Fuel tanks (A.5.2.2) ISO 13591; ISO 8469

Transcription

1 Welcome Aord! 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 troule-free fmily fun. Refer to your Opertion nd Mintennce Mnul for full detils of your wrrnty coverge. Detils of your nerest deler cn e 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. Declrtion of Conformity This outord motor s seril numer plte contins in the lower corner left hnd corner either the CE mrk lone or the CE mrk ccompnied y notified ody numer. This outord motor mnufctured y Mercury Mrine, Fond du Lc, WI, USA or Mrine Power Europe Inc. Prk Industriel, de Petit-Rechin, Belgium complies with the requirements of the following directives y meeting the ssocited stndrds, s mended: If the CE mrk is ccompnied y notified ody numer, the following Recretionl Crft Directive pplies: Recretionl Crft Directive: 2003/44/EC mending 94/25/EC Owner's mnul (A.2.5) ISO Hndling chrcteristics (A.4) ISO 8665 Outord engine strting (A.5.1.4) ISO Fuel tnks (A.5.2.2) ISO 13591; ISO 8469 Generl steering system ABYC P-17 Exhust emission requirements (B.2) ISO 8178 Owner's mnul (B.4) ISO 8665 Noise emission levels (C.1) ISO The notified ody responsile for surveillnce of the qulity system under Full Qulity Assurnce Module H of Directive 2003/44/EC is: Det Norske Verits Norwy Notified Body Numer: 0575 If the CE mrk is not ccompnied y notified ody numer, the following Recretionl Crft Directive lnguge pplies: Recretionl Crft Directive: Owner's mnul (A.2.5) ISO Hndling chrcteristics (A.4) ISO 8665 Outord engine strting (A.5.1.4) ISO /25/EC Fuel tnks (A.5.2.2) ISO 13591; ISO 8469 Generl steering system ABYC P-17 The following pplies to ll product covered y this mnul: 2007 Mercury Mrine 80/100/115 EFI (4-Stroke) R i

2 Sfety of Mchinery Directive 98/37/EC Principles of sfety integrtion (1.1.2) EN 292-1; EN 292-2; EN 1050 Noise (1.5.8) ICOMIA 39/94 Virtion ICOMIA 38/94 Electromgnetic Comptiility Directive 89/336/EC Generic emission stndrd EN Generic immunity stndrd EN Vehicles, ots nd internl comustion engine driven devices - rdio disturnce chrcteristics SAE J551 (CISPR 12) Electrosttic dischrge testing EN ; EN ; EN This declrtion is issued under the sole responsiility of Mercury Mrine nd Mrine Power Europe. Ptrick C. Mckey President, Mercury Mrine, Fond du Lc, WI USA Europen Regultions Contct: Regultions nd Product Sfety Deprtment, Mercury Mrine, Fond du Lc, WI USA ii

3 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 FourStroke Outord Limited Wrrnty United Sttes, Cnd, Europe nd Confedertion of Independent Sttes...2 FourStroke Outord Limited Wrrnty (Middle Est, nd Afric) Yer Limited Wrrnty Aginst Corrosion... 4 Wrrnty Coverge And Exclusions... 6 Generl Informtion Boter's Responsiilities...8 Before Operting Your Outord... 8 Bot Horsepower Cpcity...8 High Speed nd High Performnce Bot Opertion... 9 Outord Remote Control Models...9 Remote Steering Notice...9 Outord Mounting Notice...10 Propeller Selection...11 Lnyrd Stop Switch...11 Protecting People In The Wter Pssenger Sfety Messge Pontoon Bots And Deck Bots...13 Wve And Wke Jumping Impct With Underwter Hzrds...15 Exhust Emissions Selecting Accessories For Your Outord...17 Sfe Boting Suggestions Recording Seril Numer /100/115 Specifictions Interntionl...18 Component Identifiction...19 Trnsporting Trilering Bot/Outord Fuel nd Oil Fuel Recommendtions...21 Filling Fuel Tnk Engine Oil Recommendtions...22 Checking nd Adding Engine Oil...22 Fetures nd Controls Remote Control Fetures Wrning System Power Trim nd Tilt...26 iii

4 TABLE OF CONTENTS Opertion Pre Strting Check List...29 Operting In Freezing Tempertures...29 Operting In Slt Wter Or Polluted Wter...29 Setting Trim Angle while Running Engine t Idle Speed Engine Brek in Procedure...30 Strting The Engine Remote Control Models...30 Ger Shifting...32 Stopping The Engine...33 Mintennce Outord Cre...34 EPA Emissions...34 Inspection nd Mintennce Schedule...34 Flushing the Cooling System Top Cowl Removl nd Instlltion...36 Flywheel Cover Removl nd Instlltion...37 Clening Cre for Top nd Bottom Cowls Clening Cre for the Powerhed (Sltwter Use) Bttery Inspection...38 Air Filter Fuel System...40 Corrosion Control Anode...42 Propeller Replcement...43 Sprk Plug Inspection nd Replcement...46 Fuse Replcement...47 Alterntor Drive Belt Inspection...48 Luriction Points...49 Checking Power Trim Fluid...51 Chnging Engine Oil...51 Gercse Luriction...52 Storge Storge Preprtion...55 Protecting Externl Outord Components...55 Protecting Internl Engine Components...55 Gercse...56 Positioning Outord For Storge Bttery Storge...56 Trouleshooting Strter Motor Will Not Crnk the Engine...57 Engine Will Not Strt...57 Engine Runs Errticlly Performnce Loss...57 Bttery Will Not Hold Chrge iv

5 TABLE OF CONTENTS Owner Service Assistnce Locl Repir Service...59 Service Awy From Home Prts And Accessories Inquiries...59 Service Assistnce Mercury Mrine Service Offices Outord Instlltion Importnt Informtion...61 Bot Horsepower Cpcity...61 Strt in Ger Protection Selecting Accessories For Your Outord...61 Fuel Tnks...61 Filling the Fuel System Instlltion Specifictions Lifting Outord Steering Cle Strord Side Routed Cle...63 Steering Link Rod Fsteners Determining Recommended Outord Mounting Height...66 Drilling Outord Mounting Holes...67 Fstening the Outord to the Trnsom Electricl, Fuel Hose, nd Control Cles...70 Trim In Pin v

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7 Trnsfer Of Wrrnty WARRANTY INFORMATION The limited wrrnty is trnsferle to susequent purchser, ut 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 susequent owner, send or fx copy of the ill of sle or purchse greement, new owner s nme, ddress nd engine seril numer to Mercury Mrine s wrrnty registrtion deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment 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 y mil. There is no chrge for this service. For products purchsed outside the United Sttes nd Cnd, contct the distriutor 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, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril numer to Mercury Mrine s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx NOTE: Registrtion lists must e mintined y Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act e required. 2. To e eligile for wrrnty coverge, the product must e registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely sumit 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 y 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 distriutor or Mrine Power Service Center responsile for dministering the wrrnty registrtion/ clim progrm for your re. 2. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril numers, dte of sle, type of use nd the selling distriutor's/deler's code numer, nme nd ddress. The distriutor/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 e given to you immeditely fter the crd hs een completely filled out y the selling distriutor/deler. This crd represents your fctory registrtion identifiction, nd should e retined y 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

8 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 distriutor/deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser's Copy tht you received from the distriutor/deler when you purchsed the product. Ask your distriutor/deler if this plstic crd progrm pplies to you. IMPORTANT: Registrtion lists must e mintined y the fctory nd deler in some countries y lw. It is our desire to hve ALL products registered t the fctory should it ever e necessry to contct you. Mke sure your deler/distriutor 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. FourStroke Outord Limited Wrrnty United Sttes, Cnd, Europe nd Confedertion of Independent Sttes Outside the United Sttes, Cnd, Europe nd Confedertion of Independent Sttes - check with locl distriutor. WHAT IS COVERED: Mercury Mrine wrrnts its new products to e free of defects in mteril nd workmnship during the period descried elow. 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 one (1) yer from the dte of first retil sle, or one (1) yer from the dte in which the product ws first put into service, 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 eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one recretionl use customer to susequent recretionl use customer upon proper re registrtion of the product. Unexpired wrrnt coverge cnnot e trnsferred either to or from commercil use customer. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute 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 ecomes ville upon proper registrtion of the product y the uthorized deler. Routine mintennce outlined in the Opertion nd Mintennce Mnul must e timely performed in order to mintin wrrnty coverge. 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 oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured 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 oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y 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 e 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 y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. 2

9 WARRANTY INFORMATION WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused y use, norml 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, sumersion, 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 y us, jet pump impellers nd liners, opertion with fuels, oils or luricnts which re not suitle 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, or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody, running the engine out of wter, mounting the engine too high on the trnsom, or running the ot with the engine trimmed out too fr.. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even y 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 y this wrrnty. Also, expenses ssocited with the removl nd/or replcement of ot prtitions or mteril cused y ot design for ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y 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 e enforcele ginst Mercury Mrine. For dditionl informtion regrding events nd circumstnces covered y this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported y 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. FourStroke Outord Limited Wrrnty (Middle-Est, nd Afric) WHAT IS COVERED: Mercury Mrine wrrnts its new Outord nd Jet Products to e free of defects in mteril nd workmnship during the period descried elow. 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 one (1) yer from the dte on which the product ws first put into service, 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 eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one recretionl use customer to susequent recretionl use customer upon proper reregistrtion of the product. Unexpired wrrnty coverge cnnot e trnsferred either to or from commercil use customer. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute 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 ecomes ville upon proper registrtion of the product y the uthorized deler. Routine mintennce outlined in the Opertion nd Mintennce Mnul must e timely performed in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent on proof of proper mintennce. 3

10 WARRANTY INFORMATION WHAT MERCURY WILL DO: Mercury s sole nd exclusive oligtion 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 oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y 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 e 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 y this wrrnty, purchser shll py for ll relted lornd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused y use, norml 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, sumersion, 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 y us, jet pump impellers nd liners, opertion with fuels, oils or luricnts which re not suitle 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, or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody, running the engine out of wter, mounting the engine too high on the trnsom, or running the ot with the engine trimmed out too fr. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even y 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 coveredy this wrrnty. Also, expenses ssocited with the removl nd/or replcement of ot prtitions or mteril cused y ot design for ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y 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 e enforcele ginst Mercury Mrine. For dditionl informtion regrding events nd circumstnces covered y this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported y 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. 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 y Mercury Mrine Outord, Mercury MerCruiser Inord or Sterndrive Engine (Product) will not e rendered inopertive s direct result of corrosion for the period of time descried elow. 4

