUTION
Never start or operate your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or
overheating of the engine.
1.
Make sure the cooling water intake is submerged.
ob01310
2.
Check the engine oil level.
3.
Open fuel tank vent on manual venting type tanks.
ob00667
40
OPERATION
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN" position.
4.
Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop
Switch.
5.
Shift outboard to neutral (N) position.
ob00350
N
R
F
3417
6.
Turn the ignition key to "START" position and release the key. The electronic starting system will
automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking.
Return the key to "START" position and try again.
ACC ON
ART
ST
F ACC ON
OF
ART
ST
F
OF
3485
7.
The "ACTIVE" light located on the console remote control key pad will become illuminated once
the engine is started and communicating with the remote control.
41
OPERATION
ACTIVE
THROTTLE
ONLY
STATION SELECT
3418
Warming up engine
Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for
warm‑up, without shifting the engine into gear.
ACTIVE
THROTTLE
ONLY
STATION SELECT
3419
1.
Move the control handle into neutral position.
2.
Press and hold the throttle only/station select button while moving the control handle ahead to
the forward detent.
3.
Hold in the button until the horn sounds twice and the neutral light starts flashing. The flashing
light indicates that the throttle only is engaged.
4.
Advance the control handle to increase engine RPM. Engine RPM is limited to prevent engine
damage.
5.
To disengage, return the control handle back to neutral position.
CONSOLE MOUNT - DUAL ENGINE STARTING PROCEDURE
Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in
Procedure in the Operation Section.
! CAUTION
Never start or operate your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or
overheating of the engine.
1.
Make sure the cooling water intake is submerged.
42
OPERATION
ob01310
2.
Check the engine oil level.
ob00667
3.
Open fuel tank vent on manual venting type tanks.
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN" position.
4.
Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop
Switch.
5.
Shift outboard to neutral (N) position.
ob00350
N
R
F
3417
43
OPERATION
6.
Turn the ignition key to "START" position and release the key. The electronic starting system will
automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking.
Return the key to "START" position and try again. Repeat the procedure for the second engine.
ACC ON
ART
ST
F
OF
ART
ST
F ACC ON
OF
3485
7.
The "ACTIVE" light located on the console remote control key pad will become illuminated once
the engine is started and communicating with the remote control.
ACTIVE
THROTTLE
ONLY
SYNC
STATION SELECT
3424
Warming up engine
Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for
warm‑up, without shifting the engines into gear.
ACTIVE
THROTTLE
ONLY
SYNC
STATION SELECT
3425
1.
Move the control handles into neutral position.
2.
Press and hold the throttle only/station select button while moving the control handles ahead to
the forward detent.
3.
Hold in the button until the horn sounds twice and the neutral lights starts flashing. The flashing
lights indicates that the throttle only is engaged.
4.
Advance the control handles to increase engine RPM. Engine RPM is limited to prevent engine
damage.
5.
To disengage, return the control handles back to neutral position.
6.
The warm up mode can be re‑activated by turning off and re‑starting the engine.
44
OPERATION
SLIM BINNACLE - SINGLE ENGINE STARTING PROCEDURE
Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in
Procedure in the Operation Section.
! CAUTION
Never start or operate your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or
overheating of the engine.
1.
Make sure the cooling water intake is submerged.
2.
Check the engine oil level.
ob01310
ob00667
3.
Open fuel tank vent on manual venting type tanks.
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN" position.
4.
Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop
Switch.
5.
Shift outboard to neutral (N) position.
ob00350
45
OPERATION
N
R
F
3417
NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote
control panel.
6.
Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic
starting system will automatically crank the engine for starting. If the engine fails to start, the
engine will stop cranking. Turn the key to "START" position again until engine starts.
ACC ON
ART
ST
F ACC ON
OF
ART
ST
F
OF
3485
7.
Start/stop button ‑ Turn the ignition key to "ON" position and press start/stop button and release.
The electronic starting system will automatically crank the engine for starting. If the engine fails
to start, the engine will stop cranking. Press start/stop button and release again until engine starts.
NEUTRAL
START
STOP
11774
8.
The "ACTIVE" light located on the remote control panel will become illuminated once the engine
is started and communicating with the remote control.
NEUTRAL
START
STOP
11776
46
OPERATION
Warming up engine
Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for
warm‑up, without shifting the engine into gear.
NEUTRAL
START
STOP
12204
1.
Move the control handle into neutral position.
2.
Depress shift lock button, press and hold the throttle only/station select button while moving the
control handle ahead to the forward detent.
3.
Hold in the button until the horn sounds twice and the neutral light starts flashing. The flashing
light indicates that the throttle only is engaged.
4.
Advance the control handle to increase engine RPM. Engine RPM is limited to prevent engine
damage.
