EMC Directive: 89/336/EC; std. EN , SAE J551 (CISPR Pub. 12), EN , IEC PT4-2, IEC PT4-3

Transcription

1 Welcome Abord! Proper cre nd mintennce is n importnt prt in keeping your Mercury Product operting t pek efficiency for mximum performnce nd economy. The enclosed Owner's Registrtion Crd is your key to trouble-free fmily fun. Refer to your Opertion nd Mintennce Mnul for full detils of your wrrnty coverge. Detils of your nerest deler cn be found on where country mps nd full contct informtion re displyed. Is your engine properly registered for wrrnty purpose? Plese check on If necessry, plese contct your locl deler. If the outbord motor s seril number plte contins the CE mrk in the lower left-hnd corner, the following sttement pplies: This outbord motor mnufctured by Mercury Mrine, Fond du Lc, WI, USA or Mrine Power Europe Inc. Prk Industrel, de Petit-Rechin, Belgium complies with the requirements of the following directives nd stndrds, s mended: Recretionl Crft Directive: 94/25/EC; std. ISO 8665, ISO Mchinery Directive: 98/37/EC, EMC Directive: 89/336/EC; std. EN , SAE J551 (CISPR Pub. 12), EN , IEC PT4-2, IEC PT4-3 Ptrick C. Mckey President, Mercury Mrine, Fond du Lc, WI USA Europen Regultions Contct: Product Environmentl Engineering Deprtment, Mercury Mrine, Fond du Lc, WI USA 2004 Mercury Mrine 8/9.9 & 9.9 Bigfoot 4-Stroke i

2 TABLE OF CONTENTS Wrrnty Informtion Trnsfer Of Wrrnty...1 Wrrnty Registrtion United Sttes And Cnd... 1 Wrrnty Registrtion Outside The United Sttes And Cnd... 1 Mercury Mrine Two Yers Limited Wrrnty (Europe)... 2 Mercury Mrine One Yer Limited Wrrnty (Confedertion of Independent Sttes, Middle-Est, Afric) Yer Limited Wrrnty Aginst Corrosion...5 Wrrnty Coverge And Exclusions...6 Generl Informtion Boter's Responsibilities... 8 Before Operting Your Outbord... 8 Bot Horsepower Cpcity... 8 High-Speed And High-Performnce Bot Opertion... 9 Outbord Remote Control Models...9 Remote Steering Notice...9 Lnyrd Stop Switch...10 Protecting People In The Wter Pssenger Sfety Messge - Pontoon Bots And Deck Bots...12 Wve And Wke Jumping Impct with Underwter Hzrds...13 Exhust Emissions...14 Selecting Accessories For Your Outbord...15 Sfe Boting Suggestions...16 Recording Seril Number /9.9 4-Stroke Specifictions - Interntionl...17 Component Identifiction - Stndrd Models...19 Component Identifiction - Bigfoot Models...22 Instlltion Instlling Outbord...23 Bttery Instlltion - Electric Strt Models...24 Bttery Connections...24 Propeller Selection...24 Trnsporting Crrying, Storing nd Trnsporting Your Outbord When Removed From Bot...25 Trnsporting Portble Fuel Tnks Trilering Bot/Outbord - Models with Power Tilt...26 Trilering Bot/Outbord - Models without Power Tilt...27 Fuel nd Oil Gsoline Recommendtions...28 Filling Fuel Tnk...28 Engine Oil Recommendtions...29 ii

3 TABLE OF CONTENTS Checking Engine Oil...29 Fetures nd Controls Tiller Hndle Fetures Remote Control Fetures Wrning System Power Tilt (if equipped) Setting The Trnsom Angle Of Your Outbord Adjusting Trnsom Angle Shllow Wter Opertion Tilting Outbord Trim Tb Adjustment Opertion Pre-Strting Check List Operting In Freezing Tempertures Operting In Slt Wter Or Polluted Wter Operting Outbord As An Auxiliry Engine Pre-Strting Instructions Engine Brek-in Procedure Strting The Engine - Tiller Hndle Models...44 Strting The Engine - Remote Control Models...47 Strting Hot Engine Ger Shifting...49 Stopping The Engine Emergency Strting Mintennce Outbord Cre...52 EPA Emissions Inspection And Mintennce Schedule Flushing The Cooling System...53 Top Cowl Removl And Instlltion...54 Bttery Inspection...55 Exterior Cre Fuel System...55 Steering Link Rod Fsteners Corrosion Control Anode Propeller Replcement Fuse Replcement - Electric Strt Models Sprk Plug Inspection And Replcement Timing Belt Inspection Chnging Engine Oil...61 Lubriction Points Gercse Lubriction Checking Power Tilt Fluid Submerged Outbord iii

4 TABLE OF CONTENTS Storge Storge Preprtion Protecting Externl Outbord Components...67 Protecting Internl Engine Components Gercse...67 Positioning Outbord For Storge...67 Bttery Storge...68 Troubleshooting Strter Motor Will Not Crnk The Engine (Electric Strt Models)...69 Engine Will Not Strt Engine Runs Errticlly Performnce Loss Bttery Will Not Hold Chrge...70 Owner Service Assistnce Locl Repir Service Service Awy From Home...71 Prts And Accessories Inquiries...71 Service Assistnce Mercury Mrine Service Offices iv

5 Trnsfer Of Wrrnty WARRANTY INFORMATION The limited wrrnty is trnsferble to subsequent purchser, but only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the subsequent owner, send or fx copy of the bill of sle or purchse greement, new owner s nme, ddress nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product by mil. There is no chrge for this service. For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Wrrnty Registrtion United Sttes And Cnd 1. You my chnge your ddress t ny time, including t time of wrrnty clim, by clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx NOTE: Registrtion lists must be mintined by Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act be required. 2. To be eligible for wrrnty coverge, the product must be registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely submit it to Mercury Mrine vi MercNET, E-mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. 3. Upon processing the wrrnty registrtion, Mercury Mrine will send registrtion verifiction by mil to the purchser of the product. If this registrtion verifiction is not received within 30 dys, plese contct your selling deler immeditely. Wrrnty coverge is not effective until your product is registered with Mercury Mrine. Wrrnty Registrtion Outside The United Sttes And Cnd 1. It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the distributor or Mrine Power Service Center responsible for dministering the wrrnty registrtion/clim progrm for your re. 2. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril numbers, dte of sle, type of use nd the selling distributor's/deler's code number, nme nd ddress. The distributor/ deler lso certifies tht you re the originl purchser nd user of the product. 3. A copy of the Wrrnty Registrtion Crd, designted s the Purchser's Copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor/deler. This crd represents your fctory registrtion identifiction, nd should be retined by you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the Wrrnty Registrtion Crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim forms. 1

6 WARRANTY INFORMATION 4. In some countries, the Mrine Power Service Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter receiving the Fctory Copy of the Wrrnty Registrtion Crd from your distributor/deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser's Copy tht you received from the distributor/deler when you purchsed the product. Ask your distributor/ deler if this plstic crd progrm pplies to you. IMPORTANT: Registrtion lists must be mintined by the fctory nd deler in some countries by lw. It is our desire to hve ALL products registered t the fctory should it ever be necessry to contct you. Mke sure your deler/distributor fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. 5. For further informtion concerning the Wrrnty Registrtion Crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. Mercury Mrine Two Yers Limited Wrrnty (Europe) WHAT IS COVERED: Mercury Mrine wrrnts ech new Mercury Outbord, Mriner Outbord, Jet Products, Thruster Electric Trolling Motors, Mercruiser Inbord or Sterndrive engine products to be free of defects in mteril nd workmnship during the period described below. DURATION OF COVERAGE: This Limited Wrrnty provides coverge for two (2) yers from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge of two (2) yers from the dte of first retil sle, or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to one recretionl use to subsequent recretionl use customer upon proper re registrtion of the product. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or subsequent chnge of use from recretionl to commercil (unless properly re registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed in order to mintin wrrnty coverge. If this mintennce is performed by the retil customer Mercury Mrine reserves the right to mke future wrrnty coverge contingent on proof of proper mintennce. WHAT MERCURY WILL DO: Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. 2

7 WARRANTY INFORMATION WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended wide open throttle RPM rnge (see the Opertion nd Mintennce Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion nd Mintennce Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion nd Mintennce Mnul), ltertion or removl of prts, or wter entering the engine through the fuel intke, ir intke or exhust system. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. For dditionl informtion regrding events nd circumstnces covered by this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported by reference into this wrrnty. 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. Mercury Mrine One Yer Limited Wrrnty (Confedertion of Independent Sttes, Middle-Est, Afric) WHAT IS COVERED: Mercury Mrine wrrnts ech new Mercury outbord, Mriner outbord, Jet Products, Thruster Electric Trolling Motors, Mercruiser Inbord or Sterndrive engine products to be free of defects in mteril nd workmnship during the period described below. DURATION OF COVERAGE: This Limited Wrrnty provides coverge for one (1) yer from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge of one (1) yers from the dte of first retil sle, or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent purchser upon proper re registrtion of the product. 3

8 WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or subsequent chnge of use from recretionl to commercil (unless properly re registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed in order to mintin wrrnty coverge. If this mintennce is performed by the retil customer Mercury Mrine reserves the right to mke future wrrnty coverge contingent on proof of proper mintennce. WHAT MERCURY WILL DO: Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbornd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. The wrrnty registrtion crd is the only vlid registrtion identifictionnd must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended wide open throttle RPM rnge (see the Opertion nd Mintennce Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion nd Mintennce Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion nd Mintennce Mnul), ltertion or removl of prts, or wter entering the engine through the fuel intke, ir intke or exhust system. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not coveredby this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. For dditionl informtion regrding events nd circumstnces covered by this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported by reference into this wrrnty. 4