11 WARRANTY INFORMATION 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 eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred to susequent (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 ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute 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 ecomes ville upon proper registrtion of the product y the uthorized deler. Corrosion prevention devices specified in the Opertion nd Mintennce Mnul must e in use on the ot, nd routine mintennce outlined in the Opertion nd Mintennce Mnul must e timely performed (including without limittion the replcement of scrificil nodes, use of specified luricnts, 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 oligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured 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 oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y 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 e 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 y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, use 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 y 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. Corrosion dmge cused y stry electricl currents (on-shore power connections, nery ots, sumerged metl) is not covered y this corrosion wrrnty nd should e protected ginst y the use of corrosion protection system, such s the Mercury Precision Prts or Quicksilver MerCthode system nd/or Glvnic Isoltor. Corrosion dmge cused y improper ppliction of copper se nti-fouling pints is lso not covered y this limited wrrnty. If nti-fouling protection is required, Tri-Butyl-Tin-Adipte (TBTA) se nti-fouling pints re recommended on Outord nd MerCruiser oting pplictions. In res where TBTA se pints re prohiited y lw, copper se pints cn e used on the hull nd trnsom. Do not pply pint to the outord or MerCruiser product. In ddition, cre must e tken to void n electricl interconnection etween the wrrnted product nd the pint. For MerCruiser product, n unpinted gp of t lest 38 mm (1.5 in.) should e left round the trnsom ssemly. Refer to the Opertion nd Mintennce Mnul for dditionl detils. For dditionl informtion regrding events nd circumstnces covered y this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported y reference into this wrrnty. 5

12 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. 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 y wrrnty. The provisions set forth following hve een incorported y reference into the Three Yer Limited Wrrnty Aginst Corrosion Filure, the Interntionl Limited Outord Wrrnty, nd the United Sttes nd Cnd Limited Outord Wrrnty. Keep in mind tht wrrnty covers repirs tht re needed within the wrrnty period ecuse 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, ut only when the consumer sle is mde in the country to which distriution is uthorized y us. Should you hve ny questions concerning wrrnty coverge, contct your uthorized deler. They will e 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, cruretor settings, filters, elts, controls, nd checking luriction 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 y impct or wer, nd wter dmged drive shft erings s result of improper mintennce. 3. Dmge cused y neglect, lck of mintennce, ccident, norml opertion or improper instlltion or service. 4. Hul out, lunch, towing chrges, removl nd/or replcement of ot prtitions or mteril ecuse of ot design for necessry ccess to the product, ll relted trnsporttion chrges nd/or trvel time, etc. Resonle ccess must e provided to the product for wrrnty service. Customer must deliver product to n uthorized deler. 5. Additionl service work requested y customer other thn tht necessry to stisfy the wrrnty oligtion. 6. Lor performed y other thn n uthorized deler my e covered only under following circumstnces: When performed on emergency sis (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 een 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 responsiility. 8. Use of other thn Mercury Precision or Quicksilver prts when mking wrrnty repirs. 9. Oils, luricnts or fluids chnged s mtter of norml mintennce is customer's responsiility unless loss or contmintion of sme is cused y product filure tht would e eligile for wrrnty considertion. 10. Prticipting in or prepring for rcing or other competitive ctivity or operting with rcing type lower unit. 6

13 WARRANTY INFORMATION 11. Engine noise does not necessrily indicte serious engine prolem. If dignosis indictes serious internl engine condition which could result in filure, condition responsile for noise should e corrected under the wrrnty. 12. Lower unit nd/or propeller dmge cused y striking sumerged oject is considered mrine hzrd. 13. Wter entering engine through the fuel intke, ir intke or exhust system or sumersion. 14. Filure of ny prts cused y lck of cooling wter, which results from strting motor out of wter, foreign mteril locking inlet holes, motor eing mounted too high or trimmed too fr out. 15. Use of fuels nd luricnts which re not suitle 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 y the instlltion or use of prts nd ccessories which re not mnufctured or sold y 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

14 Boter's Responsiilities GENERAL INFORMATION The opertor (driver) is responsile for the correct nd sfe opertion of the ot nd sfety of its occupnts nd generl pulic. It is strongly recommended tht ech opertor (driver) red nd understnd this entire mnul efore operting the outord. Be sure t lest one dditionl person on ord is instructed in the sics of strting nd operting the outord nd ot hndling in cse the driver is unle to operte the ot. Before Operting Your Outord Red this mnul crefully. Lern how to operte your outord 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 lels posted on the outord use the following sfety lerts to drw your ttention to specil sfety instructions tht should e followed.! DANGER Indictes hzrdous sitution which, if not voided, will result in deth or serious injury.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. Bot Horsepower Cpcity! WARNING Exceeding the ot's mximum horsepower rting cn cuse serious injury or deth. Overpowering the ot cn ffect ot control nd flottion chrcteristics or rek the trnsom. Do not instll n engine tht exceeds the ot's mximum power rting. 8

15 GENERAL INFORMATION Do not overpower or overlod your ot. Most ots will crry required cpcity plte indicting the mximum cceptle power nd lod s determined y the mnufcturer following certin federl guidelines. If in dout, contct your deler or the ot mnufcturer. U.S. COAST GUARD CAP ACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY XXX XXX High-Speed nd High-Performnce Bot Opertion If your outord is to e used on high speed or high performnce ot with which you re unfmilir, we recommend tht you never operte it t its high speed cpility without first requesting n initil orienttion nd fmiliriztion demonstrtion ride with your deler or n opertor experienced with your ot/outord comintion. For dditionl informtion, otin copy of our Hi-Performnce Bot Opertion ooklet from your deler, distriutor, or Mercury Mrine. Outord Remote Control Models The remote control connected to your outord must e 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 Strting the engine with the drive in ger cn cuse serious injury or deth. Never operte ot tht does not hve neutrl-sfety-protection device. Remote Steering Notice The steering link rod tht connects the steering cle to the engine must e fstened utilizing self-locking nuts. These self-locking nuts must never e replced with common nuts (non-locking) s they will work loose nd virte off, freeing the link rod to disengge. 9

16 GENERAL INFORMATION! WARNING Improper fsteners or improper instlltion procedures cn result in loosening or disenggement of the steering link rod. This cn cuse sudden, unexpected loss of ot control, resulting in serious injury or deth due to occupnts eing thrown within or out of the ot. Alwys use required components nd follow instructions nd torque procedures. - Self-locking nuts Outord Mounting Notice! WARNING Filure to correctly fsten the outord could result in the outord propelling off the ot trnsom resulting in property dmge, serious injury, or deth. Before opertion, the outord must e correctly instlled with the required mounting hrdwre. Do not ccelerte ove idle speed in wter tht my contin underwter ostcles if the outord is not ttched to the trnsom correctly. We strongly recommend tht your deler instll your outord nd relted ccessories to ensure proper instlltion nd good performnce. If you instll the outord yourself, refer to the Outord Instlltion section. The outord must e secured to the trnsom with the four 12.7 mm (1/2 in.) dimeter mounting olts nd locknuts provided. Instll two olts through the upper set of holes nd two olts through the lower set of holes

17 Propeller Selection GENERAL INFORMATION For est ll round performnce from your outord/ot comintion, select propeller tht llows the engine to operte in the upper hlf of the recommended full throttle RPM rnge with the ot normlly loded (refer to Generl Informtion - Specifictions). This RPM rnge llows for etter ccelertion while mintining mximum ot speed If chnging conditions cuse the RPM to drop elow the recommended rnge, such s wrmer, more humid wether, opertion t higher elevtions, incresed ot lod, or dirty ot ottom/gercse, propeller chnge or clening my e required to mintin performnce nd ensure the outords durility. Check full-throttle RPM, using n ccurte tchometer, with the engine trimmed out to lnced-steering condition (steering effort equl in oth directions) without cusing the propeller to rek loose. 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 outords nd some remote control units re equipped with lnyrd stop switch. A lnyrd stop switch cn e instlled s n ccessory - generlly on the dshord or side djcent to the opertor's position. The lnyrd is cord usully cm (4-5 feet) in length when stretched out, with n element on one end mde to e 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 possile to minimize the likelihood of lnyrd entnglement with nery ojects. 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 Lnyrd cord - Lnyrd stop switch Red the following Sfety Informtion efore proceeding. 11

18 GENERAL INFORMATION 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 overord or moves within the ot sufficient distnce from the opertor's position. Flling overord nd ccidentl ejections re more likely to occur in certin types of ots such s low sided infltles, ss ots, high performnce ots, nd light, sensitive hndling fishing ots operted y hnd tiller. Flling overord nd ccidentl ejections re lso likely to occur s result of poor operting prctices such s sitting on the ck of the set or gunwle t plning speeds, stnding t plning speeds, sitting on elevted fishing ot decks, operting t plning speeds in shllow or ostcle 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 ot mneuvers. While ctivtion of the lnyrd stop switch will stop the engine immeditely, ot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the ot will not complete full circle. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We strongly recommend tht other occupnts e instructed on proper strting nd operting procedures should they e required to operte the engine in n emergency (e.g. if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot 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 possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion - prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y 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 ot heding in his/ her direction, even t slow speed Alwys slow down nd exercise extreme cution ny time you re oting in n re where there might e people in the wter. 12

19 GENERAL INFORMATION Whenever ot is moving (costing) nd the outord ger shift is in neutrl position, there is sufficient force y the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. WHILE BOAT IS STATIONARY! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. Shift outord into neutrl nd shut off the engine efore llowing people to swim or e in the wter ner your ot. Pssenger Sfety Messge - Pontoon Bots And Deck Bots Whenever the ot is in motion, oserve 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 ot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of ot direction, could throw them over the front of the ot. Flling over the front of the ot etween the two pontoons will position them to e run over y the outord. BOATS HAVING AN OPEN FRONT DECK No one should ever e on the deck in front of the fence while the ot is in motion. Keep ll pssengers ehind the front fence or enclosure. Persons on the front deck could esily e thrown overord or persons dngling their feet over the front edge could get their legs cught y wve nd pulled into the wter.! WARNING Sitting or stnding in n re of the ot not designed for pssengers t speeds ove idle cn cuse serious injury or deth. Sty ck from the front end of deck ots or rised pltforms nd remin seted while the ot is in motion. BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevted fishing sets re not intended for use when the ot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. 13

20 GENERAL INFORMATION Any unexpected, sudden reduction in ot speed could result in the elevted pssenger flling over the front of the ot. Wve And Wke Jumping Operting recretionl ots over wves nd wke is nturl prt of oting. However, when this ctivity is done with sufficient speed to force the ot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the ot re-enters the wter The primry concern is the ot chnging direction while in the midst of the jump. In such cse the lnding my cuse the ot to veer violently in new direction. Such shrp chnge in direction cn cuse occupnts to e thrown out of their sets, or out of the ot.! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts eing thrown within or out of the ot. Avoid wve or wke jumping whenever possile. There is nother less common hzrdous result from llowing your ot to lunch off wve or wke. If the ow of your ot pitches down fr enough while irorne, upon wter contct it my penetrte under the wter surfce nd sumrine for n instnt. This will ring the ot to nerly instntneous stop nd cn send the occupnts flying forwrd. The ot my lso steer shrply to one side. 14

