2016 Mercury Marine. 3.0L Diesel Spark Ignition

Transcription

1 2016 Mercury Mrine 3.0L Diesel Sprk Ignition 8M eng

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3 Declrtion of Conformity DSI Outbord, Not RCD Complint The outbord engines covered by this Declrtion of Conformity re not intended for instlltion on recretionl crft in the Europen Union. These engines do not conform to the exhust nd noise emission requirements of the Recretionl Crft Directive. This outbord motor mnufctured by Mercury Rcing complies with the requirements of the following directives nd stndrds, s mended: Nme of engine mnufcturer: Mercury Rcing Address: N7480 County Rod UU Town: Fond du Lc, WI Post Code: Country: USA Nme of uthorized representtive: Brunswick Mrine in EMEA Inc. Address: Prc Industriel de Petit Rechin Town: Verviers Post Code: B 4800 Country: Belgium Sfety of Mchinery Directive 2006/42/EC Principles of sfety integrtion (1.1.2) EN ISO 12100:2010 Noise (1.5.8) ICOMIA 39/94 Vibrtion (1.5.9) ICOMIA 38/94 Electromgnetic comptibility Directive 2014/30/EU Generic emission stndrd EN Generic emission stndrd EN Vehicles, bots nd internl combustion engine driven devices Rdio disturbnce chrcteristics SAE J551 CISPR 12; EN 55012:2007/ A1:2009 Engine type Fuel type Combustion cycle Outbord Diesel 2 Stroke, sprk ignited, direct injection This declrtion is issued under the sole responsibility of Mercury Mrine nd Brunswick Mrine in EMEA Inc. eng i

4 Nme / function: John Pfeifer, President, Mercury Mrine Dte nd plce of issue: Mrch 03, 2016 Mercury Mrine, Fond du Lc, WI USA Europen Regultions Contct: Regultions nd Product Sfety Deprtment, Mercury Mrine, Fond du Lc, WI USA Welcome You hve selected one of the finest outbords vilble. It incorportes numerous design fetures to ensure operting ese nd durbility. With proper cre nd mintennce, you will enjoy using this product for mny boting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. This mnul contins specific instructions for using nd mintining your product. We recommend tht this mnul remin with the product for redy reference whenever you re on the wter. Thnk you for purchsing one of our products. We sincerely hope your boting will be plesnt! Mercury Mrine Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Mercury Mrine. The terms of the wrrnty re set forth in the Wrrnty Informtion section of this mnul. The wrrnty sttement contins description of wht is covered, wht is not covered, the durtion of coverge, how to best obtin wrrnty coverge, importnt disclimers nd limittions of dmges, nd other relted informtion. Plese review this informtion. The description nd specifictions contined herein were in effect t the time this mnul ws pproved for printing. Mercury Mrine, whose policy is one of continued improvement, reserves the right to discontinue models t ny time, nd to chnge specifictions, designs, methods, or procedures without notice nd without incurring obligtion. Copyright nd Trdemrk Informtion MERCURY MARINE. All rights reserved. Reproduction in whole or in prt without permission is prohibited. ii eng

5 Alph, Axius, Brvo One, Brvo Two, Brvo Three, Circle M with Wves Logo, K plnes, Mriner, MerCthode, MerCruiser, Mercury, Mercury with Wves Logo, Mercury Mrine, Mercury Precision Prts, Mercury Propellers, Mercury Rcing, MotorGuide, OptiMx, Quicksilver, SeCore, Skyhook, SmrtCrft, Sport Jet, Verdo, VesselView, Zero Effort, Zeus, #1 On the Wter nd We're Driven to win re registered trdemrks of Brunswick Corportion. Pro XS is trdemrk of Brunswick Corportion. Mercury Product Protection is registered service mrk of Brunswick Corportion. eng iii