9 DISCLAIMERS AND LIMITATIONS: WARRANTY INFORMATION 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 Yer Limited Wrrnty Aginst Corrosion WHAT IS COVERED: Mercury Mrine wrrnts tht ech new Mercury, Mriner, Mercury Rcing, Sport Jet, M 2 Jet Drive, Trcker by Mercury Mrine Outbord, MerCruiser Inbord or sterndrive engine (Product) will not be rendered inopertive s direct result of corrosion for the period of time described below. DURATION OF COVERAGE: This limited corrosion wrrnty provides coverge for three (3) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir or replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent (non-commercil use) purchser upon proper re-registrtion of the product. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre-delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Corrosion prevention devices specified in the Opertion nd Mintennce Mnul must be in use on the bot, nd routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed (including without limittion the replcement of scrificil nodes, use of specified lubricnts, nd touch-up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO: Mercury's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified re-mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, buse or improper service; corrosion to ccessories, instruments, steering systems; corrosion to fctory instlled jet drive unit; dmge due to mrine growth; product sold with less thn one yer limited Product wrrnty; replcement prts (prts purchsed by customer); products used in commercil ppliction. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. 5

10 WARRANTY INFORMATION Corrosion dmge cused by stry electricl currents (on-shore power connections, nerby bots, submerged metl) is not covered by this corrosion wrrnty nd should be protected ginst by the use of corrosion protection system, such s the Mercury Precision Prts or Quicksilver MerCthode system nd/or Glvnic Isoltor. Corrosion dmge cused by improper ppliction of copper bse nti-fouling pints is lso not covered by this limited wrrnty. If nti-fouling protection is required, Tri-Butyl-Tin-Adipte (TBTA) bse nti-fouling pints re recommended on Outbord nd MerCruiser boting pplictions. In res where TBTA bse pints re prohibited by lw, copper bse pints cn be used on the hull nd trnsom. Do not pply pint to the outbord or MerCruiser product. In ddition, cre must be tken to void n electricl interconnection between the wrrnted product nd the pint. For MerCruiser product, n unpinted gp of t lest 38 mm (1.5 in.) should be left round the trnsom ssembly. Refer to the Opertion nd Mintennce Mnul for dditionl detils. For dditionl informtion regrding events nd circumstnces covered by this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported by reference into this wrrnty. 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. Wrrnty Coverge And Exclusions The purpose of this section is to help eliminte some of the more common misunderstndings regrding wrrnty coverge. The following informtion explins some of the types of services tht re not covered by wrrnty. The provisions set forth following hve been incorported by reference into the Three Yer Limited Wrrnty Aginst Corrosion Filure, the Interntionl Limited Outbord Wrrnty, nd the United Sttes nd Cnd Limited Outbord Wrrnty. Keep in mind tht wrrnty covers repirs tht re needed within the wrrnty period becuse of defects in mteril nd workmnship. Instlltion errors, ccidents, norml wer, nd vriety of other cuses tht ffect the product re not covered. Wrrnty is limited to defects in mteril or workmnship, but only when the consumer sle is mde in the country to which distribution is uthorized by us. Should you hve ny questions concerning wrrnty coverge, contct your uthorized deler. They will be plesed to nswer ny questions tht you my hve. GENERAL EXCLUSIONS FROM WARRANTY 1. Minor djustments nd tune-ups, including checking, clening or djusting sprk plugs, ignition components, crburetor settings, filters, belts, controls, nd checking lubriction mde in connection with norml services. 2. Fctory instlled jet drive units - Specific prts excluded from the wrrnty re: The jet drive impeller nd jet drive liner dmged by impct or wer, nd wter dmged drive shft berings s result of improper mintennce. 3. Dmge cused by neglect, lck of mintennce, ccident, bnorml opertion or improper instlltion or service. 4. Hul out, lunch, towing chrges, removl nd/or replcement of bot prtitions or mteril becuse of bot design for necessry ccess to the product, ll relted trnsporttion chrges nd/or trvel time, etc. Resonble ccess must be provided to the product for wrrnty service. Customer must deliver product to n uthorized deler. 5. Additionl service work requested by customer other thn tht necessry to stisfy the wrrnty obligtion. 6

11 WARRANTY INFORMATION 6. Lbor performed by other thn n uthorized deler my be covered only under following circumstnces: When performed on emergency bsis (providing there re no uthorized delers in the re who cn perform the work required or hve no fcilities to hul out, etc., nd prior fctory pprovl hs been given to hve the work performed t this fcility). 7. All incidentl nd/or consequentil dmges (storge chrges, telephone or rentl chrges of ny type, inconvenience or loss of time or income) re the owner's responsibility. 8. Use of other thn Mercury Precision or Quicksilver prts when mking wrrnty repirs. 9. Oils, lubricnts or fluids chnged s mtter of norml mintennce is customer's responsibility unless loss or contmintion of sme is cused by product filure tht would be eligible for wrrnty considertion. 10. Prticipting in or prepring for rcing or other competitive ctivity or operting with rcing type lower unit. 11. Engine noise does not necessrily indicte serious engine problem. If dignosis indictes serious internl engine condition which could result in filure, condition responsible for noise should be corrected under the wrrnty. 12. Lower unit nd/or propeller dmge cused by striking submerged object is considered mrine hzrd. 13. Wter entering engine through the fuel intke, ir intke or exhust system or submersion. 14. Filure of ny prts cused by lck of cooling wter, which results from strting motor out of wter, foreign mteril blocking inlet holes, motor being mounted too high or trimmed too fr out. 15. Use of fuels nd lubricnts which re not suitble for use with or on the product. Refer to the Mintennce section. 16. Our limited wrrnty does not pply to ny dmge to our products cused by the instlltion or use of prts nd ccessories which re not mnufctured or sold by us. Filures which re not relted to the use of those prts or ccessories re covered under wrrnty if they otherwise meet the terms of the limited wrrnty for tht product. 7

12 Boter's Responsibilities GENERAL INFORMATION The opertor (driver) is responsible for the correct nd sfe opertion of the bot nd sfety of its occupnts nd generl public. It is strongly recommended tht ech opertor (driver) red nd understnd this entire mnul before operting the outbord. Be sure t lest one dditionl person on bord is instructed in the bsics of strting nd operting the outbord nd bot hndling in cse the driver is unble to operte the bot. Before Operting Your Outbord Red this mnul crefully. Lern how to operte your outbord properly. If you hve ny questions, contct your deler. Sfety nd operting informtion tht is prcticed, long with using good common sense, cn help prevent personl injury nd product dmge. This mnul s well s sfety lbels posted on the outbord use the following sfety lerts to drw your ttention to specil sfety instructions tht should be followed.! DANGER DANGER - indictes n imminently hzrdous sitution tht, if not voided, will result in deth or serious injury.! WARNING WARNING - indictes potentilly hzrdous sitution tht, if not voided, could result in deth or serious injury.! CAUTION CAUTION - indictes potentilly hzrdous sitution tht, if not voided, my result in minor or moderte injury or property dmge. It my lso be used to lert ginst unsfe prctices. Bot Horsepower Cpcity! WARNING Using n outbord tht exceeds the mximum horsepower limit of bot cn: 1) cuse loss of bot control 2) plce too much weight t the trnsom ltering the designed flottion chrcteristics of the bot or 3) cuse the bot to brek prt prticulrly round the trnsom re. Overpowering bot cn result in serious injury, deth or bot dmge. Do not overpower or overlod your bot. Most bots will crry required cpcity plte indicting the mximum cceptble power nd lod s determined by the mnufcturer following certin federl guidelines. If in doubt, contct your deler or the bot mnufcturer. 8

13 GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY XXX XXX ob00306 High-Speed And High-Performnce Bot Opertion If your outbord is to be used on high speed or high performnce bot with which you re unfmilir, we recommend tht you never operte it t its high speed cpbility without first requesting n initil orienttion nd fmiliriztion demonstrtion ride with your deler or n opertor experienced with your bot/outbord combintion. For dditionl informtion, obtin copy of our Hi-Performnce Bot Opertion booklet (prt number R 2) from your deler, distributor, or Mercury Mrine. Outbord Remote Control Models ob00307 The remote control connected to your outbord must be equipped with strt in neutrl only protection device. This prevents the engine from strting when the shift is ctuted in ny position other thn neutrl.! WARNING Avoid serious injury or deth from sudden unexpected ccelertion when strting your engine. The design of this outbord requires tht the remote control used with it must hve built in strt in neutrl only protection device. Remote Steering Notice ob00308 The steering link rod tht connects the steering cble to the engine must be fstened utilizing self-locking nuts. These self-locking nuts must never be replced with common nuts (non-locking) s they will work loose nd vibrte off, freeing the link rod to disengge. 9

14 GENERAL INFORMATION! WARNING Disenggement of steering link rod cn result in the bot tking full, sudden, shrp turn. This potentilly violent ction cn cuse occupnts to be thrown overbord exposing them to serious injury or deth. - Self-locking nuts (2) ob00500_01 Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves fr enough wy from the opertor's position (s in ccidentl ejection from the opertor's position) to ctivte the switch. Tiller hndle outbords nd some remote control units re equipped with lnyrd stop switch. A lnyrd stop switch cn be instlled s n ccessory - generlly on the dshbord or side djcent to the opertor's position. The lnyrd is cord usully between 122 nd 152 cm (4 nd 5 feet) in length when stretched out, with n element on one end mde to be inserted into the switch nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t-rest condition s short s possible to minimize the likelihood of lnyrd entnglement with nerby objects. Its stretched-out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. b - Lnyrd cord b - Lnyrd stop switch ob00310 Red the following Sfety Informtion before proceeding. Importnt Sfety Informtion: The purpose of lnyrd stop switch is to stop the engine when the opertor moves fr enough wy from the opertor's position to ctivte the switch. This would occur if the opertor ccidentlly flls overbord or moves within the bot sufficient distnce from the opertor's position. Flling overbord nd ccidentl ejections re more likely to occur in certin types of bots such s low sided infltbles, bss bots, high performnce bots, nd light, sensitive hndling fishing bots operted by hnd tiller. Flling overbord nd ccidentl ejections re lso likely to occur s result of poor operting prctices such s sitting on the bck of the set or gunwle t plning speeds, stnding t plning speeds, sitting on elevted fishing bot decks, operting t plning speeds in shllow or obstcle infested wters, relesing your grip on steering wheel or tiller hndle tht is pulling in one direction, drinking lcohol or consuming drugs, or dring high speed bot mneuvers. While ctivtion of the lnyrd stop switch will stop the engine immeditely, bot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the bot will not complete full circle. While the bot is costing, it cn cuse injury to nyone in the bot's pth s seriously s the bot would when under power. 10

