Mercury OUTBOARD MOTOR Installation Manual
The Mercury Outboard Motor is a powerful and reliable engine designed for a variety of boating applications. It features a robust construction, advanced technology, and a range of options for customization. This manual provides detailed instructions for installing, operating, and maintaining your Mercury Outboard Motor. The guide covers essential steps, from securing the motor to the boat transom to connecting the remote control and adjusting the tilt pin for optimal performance.
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D
IMPORTANT INFORMATION
OUTBOARD MOTOR INSTALLATION
D
IMPORTANT INFORMATION
OUTBOARD MOTOR INSTALLATION
90-826148R2 MARCH 19971D-0 - IMPORTANT INFORMATION
Table of Contents Page
Notice to Installer and Owner 1D-1. . . . . . . . . . . .
Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . .
Outboard Remote Control 1D-1. . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 1D-1. .
Selecting Steering Cables and Remote
Control Cables 1D-2. . . . . . . . . . . . . . . . . . . . . . . . .
Locate Centerline Of The Outboard 1D-2. . . . . . .
Lifting Outboard 1D-2. . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard to Boat Transom 1D-3. . . . . .
Models Without Transom Bracket
Thumb Screws 1D-3. . . . . . . . . . . . . . . . . . . . . .
Models With Transom Bracket
Thumb Screws 1D-4. . . . . . . . . . . . . . . . . . . . . .
Fastening outboard to the boat transom 1D-5
Single Steering Cable and Steering Link
Rod Installation 1D-5. . . . . . . . . . . . . . . . . . . . . . . .
Installing Ride Guide Steering Cable
To The Outboard 1D-5. . . . . . . . . . . . . . . . . . . .
Steering Link Rod Installation 1D-6. . . . . . . . .
Remote Control Installation 1D-6. . . . . . . . . . . . . .
Required Side Mount Remote Control or
Ignition Key Switch Assembly 1D-7. . . . . . . . . . . .
Boats Equipped with Side Mount Remote
Control 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boats Equipped with Panel Or
Console Mount Remote Control 1D-7. . . . . . .
Remote Wiring Connections 1D-7. . . . . . . . . . . . .
Electric Start Remote Control Model 1D-7. . .
Manual Start Models Using Quicksilver
2000 Series Side Mount Remote Control 1D-7
Shift and Throttle Cable Installation
To The Outboard 1D-8. . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 1D-8. . . . . . . . . . . . . . . .
Throttle Cable Installation 1D-9. . . . . . . . . . . . .
Battery Connections 1D-10. . . . . . . . . . . . . . . . . . . .
Set Up Instructions For Oil Injection System 1D-10
Filling The Oil Injection System 1D-10. . . . . . . .
Bleeding Air From The Oil
Injection System 1D-11. . . . . . . . . . . . . . . . . . . . .
Adjusting The Oil Injection Pump 1D-11. . . . . .
Propeller Installation 1D-11. . . . . . . . . . . . . . . . . . . .
Tilt Pin Adjustment 1D-12. . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 1D-13. . . . . . . . . . . . . . . . . . . .
Table of Contents Page
Notice to Installer and Owner 1D-1. . . . . . . . . . . .
Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . .
Outboard Remote Control 1D-1. . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 1D-1. .
Selecting Steering Cables and Remote
Control Cables 1D-2. . . . . . . . . . . . . . . . . . . . . . . . .
Locate Centerline Of The Outboard 1D-2. . . . . . .
Lifting Outboard 1D-2. . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard to Boat Transom 1D-3. . . . . .
Models Without Transom Bracket
Thumb Screws 1D-3. . . . . . . . . . . . . . . . . . . . . .
Models With Transom Bracket
Thumb Screws 1D-4. . . . . . . . . . . . . . . . . . . . . .
Fastening outboard to the boat transom 1D-5
Single Steering Cable and Steering Link
Rod Installation 1D-5. . . . . . . . . . . . . . . . . . . . . . . .
Installing Ride Guide Steering Cable
To The Outboard 1D-5. . . . . . . . . . . . . . . . . . . .