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7 WARRANTY INFORMATION Wrrnty Registrtion United Sttes nd Cnd... 1 Trnsfer of Wrrnty United Sttes nd Cnd...1 Products Sold to Government Agencies... 2 Mercury Rcing Division Two Yer Limited Government Wrrnty United Sttes nd Cnd... 2 Wrrnty Coverge nd Exclusions for Mercury Rcing Outbord Products Yer Limited Wrrnty Aginst Corrosion... 6 U.S. EPA Emissions Limited Wrrnty... 8 Emission Control System Components... 8 Cliforni Emissions Limited Wrrnty... 9 Cliforni Air Resources Bord Explntion of Your Cliforni Emission Control Wrrnty Sttement Generl Informtion Boter's Responsibilities Before Operting Your Outbord Bot Horsepower Cpcity High Speed nd High Performnce Bot Opertion Outbord Remote Control Models Remote Steering Notice...15 Lnyrd Stop Switch Protecting People in the Wter Exhust Emissions Pssenger Sfety Messge Pontoon Bots nd Deck Bots...20 Impct with Underwter Hzrds...22 Selecting Accessories for Your Outbord Sfe Boting Recommendtions Recording Seril Number Component Identifiction Specifictions...27 Propeller Selection...28 Trnsporting Trilering Bot/Outbord eng v

8 Fuel nd Oil Fuel Requirements Oil Requirement Avoiding Fuel Flow Restrictions...30 Low Permetion Fuel Hose Requirement Filling Remote Oil Tnk Filling Engine Mounted Oil Reservoir Tnk Filling Fuel Tnk Fetures nd Controls Remote Control Fetures Zero Effort Control Fetures Glow Plug Indictor...35 Wrning System Power Trim nd Tilt...37 Opertion Importnt Informtion...42 Engine Brek in Engine Brek in Fuel Mixture Prestrting Check List...43 Operting in Freezing Tempertures Operting in Sltwter or Polluted Wter Operting t High Elevtions Effects of Elevtion nd Wether on Performnce Setting Trim Angle While Running Engine t Idle Speed Operting in Shllow Wter Strting the Engine Mximum Idle Durtion Ger Shifting Stopping the Engine vi eng

9 Mintennce Power Pckge Cre Submerged Power Pckge Replcement Prts for Your Power Pckge Inspection nd Mintennce Schedule Flushing the Cooling System (Powerhed) Flushing the Cooling System (Lower Unit) Top Cowl Removl nd Instlltion Clening Cre for Top Cowl Fuel System Steering Link Rod Fsteners Fuses Corrosion Control Anode Sprk Plug Inspection nd Indexing Instlltion Bttery Inspection Fusible Link...70 Replcing the Propeller Lubriction Points Checking Power Trim Fluid (Three Rm Trim Systems) Gercse Lubricnt mm (4.8 in.) Dimeter Gercse Storge Protecting Externl Outbord Components Gercse Positioning Outbord for Storge Bttery Storge Troubleshooting Strter Motor Will Not Crnk the Engine...80 Engine Will Not Strt...80 Engine Runs Errticlly Performnce Loss...81 Wrning Horn Activtes (With Power Loss) Wrning Horn Activtes (No Power Loss) Bttery Will Not Hold Chrge eng vii

10 Owner Service Assistnce Service Assistnce Ordering Literture...85 Outbord Instlltion Mercury Mrine Vlidted Engine Mounting Hrdwre Accessories Mounted to the Trnsom Clmp Brcket Bot Horsepower Cpcity Strt in Ger Protection Selecting Accessories for Your Outbord Fuel System Instlltion Specifictions Lifting the Outbord Steering Cble Strbord Side Routed Cble Steering Link Rod Fsteners Recommended Mounting Height Drilling Outbord Mounting Holes Fstening the Outbord to the Trnsom Electricl, Hoses, Control Cbles, nd Front Clmp Oil Injection Set Up Trim In Pin Mintennce Log Mintennce Log viii eng

11 WARRANTY INFORMATION Wrrnty Registrtion United Sttes nd Cnd To be eligible for wrrnty coverge, the product must be registered with Mercury Mrine. At the time of sle, the selling deler should complete the wrrnty registrtion nd immeditely submit it to Mercury Mrine vi MercNET, e mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. A copy of the wrrnty registrtion should be provided to you by your selling deler. For Mercury Mrine's Privcy Policy, visit privcy policy/ NOTE: Registrtion lists must be mintined by Mercury Mrine nd ny deler of Mercury Mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act be required. You my chnge your registered ddress t ny time, including t time of wrrnty clim, by clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx OUTSIDE UNITED STATES AND CANADA For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Trnsfer of Wrrnty United Sttes nd Cnd The limited wrrnty is trnsferble to subsequent purchser, but only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the subsequent owner, send or fx copy of the bill of sle or purchse greement, new owner s nme, ddress, nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. In the United Sttes nd Cnd, mil to: eng 1