15 GENERAL INFORMATION We strongly recommend tht other occupnts be instructed on proper strting nd operting procedures should they be required to operte the engine in n emergency (e.g. if the opertor is ccidentlly ejected).! WARNING Should the opertor fll out of the bot, the possibility of serious injury or deth from being run over by the bot cn be gretly reduced by stopping the engine immeditely. Alwys properly connect both ends of the stop switch lnyrd to the stop switch nd the opertor.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The bot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Accidentl or unintended ctivtion of the switch during norml opertion is lso possibility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could be thrown forwrd due to unexpected loss of forwrd motion - prticulr concern for pssengers in the front of the bot who could be ejected over the bow nd possibly struck by the gercse or propeller. Loss of power nd directionl control in hevy ses, strong current or high winds. Loss of control when docking. Protecting People In The Wter WHILE YOU ARE CRUISING It is very difficult for person stnding or floting in the wter to tke quick ction to void bot heding in his/ her direction, even t slow speed. ob00311 Alwys slow down nd exercise extreme cution ny time you re boting in n re where there might be people in the wter. Whenever bot is moving (costing) nd the outbord ger shift is in neutrl position, there is sufficient force by the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. WHILE BOAT IS STATIONARY! WARNING Stop your engine immeditely whenever nyone in the wter is ner your bot. Serious injury to the person in the wter is likely if contcted by rotting propeller, moving bot, moving gercse, or ny solid device rigidly ttched to moving bot or gercse. Shift outbord into neutrl nd shut off the engine before llowing people to swim or be in the wter ner your bot. 11

16 GENERAL INFORMATION Pssenger Sfety Messge - Pontoon Bots And Deck Bots Whenever the bot is in motion, observe the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in bot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of bot direction, could throw them over the front of bot. Flling over the front of the bot between the two pontoons will position them to be run over by the outbord. BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the bot is in motion. Keep ll pssengers behind the front fence or enclosure. Persons on the front deck could esily be thrown overbord or persons dngling their feet over the front edge could get their legs cught by wve nd pulled into the wter.! WARNING ob00312 Avoid serious injury or deth from flling over the front end of pontoon or deck bot nd being run over by the outbord. Sty bck from the front end of the deck nd remin seted while the bot is in motion. BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevted fishing sets re not intended for use when the bot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Any unexpected, sudden reduction in bot speed could result in the elevted pssenger flling over the front of the bot. ob00313 Wve And Wke Jumping Operting recretionl bots over wves nd wke is nturl prt of boting. However, when this ctivity is done with sufficient speed to force the bot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the bot re-enters the wter. 12

17 GENERAL INFORMATION ob00314 The primry concern is the bot chnging direction while in the midst of the jump. In such cse the lnding my cuse the bot to veer violently in new direction. Such shrp chnge in direction cn cuse occupnts to be thrown out of their sets, or out of the bot.! WARNING Avoid serious injury or deth from being thrown within or out of bot when it lnds fter jumping wve or wke. Avoid wve or wke jumping whenever possible. Instruct ll occupnts tht if wke or wve jump occurs, get low nd hng on to bot hnd hold. There is nother less common hzrdous result from llowing your bot to lunch off wve or wke. If the bow of your bot pitches down fr enough while irborne, upon wter contct it my penetrte under the wter surfce nd submrine for n instnt. This will bring the bot to nerly instntneous stop nd cn send the occupnts flying forwrd. The bot my lso steer shrply to one side. Impct with Underwter Hzrds Reduce speed nd proceed with cution whenever you drive bot in shllow wter res, or in res where you suspect underwter obstcles my exist which could be struck by the outbord or the bot bottom. The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter object is to control the bot speed. Under these conditions, bot speed should be kept to minimum plning speed 24 to 40 km/h (15 to 25 MPH). ob00315! WARNING To void serious injury or deth from ll or prt of n outbord coming into the bot fter striking floting or underwter obstcle mintin top speed no greter thn minimum plning speed. Striking floting or underwter object could result in n infinite number of situtions. Some of these situtions could result in the following: Prt of the outbord or the entire outbord could brek loose nd fly into the bot. The bot could move suddenly in new direction. Such shrp chnge in direction cn cuse occupnts to be thrown out of their sets or out of the bot. 13

18 GENERAL INFORMATION A rpid reduction in speed. This will cuse occupnts to be thrown forwrd, or even out of the bot. Impct dmge to the outbord nd/or bot. Keep in mind, the most importnt thing you cn do to help reduce injury or impct dmge during n impct is control the bot speed. Bot speed should be kept to minimum plning speed when driving in wters known to hve underwter obstcles. After striking submerged object, stop the engine s soon s possible nd inspect it for ny broken or loose prts. If dmge is present or suspected, the outbord should be tken to n uthorized deler for thorough inspection nd necessry repir. The bot should lso be checked for ny hull frctures, trnsom frctures, or wter leks. Operting dmged outbord could cuse dditionl dmge to other prts of the outbord, or could ffect control of the bot. If continued running is necessry, do so t gretly reduced speeds.! WARNING Avoid serious injury or deth from loss of bot control. Continued boting with mjor impct dmge cn result in sudden outbord component filure with or without subsequent impcts. Hve the outbord thoroughly inspected nd ny necessry repirs mde. SAFETY INSTRUCTIONS FOR HAND TILLED OUTBOARDS No person or crgo should occupy the re directly in front of the outbord while the bot is in motion. If n underwter obstcle is struck, the outbord will tilt up nd could seriously injure nyone occupying this re. Models With Clmp Screws: Some outbords come with trnsom brcket clmp screws. The use of clmp brcket screws lone, is insufficient to properly nd sfely secure the outbord to the trnsom. Proper instlltion of the outbord includes bolting the engine to the bot through the trnsom. Refer to Instlltion - Instlling Outbord for more complete instlltion informtion.! WARNING Avoid serious injury or deth from being struck by disconnected outbord. Do not ccelerte bove idle speed in wter suspected of contining underwter obstcles if the outbord is not ttched to the trnsom correctly. If n obstcle is struck t plning speed nd the outbord is not securely fstened to the trnsom, it is possible the outbord could lift off the trnsom nd lnd in the bot. Exhust Emissions BE ALERT TO CARBON MONOXIDE POISONING Crbon monoxide is present in the exhust fumes of ll internl combustion engines. This includes the outbords, sterndrives nd inbord engines tht propel bots, s well s the genertors tht power vrious bot ccessories. Crbon monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of crbon monoxide poisoning which should not be confused with sesickness or intoxiction, include hedche, dizziness, drowsiness, nd nuse.! WARNING Avoid the combintion of running engine nd poor ventiltion. Prolonged exposure to crbon monoxide in sufficient concentrtion cn led to unconsciousness, brin dmge, or deth. GOOD VENTILATION Ventilte pssenger re, open side curtins, or forwrd htches to remove fumes. 14

19 GENERAL INFORMATION ob00316 Exmple of desired ir flow through the bot. POOR VENTILATION Under certin running nd/or wind conditions, permnently enclosed or cnvs enclosed cbins or cockpits with insufficient ventiltion my drw in crbon monoxide. Instll one or more crbon monoxide detectors in your bot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n enclosed re of sttionry bot tht contins or is ner running engine my be exposed to hzrdous level of crbon monoxide. WHILE BOAT IS STATIONARY b - b - Running the engine when the bot is moored in confined spce. Mooring close to nother bot tht hs its engine running. ob00317 WHILE BOAT IS MOVING b - b - Running the bot with the trim ngle of the bow too high. Running the bot with no forwrd htches open. ob00318 Selecting Accessories For Your Outbord Genuine Mercury Precision or Quicksilver Accessories hve been specificlly designed nd tested for your outbord. These ccessories re vilble from Mercury Mrine delers.! WARNING Check with your deler before instlltion of ccessories. The misuse of cceptble ccessories or the use of uncceptble ccessories cn result in serious injury, deth, or product filure. 15