5.
To disengage, return the control handle back to neutral position.
SHADOW MODE REMOTE CONTROL ENGINE STARTING PROCEDURE
Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in
Procedure in the Operation Section.
! CAUTION
Never start or operate your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or
overheating of the engine.
1.
Make sure the cooling water intakes are submerged.
ob01310
2.
Check the engine oil level.
47
OPERATION
ob00667
3.
Open fuel tank vent on manual venting type tanks.
ob00348
NOTE: The engines will not start unless the lanyard is set to the "RUN" position.
4.
Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop
Switch.
5.
Shift outboards to neutral (N) position.
ob00350
N
R
F
3417
6.
Turn each ignition key to "START" position and release the key. The electronic starting system
will automatically crank the engine for starting. If engine fails to start, the engine will stop cranking.
Return the key to "START" position and try again. Repeat the procedure for the other engines.
ACC ON
ART
ST
F ACC ON
OF
ART
ST
F
OF
3485
7.
The "ACTIVE" light will become illuminated to show the helm is active and ready for use.
48
OPERATION
NEUTRAL
SELECT
SYNC
ACTIVE
THROTTLE
ONLY
STATION SELECT
14657
Warming up engines
Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for
warm‑up, without shifting the engines into gear.
NEUTRAL
SELECT
SYNC
ACTIVE
THROTTLE
ONLY
STATION SELECT
14658
1.
Move the control handles into neutral position.
2.
Press and hold the throttle only/station select button while moving the control handles ahead to
the forward detent.
3.
Hold in the button until the horn sounds twice and the neutral lights starts flashing. The flashing
lights indicates that the throttle only is engaged.
4.
Advance the control handles to increase engine RPM. Engine RPM is limited to prevent engine
damage.
5.
To disengage, return the control handles back to neutral position.
6.
The warm up mode can be re‑activated by turning off and re‑starting the engines.
Gear Shifting
DTS PANEL MOUNT REMOTE CONTROL
IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into
forward or reverse when the engine is not running.
•
The outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and
Reverse (R).
49
OPERATION
N
R
F
3427
•
When shifting, always stop at neutral position and allow the engine speed to return to idle.
•
Panel mount remote control requires the operator to always press shift lock while moving the
control handle out of the neutral position.
3428
•
Advance the control lever to further increase speed.
DTS CONSOLE MOUNT REMOTE CONTROL
IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into
forward or reverse when the engine is not running.
•
The outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and
Reverse (R).
N
R
F
3417
•
When shifting, always stop at neutral position and allow the engine speed to return to idle.
•
Advance the control lever to further increase speed.
Dual Helm Station Transfer
The throttle only/station select button allows the boat operator to select which remote control is in control
of the engine operation.
50
OPERATION
The active light is illuminated at the remote control station that is in control of the engine.
! WARNING
Avoid serious injury or death from loss of boat control. The boat operator should never leave the active
station while engine is in gear. Helm transfer should only be attempted while both stations are manned.
One person helm transfer should only be performed while engine is in neutral.
NOTE: Idle position is preferred when doing a station transfer. If conditions do not allow the remote
control to be placed at idle position, a station transfer can be done while in gear.
NOTE: Pressing and releasing station select button at new station allows the engine control to be
transferred to the new station. The control will automatically start adjusting engine RPM and gear position
to match the control handle setting at the new station. Adjust control handles to the desired throttle and
gear position.
1.
Place active remote control lever to idle position.
2.
Proceed to the inactive helm station and position remote control lever to the idle position.
3.
Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the
remote control station is in control of the engine.
b
b
ACTIVE
ACTIVE
THROTTLE
ONLY
a
a
4.
THROTTLE
ONLY
STATION SELECT
STATION SELECT
a-
SYNC
Active light
b-
3433
Throttle only/station select button
The active light will switch off at the original remote control station.
SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER
Pressing the station select button and holding it in allows the boat operator 10 seconds to match up the
control handle settings at the new station with the handle settings that are at the old (to be inactive)
station. If the handles are not matched, the neutral light will flash. The light blinks faster as the handles
are nearing match position. Once the light stays on continuously, the handles are matched and the button
can be released. Transfer process is complete and the new station is now in control. If the button is held
for over 10 seconds, the station transfer is cancelled.
Synchronizing Dual Engines
The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match
the speed of the starboard engine.
Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM
for two seconds and remote control handles are positioned within 5° of each other.
Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the
engines are synchronized.
51
OPERATION
ACTIVE
SYNC
THROTTLE
ONLY
STATION SELECT
3434
To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed
below 900 RPM, or increase engine speed beyond 95%.