12 Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will record the new owner's informtion. There is no chrge for this service. OUTSIDE THE UNITED STATES AND CANADA For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Products Sold to Government Agencies Contct the Mercury Rcing Sles Deprtment for copy of the Government Agencies Wrrnty Pcket Kit, which explins the conditions required for government gencies to receive wrrnty when purchsing Mercury Rcing Outbord or Sterndrive product. Mercury Rcing Sles Deprtment N7480 County Rod UU Fond du Lc, WI Fx WARRANTY INFORMATION Mercury Rcing Division Two Yer Limited Government Wrrnty United Sttes nd Cnd WHAT IS COVERED: Mercury Mrine wrrnts its new products nd refurbished products sold under the term of Pcemker, to be free of defects in mteril nd workmnship during the period described below. DURATION OF WARRANTY COVERAGE FOR GOVERNMENT USE: The limited wrrnty provides coverge for two (2) yers from either the dte the product is first sold to n uthorized government gency, or the dte on which the product is first put into service, whichever occurs first. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. 2 eng

13 CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is vilble to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, or to government gencies with n pproved Mercury ccount, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed 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 Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury Mrine with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury Mrine deler uthorized to service the product. If the purchser cnnot deliver the product to such deler, written notice must be given to Mercury Mrine. Mercury Mrine will then rrnge for the inspection nd ny covered repir. The purchser, in tht cse, shll py for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered by this wrrnty, the purchser shll py for ll relted lbor nd mteril nd ny other expenses ssocited with tht service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, nd fded pint. This limited wrrnty lso does not cover dmge cused by ny of the following: Abuse Abnorml use WARRANTY INFORMATION Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge. Refer to the Opertion nd Mintennce Mnul. Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle. Refer to the Opertion nd Mintennce Mnul. eng 3

14 Neglect Accident Submersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Use of n ccessory or prt tht ws not mnufctured or sold by Mercury Mrine nd tht dmges the Mercury product Opertion with fuels, oils, or lubricnts tht re not suitble for use with the product. Refer to the Opertion nd Mintennce Mnul. Altertion or removl of prts Wter entering the engine through the fuel intke, ir intke, or exhust system Insufficient cooling wter cused by blockge of the cooling system by foreign body, running the engine out of wter, mounting the engine too high on the trnsom, or running the bot with the engine/drive trimmed out too fr Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, tournment fees, club fees, prize money, or ny other type of incidentl or consequentil dmges. Expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product WHAT WILL VOID THE WARRANTY: Use of the product for rcing or other competitive ctivity, t ny point, even by prior owner of the product, voids the wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge is terminted for used product obtined in ny of the following wys: Repossession from retil customer Purchse t n uction Purchse from slvge yrd WARRANTY INFORMATION Purchse from n insurnce compny tht obtined the product s result of n insurnce clim 4 eng

15 WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Wrrnty Coverge nd Exclusions for Mercury Rcing Outbord Products The purpose of this section is to help eliminte some of the more common misunderstndings regrding wrrnty coverge. The following informtion explins some of the types of services tht re not covered by wrrnty. The provisions set forth following hve been incorported by reference into the Mercury Rcing Division Three Yer Limited Wrrnty Aginst Corrosion Filure, the Mercury Rcing Division One nd Two Yer Limited Wrrnties. Keep in mind tht wrrnty covers repirs tht re needed within the wrrnty period becuse of defects in mteril nd workmnship. Instlltion errors, ccidents, norml wer, nd vriety of other cuses tht ffect the product re not covered. Wrrnty is limited to defects in mteril or workmnship, but only to retil customers tht purchse from deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Should you hve ny questions concerning wrrnty coverge, contct your uthorized deler. They will be plesed to nswer ny questions tht you my hve. GENERAL EXCLUSIONS FROM WARRANTY 1. Minor djustments nd tune ups, including checking, clening or djusting sprk plugs, ignition components, crburetor or EFI settings, filters, belts, controls, nd checking lubriction mde in connection with norml services. 2. Dmge cused by lck of mintennce. 3. Hul out, lunch, towing chrges, nd ll relted trnsporttion chrges nd/or trvel time, etc. 4. Additionl service work requested by customer other thn tht necessry to stisfy the wrrnty obligtion. eng 5