21 GENERAL INFORMATION Impct With Underwter Hzrds Reduce speed nd proceed with cution whenever you drive ot in shllow wter res, or in res where you suspect underwter ostcles my exist which could e struck y the outord or the ot ottom. The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter oject is to control the ot speed. Under these conditions, ot speed should e kept to minimum plning speed of 24 to 40 km/h (15 to 25 MPH) Striking floting or underwter oject could result in n infinite numer of situtions. Some of these situtions could result in the following: Prt of the outord or the entire outord could rek loose nd fly into the ot. The ot could move suddenly in new direction. Such shrp chnge in direction cn cuse occupnts to e thrown out of their sets or out of the ot. A rpid reduction in speed. This will cuse occupnts to e thrown forwrd, or even out of the ot. Impct dmge to the outord nd/or ot. Keep in mind, the most importnt thing you cn do to help reduce injury or impct dmge during n impct is control the ot speed. Bot speed should e kept to minimum plning speed when driving in wters known to hve underwter ostcles. After striking sumerged oject, stop the engine s soon s possile nd inspect it for ny roken or loose prts. If dmge is present or suspected, the outord should e tken to n uthorized deler for thorough inspection nd necessry repir. The ot should lso e checked for ny hull frctures, trnsom frctures, or wter leks. Operting dmged outord could cuse dditionl dmge to other prts of the outord, or could ffect control of the ot. If continued running is necessry, do so t gretly reduced speeds.! WARNING Operting ot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Exhust Emissions BE ALERT TO CARBON MONOXIDE POISONING Cron monoxide is present in the exhust fumes of ll internl comustion engines. This includes the outords, sterndrives nd inord engines tht propel ots, s well s the genertors tht power vrious ot ccessories. Cron monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of cron monoxide poisoning which should not e confused with sesickness or intoxiction, include hedche, dizziness, drowsiness, nd nuse. 15

22 GENERAL INFORMATION! WARNING Cron monoxide poisoning cn led to unconsciousness, rin dmge, or deth. Keep the ot well ventilted while t rest or underwy nd void prolonged exposure to cron monoxide. GOOD VENTILATION Ventilte pssenger re, open side curtins, or forwrd htches to remove fumes. POOR VENTILATION Exmple of desired ir flow through the ot Under certin running nd/or wind conditions, permnently enclosed or cnvs enclosed cins or cockpits with insufficient ventiltion my drw in cron monoxide. Instll one or more cron monoxide detectors in your ot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n enclosed re of sttionry ot tht contins or is ner running engine my e exposed to hzrdous level of cron monoxide. WHILE BOAT IS STATIONARY - Running the engine when the ot is moored in confined spce Mooring close to nother ot tht hs its engine running WHILE BOAT IS MOVING - Running the ot with the trim ngle of the ow too high Running the ot with no forwrd htches open 16

23 GENERAL INFORMATION Selecting Accessories For Your Outord Genuine Mercury Precision or Quicksilver Accessories hve een specificlly designed nd tested for your outord. These ccessories re ville from Mercury Mrine delers. IMPORTANT: Check with your deler efore instlling ccessories. The misuse of pproved ccessories or the use of non-pproved ccessories cn dmge the product. Some ccessories not mnufctured or sold y Mercury Mrine re not designed to e sfely used with your outord or outord 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 oting regultions nd restrictions, nd consider the following suggestions. Use flottion devices. Hve n pproved personl flottion device of suitle size for ech person ord (it is the lw) nd hve it redily ccessile. Do not overlod your ot. Most ots re rted nd certified for mximum lod (weight) cpcities (refer to your ot cpcity plte). If in dout, contct your deler or the ots mnufcturer. Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Know nd oey ll nuticl rules nd lws of the wterwys. Bot opertors should complete oting sfety course. Courses re offered in the U.S.A. y 1) The U.S. Cost Gurd Auxiliry, 2) The Power Squdron, 3) The Red Cross nd 4) your stte oting lw enforcement gency. Inquiries my e mde to the Boting Hotline, or the Bot U.S. Foundtion informtion numer BOAT. Mke sure everyone in the ot is properly seted. Do not llow nyone to sit or ride on ny prt of the ot tht ws not intended for such use. This includes the ck of sets, gunwles, trnsom, ow, decks, rised fishing sets, ny rotting fishing set; or nywhere tht n unexpected ccelertion, sudden stopping, unexpected loss of ot control, or sudden ot movement could cuse person to e thrown overord or into the ot. Never e under the influence of lcohol or drugs while oting (it is the lw). Alcohol or drug use impirs your judgment nd gretly reduces your ility to rect quickly. Prepre other ot opertors. Instruct t lest one other person on ord in the sics of strting nd operting the outord, nd ot hndling, in cse the driver ecomes disled or flls overord. Pssenger ording. Stop the engine whenever pssengers re ording, unloding, or re ner the ck (stern) of the ot. Just shifting the outord into neutrl is not sufficient. Be lert. The opertor of the ot is responsile y lw to mintin proper lookout y sight nd hering. The opertor must hve n unostructed view prticulrly to the front. No pssengers, lod, or fishing sets should lock the opertors view when operting the ot ove idle speed. Never drive your ot directly ehind wter skier in cse the skier flls. As n exmple, your ot 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 ot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the ot while returning to ssist the skier. The opertor should lwys hve the down skier in sight nd never ck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required y lw to file Boting Accident Report with their stte oting lw enforcement gency when their ot is involved in certin oting ccidents. A oting ccident must e reported if 1) there is loss of life or prole loss of life, 2) there is personl injury requiring medicl tretment eyond first id, 3) there is dmge to ots or other property where the dmge vlue exceeds $ or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. 17

24 Recording Seril Numer GENERAL INFORMATION It is importnt to record this numer for future reference. The seril numer is locted on the outord s shown. XXXXXXXX XXXX XXXX c e XX d c - Seril numer Model yer Model designtion d - e - Yer mnufctured Certified Europe Insigni (s pplicle) 80/100/115 Specifictions - Interntionl Models 80/100/115 Horsepower 80/100/115 Kilowtts 60/75/86 Full Throttle RPM Rnge Idle Speed in Neutrl Ger 1. 80/100 HP HP RPM Numer of Cylinders 4 Piston Displcement Cylinder Bore Stroke Recommended Sprk Plug Sprk Plug Gp Sprk Plug Hex Size Ger Rtio Recommended Gsoline Recommended Oil Gercse Luricnt Cpcity Engine Oil Cpcity With Oil Filter Replcement Bttery Rting 1,731 cc (105.6 cid) 82 mm (3.23 in.) 82 mm (3.23 in.) NGK LFR4A-E 0.8 mm (0.032 in.) 16 mm 80/100 HP :1 115 HP :1 Refer to Fuel & Oil Refer to Fuel & Oil 710 ml (24 fl. oz.) 5.0 liters (5.3 qt.) 1000 Mrine Crnking Amps (MCA), 800 Cold Crnking AMPS (CCA) or 180 Ampere Hour (Ah) 1. With engine fully wrmed up. 18

25 GENERAL INFORMATION Models 80/100/115 Sound t Drivers Er (ICOMIA 39-94) 82.9 Component Identifiction g c h d e i f j Top cowl f - Trim t - Bottom cowl g - Auxiliry tilt switch c - Wter pump indictor hole h - Trnsom rckets d - Driveshft housing i - Cooling wter intke holes e - Anti-ventiltion plte j - Gercse 19

26 Trilering Bot/Outord TRANSPORTING Triler your ot with the outord tilted down in verticl operting position. If dditionl ground clernce is required, the outord should e tilted up using n ccessory outord support device. Refer to your locl deler for recommendtions. Additionl clernce my e required for rilrod crossings, drivewys, nd triler ouncing IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to mintin proper ground clernce for trilering. The outord tilt support lever is not intended to support the outord for trilering. Shift the outord to forwrd ger. This prevents the propeller from spinning freely. 20

27 Fuel Recommendtions FUEL AND OIL IMPORTANT: Use of improper gsoline cn dmge your engine. Engine dmge resulting from the use of improper gsoline is considered misuse of the engine, nd dmge cused therey will not e covered under the limited wrrnty. FUEL RATINGS Mercury Mrine engines will operte stisfctorily when using mjor rnd of unleded gsoline meeting the following specifictions: USA nd Cnd - hving posted pump Octne Rting of 87 (R+M)/2 minimum. Premium gsoline [92 (R+M)/ 2 Octne] is lso cceptle. Do NOT use leded gsoline. Outside USA nd Cnd - hving posted pump Octne Rting of 90 RON minimum. Premium gsoline (98 RON) is lso cceptle. If unleded gsoline is not ville, use mjor rnd of leded gsoline. USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY) This type of gsoline is required in certin res of the USA. The 2 types of oxygentes used in these fuels re Alcohol (Ethnol) or Ether (MTBE or ETBE). If Ethnol is the oxygente tht is used in the gsoline in your re, refer to Gsolines Contining Alcohol. These Reformulted Gsolines re cceptle for use in your Mercury Mrine engine. GASOLINES CONTAINING ALCOHOL If the gsoline in your re contins either methnol (methyl lcohol) or ethnol (ethyl lcohol), you should e wre of certin dverse effects tht cn occur. These dverse effects re more severe with methnol. Incresing the percentge of lcohol in the fuel cn lso worsen these dverse effects. Some of these dverse effects re cused ecuse the lcohol in the gsoline cn sor moisture from the ir, resulting in seprtion of the wter/lcohol from the gsoline in the fuel tnk. The fuel system components on your Mercury Mrine engine will withstnd up to 10% lcohol content in the gsoline. We do not know wht percentge your ot's fuel system will withstnd. Contct your ot mnufcturer for specific recommendtions on the ot's fuel system components (fuel tnks, fuel lines, nd fittings). Be wre tht gsolines contining lcohol my cuse incresed: Corrosion of metl prts Deteriortion of ruer or plstic prts Fuel permetion through ruer fuel lines Strting nd operting difficulties! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement efore further engine opertion. Becuse of possile dverse effects of lcohol in gsoline, it is recommended tht only lcohol-free gsoline e used where possile. If only fuel contining lcohol is ville, or if the presence of lcohol is unknown, incresed inspection frequency for leks nd normlities is required. IMPORTANT: When operting Mercury Mrine engine on gsoline contining lcohol, storge of gsoline in the fuel tnk for long periods should e voided. Long periods of storge, common to ots, crete unique prolems. In crs, lcohol-lend fuels normlly re consumed efore they cn sor enough moisture to cuse troule, ut ots often sit idle long enough for phse seprtion to tke plce. In ddition, internl corrosion my tke plce during storge if lcohol hs wshed protective oil films from internl components. 21