Steering Link Rod Installation 1D-6. . . . . . . . .
Remote Control Installation 1D-6. . . . . . . . . . . . . .
Required Side Mount Remote Control or
Ignition Key Switch Assembly 1D-7. . . . . . . . . . . .
Boats Equipped with Side Mount Remote
Control 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boats Equipped with Panel Or
Console Mount Remote Control 1D-7. . . . . . .
Remote Wiring Connections 1D-7. . . . . . . . . . . . .
Electric Start Remote Control Model 1D-7. . .
Manual Start Models Using Quicksilver
2000 Series Side Mount Remote Control 1D-7
Shift and Throttle Cable Installation
To The Outboard 1D-8. . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 1D-8. . . . . . . . . . . . . . . .
Throttle Cable Installation 1D-9. . . . . . . . . . . . .
Battery Connections 1D-10. . . . . . . . . . . . . . . . . . . .
Set Up Instructions For Oil Injection System 1D-10
Filling The Oil Injection System 1D-10. . . . . . . .
Bleeding Air From The Oil
Injection System 1D-11. . . . . . . . . . . . . . . . . . . . .
Adjusting The Oil Injection Pump 1D-11. . . . . .
Propeller Installation 1D-11. . . . . . . . . . . . . . . . . . . .
Tilt Pin Adjustment 1D-12. . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 1D-13. . . . . . . . . . . . . . . . . . . .
90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1D-1
Notice to Installer and Owner
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 - Immediate hazards which WILL result
in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which
COULD result in severe personal injury or death.
CAUTION
CAUTION - Hazards or unsafe practices which
could result in minor injury or product or proper-
ty damage.
Boat Horsepower Capacity
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
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 guide-
lines. If in doubt, contact your dealer or the boat man-
ufacturer.
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.
3. Cause the boat to break apart particularly
around the transom area. Overpowering a
boat can result in serious injury, death, or
boat damage.
Outboard Remote Control
The remote control connected to your outboard must
be equipped with a start-in-gear protection device.
This prevents the engine from starting when the out-
board is in gear.
WARNING
Avoid serious injury or death from a sudden un-
expected acceleration when starting your en-
gine. The design of this outboard requires that
the remote control used with it must have a built
in start-in-gear protection device.
Selecting Accessories For
The Outboard
Genuine Mercury Marine Quicksilver Accessories
have been specifically designed and tested for your
outboard.
Mercury Marine Quicksilver accessories are avail-
able from Mercury Marine dealers.
Some accessories not manufactured or sold by Mer-
cury Marine are not designed to be safely used with
your outboard or outboard operating system. Acquire
and read the installation, operation, and mainte-
nance manuals for all your selected accessories.
WARNING
Check with your dealer before installation of ac-
cessories. The misuse of acceptable accesso-
ries or the use of unacceptable accessories can
result in serious injury, death, or product failure.
Notice to Installer and Owner
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 - Immediate hazards which WILL result
in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which
COULD result in severe personal injury or death.
CAUTION
CAUTION - Hazards or unsafe practices which
could result in minor injury or product or proper-
ty damage.
Boat Horsepower Capacity
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
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 guide-
lines. If in doubt, contact your dealer or the boat man-
ufacturer.
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.
3. Cause the boat to break apart particularly
around the transom area. Overpowering a
boat can result in serious injury, death, or
boat damage.
Outboard Remote Control
The remote control connected to your outboard must
be equipped with a start-in-gear protection device.
This prevents the engine from starting when the out-
board is in gear.
WARNING
Avoid serious injury or death from a sudden un-
expected acceleration when starting your en-
gine. The design of this outboard requires that
the remote control used with it must have a built
in start-in-gear protection device.
Selecting Accessories For
The Outboard
Genuine Mercury Marine Quicksilver Accessories
have been specifically designed and tested for your
outboard.
Mercury Marine Quicksilver accessories are avail-
able from Mercury Marine dealers.