16 5. Lbor performed by other thn n uthorized deler my be covered only under following circumstnces: When performed on emergency bsis (providing there re no uthorized delers in the re who cn perform the work required or hve no fcilities to hul out, etc., nd prior fctory pprovl hs been given to hve the work performed t this fcility). 6. Use of other thn Mercury Precision or Quicksilver prts when mking wrrnty repirs. 7. Engine noise does not necessrily indicte serious engine problem. If dignosis indictes serious internl engine condition, which could result in filure, condition responsible for noise should be corrected under the wrrnty. 8. Lower unit nd/or propeller dmge cused by striking submerged object is considered mrine hzrd. 9. Wter in the strter motor. WARRANTY INFORMATION 10. Strter motors nd/or rmtures or field coil ssembly, which re burned, or where led is thrown out of commuttor becuse of excess crnking. 11. Vlve or vlve set grinding required becuse of wer. 3 Yer Limited Wrrnty Aginst Corrosion WHAT IS COVERED: Mercury Mrine wrrnts tht ech new Mercury, Mriner, Mercury Rcing Outbords, Sport Jet, M 2 Jet Drive, Trcker by Mercury Mrine Outbord, Mercury MerCruiser Inbord or Sterndrive Engine (Product) will not be rendered inopertive s direct result of corrosion for the period of time described below. DURATION OF COVERAGE: This limited corrosion wrrnty provides coverge for three (3) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent (noncommercil use) purchser upon proper reregistrtion of the product. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Corrosion prevention devices specified in the Opertion nd Mintennce Mnul must be in use on the bot, nd routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed (including, without limittion, the replcement of scrificil nodes, use of specified lubricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. 6 eng

17 WARRANTY INFORMATION WHAT MERCURY WILL DO: Mercury Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury Mrine with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury Mrine deler uthorized to service the product. If the purchser cnnot deliver the product to such deler, written notice must be given to Mercury Mrine. Mercury Mrine will then rrnge for the inspection nd ny covered repir. The purchser, in tht cse, shll py for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered by this wrrnty, the purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, buse, or improper service; corrosion to ccessories, instruments, steering systems; corrosion to fctory instlled jet drive unit; dmge due to mrine growth; product sold with less thn one yer limited Product wrrnty; replcement prts (prts purchsed by customer); products used in commercil ppliction. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. Corrosion dmge cused by stry electricl currents (onshore power connections, nerby bots, submerged metl) is not covered by this corrosion wrrnty nd should be protected ginst by the use of corrosion protection system, such s the Mercury Precision Prts or Quicksilver MerCthode system nd/or Glvnic Isoltor. Corrosion dmge cused by improper ppliction of copper bse ntifouling pints is lso not covered by this limited wrrnty. If ntifouling protection is required, Tri Butyl Tin Adipte (TBTA) bse ntifouling pints re recommended on Outbord nd MerCruiser boting pplictions. In res where TBTA bse pints re prohibited by lw, copper bse pints cn be used on the hull nd trnsom. Do not pply pint to the Outbord or MerCruiser product. In ddition, cre must be tken to void n electricl interconnection between the wrrnted product nd the pint. For MerCruiser product, n unpinted gp of t lest 38 mm (1.5 in.) should be left round the trnsom ssembly. Refer to the Opertion nd Mintennce Mnul for dditionl detils. eng 7

18 For dditionl informtion regrding events nd circumstnces covered by this wrrnty, nd those tht re not, see the Wrrnty Coverge section of the Opertion nd Mintennce Mnul, incorported by reference into this wrrnty. DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. U.S. EPA Emissions Limited Wrrnty Consistent with the obligtions creted by 40 CFR Prt 1045, Subprt B, Mercury Mrine provides five yer or 175 hours of engine use wrrnty, whichever occurs first, to the retil customer, tht the engine is designed, built, nd equipped so s to conform t the time of sle with pplicble regultions under section 213 of the Clen Air Act, nd tht the engine is free from defects in mterils nd workmnship tht cuse the engine to fil to conform with pplicble regultions. This emission relted wrrnty covers ll the components listed in the Emission Control System Components. Emission Control System Components The EPA nd Cliforni emission relted wrrnty covers ll the following list of components: COMPONENTS OF THE EMISSIONS CONTROL SYSTEM: 1. Fuel metering system. Crburetor nd internl prts (nd/or pressure regultor or fuel injection system) b. Cold strt enrichment system c. Intke vlves 2. Air induction system. Intke mnifold b. Turbochrger or superchrger systems (where pplicble) 3. Ignition system. Sprk plugs WARRANTY INFORMATION b. Mgneto or electronic ignition system 8 eng