28 Filling Fuel Tnk FUEL AND OIL! WARNING Avoid serious injury or deth from gsoline fire or explosion. Use cution when filling fuel tnks. 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 portle fuel tnks from ot to refill them. Alwys stop engine efore 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 ot so the vent is higher thn the fuel level under norml ot operting conditions. Engine Oil Recommendtions Mercury or Quicksilver NMMA FC-W certified synthetic lend 25W-40 multi-viscosity 4-Stroke Outord Oil is recommended for generl, ll-temperture use. If the recommended Mercury or Quicksilver NMMA FC-W certified oil is not ville, mjor rnd of NMMA FC-W certified 4-Stroke Outord Oil of similr viscosity my e used. IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other thn Mercury or Quicksilver NMMA FC- W certified oil or mjor rnd NMMA FC-W certified oil), synthetic oils, low qulity oils or oils tht contin solid dditives re not recommended. MERCURY 4-STROKE ENGINE OIL OIL CAPACITY: 5.0L (5.3 U.S.qt.) F C Checking nd Adding Engine Oil IMPORTANT: Do not overfill. Tilt outord out/up pst verticl for pproximtely one minute to llow trpped oil to drin ck to the oil sump. Tilt outord to verticl (not tilted) position when checking engine oil. For ccurte redings, check oil only when engine is cold or fter engine hs not run for t lest n hour. 1. Before strting (cold engine) tilt outord out/up pst verticl to llow trpped oil to drin ck to the oil sump. Allow outord to remin tilted for pproximtely one minute. 2. Tilt outord to verticl operting position. 3. Remove the top cowl. Refer to Mintennce - Top Cowl Removl nd Instlltion. 4. Pull out the dipstick. Wipe the dipstick end with clen rg or towel nd push it ck in ll the wy. 5. Pull the dipstick ck out gin nd oserve the oil level. Oil should e in the operting rnge (cross htched region). 22

29 FUEL AND OIL IMPORTANT: Do not try to fill the oil level to the top of the operting rnge (cross htched region). Oil level is correct s long s it ppers in the operting rnge (cross htched region). - Oil level operting rnge If the oil level is elow the operting rnge (cross htched region), remove the oil filler cp nd dd pproximtely 500 ml (16 oz.) of the specified outord motor oil. Allow few minutes for the dded oil to drin to the oil sump nd recheck the dipstick. Repet the process until the oil level is on the operting rnge (cross htched region). Do not try to fill to the upper end of the opertion rnge (cross htched region) 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 y your deler. 7. Push the dipstick ck in ll the wy. 8. Reinstll the oil fill cp hnd-tight. 9. Reinstll top cowl. 23

30 Remote Control Fetures FEATURES AND CONTROLS Your ot my e 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. c c c f h g i i e d d e f g f c - d - 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. e - Lnyrd - Refer to Generl Informtion - Lnyrd Stop Switch. f - Throttle friction djustment - Console controls require cover removl for djustment. g - Ignition key switch - "OFF," "ON," START." h - Fst idle lever - Refer to Opertion - Strting the Engine. i - Throttle only utton - Refer to Opertion - Strting the Engine. Wrning System WARNING HORN SIGNALS When the key switch is turned to the "ON" position, the horn will turn on for moment s test to indicte the horn is working. The wrning horn will emit either continuous eep or intermittent short eeps. This will lert the opertor nd help identify the following listed situtions. For visul disply of the specific engine functions nd for dditionl engine dt, refer to SmrtCrft Product informtion, following. Wrning Horn Function Sound Description Strt up Single eep Norml system test. Low ttery Four eeps every 2 minutes Bttery chrging unle to keep up with demnd. Rise engine speed, to increse chrge, or shut down ccessories, to reduce demnd. 24

31 FEATURES AND CONTROLS Wrning Horn Function Sound Description Cooling system prolem Continuous Engine Gurdin System is ctivted. Power limit will vry with level of overhet. Shift outord into neutrl nd check for stedy strem of wter coming out of the wter pump indictor hole. If no wter is coming out of the wter pump indictor hole, or flow is intermittent, stop engine nd check wter intke holes for ostruction. Oil pressure low Continuous Engine Gurdin System is ctivted. Power limit will vry depending on ville oil pressure. Stop engine nd check oil dipstick. Add oil if necessry. Refer to Fuel nd Oil - Checking nd Adding Engine Oil. Engine overspeed Continuous The wrning horn is ctivted ny time the engine speed exceeds the mximum llowle RPM. The system will limit the engine speed to within the llowle rnge. Engine overspeed indictes condition tht should e corrected. Overspeed could e cused y incorrect propeller pitch, engine height, trim ngle, tilt ngle (shllow wter opertion) etc. Sensor/Actutor out of rnge Single eep (engine running) My e prolem with one of the engine functions. Hve your deler check the engine soon. Continuous Engine Gurdin System is ctivted. Power limit will restrict engine speed to either idle or 55%, depending on fult. ENGINE GUARDIAN SYSTEM The Engine Gurdin System monitors the criticl sensors on the engine for ny erly indictions of prolems. The system will respond to prolem y emitting continuous eep nd/or reducing engine power in order to provide engine protection. If Gurdin System hs een ctivted, reduce throttle speed. The prolem will need to e identified nd corrected, if possile. The system must e reset efore the engine will operte t higher speeds. Moving the throttle lever ck to the idle position will reset the system. SMARTCRAFT PRODUCT A Mercury SmrtCrft System instrument pckge cn e purchsed for this outord. A few of the functions the instrument pckge will disply re engine RPM, coolnt temperture, oil pressure, wter pressure, ttery voltge, fuel consumption nd engine operting hours. The SmrtCrft Instrument pckge will lso id in Engine Gurdin dignostics. The SmrtCrft Instrument pckge will disply criticl engine lrm dt nd potentil prolems. 25

32 Power Trim nd Tilt FEATURES AND CONTROLS The outord hs trim/tilt control clled power trim. This enles the opertor to esily djust the position of the outord y pressing the trim switch. Moving the outord in closer to the ot trnsom is clled trimming in or down. Moving the outord further wy from the ot trnsom is clled trimming out or up. The term trim generlly refers to the djustment of the outord within the first 20 rnge of trvel. This is the rnge used while operting the ot on plne. The term tilt is generlly used when referring to djusting the outord further up out of the wter. With the engine turned off nd ignition switch turned on, the outord cn e tilted out of the wter. At low idle speed, the outord cn lso e tilted up pst the trim rnge to permit, for exmple, shllow wter opertion c - - Trim switch Tilt rnge c - Trim rnge POWER TRIM OPERATION With most ots, operting round the middle of the trim rnge will give stisfctory results. However, to tke full dvntge of the trimming cpility there my e times when you choose to trim your outord ll the wy in or out. Along with n improvement in some performnce spects comes greter responsiility for the opertor, nd this is eing wre of some potentil control hzrds. The most significnt control hzrd is pull or torque tht cn e felt on the steering wheel or tiller hndle. This steering torque results from the outord eing trimmed so tht the propeller shft is not prllel to the wter surfce.! WARNING Trimming the outord eyond neutrl steering condition my result in pull on the steering wheel or tiller hndle nd loss of ot control. Mintin control of the ot if trimming eyond neutrl steering condition. Consider the following lists crefully. 1. Trimming In or Down Cn: Lower the ow. Result in quicker plning off, especilly with hevy lod or stern hevy ot. Generlly improve the ride in choppy wter. Increse steering torque or pull to the right (with the norml right hnd rottion propeller). In excess cn lower the ow of some ots to point where they egin to plow with their ow in the wter while on plne. This cn result in n unexpected turn in either direction (clled ow steering or over-steering) if ny turn is ttempted, or if significnt wve is encountered. 26

33 FEATURES AND CONTROLS! WARNING Operting the ot t high speeds with the outord trimmed too fr under cn crete excessive ow steer, resulting in the opertor losing control of the ot. Instll the trim limit pin in position tht prevents excessive trim under nd operte the ot in sfe mnner. In rre circumstnces, the owner my decide to limit the trim in. This cn e ccomplished y purchsing stinless steel tilt pin from your deler nd inserting it in whtever djustment hole in the trnsom rckets is desired. The non-stinless steel shipping olt should not e used in this ppliction other thn on temporry sis. 2. Trimming Out or Up cn: Lift the ow higher out of the wter. Generlly increse top speed. Increse clernce over sumerged ojects or shllow ottom. Increse steering torque or pull to the left t norml instlltion height (with the norml right hnd rottion propeller). In excess cn cuse ot porpoising (ouncing) or propeller ventiltion. Cuse engine overheting if ny cooling wter intke holes re ove the wter line. TILTING OPERATION To tilt outord, shut off the engine nd press the trim/tilt switch or uxiliry tilt switch to the up position. The outord will tilt up until the switch is relesed or it reches its mximum tilt position. 1. Engge the tilt support lever, y rotting kno to ring the support lever upwrd. 2. Lower outord to rest on the tilt support lever. 3. Disengge the tilt support lever, y rising the outord off the support lever nd rotting the lever down. Lower the outord Tilt support lever - Kno MANUAL TILTING If the outord cnnot e tilted using the power trim/tilt switch, the outord cn e mnully tilted. NOTE: The mnul tilt relese vlve must e tightened efore operting the outord to prevent the outord from tilting up during reverse opertion. 27

34 FEATURES AND CONTROLS 1. Turn out the mnul tilt relese vlve 3 turns counterclockwise. This llows mnul tilting of the outord. Tilt the outord to the desired position nd tighten the mnul tilt relese vlve. AUXILIARY TILT SWITCH This switch cn e used to tilt the outord up or down using the power trim system. - Auxiliry tilt switch SHALLOW WATER OPERATION When operting your ot in shllow wter, you cn tilt the outord eyond the mximum trim rnge to prevent hitting ottom. 1. Reduce engine speed elow 2000 RPM. 2. Tilt outord up. Mke sure ll the wter intke holes sty sumerged t ll times. 3. Operte the engine t slow speed only. If engine speed exceeds 2000 RPM, the outord will utomticlly return down to the mximum trim rnge. 28

35 Pre-Strting Check List OPERATION Opertor knows sfe nvigtion, oting, nd operting procedures. An pproved personl flottion device of suitle size for ech person ord nd redily ccessile (it is the lw). A ring type life uoy or uoynt cushion designed to e thrown to person in the wter. Know your ots mximum lod cpcity. Look t the ot cpcity plte. Fuel supply OK. Arrnge pssengers nd lod in the ot so the weight is distriuted 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 ot while under the influence of lcohol or drugs. Know the wters nd re you will e oting; tides, currents, snd rs, rocks, nd other hzrds. Mke inspection checks listed in Mintennce - Inspection nd Mintennce Schedule. Operting In Freezing Tempertures When using your outord or hving your outord moored in freezing or ner freezing tempertures, keep the outord tilted down t ll times so the gercse is sumerged. This prevents trpped wter in gercse from freezing nd cusing possile dmge to the wter pump nd other components. If there is chnce of ice forming on the wter, the outord should e removed nd drined completely of wter. If ice should form t the wter level inside the outord driveshft housing, it will lock wter flow to the engine cusing possile dmge. Operting In Slt Wter Or Polluted Wter We recommend tht you flush the internl wter pssges of your outord with fresh wter fter ech use in slt or polluted wter. This will prevent uildup of deposits from clogging the wter pssges. Refer to Mintennce - Flushing The Cooling System. If you keep your ot moored in the wter, lwys tilt the outord so the gercse is completely out of wter (except in freezing tempertures) when not in use. Wsh the outord 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. 29