Stopping The Engine
IMPORTANT: Turning key to the "START" position while the engine is running will result in engine shut
down, while leaving the DTS system active. This will allow the use of the power trim/tilt from the remote
control handle.
Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position.
ACC ON
ART
ST
F ACC ON
OF
ART
ST
F
OF
3482
Remote Control Adjustments
a
-
+
-
b
a
+
b
5176
ob01170
a-
Detent tension adjustment
b-
Control handle friction adjustment screw
1.
Remove cover to gain access to screws.
2.
Detent tension adjustment ‑ The detent screw can be adjusted to increase or decrease the effort
needed to move the control handle into or out of detent position.
3.
Control handle friction adjustment ‑ The friction adjustment screw can be adjusted to increase or
decrease the overall effort to move the control handle. This will help prevent unwanted motion of
the handle in rough water.
52
OPERATION
4.
Turn screw towards "+" to increase friction or towards "–" to decrease friction.
5.
Reinstall cover.
53
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.
! WARNING
Neglected inspection and maintenance service of your outboard or attempting to perform maintenance
or repair on your outboard if you are not familiar with the correct service and safety procedures could
cause personal injury, death, or product failure.
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.
! WARNING
Using a replacement part that is inferior to the original part could result in personal injury, death, or
product failure.
EPA Emissions
EMISSION CERTIFICATION LABEL
An emission certification label, showing emission levels and engine specifications directly related to
emissions, is placed on the engine at time of manufacture.
a
f
g
b
c
h
d
e
i
ob00366
abcde-
Idle speed
Engine horsepower
Piston displacement
Date of manufacture
Valve clearance (if applicable)
fghi-
Family number
Maximum emission output for the engine
family
Timing specification
Recommended spark plug and gap
OWNER RESPONSIBILITY
The owner/operator is required to have routine engine maintenance performed to maintain emission
levels within prescribed certification standards.
54
MAINTENANCE
The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow
emissions levels to exceed their predetermined factory specifications.
Inspection And Maintenance Schedule
BEFORE EACH USE
•
Check engine oil level. See Fuel & Oil ‑ Checking and Adding Engine Oil.
•
Check that lanyard stop switch stops the engine.
•
Visually inspect the fuel system for deterioration or leaks.
•
Check outboard for tightness on transom.
•
Check steering system for binding or loose components.
•
Visually check power steering fittings and hoses for leaks or signs of damage. Check tie bar
fasteners (multiple outboard rigs) for proper tightness.
•
Check propeller blades for damage.
AFTER EACH USE
•
Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the
Cooling System.
•
Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh
water if operating in salt water.
EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS
FIRST
•
Change engine oil and replace the oil filter. The oil should be changed more often when the engine
is operated under adverse conditions such as extended trolling. See Changing Engine Oil.
•
Inspect thermostat visually for corrosion and/or for a broken spring. Make sure thermostat closes
•
Check engine water separating fuel filter for contaminants. Clean and/or replace filter. See Fuel
System.
•
Check corrosion control anodes. Check more frequently when used in salt water. See Corrosion
Control Anodes.
completely at room temperature.1.
•
Drain and replace gearcase lubricant. See Gearcase Lubrication.
•
Check power steering fluid. See Checking Power Steering Fluid.
•
Inspect battery. See Battery Inspection.
•
Saltwater usage. Remove and inspect spark plugs for corrosion and replace spark plugs as
necessary. Apply a thin coating of Anti‑Seize Compound only on threads of spark plug prior to
installation. See Maintenance ‑ Spark Plug Inspection and Replacement.
•
Check wiring and connectors
•
Check tightness of bolts, nuts, and other fasteners.
•
Check cowl seals to make sure seals are intact and not damaged.
•
Check internal cowl sound reduction foam (if equipped) to make sure foam is intact and not
damaged.
•
Check that the intake silencer (if equipped) is in place.
•
Check that the idle relief muffler (if equipped) is in place.
•
Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly.
EVERY 300 HOURS OF USE OR THREE YEARS
IMPORTANT: Engine oil must be drained before removing gearcase to avoid oil spillage. Perform
scheduled water pump replacement in combination with an engine oil change.
•
Replace water pump impeller (more often if overheating occurs or reduced water pressure is
noted).1.
1. These items should be serviced by an authorized dealer.
55
MAINTENANCE
•
Check power trim fluid. See Checking Power Trim Fluid.
•
Replace high pressure in‑line fuel filter1.
•
Replace spark plugs at first 300 hours or three years. After that, inspect spark plugs every 300
hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and
Replacement.
•
Replace accessory drive belt. See Accessory Drive Belt Inspection.1.
BEFORE PERIODS OF STORAGE
•
Refer to Storage procedure. See Storage section.
Flushing The Cooling System
Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or
muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.