20 GENERAL INFORMATION Some ccessories not mnufctured or sold by Mercury Mrine re not designed to be sfely used with your outbord or outbord operting system. Acquire nd red the instlltion, opertion, nd mintennce mnuls for ll your selected ccessories. Sfe Boting Suggestions In order to sfely enjoy the wterwys, fmilirize yourself with locl nd other governmentl boting regultions nd restrictions, nd consider the following suggestions. Use flottion devices. Hve n pproved personl flottion device of suitble size for ech person bord (it is the lw) nd hve it redily ccessible. Do not overlod your bot. Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot cpcity plte). If in doubt, contct your deler or the bots mnufcturer. Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Know nd obey ll nuticl rules nd lws of the wterwys. Bot opertors should complete boting sfety course. Courses re offered in the U.S.A. by 1) The U.S. Cost Gurd Auxiliry, 2) The Power Squdron, 3) The Red Cross nd 4) your stte boting lw enforcement gency. Inquiries my be mde to the Boting Hotline, or the Bot U.S. Foundtion informtion number BOAT. Mke sure everyone in the bot is properly seted. Do not llow nyone to sit or ride on ny prt of the bot tht ws not intended for such use. This includes the bck of sets, gunwles, trnsom, bow, decks, rised fishing sets, ny rotting fishing set; or nywhere tht n unexpected ccelertion, sudden stopping, unexpected loss of bot control, or sudden bot movement could cuse person to be thrown overbord or into the bot. Never be under the influence of lcohol or drugs while boting (it is the lw). Alcohol or drug use impirs your judgment nd gretly reduces your bility to rect quickly. Prepre other bot opertors. Instruct t lest one other person on bord in the bsics of strting nd operting the outbord, nd bot hndling, in cse the driver becomes disbled or flls overbord. Pssenger bording. Stop the engine whenever pssengers re bording, unloding, or re ner the bck (stern) of the bot. Just shifting the outbord into neutrl is not sufficient. Be lert. The opertor of the bot is responsible by lw to mintin proper lookout by sight nd hering. The opertor must hve n unobstructed view prticulrly to the front. No pssengers, lod, or fishing sets should block the opertors view when operting the bot bove idle speed. Never drive your bot directly behind wter skier in cse the skier flls. As n exmple, your bot trveling t 40 km/h (25 MPH) will overtke fllen skier 61 m (200 ft.) in front of you in 5 seconds. Wtch fllen skiers. When using your bot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the bot while returning to ssist the skier. The opertor should lwys hve the down skier in sight nd never bck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required by lw to file Boting Accident Report with their stte boting lw enforcement gency when their bot is involved in certin boting ccidents. A boting ccident must be reported if 1) there is loss of life or probble loss of life, 2) there is personl injury requiring medicl tretment beyond first id, 3) there is dmge to bots or other property where the dmge vlue exceeds $ or 4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement. Recording Seril Number It is importnt to record this number for future reference. The seril number is locted on the outbord s shown. 16

21 GENERAL INFORMATION XXXXXXXX XXXX XXXX b c - b - c - Seril number Model yer Model designtion e XX d - e - d ob01144 Yer mnufctured Certified Europe Insigni (s pplicble) 8/9.9 4-Stroke Specifictions - Interntionl Models Bigfoot Horsepower Kilowtts Weight MH 38.3 kg (84 lb.) N/A MLH 39.2 kg (86 lb.) 43.5 kg (95.9 lb.) MXLH N/A 45 kg (99.2 lb.) EH 41.1 kg (91 lb.) N/A ELH 42.3 kg (93 lb.) 46.6 kg (102.7 lb.) EXLH N/A 48.1 kg (106 lb.) ELHPT N/A 50.4 kg (111.1 lb.) EXLHPT N/A 51.9 kg (114.4 lb.) MRC 36.5 kg (80 lb.) N/A ELRC 40.7 kg (90 lb.) 45.1 kg (99.4 lb.) EXLRC N/A 46.6 kg (102.7 lb.) ELPT N/A 48.9 kg (107.8 lb.) EXLRCPT N/A 50.4 kg (111.1 lb.) Number of Cylinders 2 Full Throttle RPM Rnge Idle Speed in Forwrd Ger RPM 900 RPM 17

22 GENERAL INFORMATION Models Bigfoot Piston Displcement Cylinder Bore Piston Stroke cc (12.8 cu. in.) 55 mm (2.17 in.) 44 mm (1.73 in.) Vlve Clernce (Cold) Intke Vlve Exhust Vlve Recommended Sprk Plug Sprk Plug Gp mm ( in.) mm ( in.) NGK DCPR6E mm ( in.) Ger Rtio 2.08:1 2.42:1 Recommended Gsoline Recommended Oil Engine Oil Cpcity Gercse Lubricnt Cpcity Bttery Rting (electric strt models) Refer to Fuel & Oil Refer to Fuel & Oil 800 ml (27.0 fl. oz.) 320 ml (10.8 fl. oz.) 370 ml (12.5 fl. oz.) 465 Mrine Crnking Amps (MCA) or 350 Cold Crnking Amps (CCA) Sound t Drivers Er (ICOMIA 39-94) 4 - Stroke 78 18

23 GENERAL INFORMATION Component Identifiction - Stndrd Models STARBOARD SIDE VIEW c b e d f g h i k j ob Cowl ltch g - Engine flush plug b - Throttle only button h - Ger lubricnt level plug c - Throttle friction djustment knob i - Wter inlet d - Wter pump indictor hole j - Ger lubricnt fill/drin plug e - Oil drin plug k - Trim tb f - Trnsom ngle preset knob 19

24 GENERAL INFORMATION FRONT VIEW b c d e g f ob Choke/fst idle knob e - Strt switch (electric tiller hndle) b - Fuel primer f - Lnyrd sfety switch c - Oil pressure light g - Trim/tilt position indictor d - Fuel line connector 20

25 GENERAL INFORMATION PORT VIEW b c d ob b - Tiller lock relese lever Strt switch (electric tiller hndle model) c - d - Steering friction djustment lever (tiller model only) Tilt lock knob 21

26 GENERAL INFORMATION Component Identifiction - Bigfoot Models o i n h m l j c b g k d f e Trnsom brcket i - Cowl ltch b - Tilt support lever j - Oil drin screw c - Ger lubricnt level plug k - Power tilt d - Wter inlet l - Kicker strp e - Ger lubricnt fill/drin plug m - Throttle only button f - Anti-ventiltion plte n - Throttle grip friction knob g - Engine flush plug o - Power tilt button h - Wter pump indictor hole 22

27 Instlling Outbord INSTALLATION! WARNING Before opertion, the outbord must be correctly instlled with the required mounting hrdwre s shown. Filure to correctly fsten outbord could result in outbord ejecting off bot trnsom cusing serious injury, deth, or property dmge. BOAT TRANSOM HEIGHT REQUIREMENT 1. Mesure the trnsom height of your bot. The bot bottom should be ligned or be within 25 mm (1 in.) bove the nti-ventiltion plte of the outbord. - Anti-ventiltion plte ob00502 INSTALLING OUTBOARD ON TRANSOM 1. Plce outbord on center line of trnsom. ob Tighten trnsom clmp screws. ob To prevent loss of outbord, fsten outbord by drilling two 7.9 mm (5/16 in.) holes through the trnsom using trnsom clmp holes s templte. Fsten with two bolts, flt wshers nd locknuts. Use mrine wterproofing seler in holes nd round bolts to mke the instlltion wter tight. 23

28 INSTALLATION b c ob Bolts (2) b - Wsher (2) c - Locknut (2) Bttery Instlltion - Electric Strt Models MOUNTING BATTERY Follow the bttery mnufcturer's instructions crefully. Mount bttery in the bot so it is secured ginst movement, preferbly in bttery box. Mke sure bttery is equipped with nonconductive shield to prevent ccidentl shorting of bttery terminls. NOTE: Electric strting outbords must hve the bttery cbles connected to bttery whenever the engine is running. Even if strted mnully, s dmge to the chrging system could result. Bttery Connections CONNECTING OUTBOARD BATTERY CABLES 1. First, connect the red bttery cble to the (+) positive bttery terminl nd then connect the blck bttery cble to the (-) negtive bttery terminl. DISCONNECTING OUTBOARD BATTERY CABLES 1. First, disconnect the blck bttery cble from the (-) negtive terminl nd then disconnect the red bttery cble from the (+) positive terminl. Propeller Selection ob00506 The propeller supplied with your outbord provides the best overll performnce under verge operting conditions. Alterntive propellers re vilble for specific boting requirements. See your outbord deler. 24

29 TRANSPORTING Crrying, Storing nd Trnsporting Your Outbord When Removed From Bot! CAUTION Trnsport nd store the outbord only s shown. Otherwise, engine dmge or property dmge could result from leking oil. 1. With the outbord still in the wter, disconnect the remote fuel line nd run engine until it stops. This will drin fuel from the crburetor. Instll the protector cp over the fuel connector. ob Protector cp 2. Remove outbord nd hold it upright until the wter is drined out. Keep the outbord in n upright position when crrying. ob Crry, trnsport or store the outbord only in the upright position or tiller hndle down position. These positions will prevent oil from drining out of the crnkcse. b ob Upright position b - Tiller hndle down position 4. Never crry, store or trnsport the outbord in these positions. Engine dmge could result from oil drining out of the crnkcse. 25

30 TRANSPORTING ob00453 Trnsporting Portble Fuel Tnks! WARNING Avoid serious injury or deth from gsoline fire or explosion. Follow portble fuel tnk trnsporting instructions. Trnsport the fuel tnk in well ventilted re wy from open flme or sprks. MANUAL VENTING TYPE FUEL TANK 1. Close fuel tnk ir vent when trnsporting tnk. This will prevent escpe of fuel or vpors from tnk. AUTO-VENTING TYPE FUEL TANK ob Disconnect the remote fuel line from tnk. This will close the ir vent nd prevent escpe of fuel or vpors from tnk. 2. Instll tether cp over the fuel line connector stem. This will protect the connector stem from being ccidently pushed-in, thus, llowing fuel or vpor to escpe. F b ob Connector stem b - Tether cp Trilering Bot/Outbord - Models with Power Tilt Triler your bot with the outbord tilted down in verticl operting position. If dditionl ground clernce is required, the outbord should be tilted up using n ccessory outbord support device. Refer to your locl deler for recommendtions. Additionl clernce my be required for rilrod crossings, drivewys nd triler bouncing. 26

31 TRANSPORTING ob00324 IMPORTANT: Do not rely on the power tilt system or tilt support lever to mintin proper ground clernce for trilering. The outbord tilt support lever is not intended to support the outbord for trilering. Shift the outbord to forwrd ger. This prevents the propeller from spinning freely. Trilering Bot/Outbord - Models without Power Tilt Triler your bot with the outbord tilted down in verticl operting position. If dditionl ground clernce is required, the outbord should be tilted up using the shllow wter drive/trilering brcket. Additionl clernce my be required for rilrod crossings, drivewys, nd triler bouncing. IMPORTANT: The tilt lock lever should be used to lock the outbord down when trilering. This will prevent the outbord from bouncing nd cusing possible dmge to the outbord. Shift the outbord to forwrd ger. This prevents the propeller from spinning freely. 27