36 OPERATION Setting Trim Angle while Running Engine t Idle Speed The exhust relief hole on the outord cn ecome sumerged on some ots if the engine is trimmed full in while running t idle speed. This my result in exhust restriction, rough idle, excessive smoke, nd fouled sprk plugs. If this condition exists, trim outord up until exhust relief hole is out of the wter Relief hole sumerged (wrong) - Relief hole ove wter line (correct) Engine Brek-in Procedure IMPORTANT: Filure to follow the engine rek-in procedures cn result in poor performnce throughout the life of the engine nd cn cuse engine dmge. Alwys follow rek-in procedures. 1. For the first two hours of opertion, run the engine t vried throttle settings up to 4500 RPM or t threequrter throttle, nd t full throttle for pproximtely one minute every ten minutes. 2. For the next eight hours of opertion, void continuous opertion t full throttle for more thn five minutes t time. Strting The Engine - Remote Control Models Before strting, red the Pre-Strting Check List, nd Engine Brek-in Procedure in the Opertion section. NOTICE Filure to provide sufficient cooling wter will dmge the wter pump nd cuse the engine to overhet. Provide sufficient supply of wter t the wter inlets during opertion. 1. Check the engine oil level

37 OPERATION 2. Ensure the cooling wter intke is sumerged. 3. Open fuel tnk vent screw (in filler cp) on mnul venting type fuel tnks Set the lnyrd stop switch to RUN position. Refer to Generl Informtion - Lnyrd Stop Switch Shift outord to neutrl (N) position. N NOTE: For initil strt of new engine or for n engine tht rn out of fuel or ws drined of fuel, the fuel system should e filled s follows: Turn the ignition key switch to the "ON" position for pproximtely one minute. This opertes the fuel lift pump. Turn the ignition key switch ck to the "OFF" position nd then return the ignition key switch to the "ON" position gin for n dditionl minute. Turn the ignition key switch ck to the "OFF" position. The filling of the fuel system is complete. 31

38 OPERATION 6. Turn ignition key to the "START" position. If engine fils to strt in ten seconds, return key to "ON" position, wit 30 seconds nd try gin After engine strts, check for stedy strem of wter flowing out of the wter pump indictor hole IMPORTANT: If no wter is coming out of the wter pump indictor hole, stop engine nd check cooling wter intke for ostruction. No ostruction my indicte wter pump filure or lockge in the cooling system. These conditions will cuse the engine to overhet. Hve the outord checked y your deler. Operting the engine while overheted will cuse engine dmge. WARMING UP ENGINE Before eginning opertion, llow the engine to wrm up t idling speed for three minutes. Ger Shifting IMPORTANT: Oserve the following: Never shift outord into ger unless engine speed is t idle. Do not shift outord into reverse when the engine is not running. Your outord hs three ger shift positions to provide opertion. Forwrd (F), Neutrl (N) nd Reverse (R). When shifting, lwys stop t neutrl position nd llow the engine speed to return to idle. Alwys shift outord into ger with quick motion. After shifting outord into ger, dvnce the lever further to increse speed. F N R

39 Stopping The Engine OPERATION Reduce engine speed nd shift outord to neutrl position. Turn ignition key to "OFF" position

40 MAINTENANCE Outord Cre To keep your outord in the est operting condition, it is importnt tht your outord 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 dependility. Record mintennce performed in the Mintennce Log t the ck of this ook. 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 Luricnts. EPA Emissions EMISSION CERTIFICATION LABEL An emission certifiction lel, showing emission levels nd engine specifictions directly relted to emissions, is plced on the engine t time of mnufcture. c f g d h e i Idle speed f - Fmily numer - c - d - e - Engine horsepower Piston displcement Prt numer Vlve clernce (if pplicle) g - h - i - 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 prescried certifiction stndrds. 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 nd Mintennce Schedule BEFORE EACH USE Check engine oil level. See Fuel nd Oil - Checking nd Adding Engine Oil. Check tht lnyrd stop switch stops the engine. Visully inspect the fuel system for deteriortion or leks. Check outord for tightness on trnsom. Check steering system for inding or loose components. Check propeller ldes for dmge. AFTER EACH USE Flush out the outord cooling system if operting in slt or polluted wter. See Flushing the Cooling System. 34

41 MAINTENANCE Wsh off ll slt deposits nd flush out the exhust outlet of the propeller nd gercse with fresh wter if operting in sltwter. If operting in sltwter, inspect the powerhed nd powerhed components for slt uild-up. See Clening Cre for the Powerhed (Sltwter Use). EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST Chnge engine oil nd replce the oil filter. The oil should e chnged more often when the engine is operted under dverse conditions such s extended trolling. See Chnging Engine Oil. Inspect the thermostt visully for corrosion nd or for roken spring. Mke sure the thermostt closes completely t room temperture. 1. Check low pressure fuel filter for contminnts. Replce filter if required. See Fuel System. Check corrosion control nodes. Check more frequently when used in sltwter. See Corrosion Control Anode. Drin nd replce gercse luricnt. See Gercse Luriction. Check power trim fluid. See Checking Power Trim Fluid. Inspect ttery. See Bttery Inspection. Sltwter usge. Remove nd inspect sprk plugs for corrosion nd replce sprk plugs s necessry. Apply thin coting of Anti-Seize Compound only on threds of sprk plug prior to instlltion. See Sprk Plug Inspection nd Replcement. Tue Ref No. Description Where Used Prt No. 81 Anti-Seize Compound Sprk plug threds K1 Check wiring nd connectors. Check tightness of olts, nuts, nd other fsteners. Check cowl sels to mke sure sels re intct nd not dmged. Check internl cowl sound reduction fom (if equipped) to mke sure fom is intct nd not dmged. Check tht the intke silencer (if equipped) is in plce. Check tht the idle relief muffler (if equipped) is in plce. Check for loose hose clmps nd ruer oots (if equipped) on the ir intke ssemly. EVERY 300 HOURS OF USE OR THREE YEARS Replce wter pump impeller (more often if overheting occurs or reduced wter pressure is noted). 1. Replce high pressure in-line fuel filter. 1. Replce sprk plugs fter the first 300 hours or three yers. After tht, inspect sprk plugs every 300 hours or three yers. Replce sprk plugs s needed. See Sprk Plug Inspection nd Replcement. Replce ccessory drive elt. See Accessory Drive Belt Inspection. 1. BEFORE PERIODS OF STORAGE See Storge section. Flushing the Cooling System Flush the internl wter pssges of the outord with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent uild-up of deposits from clogging the internl wter pssges. IMPORTANT: The engine must e run during flushing in order to open the thermostt nd circulte wter through the wter pssges. 1. These items should e serviced y n uthorized deler. 35

42 MAINTENANCE NOTE: You cn hve the outord tilted or in the verticl operting position during flushing.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. 1. Plce the outord in either the operting position (verticl) or in tilted position. 2. Remove propeller. Refer to Propeller Replcement. 3. Thred wter hose into the rer fitting. Prtilly open the wter tp (1/2 mximum). Do not open the wter tp ll the wy, s this llows high pressure flow of wter. IMPORTANT: Do not run engine ove idle when flushing. 4. Shift outord into neutrl. Strt the engine nd flush the cooling system for t lest five minutes. Keep engine speed t idle. 5. Stop the engine. Turn off the wter nd remove the hose. Reinstll the propeller. FOURSTROKE Top Cowl Removl nd Instlltion REMOVAL 1. Pull out the front cowl ltch

43 MAINTENANCE 2. Pull down the rer cowl ltch. Remove the top cowl INSTALLATION 1. Lower the top cowl into position over the engine. 2. Pull up the rer cowl ltch to lock down the rer. Push in the front cowl ltch to lock down the front. Flywheel Cover Removl nd Instlltion REMOVAL Lift the cover off the rer mounting pin nd slide the cover forwrd to relese the cover from the front mounting pins. c Flywheel cover c - Rer mounting pin - Front mounting pins INSTALLATION Position the cover onto the two front pins nd then secure the cover in plce y pushing the cover down onto the rer mounting pin. 37

44 MAINTENANCE Clening Cre for Top nd Bottom Cowls IMPORTANT: Dry wiping (wiping the plstic surfce when it is dry) will result in minor surfce scrtches. Alwys wet the surfce efore clening. Do not use detergents contining hydrochloric cid. Follow the clening nd wxing procedure. CLEANING AND WAXING PROCEDURE 1. Before wshing, rinse the cowls with clen wter to remove dirt nd dust tht my scrtch the surfce. 2. Wsh the cowls with clen wter nd mild non-rsive sop. Use soft clen cloth when wshing. 3. Dry thoroughly with soft clen cloth. 4. Wx the surfce using non-rsive utomotive polish (polish designed for cler cot finishes). Remove the pplied wx y hnd using clen soft cloth. 5. To remove minor scrtches, use Mercury Mrine Cowl Finishing Compound ( K 1). Clening Cre for the Powerhed (Sltwter Use) If the outord is operted in sltwter, remove the top cowl nd flywheel cover. Inspect the powerhed nd powerhed components for slt uild-up. Wsh off ny slt uild-up from the powerhed nd powerhed components with fresh wter. Keep wter spry out of the ir filter/intke nd lterntor. After wshing, llow the powerhed nd components to dry. Apply Quicksilver or Mercury Precision Luricnts Corrosion Gurd spry on the externl metl surfces of the powerhed nd powerhed components. Do not llow the Corrosion Gurd spry to come in contct with the lterntor drive elt or elt pulleys. IMPORTANT: Do not llow luricnt or Corrosion Gurd spry to come in contct with the lterntor drive elt or the elt pulleys. The lterntor drive elt could slip nd e dmged if it ecomes coted with ny luricnt or Corrosion Gurd spry. Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Externl metl surfces of the powerhed nd powerhed components Q55 Bttery Inspection The ttery should e inspected t periodic intervls to ensure proper engine strting cpility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your ttery. 1. Turn off the engine efore servicing the ttery. 2. Add wter s necessry to keep the ttery full. 3. Mke sure the ttery is secure ginst movement. 4. Bttery cle terminls should e clen, tight, nd correctly instlled. Positive to positive nd negtive to negtive. 5. Mke sure the ttery is equipped with non-conductive shield to prevent ccidentl shorting of ttery terminls. Air Filter The ir filter is one piece ssemly. The ir filter removes irorne prticles which my dmge engine components. The ir filter design llows for mximum unrestricted ir flow during engine opertion. 38