NOTE: The outboard can be tilted or in the vertical operating position during flushing.
1.
With the engine turned off, place the outboard in either the operating position (vertical) or in a
tilted position.
2.
Disconnect the flush connector from fitting on the bottom cowl.
ob01236
3.
Thread a water hose into the flush fitting.
4.
Turn on the water tap (1/2 maximum) and let the water flush through the cooling system for about
15 minutes.
5.
When flushing is complete, turn off water and disconnect the water hose.
6.
Reinstall the flushing connector to the fitting on the bottom cowl. Tighten the connector securely.
ob01237
Cowl Removal and Installation
COWL REMOVAL
IMPORTANT: Most maintenance points are accessible by removing the top cowl only.
56
MAINTENANCE
1.
Pull up on the top cowl lock latch.
2.
Pull top cowl forward and lift off.
3.
Pull lower cowl release latch up.
4.
Remove rear cowl towards aft of outboard.
ob01324
ob01257
COWL INSTALLATION
1.
Position lower cowl from aft side of outboard. Make sure it fits properly in the rubber seal.
2.
Lock cowl in place by pulling lower cowl latch down.
57
MAINTENANCE
ob01671
3.
Place top cowl into position over engine, front first. Ensure cowl fits properly into the rubber seal.
4.
The top cowl will lock into place when downward pressure is applied to the back side of cowl.
Ensure cowl is securely fastened by pulling up on back of cowl.
Cleaning Care for Top and Bottom Cowls
IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches.
Always wet the surface before cleaning. Do not use detergents containing hydrochloric acid. Follow the
cleaning and waxing procedure.
CLEANING AND WAXING PROCEDURE
1.
Before washing, rinse the cowls with clean water to remove dirt and dust that may scratch the
surface.
2.
Wash the cowls with clean water and a mild non‑abrasive soap. Use a soft clean cloth when
washing.
3.
Dry thoroughly with a soft clean cloth.
4.
Wax the surface using a non‑abrasive automotive polish (polish designed for clear coat finishes).
Remove the applied wax by hand using a clean soft cloth.
5.
To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1).
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capability.
IMPORTANT: Read the safety and maintenance instructions which accompany your battery.
1.
Turn off the engine before servicing the battery.
2.
Add water as necessary to keep the battery full.
3.
Make sure the battery is secure against movement.
4.
Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and
negative to negative.
5.
Make sure the battery is equipped with a non‑conductive shield to prevent accidental shorting of
battery terminals.
58
MAINTENANCE
DTS Battery Specifications
IMPORTANT: Do not use deep cycle batteries for the main engine starting battery.
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard
regulations must be adhered to when installing the battery. Ensure that battery cable installation meets
the pull test requirements and that positive battery terminal is properly insulated in accordance with
regulations.
IMPORTANT: It is recommended (required in some states) that the battery be installed in an enclosed
case. Refer to regulations for your area.
Minimum SAE Starting Battery Requirements ‑ BCI GRP 24
MCA
1000
CCA
800
Ah
180 (International Rating)
NOTE: Due to the wide variety of battery manufacturers throughout the world, ratings and physical battery
sizes will vary. Check with the manufacturer for a starting battery with a MCA, CCA, or Ah specification
that will be equal to or greater than the SAE Standard J537 specified previously.
IMPORTANT: For DTS products, each engine must be equipped with its own starting battery. If your
boat application requires additional battery loads for boat accessories or marine electronics, it is
recommended that an auxiliary battery or batteries be installed.
! CAUTION
Hex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque
nuts to specifications.
Description
Nm
lb. in.
Hex nuts
13.5
120
lb. ft.
IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine
installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one
3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied.
59
MAINTENANCE
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
Air Filter
The air filter assembly is a serviceable item and can be cleaned with warm soap water if required.
AIR FILTER REMOVAL AND CLEANING
1.
Loosen air filter clamp screw.
2.
Remove crankcase ventilation hose.
a
b
c
d
ab-
3.
3664
Crankcase ventilation hose
Fuel System Module (FSM) purge
valve hose
cd-
Filter assembly
Clamp screw
Remove air filter assembly and disconnect Fuel System Module (FSM) purge valve hose by
rotating the air filter assembly and pulling on hose.
60
MAINTENANCE
3665
4.
Wash air filter assembly in warm soap water.
5.
Dry filter assembly with compressed air.
6.
Apply 4‑Cycle Outboard Oil on rag or towel and lightly pad air filter element. Wipe off excess oil.
Air filter element should be moist to the touch.
Tube Ref No.
110
Description
4 Stroke 10W30
Outboard Oil
Where Used
Part No.
Air filter element
92-802833Q1
AIR FILTER INSTALLATION
1.