32 Gsoline Recommendtions UNITED STATES AND CANADA FUEL AND OIL Use mjor brnd of utomotive unleded gsoline with minimum posted octne rting of 87. Mid-grde utomotive gsolines tht contin fuel injector clener re preferred for dded internl engine clenliness. Leded gsoline is not recommended. INTERNATIONAL Use mjor brnd of utomotive unleded gsoline with minimum posted octne rting of 90RON. Automotive gsolines tht contin fuel injector clener re preferred for dded internl engine clenliness. Leded gsoline is cceptble in res where unleded gsoline is not vilble. USING REFORMULATED (OXYGENATED) FUELS - UNITED STATES ONLY This type of fuel is required in certin res of the United Sttes. The two types of reformulted ingredients in these fuels re lcohol (Ethnol) or Ether (MTBE or ETBE). If Ethnol is the oxygentes tht is used in the gsoline, refer to Alcohol in Gsoline. These reformulted fuels re cceptble for use in the Mercury engine. ALCOHOL IN GASOLINE We do not recommend the use of gsoline which contins lcohol becuse of the possible dverse effect the lcohol my hve on the fuel system. In generl, if only gsoline contining lcohol is vilble, it must not contin more thn 10% ethnol or 5% methnol, nd the ddition of wter seprting fuel filter is recommended. If gsoline contining lcohol is used or if you suspect the presence of lcohol in your gsoline, increse your inspection of the fuel system, visully checking for fuel leks or bnormlities. Gsoline contining lcohol my cuse the following problems to your outbord nd fuel system: Corrosion of metl prts Deteriortion of elstomers nd plstic prts Wer nd dmge of internl engine prts Strting nd operting difficulties Vpor lock or fuel strvtion Some of these dverse effects re due to the tendency of gsoline contining lcohol to bsorb moisture from the ir, resulting in phse of wter nd lcohol which seprtes from the gsoline in the fuel tnk. The dverse effects of lcohol re more severe with methnol nd re worse with incresing content of lcohol. Filling Fuel Tnk! WARNING Avoid serious injury or deth from gsoline fire or explosion. Alwys stop the engine nd do not smoke or llow open flmes or sprks in the re while filling fuel tnks. Fill fuel tnks outdoors wy from het, sprks, nd open flmes. Remove portble fuel tnks from bot to refill them. Alwys stop engine before refilling tnks. Do not completely fill the fuel tnks. Leve pproximtely 10% of the tnk volume unfilled. Fuel will expnd in volume s its temperture rises nd cn lek under pressure if the tnk is completely filled. PORTABLE FUEL TANK PLACEMENT IN THE BOAT Plce the fuel tnk in the bot so the vent is higher thn the fuel level under norml bot operting conditions. 28

33 Engine Oil Recommendtions FUEL AND OIL We recommend the use of Mercury or Quicksilver SAE 10W-30 multi-viscosity 4-Stroke Outbord Oil for generl, ll-temperture use. If SAE 25W-40 multi-viscosity oil is preferred, use Mercury MerCruiser 4-cycle engine oil or Quicksilver sterndrive & inbord 4-cycle engine oil. Never use 4-cycle engine oil tht is not certified to meet or exceed ny one or combintion of the following Americn Petroleum Institute (API) Service Clssifiction SH, SG, SF, CF-4, CE, CD, CDII. Severe engine dmge my result from use of n inferior oil. F C b ob00327 Recommended SAE Viscosity for Engine Oil - b - SAE 25W-40 viscosity oil my be used t tempertures bove 4 C (40 F) SAE 10W-30 viscosity oil is recommended for use in ll tempertures. Checking Engine Oil IMPORTANT: Do not overfill. Be sure tht the outbord is upright (not tilted) when checking oil. 1. Turn the engine off. Hve the outbord in level operting position. Remove the top cowl. 2. Remove dipstick. Wipe dipstick with clen rg or towel nd push it bck in ll the wy. 3. Pull the dipstick out gin nd observe the oil level. If oil level is low, remove oil filler cp nd fill to (but not over) the full mrk with the recommended oil. IMPORTANT: Inspect oil for signs of contmintion. Oil contminted with wter will hve milky color to it; oil contminted with fuel will hve strong fuel smell. If contminted oil is noticed, hve the engine checked by your deler. 29

34 4. Reinstll the oil filler cp nd tighten securely. FUEL AND OIL b - Dipstick b - Oil filler cp

35 Tiller Hndle Fetures FEATURES AND CONTROLS IMPORTANT: Avoid engine flooding - Do not rotte the throttle grip while engine is not running. Doing so will inject fuel into the engine nd cuse possible hrd strting flooded condition. Tiller Hndle - Hndle cn be tilted 180 for convenient hndling during trnsporttion nd storge. ob01153 Tiller Lock Relese Lever - Push lever to move tiller hndle from one position to nother. Tiller Hndle Lock Cp - Remove the lock cp on top of tiller hndle to lock in up position. Push tiller lock relese lever to relese the hndle from the locked up position

36 FEATURES AND CONTROLS b - Lock cp b - Locking mechnism 3273 Strter Rope - Pulling the strter rope crnks the engine over for strting. ob01154 Lnyrd Stop Switch - Refer to Generl Informtion - Lnyrd Stop Switch. Engine Stop Switch - Push in to stop engine. ob00350 ob01155 Power Tilt Switch - Push to tilt engine up/down. 32

37 FEATURES AND CONTROLS Throttle Grip Friction Knob - Turn friction knob to set nd mintin the throttle t desired speed. Turn knob clockwise to tighten friction or turn knob counterclockwise to loosen friction b ob b - Loosen friction (counterclockwise) Tighten friction (clockwise) Throttle Only Button - Pressing the button in while the outbord is in neutrl disbles the ger shift control of the tiller hndle. Throttle Grip - Controls engine speed nd shifting. ob01162 b - Reverse b - Forwrd ob01157 Choke - Pull out when strting cold engine. 33

38 FEATURES AND CONTROLS ob01158 Fuel primer - Press in when strting cold engine. Refer to Opertion - Strting The Engine. ob01160 Low oil pressure wrning light - Wrns the opertor the engine hs low oil pressure. When the low oil pressure light is on or is blinking, the engine will run rough nd will not exceed 3000 RPM. Electric Strt Button (Electric Strt Models) - Press button to strt engine. ob01161! WARNING ob01150 Avoid possible serious injury or deth from loss of bot control. Mintin sufficient steering friction to prevent the outbord from steering into full turn if the tiller hndle or steering wheel is relesed. 34

39 FEATURES AND CONTROLS Steering Friction Adjustment - Adjust this lever to chieve the desired steering friction (drg) on the tiller hndle. Move lever to the left to tighten, or move lever to the right to loosen. b ob b - Tighten Loosen Tilt Lock Knob - Locks the engine in the full tilt position. ob01174 Trim Position Knob - Pre-sets the trim position. ob01163 Kicker Strp (Power Tilt Models) - Prevents the engine from turning while tilted up. 35

40 FEATURES AND CONTROLS Remote Control Fetures Your bot my be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your deler for description of the functions nd opertions of the remote control f c d e b c h g d e f b g i i c ob00329 f - b - c - d - e - f - g - h - i - Control hndle - forwrd, neutrl, reverse. Neutrl relese lever Trim/tilt switch (if equipped). - Refer to Fetures & Controls - Power Trim nd Tilt. Lnyrd stop switch - Refer to Generl Informtion - Lnyrd Stop Switch. Lnyrd - Refer to Generl Informtion - Lnyrd Stop Switch. Throttle friction djustment - Console controls require cover removl for djustment. Ignition key switch - off, on, strt. Fst idle lever - Refer to Opertion - Strting the Engine. Throttle only button - Refer to Opertion - Strting the Engine. Wrning System The wrning system on this engine does not hve wrning horn. Insted, there is n oil pressure light locted on the front of the engine. If oil pressure drops below 25 kp (3.6 PSI) the oil pressure light will illuminte, the Engine Gurdin System will be ctivted, nd engine RPM will be limited to The Engine Gurdin System will lso limit RPM of the engine in the event of n over-speed condition due to cvittion, no lod on propeller, nd/or under propped. 36

41 Power Tilt (if equipped) FEATURES AND CONTROLS This outbord hs tilt control clled power tilt. This enbles the opertor to esily djust the position of the outbord by pressing the tilt switch. With the engine turned off, the outbord cn be tilted out of the wter. At low idle speed, the outbord cn lso be tilted up to permit shllow wter opertion. TILTING OPERATION To tilt outbord, shut off the engine nd press the tilt switch to the up position. The outbord will tilt up until the switch is relesed or it reches its mximum tilt position. Tiller hndle models hve kicker strp locted on ech side of the outbord, preventing the outbord from turning when tilted up

42 FEATURES AND CONTROLS Engge the tilt support lever by rotting lever down. 2. Lower outbord to rest on the tilt support lever. 3. Disengge the tilt support lever, by rising the outbord off the support lever nd lifting the knob. Lower the outbord Tilt support lever b - Knob b

43 FEATURES AND CONTROLS Setting The Trnsom Angle Of Your Outbord The verticl trnsom ngle of your outbord is djusted by chnging the position of the preset tilt knob in one of the three djustment holes provided. Proper djustment llows the bot to chieve optimum performnce, stbility, nd minimize steering effort. NOTE: Refer to the following lists when djusting the trnsom ngle of your outbord. The preset tilt knob should be djusted so the outbord is positioned to run perpendiculr to the wter when the bot is running t full speed. This llows the bot to be driven prllel to the wter. Arrnge pssengers nd lod in the bot so the weight is distributed evenly. b c ob b - c - Too much ngle (stern down - bow up) Not enough ngle (stern up - bow down) Angle djusted properly (bow slightly up) Consider the following lists crefully when djusting the operting ngle of your outbord. Adjusting the outbord close to the bot trnsom cn: Lower the bow. Result in quicker plning off, especilly with hevy lod or stern hevy bot. Generlly improve the ride in choppy wter. Increse steering torque or pull to the right. In excess cn lower the bow of some bots to point where they begin to plow with their bow in the wter while on plne. This cn result in n unexpected turn in either direction (clled bow steering or over-steering) if ny turn is ttempted or if significnt wve is encountered. 39