45 AIR FILTER ASSEMBLY REMOVAL 1. Remove the rether tue from the ir filter. MAINTENANCE c Air filter ssemly c - Air intke - Brether tue 2. Remove the purge vent tue from the ir filter. 3. Pull the ir filter ssemly off the front of the ir intke. NOTE: To help in the removl of the ir filter ssemly, use the ottom t tht is locted on the mounting flnge of the filter nd push out on the flnge while pulling the ir filter ssemly off the ir intke. - Purge vent tue - Bottom t AIR FILTER ASSEMBLY INSTALLATION 1. Plce the ir filter ssemly over the ir intke s shown nd then push the ir filter ssemly onto the ir intke until it is fully seted. 2. Reconnect the rether tue nd purge vent tue to the ir filter. 39

46 Fuel System MAINTENANCE! WARNING Fuel is flmmle nd explosive. Ensure the key switch is off nd the lnyrd is positioned so tht the engine cnnot strt. Do not smoke or llow sources of sprk or open flme in the re while servicing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys check for leks efore ttempting to strt the engine nd wipe up ny spilled fuel immeditely. IMPORTANT: Use n pproved continer to collect nd store fuel. Wipe up spilled fuel immeditely. Mteril used to contin spilled fuel must e disposed of in n pproved receptcle. Before servicing ny prt of the fuel system: 1. Stop engine nd disconnect the ttery. 2. Perform fuel system service in well ventilted re. 3. Inspect ny completed service work for sign of fuel lekge. FUEL LINE INSPECTION Visully inspect the fuel line for crcks, swelling, leks, hrdness, or other signs of deteriortion or dmge. If ny of these conditions re found, the fuel line must e replced. FUEL FILTERS Refer to the Inspection nd Mintennce Schedule for the proper mintennce intervl. The engine is equipped with two fuel filters, One low pressure filter nd one high pressure filter. The low pressure filter cn e serviced s generl mintennce item, however the high pressure filter is under high pressure nd should only e serviced y n uthorized deler. - Low pressure fuel filter - High pressure fuel filter HIGH PRESSURE FUEL FILTER The high pressure fuel filter is under high pressure. A specil tool nd procedure is required to relese the fuel pressure efore the filter cn e removed. Hve the high pressure fuel filter serviced y n uthorized deler. 40

47 LOW PRESSURE FUEL FILTER Removl MAINTENANCE 1. Turn ignition key switch to "OFF" position. 2. Remove the cp from the fuel vpor purge relief vlve. - Fuel vpor purge relief vlve 20813! CAUTION Filure to relese pressure from the fuel system will result in fuel sprying out, which cn cuse fire or explosion. Allow the engine to cool completely nd relese ll fuel pressure efore servicing ny prt of the fuel system. Alwys protect eyes nd skin from pressurized fuel nd vpors. 3. Plce rg or towel round the vlve, nd relese the fuel pressure y pushing the core of the vlve end in

48 MAINTENANCE 4. Push in on the fuel hose relese ts nd disconnect the fuel hoses from the fuel filter Fuel hose relese t - Low pressure fuel filter Instlltion 1. Instll the new fuel filter so the rrow points towrds the engine. 2. Connect the fuel hoses to the fuel filter securely with the locking hose connections. 3. If removed, plce the fuel hose into the fuel hose retiner. - Fuel hose retiner Visully inspect for fuel lekge from the fuel filter while turning the ignition key to "RUN" position, forcing fuel into the fuel filter. Repir ny fuel leks if necessry. Corrosion Control Anode The outord hs corrosion control nodes t different loctions. An node helps protect the outord ginst glvnic corrosion y scrificing its metl to e slowly eroded insted of the outord metls. Ech node requires periodic inspection, especilly in sltwter which will ccelerte the erosion. To mintin this corrosion protection, lwys replce the node efore it is completely eroded. Never pint or pply protective coting on the node s this will reduce effectiveness of the node. 42

49 MAINTENANCE Two nodes re locted on ech side of the gercse. Another node is instlled on the ottom of the trnsom rcket ssemly. Propeller Replcement! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. 1. Shift outord to neutrl (N) position. N 2. Strighten the ent ts on the propeller nut retiner

50 MAINTENANCE 3. Plce lock of wood etween gercse nd propeller to hold propeller nd remove propeller nut Pull propeller stright off shft. 5. Cot the propeller shft with Quicksilver or Mercury Precision Luricnts Anti-Corrosion Grese or 2-4- C with Teflon Tue Ref No. Description Where Used Prt No. 94 Anti-Corrosion Grese Propeller shft Q C Mrine Luricnt with Teflon Propeller shft Q1 IMPORTANT: To prevent the propeller hu from corroding nd seizing to the propeller shft, especilly in slt wter, lwys pply cot of the recommended luricnt to the entire propeller shft t the recommended mintennce intervls nd lso ech time the propeller is removed. 44

51 MAINTENANCE 6. Flo-Torq I Drive Hu Propellers - Instll thrust wsher, propeller, continuity wsher, thrust hu, propeller nut retiner, nd propeller nut onto the shft. c - - c - Propeller nut Propeller nut retiner Rer thrust hu d e f d - Continuity wsher e - Propeller f - Forwrd thrust hu 7. Flo-Torq II nd Flo-Torq III Drive Hu Propellers - Instll forwrd thrust hu, replcele drive sleeve, propeller, thrust hu, propeller nut retiner nd propeller nut onto the shft. c e f d - - c - c d e f Flo-Torq II Propeller nut Propeller nut retiner Rer thrust hu 3223 Flo-Torq III d - Propeller e - Replcele drive sleeve f - Forwrd thrust hu 8. Plce lock of wood etween the gercse nd propeller. Torque propeller nut to specifictions. Description Nm l. in. l. ft. Propeller nut

52 MAINTENANCE 9. Secure propeller nut y ending three of the ts into the thrust hu grooves. 10. Reinstll sprk plug leds Sprk Plug Inspection nd Replcement 1. Remove top cowling. Refer to Top Cowl Removl nd Instlltion. 2. Disconnect the wiring hrness connectors from the pencil coils. 3. Remove the mounting olts tht re securing the pencil coils. Pull the pencil coils from the sprk plugs using twisting motion. c d Wiring hrness connector c - Bolt - Pencil coil d - Ground strp 4. Remove the sprk plugs to inspect. Replce sprk plug if electrode is worn, threds of sel re re corroded, or the insultor is rough, crcked, roken, listered or fouled

53 5. Set the sprk plug gp to specifictions. MAINTENANCE Sprk Plug Sprk Plug Gp 0.8 mm (0.032 in.) 6. Sltwter use - Apply thin coting of Anti-Seize Compound only on threds of sprk plugs. 7. 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 l. in. l. ft. Sprk plug Push pencil coils into plce over the sprk plugs using twisting motion. 9. Secure coils with retined olts. Torque to specifictions. Description Nm l. in. l. ft. Bolts Reconnect the wiring hrness connectors to the pencil coil connections. c d Wiring hrness connector c - Bolt - Pencil coil d - Ground strp 11. Reinstll top cowl. Fuse Replcement IMPORTANT: Alwys crry spre fuses. The electricl wiring circuits on the outord re protected from overlod y fuses in the wiring. If fuse is lown, try to locte nd correct the cuse of the overlod. If the cuse is not found, the fuse my low gin. 47

54 MAINTENANCE Open the fuse holder nd look t the silver colored nd inside the fuse. If nd is roken, replce the fuse. Replce fuse with new fuse with the sme rting. f i h g c d - - c - d - e - Good fuse Blown fuse Dignostics terminl - 2 AMP fuse 14 pin remote control hrness/cowl trim switch/min power rely - 15 AMP fuse SmrtCrft dt us circuit - 5 AMP fuse e f - Electric fuel pump - 20 AMP fuse g - Ignition coils - 20 AMP fuse h - Spre fuse - 20 AMP fuse i - Fuel injectors/purge vlve/idle ir control - 20 AMP fuse Alterntor Drive Belt Inspection Inspect the lterntor drive elt nd hve it replced y n uthorized deler if ny of the following conditions re found: - Alterntor drive elt Crcks in the ck of the elt or in the se of the V grooves. 48

55 Excessive wer t the roots of the grooves. Ruer portion swollen y oil. Belt surfces roughened. MAINTENANCE Signs of wer on edges or outer surfces of elt. Luriction Points 1. Luricte the following with Quicksilver or Mercury Precision Luricnts Anti-Corrosion Grese or 2-4-C with Teflon. Tue Ref No. Description Where Used Prt No. 94 Anti-Corrosion Grese Propeller shft Q C with Teflon Propeller shft Q1 Propeller Shft - Refer to Propeller Replcement for removl nd instlltion of the propeller. Cot the entire propeller shft with luricnt to prevent the propeller hu from corroding nd seizing to the shft Luricte the following with Quicksilver or Mercury Precision Luricnts 2-4-C with Teflon or Specil Luricnt 101. Tue Ref No. Description Where Used Prt No C with Teflon 34 Specil Luricnt 101 Swivel rcket, tilt support lever, tilt tue, steering cle Swivel rcket, tilt support lever, tilt tue, steering cle Q Q02 Swivel Brcket - Luricte through fitting. Tilt Support Lever - Luricte through fitting Swivel rcket - Tilt support lever 49

56 Tilt Tue - Luricte through fitting. MAINTENANCE Steering Cle Grese Fitting (If equipped) - Rotte steering wheel to fully retrct the steering cle end into the outord tilt tue. Luricte through fitting Fitting - Steering cle end! WARNING Incorrect cle luriction cn cuse hydrulic lock, leding to serious injury or deth from loss of ot control. Completely retrct the end of the steering cle efore pplying luricnt. 3. Luricte the following with light weight oil. Steering Link Rod Pivot Points - Luricte pivot points

57 Checking Power Trim Fluid MAINTENANCE 1. Tilt outord to the full up position nd engge the tilt support lever Remove fill cp nd check fluid level. The fluid level should e even with the ottom of the fill hole. Add Quicksilver or Mercury Precision Luricnts Power Trim & Steering Fluid. If not ville, use utomotive (ATF) utomtic trnsmission fluid. Chnging Engine Oil ENGINE OIL CAPACITY Engine oil cpcity is pproximtely 5 liters (5.3 qurts). OIL CHANGING PROCEDURE 1. Tilt the outord up to the triler position Turn the steering on the outord so tht the drin hole is fcing downwrd. Remove drin plug nd drin engine oil into n pproprite continer. Luricte the sel on the drin plug with oil nd reinstll. CHANGING OIL FILTER Plce rg or towel elow the oil filter to sor ny spilled oil. 2. Unscrew old filter y turning the filter to the left. 51