Install Fuel System Module (FSM) purge valve hose to air filter assembly.
3665
2.
Install crankcase ventilation hose.
3.
Install air filter assembly and tighten clamp screw securely.
61
MAINTENANCE
a
b
c
d
ab-
3664
Crankcase ventilation hose
Fuel System Module (FSM) purge
valve hose
cd-
Filter assembly
Clamp screw
Fuel System
! WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service
instructions. Always stop the engine and do not smoke or allow open flames or sparks in the area
while servicing any part of the fuel system.
IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately.
Material used to contain spilled fuel must be disposed of in an approved receptacle.
Before servicing any part of the fuel system:
1.
Stop engine and disconnect the battery.
2.
Perform fuel system service in a well ventilated area.
3.
Inspect any completed service work for sign of fuel leakage.
FUEL LINE INSPECTION
Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or
damage. If any of these conditions are found, the fuel line must be replaced.
WATER SEPARATING FUEL FILTER
NOTE: The warning system will turn on when water in the fuel filter reaches the full level. Refer to
Features and Controls ‑ Warning System.
This filter removes moisture and debris from the fuel. If the filter holder becomes filled with water, the
water can be removed. If the filter becomes plugged with debris, replace the filter.
Refer to the Inspection and Maintenance Schedule for the proper maintenance interval.
Filter Removal
1.
Turn ignition key switch to "OFF" position.
2.
Remove fuel vapor purge relief valve cap (green cap located aft of starter motor).
62
MAINTENANCE
3470
! CAUTION
Fuel vapor vent system is under pressure. Cover valve assembly with a rag or towel to prevent fuel
or fuel vapor spray. Relieve pressure slowly.
3.
Place rag or towel around valve, release pressure by pushing core of valve end in.
4.
Unscrew the filter in a counterclockwise direction to remove.
3472
63
MAINTENANCE
ob01253
Filter Draining
1.
Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter
holder.
2.
Tip the filter holder to drain any fluid into an approved container.
ob01263
Filter Installation
1.
Position filter holder onto bracket and secure filter holder in place.
2.
Lubricate the sealing ring on the filter with oil.
3.
Install the filter and tighten securely by hand.
IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition key to the run
position, forcing fuel into the filter.
64
MAINTENANCE
ob01258
Corrosion Control Anode
The outboard has corrosion control anodes at different locations. An anode helps protect the outboard
against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
Each anode requires periodic inspection, especially in salt water which will accelerate the erosion. To
maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint
or apply a protective coating on the anode as this will reduce effectiveness of the anode.
Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the
pedestal. Two more anodes are located on the bottom of each power trim ram.
ob01515
Propeller Replacement
1.
Shift outboard to neutral position.
2.
Straighten the bent tabs on the propeller nut retainer.
ob00376
3.
Place a block of wood between gearcase and propeller to hold propeller and remove propeller
nut.
65
MAINTENANCE
ob01672
4.
Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have
the propeller removed by an authorized dealer.
5.
To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the
following Mercury/Quicksilver products:
Tube Ref No.
6.
Description
Where Used
Part No.
94
Anti-Corrosion
Grease
Propeller shaft
splines
92-802867Q1
95
2-4-C Marine
Lubricant with Teflon
Propeller shaft
splines
92-802859Q1
Flo‑Torq II Drive Hub Propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller,
thrust hub, propeller nut retainer and propeller nut onto the shaft.
a
b
e
c
d
abc7.
Propeller nut
Propeller nut retainer
Thrust hub
def-
ob00421
Propeller
Replaceable drive sleeve
Forward thrust hub
Place a block of wood between gearcase and propeller and torque to specifications.
Description
Nm
Propeller nut
75
8.
f
lb. in.
lb. ft.
55
Secure propeller nut by bending three of the tabs into the thrust hub grooves.
66
MAINTENANCE
ob00422
Spark Plug Inspection and Replacement
1.
Remove top and rear cowlings. Refer to Cowl Removal and Installation.
2.
Disconnect the six wiring harness connectors from pencil coil connections.
3.
Remove mounting bolts, using a twisting motion, and pull pencil coils from spark plugs.
a
b
c
3658
ab4.
Wiring harness connector
Pencil coil
c-
Bolt
Remove the spark plugs to inspect. Replace spark plug if electrode is worn, threads of seal area
are corroded, or the insulator is rough, cracked, broken, blistered or fouled.
ob01092
5.
Set the spark plug gap to specifications.
ob00680
Spark Plug
Spark Plug Gap
6.
0.8 mm (0.0315 in.)
Saltwater use ‑ Apply a thin coating of Anti‑Seize Compound only on threads of spark plugs.