44 FEATURES AND CONTROLS Adjusting the outbord wy from the bot trnsom cn: Lift the bow out of the wter. Generlly increse top speed. Increse clernce over submerged objects or shllow bottom. Increse steering torque or pull to the left t norml instlltion height. In excess cn cuse bot porpoising (bouncing) or propeller ventiltion. Adjusting Trnsom Angle 1. Stop the engine. Shift the outbord into forwrd. Rise the engine to one of the tilt relese positions. Chnge the preset knob position nd lower the outbord to the preset trnsom ngle position. 2. Repet step number one if the trnsom ngle needs further djustment. b ob Trnsom ngle settings b - Tilt relese position Shllow Wter Opertion There re three (3) shllow wter drive positions tht enble the outbord to be tilted up to prevent hitting the bottom. 1. Stop the engine. Shift the outbord into neutrl. Tilt the outbord up to one of the shllow wter drive positions. Ensure the wter intke is submerged. 2. To relese the shllow wter drive, stop engine nd tilt outbord up to one of the tilt relese position. Gently lower the outbord to the preset trnsom ngle. 40

45 FEATURES AND CONTROLS b c ob Shllow wter drive positions c - Wter Intke b - Tilt relese positions IMPORTANT: Do not operte the outbord in reverse while using the shllow wter drive. Operte t slow speeds nd keep the wter intke submerged. Tilting Outbord 1. Stop the engine. Shift the outbord into the forwrd ger position. 2. Tke hold of the top cowl grip nd rise the outbord to the full up position. 3. Pull out on the tilt lock knob nd move it to the lock position. The outbord cnnot be lowered while the tilt lock knob is in the lock position. 4. To lower the engine, move the tilt lock knob to the unlock position. 5. Rise the outbord to the tilt relese position nd gently lower the outbord to the preset trim position. b c ob b - c - Tilt lock knob in lock position Tilt lock knob in unlock position Tilt rnge indictor 41

46 Trim Tb Adjustment FEATURES AND CONTROLS Propeller steering torque will cuse your bot to pull in one direction. This steering torque is norml thing tht results from your outbord not being trimmed so the propeller shft is prllel to the wter surfce. The trim tb cn help compenste for this steering torque in mny cses nd cn be djusted within limits to reduce ny unequl steering effort. ob00344 NOTE: Trim tb djustment will hve little effect reducing steering torque if the outbord is instlled with the nti-ventiltion plte pproximtely 50 mm (2 inches) or more bove the bot bottom. Operte your bot t norml cruising speed, trimmed to the desired position. Turn your bot left nd right nd note the direction the bot turns more esily. If djustment is necessry, loosen trim tb bolt nd mke smll djustments t time. If the bot turns more esily to the left, move the triling edge of trim tb to the left. If the bot turns more esily to the right move the triling edge of trim tb to the right. Retighten bolt nd retest. 42

47 Pre-Strting Check List OPERATION Opertor knows sfe nvigtion, boting, nd operting procedures. An pproved personl flottion device of suitble size for ech person bord nd redily ccessible (it is the lw). A ring type life buoy or buoynt cushion designed to be thrown to person in the wter. Know your bots mximum lod cpcity. Look t the bot cpcity plte. Fuel supply OK. Arrnge pssengers nd lod in the bot so the weight is distributed evenly nd everyone is seted in proper set. Tell someone where you re going nd when you expect to return. It is illegl to operte bot while under the influence of lcohol or drugs. Know the wters nd re you will be boting; tides, currents, snd brs, rocks, nd other hzrds. Mke inspection checks listed in Mintennce - Inspection nd Mintennce Schedule. Operting In Freezing Tempertures When using your outbord or hving your outbord moored in freezing or ner freezing tempertures, keep the outbord tilted down t ll times so the gercse is submerged. This prevents trpped wter in gercse from freezing nd cusing possible dmge to the wter pump nd other components. If there is chnce of ice forming on the wter, the outbord should be removed nd drined completely of wter. If ice should form t the wter level inside the outbord driveshft housing, it will block wter flow to the engine cusing possible dmge. Operting In Slt Wter Or Polluted Wter We recommend tht you flush the internl wter pssges of your outbord with fresh wter fter ech use in slt or polluted wter. This will prevent buildup of deposits from clogging the wter pssges. Refer to Mintennce - Flushing The Cooling System. If you keep your bot moored in the wter, lwys tilt the outbord so the gercse is completely out of wter (except in freezing tempertures) when not in use. Wsh the outbord exterior nd flush out the exhust outlet of the propeller nd gercse with fresh wter fter ech use. Ech month, spry Mercury Precision or Quicksilver Corrosion Gurd on externl metl surfces. Do not spry on corrosion control nodes s this will reduce the effectiveness of the nodes. Operting Outbord As An Auxiliry Engine If the outbord is used s n uxiliry engine, stop the engine nd tilt the outbord out of the wter when using the min power source. IMPORTANT: The outbord must be restrined from bouncing while operting the bot using the min power source. Bouncing cn dmge the outbord nd bot trnsom. Pre-Strting Instructions 1. Connect the remote fuel line to the outbord. Mke sure connector is snpped into plce. ob

48 OPERATION 2. Check the engine oil level. ob00555! CAUTION Never strt or operte your outbord (even momentrily) without wter circulting through ll the cooling wter intke holes in the gercse to prevent dmge to the wter pump (running dry) or overheting of the engine. 3. Mke sure the cooling wter intke is submerged. Engine Brek-in Procedure! CAUTION ob00347 Severe dmge to the engine cn result by not complying with the Engine Brek-in Procedure. 1. For the first hour of opertion, run the engine t vried throttle settings up to 2000 RPM or t pproximtely hlf throttle. 2. For the second hour of opertion, run the engine t vried throttle settings up to 3000 RPM or t three-qurter throttle, nd t full throttle for pproximtely one minute every ten minutes. 3. For the next eight hours of opertion, void continuous opertion t full throttle for more thn five minutes t time. Strting The Engine - Tiller Hndle Models Before strting, red the Pre-Strting Check List, Specil Operting Instructions, nd Engine Brek-in Procedure in the Opertion Section. IMPORTANT: Avoid engine flooding - Do not rotte the throttle grip while engine is not running. This will inject fuel into the engine nd my cuse hrd strting flooded condition. 1. Open fuel tnk vent on mnul venting type tnks. 44

49 OPERATION 2. Squeeze the fuel line primer bulb severl times until it feels firm. ob00348 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb fter engine hs wrmed up. ob Set the lnyrd stop switch to "RUN" position. Refer to Generl Informtion - Lnyrd Stop Switch. 4. Set the tiller hndle ger shift to neutrl (N) position. ob00350 ob Cold Engine - Pull out the choke knob for strting. Push in the choke knob fter engine strts. 6. Press the fuel primer in twice. ob

50 OPERATION ob01160 IMPORTANT: Outbords with bttery chrging cpbilities must not be operted with bttery cbles disconnected from the bttery. Dmge to the chrging system my result. 7. Mnul Strting Models - Pull the strter rope slowly until you feel the strter engge, then pull rpidly to crnk the engine. Allow rope to return slowly. Repet until engine strts. After the engine hs strted, push in the choke knob. ob Electric Strt Tiller Hndle Models - Push strter button nd crnk the engine. Relese button when engine strts. Do not operte strter motor continuously for longer thn ten seconds t time. If engine fils to strt, wit 30 seconds nd try gin. 9. Strting Flooded Engine - If engine will not strt, push in the throttle only button nd dvnce the throttle grip to fst throttle speed. Push in the choke knob nd retry strting the engine. After engine hs strted, immeditely reduce throttle speed to idle.! WARNING ob01162 RAPID ACCELERATION HAZARD - Before shifting your outbord from neutrl into ger, decrese engine speed to slow. This will prevent rpid ccelertion tht cn cuse people in the bot to be thrown from their sets or out of the bot, cusing injury or deth. 10. Check for stedy strem of wter flowing out of the wter pump indictor hole. 46

51 OPERATION ob00559 IMPORTANT: If no wter is coming out of the wter pump indictor hole, stop engine nd check cooling wter intke for obstruction. No obstruction my indicte wter pump filure or blockge in the cooling system. These conditions will cuse the engine to overhet. Hve the outbord checked by your deler. Operting the engine while overheted will cuse serious engine dmge. WARMING UP ENGINE Before beginning opertion, llow the engine to wrm up t idling speed for 3 minutes. Strting The Engine - Remote Control Models Before strting, red the Pre-Strting Check List, Specil Operting Instructions, nd Engine Brek-in Procedure in the Opertion Section. 1. Open fuel tnk vent screw (in filler cp) on mnul venting type tnks. 2. Squeeze the fuel line primer bulb severl times until it feels firm. ob00348 ob00349 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb fter engine hs wrmed up. 3. Set the lnyrd stop switch to "RUN" position. Refer to Generl Informtion - Lnyrd Stop Switch. 4. Set the remote control hndle to neutrl position. ob00350 IMPORTANT: Avoid engine flooding - Do not dvnce the throttle while engine is not running. This will inject fuel into the engine nd my cuse hrd strting flooded condition. 47