58 MAINTENANCE 3. Clen the mounting se. Apply film of clen oil to filter gsket. Do not use grese. Screw new filter on until gsket contcts se, then tighten 3/4 to 1 turn. - Oil filter - Loosen OIL FILLING 1. Remove the oil fill cp nd dd the recommended oil to the midpoint of the operting rnge (midpoint of the cross htched region). Adding pproximtely 5 liters (5.3 qurts) will ring the oil level to mid point of the cross htched region. 2. Idle engine for five minutes nd check for leks. Stop the engine. Allow few minutes for the oil to drin to the oil sump nd recheck the oil on the dipstick. Add oil if necessry. Gercse Luriction When dding or chnging gercse luricnt, visully check for the presence of wter in the luricnt. If wter is present, it my hve settled to the ottom nd will drin out prior to the luricnt, or it my e mixed with the luricnt, giving it milky colored ppernce. If wter is noticed, hve the gercse checked y your deler. Wter in the luricnt my result in premture ering filure or, in freezing tempertures, will turn to ice nd dmge the gercse. Exmine the drined gercse luricnt for metl prticles. A smll mount of metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte norml ger wer nd should e checked y n uthorized deler. DRAINING GEARCASE 1. Plce outord in verticl operting position. 52

59 2. Plce drin pn elow outord. MAINTENANCE 3. Remove vent plugs nd fill/drin plug nd drin luricnt Vent plugs - Fill/drin plug GEARCASE LUBRICANT CAPACITY Gercse luricnt cpcity is pproximtely 666 ml (22.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performnce Ger Luricnt. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Plce outord in verticl operting position. 2. Remove the front vent plug nd rer vent plug. 3. Remove fill/drin plug. Plce luricnt tue into the fill/drin plug hole nd dd luricnt until it ppers t the front vent hole. At this time instll the front vent plug nd seling wsher. c d e - Front vent plug d - Rer vent plug - Front vent hole e - Fill/drin plug c - Rer vent hole 4. Continue dding luricnt until it ppers t the rer vent hole. 5. Stop dding luricnt. Instll the rer vent plug nd seling wsher efore removing luricnt tue. 6. Remove luricnt tue nd reinstll clened fill/drin plug nd seling wsher. 53

60 SUBMERGED OUTBOARD MAINTENANCE A sumerged outord will require service within few hours y n uthorized deler once the outord is recovered from the wter. This immedite ttention y servicing deler is necessry once the engine is exposed to the tmosphere to minimize internl corrosion dmge to the engine. 54

61 Storge Preprtion STORAGE The mjor considertion in prepring your outord for storge is to protect it from rust, corrosion, nd dmge cused y freezing of trpped wter. The following storge procedures should e followed to prepre your outord for out of seson storge or prolonged storge (two months or longer). NOTICE Filure to provide sufficient cooling wter will dmge the wter pump nd cuse the engine to overhet. Provide sufficient supply of wter t the wter inlets during opertion. FUEL SYSTEM IMPORTANT: Gsoline contining lcohol (ethnol or methnol) cn cuse formtion of cid during storge nd cn dmge the fuel system. If the gsoline eing used contins lcohol, it is dvisle to drin s much of the remining gsoline s possile from the fuel tnk, remote fuel line, nd engine fuel system. IMPORTANT: This outord is equipped with closed fuel system when the engine is not running. With this closed system, fuel within the engine's fuel system, other thn the fuel tnk, will remin stle during norml storge periods without the ddition of fuel tretment stilizers. Fill the fuel tnk nd engine fuel system with treted (stilized) fuel to help prevent formtion of vrnish nd gum. Proceed with the following instructions. Portle Fuel Tnk - Pour the required mount of Fuel System Tretment nd Stilizer (follow instructions on continer) into fuel tnk. Tip fuel tnk ck nd forth to mix stilizer with the fuel. Permnently Instlled Fuel Tnk - Pour the required mount of Fuel System Tretment nd Stilizer (follow instructions on continer) into seprte continer nd mix with pproximtely one liter (one qurt) of gsoline. Pour this mixture into fuel tnk. Tue Ref No. Description Where Used Prt No. 124 Fuel System Tretment & Stilizer Fuel tnk Q1 Protecting Externl Outord Components Touch up ny pint nicks. See your deler for touch-up pint. Spry Quicksilver or Mercury Precision Luricnts Corrosion Gurd on externl metl surfces (except corrosion control nodes). Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Externl metl surfces Q55 Protecting Internl Engine Components IMPORTANT: Refer to Mintennce - Sprk Plug Inspection nd Replcement for correct procedure for removing sprk plugs. Remove pencil coils nd sprk plugs. Spry pproximtely 30 ml (1 fl. oz.) of Storge Sel Rust Inhiitor into ech sprk plug hole. Tue Ref No. Description Where Used Prt No. 119 Storge Sel Rust Inhiitor Sprk plug holes Q56 55

62 STORAGE Actute key/push utton strt switch to crnk the engine through one strt cycle, which will distriute the storge sel throughout the cylinders. Reinstll sprk plugs nd pencil coils. Gercse Drin nd refill the gercse luricnt (refer to Mintennce - Gercse Luriction). Positioning Outord For Storge Store outord in n upright (verticl) position to llow wter to drin out of outord. NOTICE Storing the outord in tilted position cn dmge the outord. Wter trpped in the cooling pssges or rin wter collected in the propeller exhust outlet in the gercse cn freeze. Store the outord in the full down position. Bttery Storge Follow the ttery mnufcturer's instructions for storge nd rechrging. Remove the ttery from the ot nd check wter level. Rechrge if necessry. Store the ttery in cool, dry plce. Periodiclly check the wter level nd rechrge the ttery during storge. 56

63 TROUBLESHOOTING Strter Motor Will Not Crnk the Engine POSSIBLE CAUSES Lnyrd stop switch not in "RUN" position. Blown 15 AMP fuse. Check 14 pin remote control hrness/cowl trim switch/min power rely fuse. Refer to Mintennce section. Outord is not shifted to neutrl position. Wek ttery or ttery connections re loose or corroded. Ignition key switch filure. Wiring or electricl connection fulty. Strter motor solenoid or slve solenoid filure. Engine Will Not Strt POSSIBLE CAUSES Incorrect strting procedure. Refer to Opertion section. Old or contminted gsoline. Fuel is not reching the engine. Fuel tnk is empty. Fuel tnk vent not open or restricted. Fuel line is disconnected or kinked. Fuel filter is ostructed. Refer to Mintennce section. Fuel pump filure. Fuel tnk filter ostructed. Ignition system component filure. Sprk plugs fouled or defective. Refer to Mintennce section. Engine Runs Errticlly POSSIBLE CAUSES Overheting - Wrning horn not working. Low oil pressure. Check oil level. Sprk plugs fouled or defective. Refer to Mintennce section. Incorrect setup nd djustments. Fuel is eing restricted to the engine.. Engine fuel filter is ostructed. Refer to Mintennce section.. Fuel tnk filter ostructed. c. Stuck nti-siphon vlve locted on permnently uilt-in type fuel tnks. d. Fuel line is kinked or pinched. Fuel pump filure. Ignition system component filure. Performnce Loss POSSIBLE CAUSES Overheting - Wrning horn not working. Low oil pressure. Check oil level. Throttle not opening fully. 57

64 Dmged propeller or improper propeller size. Incorrect engine timing, djustment, or setup. Bot overloded or lod improperly distriuted. Excessive wter in ilge. Bot ottom is dirty or dmged. Bttery Will Not Hold Chrge POSSIBLE CAUSES TROUBLESHOOTING Bttery connections re loose or corroded. Low electrolyte level in ttery. Worn out or inefficient ttery. Excessive use of electricl ccessories. Defective rectifier, lterntor, or voltge regultor. Open circuit in the lterntor output wire (fused link). 58

65 Locl Repir Service OWNER SERVICE ASSISTANCE Alwys return your outord to your locl uthorized deler should the need for service rise. Only he hs the fctory trined mechnics, knowledge, specil tools, equipment, nd genuine prts nd ccessories to properly service your engine should the need occur. He knows your engine est. Service Awy From Home If you re wy from your locl deler nd the need rises for service, contct the nerest uthorized deler. Refer to the Yellow Pges of the telephone directory. If, for ny reson, you cnnot otin service, contct the nerest Mercury Mrine Service Office. Prts And Accessories Inquiries All inquiries concerning genuine replcement prts nd ccessories should e directed to your locl uthorized deler. The deler hs the necessry informtion to order prts nd ccessories for you. When inquiring on prts nd ccessories, the deler requires the model nd seril numer to order the correct prts. Service Assistnce Your stisfction with your outord product is very importnt to your deler nd to us. If you ever hve prolem, question or concern out your outord product, contct your deler or ny uthorized Mercury Mrine delership. If dditionl ssistnce is required, tke these steps. 1. Tlk with the delership's sles mnger or service mnger. If this hs lredy een done, then contct the owner of the delership. 2. Should you hve question, concern, or prolem tht cnnot e resolved y your delership, plese contct Mercury Mrine Service Office for ssistnce. Mercury Mrine will work with you nd your delership to resolve ll prolems. The following informtion will e needed y the service office: Your nme nd ddress Dytime telephone numer Model nd seril numer of your outord The nme nd ddress of your delership Nture of prolem Mercury Mrine Service Offices For ssistnce, cll, fx, or write. Plese include your dytime telephone numer with mil nd fx correspondence. United Sttes Telephone (920) Mercury Mrine Fx (920) W6250 W. Pioneer Rod P.O. Box 1939 Wesite Fond du Lc, WI Cnd Telephone (905) Mercury Mrine Ltd Medowpine Blvd. Fx (905) Mississug, Ontrio L5N 7W6 Cnd 59

66 OWNER SERVICE ASSISTANCE Austrli, Pcific Telephone (61) (3) Mercury Mrine Austrli Frnkston Rod Fx (61) (3) Dndenong, Victori 3164 Austrli Europe, Middle Est, Afric Telephone (32) (87) Mrine Power - Europe, Inc. Prc Industriel de Petit-Rechin Fx (32) (87) B-4800 Verviers, Belgium Mexico, Centrl Americ, South Americ, Crien Telephone (954) Mercury Mrine Interchnge Circle North Fx (954) Mirmr, FL U.S.A. Jpn Telephone Fx Mercury Mrine - Jpn Anshin-cho Hmmtsu Shizuok-ken, Jpn Jpn Asi, Singpore Telephone Mercury Mrine Singpore 72 Loyng Wy Fx Singpore,