19 c. Sprk dvnce/retrd system d. Ignition coil nd/or control module e. Ignition wires 4. Lubriction system (4 Stroke engines excluded). Oil pump nd internl prts b. Oil injectors c. Oil meter 5. Exhust system WARRANTY INFORMATION. Exhust mnifold b. Exhust vlves 6. Miscellneous items used in bove systems. Hoses, clmps, fittings, tubing, seling gskets or devices, nd mounting hrdwre b. Pulleys, belts, nd idlers c. Vcuum, temperture, check nd time sensitive vlves nd switches d. Electronic controls The emission relted wrrnty does not cover components whose filure would not increse n engine's emissions on ny regulted pollutnt. Cliforni Emissions Limited Wrrnty The Cliforni Air Resources Bord hs promulgted ir emission regultions for outbord engines. The regultions pply to ll outbord engines sold to retil consumers in Cliforni, nd which were mnufctured for the 2001 model yer nd lter. Mercury Mrine, in complince with those regultions, provides this limited wrrnty for the emission control systems (see the components listed in the Emission Control System Components), nd further wrrnts tht the outbord engine ws designed, built, nd equipped to conform with ll pplicble regultions dopted by the Cliforni Air Resources Bord pursunt to its uthority in Chpters 1 nd 2, Prt 5, Division 26 of the Helth nd Sfety Code. For informtion regrding the limited wrrnty for the nonemission relted components of the outbord, plese see the limited wrrnty sttement for your outbord. WHAT IS COVERED: Mercury Mrine wrrnts the components of the emissions control systems (see the components listed in the Emission Control System Components) of its new, 2001 model yer nd lter outbords, sold by Cliforni deler to retil customers residing in Cliforni, to be free from defects in mteril or workmnship, tht cuse the filure of wrrnted prt to be identicl in ll mteril respects to tht prt s described in the ppliction of Mercury Mrine for certifiction from the Cliforni Air Resources Bord, for the period of time, nd under the conditions, identified below. The cost to dignose wrrnty filure is covered under the wrrnty (if the wrrnty clim is pproved). Dmge to other engine components cused by the filure of wrrnted prt will lso be repired under wrrnty. eng 9

20 WARRANTY INFORMATION DURATION OF COVERAGE: This limited wrrnty provides coverge for the components of the emissions control systems of new, 2001 model yer nd lter outbords, sold to retil customers in Cliforni for four (4) yers from either the dte the product is first sold, or first put into service, whichever occurs first, or the ccumultion of 250 hours of engine opertion (s determined by the engine's hour meter, if ny). Emission relted norml mintennce items such s sprk plugs nd filters, tht re on the wrrnted prts list, re wrrnted up to their first required replcement intervl only. Refer to Emission Control System Components nd Mintennce Schedule. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent purchser. (See instructions on trnsfer of wrrnty.) HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, plese notify Mercury Mrine nd Mercury will then rrnge for the inspection nd ny covered repir. Purchser, in tht cse, shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our expense nd t our option, repiring or replcing defective 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 obligtion to modify products previously mnufctured. WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended wide open throttle RPM rnge (see Generl Informtion Specifictions), opertion of the product in mnner inconsistent with the recommended opertion procedures, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, jet pump impellers nd liners, opertion with fuels, oils, or lubricnts which re not suitble for use with the product (see Fuel nd Oil), ltertion or removl of prts. 10 eng