52 OPERATION N ob00351 IMPORTANT: Outbords with bttery chrging cpbilities must not be operted with bttery cbles disconnected from the bttery. Dmge to the chrging system my result. 5. Do not dvnce the neutrl fst idle speed feture on the remote control for initil strting. After the engine hs strted, you cn slowly dvnce the fst idle speed feture to increse idle speed until engine is wrmed up. Keep engine speed below 2000 RPM. ob00560 NOTE: Strting Flooded Engine - lift the neutrl fst idle lever to full up nd continue to crnk the engine for strting. 6. Turn ignition key to "START" position nd strt the engine. If engine is cold, push in on key to choke the engine while crnking. If engine fils to strt in ten seconds, wit 30 seconds nd try gin. If engine begins to stll, re-choke (push key in) until engine is running smoothly. ob Check for stedy strem of wter flowing out of the wter pump indictor hole. ob00559 IMPORTANT: If no wter is coming out of the wter pump indictor hole, stop engine nd check cooling wter intke for obstruction. No obstruction my indicte wter pump filure or blockge in the cooling system. These conditions will cuse the engine to overhet. Hve the outbord checked by your deler. Operting the engine while overheted will cuse engine dmge. WARMING UP ENGINE Before beginning opertion, llow the engine to wrm up t idling speed for 3 minutes. 48

53 OPERATION Strting Hot Engine TILLER HANDLE MODELS 1. Pull out the choke knob. 2. Crnk the engine with the recoil rope or with the electric strt button. 3. Push in the choke knob fter engine hs strted. REMOTE CONTROL MODELS 1. Crnk the engine over while pushing the key in to engge the choke solenoid. 2. After the engine hs strted, relese the key. Ger Shifting IMPORTANT: Never shift outbord into ger unless engine speed is t idle. Do not shift outbord into reverse when the engine is not running. Your outbord hs three ger shift positions to provide opertion: Forwrd (F), Neutrl (N), nd Reverse (R). Tiller Hndle Models - Reduce engine speed to idle before shifting. b c ob (R) Reverse c - (F) Forwrd b - (N) Neutrl Remote Control Models - When shifting, lwys stop t neutrl position nd llow the engine speed to return to idle. F N R ob00557 Alwys shift outbord into ger with quick motion. After shifting outbord into ger, dvnce the remote control lever or rotte the throttle grip (tiller hndle) to increse speed. Stopping The Engine 1. Remote Control Models - Reduce engine speed nd shift outbord to neutrl position. Turn ignition key to "OFF" position. 49

54 OPERATION ob Tiller Hndle Models - Reduce engine speed nd shift outbord to neutrl position. Push in the engine stop button or turn ignition key to "OFF" position. ob00361 Emergency Strting If the strter system fils, use the spre strter rope (provided) nd follow this procedure.! WARNING When using emergency strter rope to strt engine, the strt in ger protection device is inopertive. Mke sure to set the outbord ger shift into neutrl to prevent outbord from strting in ger. Sudden unexpected ccelertion could result in serious injury or deth. 1. Shift the outbord into neutrl. 2. Ensure the lnyrd stop switch is in the run position. 3. Remove the top cowl. 4. Remove the three screws holding the flywheel cover on. 50

55 OPERATION b - Flywheel cover screws (3) b - Recoil neutrl interlock c c - Fuse holder ob Remove the flywheel cover. 6. Remote Control models - Ensure the key switch is in the "ON" position.! WARNING To prevent getting n electricl shock, do not touch ny ignition component, wiring, or sprk plug wire when strting or running the engine.! WARNING The exposed moving flywheel cn cuse serious injury. Keep your hnds, hir, clothing, tools, nd other objects wy from engine when strting or running the engine. Do not ttempt to reinstll the flywheel cover or top cowl when engine is running. 7. Refer to the pproprite strting procedure (cold or hot). 8. Plce the strter rope knot into the flywheel notch nd wind the rope clockwise round the flywheel. 9. Pull the strter rope quickly. 51 ob01182

56 Outbord Cre MAINTENANCE To keep your outbord in the best operting condition, it is importnt tht your outbord receive the periodic inspections nd mintennce listed in the Inspection nd Mintennce Schedule. We urge you to keep it mintined properly to ensure the sfety of you nd your pssengers, nd retin its dependbility.! WARNING Neglected inspection nd mintennce service of your outbord or ttempting to perform mintennce or repir on your outbord if you re not fmilir with the correct service nd sfety procedures could cuse personl injury, deth, or product filure. Record mintennce performed in Mintennce Log t the bck of this book. Sve ll mintennce work orders nd receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using originl Mercury Precision or Quicksilver replcement prts nd Genuine Lubricnts.! WARNING Using replcement prt tht is inferior to the originl prt could result in personl injury, deth, or product filure. EPA Emissions EMISSION CERTIFICATION LABEL An emission certifiction lbel, showing emission levels nd engine specifictions directly relted to emissions, is plced on the engine t time of mnufcture. b c d e - Idle speed b - Engine horsepower c - Piston displcement d - Dte of mnufcture e - Vlve clernce (if pplicble) f - g - h - i - f g h i ob00366 Fmily number Mximum emission output for the engine fmily Timing specifiction Recommended sprk plug nd gp OWNER RESPONSIBILITY The owner/opertor is required to hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. 52

57 MAINTENANCE The owner/opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow emissions levels to exceed their predetermined fctory specifictions. Inspection And Mintennce Schedule BEFORE EACH USE Check engine oil level. See Fuel & Oil - Checking nd Adding Engine Oil. Check tht lnyrd stop switch stops the engine. Visully inspect the fuel system for deteriortion or leks. Check outbord for tightness on trnsom. Check steering system for binding or loose components. Remote Control Models - Visully check steering link rod fsteners for proper tightness. See Steering Link Rod Fsteners. Check propeller bldes for dmge. AFTER EACH USE Flush out the outbord cooling system if operting in slt or polluted wter. See Flushing the Cooling System. Wsh off ll slt deposits nd flush out the exhust outlet of the propeller nd gercse with fresh wter if operting in slt wter. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST Lubricte ll lubriction points. Lubricte more frequently when used in slt wter. See Lubriction Points. Chnge engine oil nd replce the oil filter. The oil should be chnged more often when the engine is operted under dverse conditions such s extended trolling. See Chnging Engine Oil. Replce sprk plugs t first 100 hours or first yer. After tht, inspect sprk plugs every 100 hours or once yerly. Replce sprk plugs s needed. See Sprk Plug Inspection nd Replcement. Inspect thermostt visully for corrosion nd broken spring. Mke sure thermostt closes completely t room temperture. 1. Check fuel line filter for contminnts. See Fuel System. Check corrosion control nodes. Check more frequently when used in slt wter. See Corrosion Control Anode. Check nd djust vlve clernce, if necessry. 1. Drin nd replce gercse lubricnt. See Gercse Lubriction. Check power tilt fluid. See Checking Power Tilt Fluid. Lubricte splines on the driveshft. 1. Remote control models - Check control cble djustments. 1. Inspect timing belt. See Timing Belt Inspection. Check tightness of bolts, nuts, nd other fsteners. EVERY 300 HOURS OF USE OR THREE YEARS Replce wter pump impeller (more often if overheting occurs or reduced wter pressure is noted). 1. BEFORE PERIODS OF STORAGE Refer to Storge procedure. See Storge section. Flushing The Cooling System Flush the internl wter pssges of the outbord with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent buildup of deposits from clogging the internl wter pssges. Use Mercury Precision or Quicksilver ccessory (or equivlent) flushing ttchment. 1. These items should be serviced by n uthorized deler. 53

58 MAINTENANCE IMPORTANT: The engine must be run during flushing in order to open the thermostt nd circulte wter through the wter pssges.! WARNING To void possible injury when flushing, remove the propeller. Refer to Propeller Replcement, following. 1. Remove propeller. Refer to Propeller Replcement. Instll the flushing ttchment so the rubber cups fit tightly over the cooling wter intke. ob Attch wter hose to the flushing ttchment. Turn on the wter nd djust the flow so wter is leking round the rubber cups to ensure the engine receives n dequte supply of cooling wter. 3. Strt the engine nd run it t idle speed in neutrl shift position. IMPORTANT: Do not run engine bove idle when flushing. ob Adjust wter flow (if necessry) so excess wter continues leking out from round the rubber cups to ensure the engine is receiving n dequte supply of cooling wter. ob Check for stedy strem of wter flowing out of the wter pump indictor hole. Continue flushing the outbord for 3 to 5 minutes, crefully monitoring wter supply t ll times. 6. Stop the engine, turn off the wter, nd remove the flushing ttchment. Reinstll the propeller. Top Cowl Removl And Instlltion REMOVAL 1. Pull out the front cowl ltch. 54

59 MAINTENANCE Lift front of cowl to cler front ltch nd push towrd the rer to cler rer hook. 3. Lift top cowl to remove. INSTALLATION 1. Lower top cowl into position over engine. 2. Move the cowl towrd the rer to lign rer hook. After rer hook hs engged, move cowl towrd front nd push down front of cowl. 3. Push in ltch to secure top cowl. Bttery Inspection The bttery should be inspected t periodic intervls to ensure proper engine strting cpbility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your bttery. 1. Turn off the engine before servicing the bttery. 2. Add wter s necessry to keep the bttery full. 3. Mke sure the bttery is secure ginst movement. 4. Bttery cble terminls should be clen, tight, nd correctly instlled. Positive to positive nd negtive to negtive. 5. Mke sure the bttery is equipped with nonconductive shield to prevent ccidentl shorting of bttery terminls. Exterior Cre Your outbord is protected with durble bked enmel finish. Clen nd wx often using mrine cleners nd wxes. Fuel System! WARNING Avoid serious injury or deth from gsoline fire or explosion. Crefully follow ll fuel system service instructions. Alwys stop the engine nd do not smoke or llow open flmes or sprks in the re while servicing ny prt of the fuel system. Before servicing ny prt of the fuel system, stop engine nd disconnect the bttery. Drin the fuel system completely. Use n pproved continer to collect nd store fuel. Wipe up ny spillge immeditely. Mteril used to contin spillge must be disposed of in n pproved receptcle. Any fuel system service must be performed in well ventilted re. Inspect ny completed service work for sign of fuel lekge. FUEL LINE INSPECTION Visully inspect the fuel line nd primer bulb for crcks, swelling, leks, hrdness, or other signs of deteriortion or dmge. If ny of these conditions re found, the fuel line or primer bulb must be replced. 55