67
MAINTENANCE
Tube Ref No.
Description
Anti-Seize
Compound
81
Where Used
Part No.
Spark plug threads
92-881091K1
7.
Clean area of spark plug seat.
8.
Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger tight,
and then tighten 1/4 turn or torque to specifications.
Description
Nm
Spark plug
27
9.
lb. in.
lb. ft.
20
Push pencil coils into place over the spark plugs using a twisting motion.
10. Secure coils with retained bolts. Torque to specifications.
Description
Bolts
Nm
lb. in.
8
71
lb. ft.
11. Connect the six wiring harness connectors to pencil coil connections.
a
b
c
3658
ab-
Wiring harness connector
Pencil coil
c-
Bolt
12. Reinstall rear and top cowls.
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.
1.
Remove top cowl. Locate fuse holder on starboard side of engine.
ob01516
68
MAINTENANCE
2.
Remove the plastic cover from the fuse holder.
3.
Remove fuse puller from fuse holder.
4.
Remove suspected blown fuse to determine if the silver colored band is broken.
5.
Replace fuse with a new fuse of the same amperage rating.
ob01252
b
a
c
20
20
20
20
20
20
d
20
e
abc-
ob01259
Electronic Control Module and purge
valve "ECM" ‑ 20 amp fuse
Ignition coils "IGN. COILS" ‑ 20 amp
fuse
Fuel delivery "FUEL" ‑ 20 amp fuse
de-
Spare fuses ‑ 20 amp fuse
Injector power and boost valve "INJ.
PWR." ‑ 20 amp fuse
DTS Wiring System
! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into
any wire insulation of the DTS system. Splicing or probing will damage the wire insulation allowing
water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control.
•
Verify the harnesses are not routed near sharp edges, hot surfaces or moving parts.
•
Verify that all unused connectors and receptacles are covered with a weather cap.
•
Verify that the harnesses are fastened along the routing path.
Accessory Drive Belt Inspection
Inspect the accessory drive belt and have it replaced by an authorized dealer if any of the following
conditions are found.
•
Cracks in the back of the belt or in the base of V grooves.
•
Excessive wear at the roots of the grooves.
•
Rubber portion swollen by oil.
69
MAINTENANCE
•
Belt surfaces roughened.
•
Signs of wear on edges or outer surfaces of belt.
Checking Power Trim Fluid
1.
Tilt outboard to the full up position.
2.
Rotate the tilt support bracket down.
3.
Lower outboard until tilt support bracket rests on pedestal.
4.
Remove the power trim fill cap. The fill cap only requires 1/4 turn to remove.
b
a
c
d
ob01526
ab5.
Tilt support lever
Power trim fill cap
Tilt support bracket
Pedestal
The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver
or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive
automatic transmission fluid (ATF).
Tube Ref No.
114
6.
cd-
Description
Power Trim and
Steering Fluid
Where Used
Part No.
Power trim system
92-802880Q1
Reinstall the power trim fill cap. Tighten fill cap 1/4 turn. Cap will snap in place. Do not tighten
beyond this point.
Checking Power Steering Fluid
Remove power steering cover and fill cap to check fluid level. The fluid level should be slightly below the
bottom of the fill hole. Use SAE 0W‑30 synthetic power steering fluid, if needed.
70
MAINTENANCE
b
a
c
ob01527
ab-
Power steering cover
Fill cap
Tube Ref No.
138
c-
Description
Fill/full level
Where Used
Synthetic Power
Steering Fluid SAE
0W-30
Part No.
Power steering system 92-858002K01
Changing Engine Oil
ENGINE OIL CAPACITY
Engine oil capacity is approximately 7.0 liters (7.4 quarts).
PUMP METHOD
IMPORTANT: Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain
back to the oil sump.
IMPORTANT: To reduce or prevent oil spillage when removing the oil filter, make sure that the outboard
is upright (not tilted) and the engine is cold or has not run for at least one hour.
IMPORTANT: The pump method is preferred to remove engine oil from XXL models. If the drain method
is used, an oil drain funnel must be used to divert oil from the lower splash plate and into the container.
1.
Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back
to the oil sump.
2.
Place the outboard in a vertical position.
3.
Remove dipstick and slide adaptor tube of crankcase oil pump through oil dipstick hole, to bottom
of engine oil sump.
4.
Pump out the engine oil into an appropriate container.
71
MAINTENANCE
Crankcase Oil Pump
91‑90265A 5
Aids in the removal of engine oil
without draining the crankcase.
11591
DRAIN METHOD
1.
Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back
to the oil sump.
2.
Place the outboard in a vertical position.
3.
Place appropriate container under engine oil sump plug. Drain plug/seal washer is located
beneath the splash plate (port side of outboard).