67 Importnt Informtion OUTBOARD INSTALLATION Rigging ots, which includes proper engine instlltion hs ecome more complex over the yers. As result, Mercury Mrine recommends tht engines e instlled only y Mercury uthorized delers. If you intend to disregrd this recommendtion, nd instll the engine yourself, plese mke sure to red nd comply with these instructions. Filure to comply with these instlltion instructions could led to serious injury or deth. NOTE: Do not instll n ccessory electric fuel pump or fuel line primer ul into the fuel system of this engine. Bot Horsepower Cpcity! WARNING Exceeding the ot's mximum horsepower rting cn cuse serious injury or deth. Overpowering the ot cn ffect ot control nd flottion chrcteristics or rek the trnsom. Do not instll n engine tht exceeds the ot's mximum power rting. Do not overpower or overlod your ot. Most ots will crry required cpcity plte indicting the mximum cceptle power nd lod s determined y the mnufcturer following certin federl guidelines. If in dout, contct your deler or the ot mnufcturer. Strt in Ger Protection U.S. COAST GUARD CAP ACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY! WARNING XXX XXX Strting the engine with the drive in ger cn cuse serious injury or deth. Never operte ot tht does not hve neutrl-sfety-protection device. The remote control connected to the outord must e equipped with strt in neutrl only protection device. This prevents the engine from strting in ger. Selecting Accessories For Your Outord Genuine Mercury Precision or Quicksilver Accessories hve een specificlly designed nd tested for this outord. Some ccessories not mnufctured or sold y Mercury Mrine re not designed to e sfely used with this outord or outord operting system. Acquire nd red the instlltion, opertion, nd mintennce mnuls for ll selected ccessories. Fuel Tnks PORTABLE FUEL TANK Select suitle loction in the ot within the engine fuel line length limittions nd secure the tnk in plce. 61

68 PERMANENT FUEL TANK OUTBOARD INSTALLATION Permnent fuel tnks should e instlled in ccordnce with industry nd federl sfety stndrds, which include recommendtions pplicle to grounding, nti-siphon protection, ventiltion, etc. Filling the Fuel System NOTE: For initil strt of new engine or for n engine tht rn out of fuel or ws drined of fuel, the fuel system should e filled s follows: Turn the ignition key switch to the "ON" position for pproximtely one minute. This opertes the fuel lift pump. Turn the ignition key switch ck to the "OFF" position nd then return the ignition key switch to the "ON" position gin for n dditionl minute. Turn the ignition key switch ck to the "OFF" position. The filling of the fuel system is complete. Instlltion Specifictions Minimum trnsom opening - Engine centerline for dul engine cm (26 in.) Minimum Trnsom Opening Single engine Dul engine 84.2 cm (33 in.) cm (59 in.) Lifting Outord 1. Remove top cowl nd engine flywheel cover. 2. Instll the lifting se to the flywheel using three olts. Tighten the olts securely. 3. Thred the lifting eye into the lifting se. 4. Connect hoist tht hs minimum lift cpcity of 450 kg (1000 l.) to the lifting eye. 62

69 OUTBOARD INSTALLATION 5. Lift the outord nd plce it on the trnsom. - Lifting se - Lifting eye Flywheel Puller/Lifting Ring T Removes flywheel from engine. Used for lifting powerhed/engine. Steering Cle - Strord Side Routed Cle 1. Luricte O-ring sel nd entire cle end Tue Ref No. Description Where Used Prt No C Mrine Luricnt with Teflon O-ring sel nd entire cle end Q1 63

70 2. Insert steering cle into tilt tue. OUTBOARD INSTALLATION 3. Torque nut to specifiction Description Nm l. in. l. ft. Nut Steering Link Rod Fsteners IMPORTANT: The steering link rod tht connects the steering cle to the engine must e fstened using specil wsher hed olt ("" - Prt Numer ) nd self-locking nylon insert locknuts ("c" & "d" - Prt Numer ). These locknuts must never e replced with common nuts (non-locking) s they will work loose nd virte off, freeing the link rod to disengge. 64

71 OUTBOARD INSTALLATION! WARNING Improper fsteners or improper instlltion procedures cn result in loosening or disenggement of the steering link rod. This cn cuse sudden, unexpected loss of ot control, resulting in serious injury or deth due to occupnts eing thrown within or out of the ot. Alwys use required components nd follow instructions nd torque procedures. c d - Specil wsher hed olt ( ) - Flt wshers 2897 c - Nylon insert locknut ( ) d - Nylon insert locknut ( ) Description Nm l. in. l. ft. Specil wsher hed olt Nylon insert locknut "d" Nylon insert locknut "c" Tighten until it sets, then ck off 1/4 turn Assemle steering link rod to steering cle with two flt wshers nd nylon insert locknut. Tighten locknut until it sets, then ck nut off 1/4 turn. Assemle steering link rod to engine with specil wsher hed olt nd locknut. First torque specil wsher hed olt, then torque locknut to specifictions. 65

72 OUTBOARD INSTALLATION Determining Recommended Outord Mounting Height 63.5 cm (25 in.) e e 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) c 50.8 cm (20 in.) d 48.2 cm (19 in.) - - c - The solid line is recommended to determine the outord mounting height. The roken lines represent the extremes of known successful outord mounting height dimensions. This line my e preferred to determine outord mounting height dimension, if mximum speed is the only ojective d - e - f - f This line my e preferred to determine outord mounting height dimension for dul outord instlltion. Outord mounting height (height of outord mounting rckets from ottom of ot trnsom). For heights over 56.0 cm (22 in.), propeller tht is designed for surfcing opertion is usully preferred. Mximum ot speed (MPH) nticipted NOTICE 1. The outord should e mounted high enough on the trnsom so the exhust relief hole will sty t lest 25.4 mm (1 in.) ove the wterline when the engine is running t idle speed. Hving the exhust relief hole ove the wterline will prevent exhust restrictions. Exhust restrictions will result in poor performnce t idle. 2. Add 12.7 cm (5 in.) for XL models to the listed outord mounting heights. 3. The mounting height of the outord must not exceed 63.5 cm (25 in.) for L models, 76 cm (30 in.) for XL models. Mounting the outord higher my cuse dmge to the gercse components. Incresing the mounting height will usully: Reduce steering torque Increse top speed Increse ot stility Cuse propeller to rek loose during plning 66

73 OUTBOARD INSTALLATION Drilling Outord Mounting Holes IMPORTANT: Before drilling ny mounting holes, crefully red Determining Recommended Outord Mounting Height nd instll outord to the nerest recommended mounting height. 1. Mrk four mounting holes on the trnsom using the trnsom drilling fixture. c or Drill guide holes c - Trnsom centerline - Trnsom drilling fixture Trnsom Drilling Fixture A2 Aids in engine instlltion y cting s templte for engine mounting holes Drill four 13.5 mm (17/32 in.) mounting holes

74 OUTBOARD INSTALLATION Fstening the Outord to the Trnsom MOUNTING BOLTS Outord Trnsom Mounting Hrdwre - Supplied with Outord Prt Numer Prt Nme Description Trnsom olt 1/2-20 x 4.50 in. long (2.25 in. thred) Nylon insert locknut 1/ Wsher - Inner in. ID x 1.50 in. OD Wsher - Outer 0.53 in. ID x 0.87 in. OD Aville Trnsom Mounting Bolts Prt Numer Prt Nme Description Trnsom olt 1/2-20 x 2.50 in. long (1.25 in. thred) Trnsom olt 1/2-20 x 3.50 in. long (1.25 in. thred) Trnsom olt 1/2-20 x 4.00 in. long (2.25 in. thred) Trnsom olt 1/2-20 x 4.50 in. long (2.25 in. thred) Trnsom olt 1/2-20 x 6.50 in. long (2.75 in. thred) CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the ot trnsom. The outord mounting locknuts nd olts should e le to hold 75 Nm (55 l. ft.) of torque without the ot trnsom yielding or crcking. If the ot trnsom yields or crcks under this torque, the construction of the trnsom my not e dequte. The ot trnsom must e strengthened or the lod crrying re incresed Trnsom yielding under olt torque - Trnsom crcking under olt torque When first determining trnsom strength, use dil torque wrench. If the olt or nut continues to turn without the torque reding on the dil incresing, it is n indiction tht the trnsom is yielding. The lod re cn e incresed y using lrger wsher or trnsom reinforcement plte. 68

75 OUTBOARD INSTALLATION NOTE: The inside holes on the trnsom reinforcement plte re for the lower trnsom olts nd the outside holes re for the upper trnsom olts Lrge trnsom wsher - Trnsom reinforcement plte Description Prt Numer Lrge trnsom wsher Trnsom reinforcement plte Apply mrine seler to shnks of olts, not the threds. 2. Fsten the outord with the correct mounting hrdwre. Tighten locknuts to the specified torque. NOTE: For more ccurte torque, whenever possile turn/tighten the mounting locknuts rther thn turning the mounting olts. e d - Flt wsher (4) - 1/2 in. dimeter olt (4) c - Shnk of olt c 3729 d - Locknut (4) e - Flt wsher (4) 69

76 OUTBOARD INSTALLATION Description Nm l. in. l. ft. Outord mounting locknuts nd olts Electricl, Fuel Hose, nd Control Cles FRONT COWL GROMMET Instlltion IMPORTANT: Sufficient slck must exist in wiring hrnesses, ttery cles, nd hoses, tht re routed etween the ruer grommet nd engine ttchment points, to relieve stress nd prevent hoses from eing kinked or pinched. 1. Pull up the cowl sel. Remove the ccess cover from the ottom cowl. d e c i h g f j Access cover f - Bttery cle opening - Front grommet g - Speedometer tue opening c - d - e - Fuel hose opening Remote wiring hrness opening Throttle cle opening h - i - j - SmrtCrft hrness or dditionl hrness opening Shift cle opening Cle tie 2. Route the hoses, wiring, nd cles through the correct opening in the front grommet s shown. 3. Reinstll the ccess cover with two olts. Rettch the cowl sel. 70

77 OUTBOARD INSTALLATION 4. Attch cle tie round the outside dimeter of the front grommet. - Cle tie REMOTE WIRING HARNESS Route the remote 14 pin ot hrness through the front grommet. Connect the remote hrness to the 14 pin connector on the engine hrness pin connector - Remote 14 pin ot hrness 71

78 OUTBOARD INSTALLATION SMARTCRAFT HARNESS CONNECTION If SmrtCrft guges re eing used with the outord, route the SmrtCrft wiring hrness through the front grommet nd connect it to the SmrtCrft hrness connector on the engine. - SmrtCrft hrness connector BATTERY CABLE CONNECTIONS Single Outord (+) c - Red sleeve - positive (+) - Blck sleeve - negtive ( ) (-) c - Crnking ttery or86 72

79 OUTBOARD INSTALLATION Dul Outords Connect common ground cle (wire size sme s engine ttery cles) etween negtive ( ) terminls on strting tteries. (-) d c (-) d - Red sleeve - positive (+) - Blck sleeve - negtive ( ) c - d - Ground cle Crnking ttery or87 FUEL HOSE CONNECTION Fsten remote fuel hose to fitting with hose clmp. 73

80 Fuel Hose Size OUTBOARD INSTALLATION Minimum fuel hose inside dimeter (ID) is 8 mm (5/16 in.) with seprte fuel hose/fuel tnk pickup for ech engine Hose clmp - Fuel hose SHIFT CABLE INSTALLATION Instll cles into the remote control following the instructions provided with the remote control. NOTE: Instll the shift cle to the engine first. The shift cle is the first cle to move when the remote control hndle is moved out of neutrl. 1. Remove the ccess cover from the ottom cowl. NOTE: The high pressure fuel hose cn e moved out of the wy for dditionl ccess Access cover - High pressure fuel hose 74