60 FUEL LINE FILTER MAINTENANCE Inspect the fuel line filter. If the filter ppers to be contminted, remove nd replce. ob01186 IMPORTANT: Visully inspect for fuel lekge from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. Steering Link Rod Fsteners IMPORTANT: The steering link rod tht connects the steering cble to the engine must be fstened using the steering link rod fstening hrdwre supplied with the engine. Never replce the steering link fstening hrdwre with common bolts nd nuts (non-locking) s they will work loose nd vibrte off freeing the link rod to disengge.! WARNING Disenggement of steering link rod cn result in the bot tking full, sudden, shrp turn. This potentilly violent ction cn cuse occupnts to be thrown overbord exposing them to serious injury or deth. Assemble steering link rod to steering cble with wsher under the nylon insert locknut. Tighten locknut until it sets, then bck nut off 1/4 turn. Assemble steering link rod to engine with bolt, wshers, spcer nd locknut. Tighten the bolt/nylon insert locknut to the specified torque. 56

61 MAINTENANCE c d f e b b g ob Bolt b - Wsher (3) c - Spcer d - Nylon insert locknut e - Steering link brcket (engine) f - Steering link g - Nylon insert locknut (tighten nd bck off 1/4 turn) Description Nm lb. in. lb. ft. Nylon insert locknut Corrosion Control Anode Your outbord hs corrosion control node instlled to the gercse. An node helps protect the outbord ginst glvnic corrosion by scrificing its metl to be slowly corroded insted of the outbord metls. The node requires periodic inspection especilly in slt wter which will ccelerte the erosion. To mintin this corrosion protection, lwys replce the node before it is completely eroded. Never pint or pply protective coting on the node s this will reduce effectiveness of the node. ob

62 MAINTENANCE Propeller Replcement! WARNING If the propeller shft is rotted while the engine is in ger, there is the possibility tht the engine will crnk over nd strt. To prevent this type of ccidentl engine strting nd possible serious injury cused from being struck by rotting propeller, lwys shift outbord to neutrl position nd remove sprk plug leds when you re servicing the propeller. 1. Remove the sprk plug led to prevent engine from strting. 2. Move ger shift lever into neutrl (N). ob00375 N b ob00351 c ob Reverse c - Forwrd b - Neutrl 3. Strighten nd remove cotter pin. 4. Plce block of wood between gercse nd propeller to hold propeller nd remove propeller nut. 5. Pull propeller stright off shft. If propeller is seized to the shft nd cnnot be removed, hve the propeller removed by n uthorized deler. IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft (especilly in slt wter), lwys pply cot of the recommended lubricnt to the entire propeller shft t the recommended mintennce intervls nd lso ech time the propeller is removed. 6. Cot the propeller shft with Quicksilver or Mercury Precision Lubricnts Anti-Corrosion Grese or 2-4-C with Teflon. ob Instll front thrust wsher, propeller, rer thrust hub, nd propeller nut onto the shft. 58

63 MAINTENANCE 8. Plce block of wood between gercse nd propeller to prevent rottion nd tighten propeller nut. Secure propeller nut to the shft with cotter pin. b c d e ob Cotter pin d - Propeller b - Propeller nut e - Front thrust wsher c - Rer thrust wsher Fuse Replcement - Electric Strt Models IMPORTANT: Alwys crry spre 20 AMP fuses. The electric strting circuit is protected from overlod by 20 AMP fuse. If the fuse is blown try to locte nd correct the cuse of the overlod. If the cuse is not found, the fuse my blow gin. b ob Spre fuse b - Circuit protecting fuse 1. Open the fuse holder nd look t the silver colored bnd inside the fuse. If bnd is broken, replce the fuse. Replce fuse with new fuse with the sme rting. 59

64 MAINTENANCE b ob01185 Identifying blown fuse - Good fuse b - Blown fuse Sprk Plug Inspection And Replcement! WARNING Avoid serious injury or deth from fire or explosion cused by dmged sprk plug boots. Dmged sprk plug boots cn emit sprks. Sprks cn ignite fuel vpors under the engine cowl. To void dmging sprk plug boots, do not use ny shrp object or metl tool such s pliers, screwdriver, etc. to remove sprk plug boots. 1. Remove the sprk plug boots. Twist the rubber boots slightly nd pull off. ob Remove the sprk plugs to inspect. Replce sprk plug if electrode is worn or the insultor is rough, crcked, broken, blistered or fouled. 3. Set the sprk plug gp to specifiction. ob00423 ob00424 Sprk Plug Sprk plug gp 1.0 mm (0.040 in.) 60

65 MAINTENANCE 4. Before instlling sprk plugs, clen off ny dirt on the sprk plug sets. Instll plugs finger tight, nd then tighten 1/4 turn or torque to specifictions. Description Nm lb. in. lb. ft. Sprk plug Timing Belt Inspection 1. Inspect the timing belt nd hve it replced by n uthorized deler if ny of the following conditions re found.. Crcks in the bck of the belt or in the bse of the belt teeth. b. Excessive wer t the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfces roughened. e. Signs of wer on edges or outer surfces of belt. Chnging Engine Oil ENGINE OIL CAPACITY Engine oil cpcity is pproximtely 800 ml (27 fl. oz.). OIL CHANGING PROCEDURE 1. Lock the outbord in the full tilt up position. 2. Position outbord so the drin hole is fcing downwrd. ob Remove drin plug nd drin engine oil into n pproprite continer.! CAUTION To void internl engine dmge, do not use crnkcse oil pump when chnging the oil. 4. After the initil oil hs been drined, temporrily reinstll the drin plug. Disengge the tilt lock nd lower the outbord. Wit minute to llow the remining oil tht ws trpped in the engine to return to the drin. Return outbord to the full tilt position nd drin the remining oil. 5. Lubricte the sel on the drin plug with oil nd reinstll. 61

66 MAINTENANCE OIL FILLING ob IMPORTANT: Do not overfill. Be sure tht the outbord is upright (not tilted) when checking oil. 1. Remove the oil fill cp nd refill with 800 ml (27.0 fl. oz.) of oil. Reinstll the oil fill cp. ob Idle engine for five minutes nd check for leks. Stop engine nd check oil level on dipstick. Add oil if necessry. Lubriction Points 1. Lubricte the following with Quicksilver or Mercury Precision Lubricnts 2-4-C with Teflon or Specil Lubricnt 101. Swivel Brcket - Lubricte fitting. Trnsom Clmp Screws - Lubricte threds. Tilt Tube - Lubricte fittings. 62

67 MAINTENANCE c b ob Tilt tube grese fitting c - Trnsom clmp screws b - Swivel brcket grese fitting Lubricte the throttle nd shift cbles, moving components, pivot loctions nd shift detent. b - Throttle/shift cbles b - Shift detent ob01188 Steering Cble Grese Fitting (If Equipped) - Rotte steering wheel to fully retrct the steering cble end into the outbord tilt tube. Lubricte through fitting. b - b - Steering cble grese fitting Steering cble end ob

68 MAINTENANCE! WARNING The end of the steering cble must be fully retrcted into the outbord tilt tube before dding lubricnt. Adding lubricnt to steering cble when fully extended could cuse steering cble to become hydruliclly locked. A hydruliclly locked steering cble will cuse loss of steering control, possibly resulting in serious injury or deth. 2. Lubricte the following with Light Weight Oil. Steering Link Rod Pivot Points - Lubricte points. ob Steering link rod pivot points 3. Lubricte the following with Quicksilver or Mercury Precision Lubricnts Anti-Corrosion Grese or 2-4-C with Teflon. Propeller Shft - Refer to Propeller Replcement for removl nd instlltion of the propeller. Cot the entire propeller shft with lubricnt to prevent the propeller hub from corroding to the shft. Gercse Lubriction ob00585 When dding or chnging gercse lubricnt, visully check for the presence of wter in the lubricnt. If wter is present, it my hve settled to the bottom nd will drin out prior to the lubricnt, or it my be mixed with the lubricnt, giving it milky colored ppernce. If wter is noticed, hve the gercse checked by your deler. Wter in the lubricnt my result in premture bering filure or, in freezing tempertures, will turn to ice nd dmge the gercse. Remove the fill/drin plug nd exmine the lubricnt drining from the gercse for metl prticles. A smll mount of metl filings or fine metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte bnorml ger wer nd should be checked by n uthorized deler. DRAINING GEARCASE 1. Plce outbord in verticl operting position. 2. Plce drin pn below outbord. 3. Remove fill/drin plug nd vent plug nd drin lubricnt. 64

69 MAINTENANCE b ob Vent plug b - Fill/drin plug GEARCASE LUBRICANT CAPACITY Stndrd model gercse: Approximtely 320 ml (10.8 fl. oz.). Bigfoot model gercse: Approximtely 370 ml (12.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performnce Ger Lubricnt. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Plce outbord in verticl operting position. 2. Remove vent plug from vent hole. 3. Plce lubricnt tube into the fill hole nd dd lubricnt until it ppers t the vent hole. ob01191 IMPORTANT: Replce seling wshers if dmged. 4. Stop dding lubricnt. Instll the vent plug nd seling wsher before removing the lubricnt tube. 5. Remove lubricnt tube nd reinstll clened fill/drin plug nd seling wsher. 65

70 MAINTENANCE ob01192 Checking Power Tilt Fluid 1. Tilt outbord to the full up position nd engge the tilt lock lever. 2. Remove fill cp nd check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricnts Power Trim & Steering Fluid. If not vilble, use utomotive (ATF) utomtic trnsmission fluid Submerged Outbord A submerged outbord will require service within few hours by n uthorized deler once the outbord is recovered from the wter. This immedite ttention by servicing deler is necessry once the engine is exposed to the tmosphere to minimize internl corrosion dmge to the engine