4.
Loosen the drain plug/seal washer. Install the oil drain funnel over the drain plug/seal washer and
slide the tool onto the splash plate.
a
b
ob01264
a-
Drain plug/seal washer
b-
Oil Drain Funnel
Oil drain funnel
91‑892866A01
Diverts draining engine oil from
contacting the anti‑splash and
anti‑cavitation plates.
4993
5.
Remove drain plug/seal washer and drain engine oil into container.
6.
Reinstall drain plug/seal washer.
72
MAINTENANCE
CHANGING OIL FILTER
IMPORTANT: To reduce or prevent oil spillage when removing the oil filter ensure that the outboard is
upright (not tilted) and the engine is cold or has not run for at least one hour.
1.
Remove the top cowl.
2.
Place a rag or towel below the oil filter to absorb any spilled oil.
3.
Unscrew old filter by using oil filter wrench tool and turning the filter counterclockwise.
ob01251
Oil Filter Wrench
91‑802653Q02
Assists in removal of oil filter.
5221
4.
Clean the oil filter mounting base.
5.
Apply film of clean oil to filter gasket. Do not use grease.
6.
Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.
OIL FILLING
1.
Remove the oil fill cap and add recommended oil to the midpoint of the operating range (midpoint
of cross hatched region). Adding approximately 7 liters (7.4 quarts) will bring oil level to midpoint
of cross hatched region.
73
MAINTENANCE
ob01250
2.
Reinstall oil fill cap.
3.
With outboard in water or cooling water flush hose connected, idle engine for five minutes to check
for leaks at the oil filter.
4.
Stop engine and check oil level.
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.
Remove propeller. Refer to Propeller Replacement.
3.
Place drain pan below outboard.
4.
Remove vent plug and fill/drain plug and drain lubricant.
b
a
ob01529
a-
Vent plug
b-
Fill/drain plug
GEARCASE LUBRICANT CAPACITY
Gearcase lubricant capacity is approximately 970 ml (32.8 fl. oz.).
74
MAINTENANCE
GEARCASE LUBRICANT RECOMMENDATION
Mercury or Quicksilver High Performance Gear Lubricant.
CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE
1.
Place outboard in a vertical operating position.
2.
Remove vent plug/sealing washer.
3.
Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at
the vent hole.
a
b
a
a-
Vent hole
ob01530
b-
Fill hole
IMPORTANT: Replace sealing washers if damaged.
4.
Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
5.
Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
75
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).
! CAUTION
Never start or operate your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or
overheating of the engine.
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.
IMPORTANT: This outboard is equipped with a closed fuel system when the engine is not running. With
this closed system, fuel within the engine's fuel system, other than the fuel tank, will remain stable during
normal storage periods without the addition of fuel treatment stabilizers.
Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help prevent formation of varnish
and gum. Proceed with the following instructions.
•
Portable Fuel Tank ‑ Pour the required amount of Fuel System Treatment and Stabilizer (follow
instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
•
Permanently Installed Fuel Tank ‑ Pour the required amount of Fuel System Treatment and
Stabilizer (follow instructions on container) into a separate container and mix with approximately
one liter (one quart) of gasoline. Pour this mixture into fuel tank.
Tube Ref No.
124
Description
Fuel System
Treatment &
Stabilizer
Where Used
Part No.
Fuel tank
802875Q1
Protecting External Outboard Components
•
Touch up any paint nicks. See your dealer for touch‑up paint.
•
Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces
(except corrosion control anodes).
Tube Ref No.
120
Description
Corrosion Guard
Where Used
Part No.
External metal
surfaces
92-802878Q5
5
Protecting Internal Engine Components
IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacement for correct procedure for
removing spark plugs.
•
Remove pencil coils and spark plugs.
•
Spray approximately 30 ml (1 fl. oz.) of Storage Seal Rust Inhibitor into each spark plug hole.
76
STORAGE
Tube Ref No.
119
Description
Storage Seal Rust
Inhibitor
Where Used
Part No.
Spark plug holes
92-802878Q5
6
•
Actuate key/push button start switch to crank the engine through one start cycle, which will
distribute the storage seal throughout the cylinders.
•
Reinstall spark plugs and pencil coils.
Gearcase
•
Drain and refill the gearcase lubricant (refer to Maintenance ‑ Gearcase Lubrication).
Positioning Outboard For Storage
Store outboard in an upright (vertical) position to allow water to drain out of outboard.
! CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may
have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the
outboard.
Battery Storage
•
Follow the battery manufacturer's instructions for storage and recharging.
•
Remove the battery from the boat and check water level. Recharge if necessary.
•
Store the battery in a cool, dry place.