Some accessories not manufactured or sold by Mer-
cury Marine are not designed to be safely used with
your outboard or outboard operating system. Acquire
and read the installation, operation, and mainte-
nance manuals for all your selected accessories.
WARNING
Check with your dealer before installation of ac-
cessories. The misuse of acceptable accesso-
ries or the use of unacceptable accessories can
result in serious injury, death, or product failure.
90-826148R2 MARCH 19971D-2 - IMPORTANT INFORMATION
Selecting Steering Cables
and Remote Control Cables
Refer to “Quicksilver Accessories Guide” to deter-
mine correct length of steering cables and remote
control cables.
IMPORTANT: Steering cables and remote control
cables must be the correct length. Sharp bends
on too-short cables result in “kinks”; too-long
cables require unnecessary bends and/or loops.
Both conditions place extra stress on the cables.
Locate Centerline Of The
Outboard
Locate (and mark with pencil) the vertical centerline
of boat transom.
BA
DC
a
a - Centerline of Transom
NOTE: Dimensions “A”& “B”and “C”& “D”are equal
length.
IMPORTANT: During installation of dual out-
boards, the following is recommended. A mini-
mum of 221/2 inches (570mm) centerline to cent-
erline width is recommended. This is required to
alleviate cowling interference during lock to lock
turns if one outboard would be in the full tilt posi-
tion, while the other outboard(s) are in the verti-
cal running position.
Lifting Outboard
WARNING
Verify that the lifting ring is threaded into the fly-
wheel a minimum of 5 turns and that hoist has a
maximum lift capacity over 500 lbs. (227 kg) BE-
FORE lifting outboard.
1. Electric Start Models - Remove plastic cap from
center of flywheel. Thread lifting ring into flywheel
hub a minimum of 5 turns. Replace plastic cap af-
ter installation.
a - Lifting Ring
2. Manual Start Models - Use lifting eye on engine
and lift outboard on boat transom.
Selecting Steering Cables
and Remote Control Cables
Refer to “Quicksilver Accessories Guide” to deter-
mine correct length of steering cables and remote
control cables.
IMPORTANT: Steering cables and remote control
cables must be the correct length. Sharp bends
on too-short cables result in “kinks”; too-long
cables require unnecessary bends and/or loops.
Both conditions place extra stress on the cables.
Locate Centerline Of The
Outboard
Locate (and mark with pencil) the vertical centerline
of boat transom.
BA
DC
a
a - Centerline of Transom
NOTE: Dimensions “A”& “B”and “C”& “D”are equal
length.
IMPORTANT: During installation of dual out-
boards, the following is recommended. A mini-
mum of 221/2 inches (570mm) centerline to cent-
erline width is recommended. This is required to
alleviate cowling interference during lock to lock
turns if one outboard would be in the full tilt posi-
tion, while the other outboard(s) are in the verti-
cal running position.
Lifting Outboard
WARNING
Verify that the lifting ring is threaded into the fly-
wheel a minimum of 5 turns and that hoist has a
maximum lift capacity over 500 lbs. (227 kg) BE-
FORE lifting outboard.
1. Electric Start Models - Remove plastic cap from
center of flywheel. Thread lifting ring into flywheel
hub a minimum of 5 turns. Replace plastic cap af-
ter installation.
a - Lifting Ring
2. Manual Start Models - Use lifting eye on engine
and lift outboard on boat transom.
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Key features
Powerful and efficient performance
Quiet and smooth operation
Reliable and durable construction
Advanced engineering for enhanced control
Easy to use and maintain
Wide range of models to suit different boat sizes and applications
Frequently asked questions
Locate (and mark with pencil) the vertical centerline of boat transom. Dimensions “A”& “B”and “C”& “D”are equal length.
Install the outboard to the boat transom using thumb screws or a transom bracket with thumb screws.
Refer to “Quicksilver Accessories Guide” to determine correct length of steering cables and remote control cables. Too-short cables result in “kinks”; too-long cables require unnecessary bends and/or loops. Both conditions place extra stress on the cables.