•
Periodically check the water level and recharge the battery during storage.
77
TROUBLESHOOTING
Starter Motor Will Not Crank the Engine
POSSIBLE CAUSES
•
Lanyard stop switch not in "RUN" position.
•
Blown 5 Amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section.
•
Outboard is not shifted to neutral position.
•
Shift actuator failure. "Gear Shift Diff" error message shown on System View. Refer to
Maintenance section.
•
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
•
Incorrect starting procedure. Refer to Operation section.
•
Old or contaminated gasoline.
•
Fuel is not reaching the engine.
•
Fuel tank is empty.
•
Fuel tank vent not open or restricted.
•
Fuel line is disconnected or kinked.
•
Fuel filter is obstructed. Refer to Maintenance section.
•
Fuel pump failure.
•
Fuel tank filter obstructed.
•
Ignition system component failure.
•
Spark plugs fouled or defective. Refer to Maintenance section.
Engine Starts But Will Not Shift Into Gear
•
Shift actuator failure. "Gear Shift Diff" error message shown on System View. Refer to
Maintenance section.
Engine Runs Erratically
POSSIBLE CAUSES
•
Overheating ‑ Warning horn not working.
•
Low oil pressure. Check oil level.
•
Spark plugs fouled or defective. Refer to Maintenance section.
•
Incorrect setup and adjustments.
•
Fuel is being restricted to the engine.
a. Engine fuel filter is obstructed. Refer to Maintenance section.
b. Fuel tank filter obstructed.
c. Stuck anti‑siphon valve located on permanently built‑in type fuel tanks.
d. Fuel line is kinked or pinched.
•
Fuel pump failure.
•
Ignition system component failure.
78
TROUBLESHOOTING
Performance Loss
POSSIBLE CAUSES
•
Overheating ‑ Warning horn not working.
•
Low oil pressure. Check oil level.
•
Throttle not opening fully.
•
Damaged propeller or improper propeller size.
•
Incorrect engine timing, adjustment, or setup.
•
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).
79
OWNER SERVICE ASSISTANCE
Local Repair Service
Always return your outboard to your local authorized dealer should the need for service arise. Only he
has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and
accessories to properly service your engine should the need occur. He knows your engine best.
Service Away From Home
If you are away from your local dealer and the need arises for service, contact the nearest authorized
dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service,
contact the nearest Mercury Marine Service Office.
Parts And Accessories Inquiries
All inquiries concerning genuine replacement parts and accessories should be directed to your local
authorized dealer. The dealer has the necessary information to order parts and accessories for you.
When inquiring on parts and accessories, the dealer requires the model and serial number to order the
correct parts.
Service Assistance
Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have
a problem, question or concern about your outboard product, contact your dealer or any authorized
Mercury Marine dealership. If additional assistance is required, take these steps.
1.
Talk with the dealership's sales manager or service manager. If this has already been done, then
contact the owner of the dealership.
2.
Should you have a question, concern, or problem that cannot be resolved by your dealership,
please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you
and your dealership to resolve all problems.
The following information will be needed by the service office:
•
Your name and address
•
Daytime telephone number
•
Model and serial number of your outboard
•
The name and address of your dealership
•
Nature of problem
Mercury Marine Service Offices
For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax
correspondence.
United States
Telephone
(920) 929‑5040
Fax
(920) 929‑5893
Website
www.mercurymarine.com
Mercury Marine
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Canada
Telephone
(905) 567‑6372
Fax
(905) 567‑8515
Mercury Marine Ltd.
2395 Meadowpine Blvd.
Mississauga, Ontario L5N 7W6
Canada
80
OWNER SERVICE ASSISTANCE
Australia, Pacific
Telephone
(61) (3) 9791‑5822
Fax
(61) (3) 9793‑5880
Mercury Marine Australia
132-140 Frankston Road
Dandenong, Victoria 3164
Australia
Europe, Middle East, Africa
Telephone
(32) (87) 32 • 32 • 11
Fax
(32) (87) 31 • 19 • 65
Marine Power - Europe, Inc.
Parc Industriel de Petit-Rechain
B-4800 Verviers,
Belgium
Mexico, Central America, South America, Caribbean
Telephone
(954) 744‑3500
Fax
(954) 744‑3535
Mercury Marine
11650 Interchange Circle North
Miramar, FL 33025
U.S.A.
Japan
Telephone
81‑053‑423‑2500
Fax
81‑053‑423‑2510
Mercury Marine - Japan
Anshin-cho 283-1
Hamamatsu
Shizuoka-ken, Japan 435-0005
Japan
Asia, Singapore
Telephone
5466160
Fax
5467789
Mercury Marine Singapore
72 Loyang Way
Singapore, 508762
81