21 WARRANTY INFORMATION Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. Nonwrrnty mintennce, replcement, or repir of emission control devices nd systems my be performed by ny mrine engine repir estblishment or individul. The use of non Mercury prts for nonwrrnty mintennce or repirs will not be grounds for disllowing other wrrnty work. The use of dd on (s defined t section 1900 (b)(1) nd (b)(10) of Title 13 of the Cliforni Code of Regultions) or modified prts not exempted by the Cliforni Air Resources Bord my be grounds for disllowing wrrnty clim, t the discretion of Mercury Mrine. Filures of wrrnted prts cused by the use of nonexempted dd on or modified prt will not be covered. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. If you hve ny questions regrding your wrrnty rights nd responsibilities, you should contct Mercury Mrine t Cliforni Air Resources Bord Explntion of Your Cliforni Emission Control Wrrnty Sttement YOUR WARRANTY RIGHTS AND OBLIGATIONS: The Cliforni Air Resources Bord is plesed to explin the emission control system wrrnty on your model yer outbord engine. In Cliforni, new outbord engines must be designed, built, nd equipped to meet the Stte's stringent ntismog stndrds. Mercury Mrine must wrrnt the emission control system on your outbord engine for the periods of time listed below, provided there hs been no buse, neglect, or improper mintennce of your outbord engine. Your emission control system my include prts such s the crburetor or fuel injection system, the ignition system, nd ctlytic converter. Also included my be hoses, belts, connectors, nd other emission relted ssemblies. eng 11

22 WARRANTY INFORMATION Where wrrntble condition exists, Mercury Mrine will repir your outbord engine t no cost to you, including dignosis, prts, nd lbor. MANUFACTURER'S WARRANTY COVERAGE: Select emission control prts from model yer 2001 nd newer outbord engines re wrrnted for four (4) yers, or for 250 hours of use, whichever first occurs. However, wrrnty coverge bsed on the hourly period is only permitted for outbord engines nd personl wtercrft equipped with hour meters s defined in 2441()(13) or their equivlent. If ny emission relted prt on your engine is defective under wrrnty, the prt will be repired or replced by Mercury Mrine. OWNER'S WARRANTY RESPONSIBILITIES: As the outbord engine owner, you re responsible for the performnce of the required mintennce listed in the Mintennce section. Mercury Mrine recommends tht you retin ll receipts covering mintennce on your outbord engine, but Mercury Mrine cnnot deny wrrnty solely for the lck of receipts or your filure to ensure the performnce of ll scheduled mintennce. As the outbord engine owner, you should, however, be wre tht Mercury Mrine my deny you wrrnty coverge if your outbord engine or prt hs filed due to buse, neglect, improper mintennce, or unpproved modifictions. You re responsible for presenting your outbord to Mercury deler uthorized to service the product s soon s problem exists. The wrrnty repirs will be completed in resonble mount of time, not to exceed 30 dys. If you hve ny questions regrding your wrrnty rights nd responsibilities, you should contct Mercury Mrine t eng

23 Boter's Responsibilities GENERAL INFORMATION The opertor (driver) is responsible for the correct nd sfe opertion of the bot nd the sfety of its occupnts nd generl public. It is strongly recommended tht ech opertor red nd understnd this entire mnul before operting the outbord. Be sure tht t lest one dditionl person onbord is instructed in the bsics of strting nd operting the outbord nd bot hndling in cse the driver is unble to operte the bot. Before Operting Your Outbord Red this mnul crefully. Lern how to operte your outbord properly. If you hve ny questions, contct your deler. This mnul s well s sfety lbels posted on the outbord use the following sfety lerts to drw your ttention to specil sfety instructions tht should be followed.! 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. Bot Horsepower Cpcity! WARNING Exceeding the bot's mximum horsepower rting cn cuse serious injury or deth. Overpowering the bot cn ffect bot control nd flottion chrcteristics or brek the trnsom. Do not instll n engine tht exceeds the bot's mximum power rting. eng 13

24 GENERAL INFORMATION Do not overpower or overlod your bot. Most bots will crry required cpcity plte indicting the mximum cceptble power nd lod s determined by the mnufcturer following certin federl guidelines. If in doubt, contct your deler or the bot mnufcturer. 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 outbord is to be used on high speed or high performnce bot with which you re unfmilir, we recommend tht you do not operte it t its high speed cpbility without first requesting n initil orienttion nd fmiliriztion demonstrtion ride with your deler or n opertor experienced with your bot/ outbord combintion. For dditionl informtion, obtin copy of our Hi Performnce Bot Opertion booklet from your deler, distributor, or Mercury Mrine. Outbord Remote Control Models The remote control connected to your outbord must be equipped with strt in neutrl only protection device. This prevents the engine from strting when the shift is ctuted in ny position other thn neutrl.! WARNING Strting the engine with the drive in ger cn cuse serious injury or deth. Never operte bot tht does not hve neutrl sfety protection device. N eng

25 Remote Steering Notice GENERAL INFORMATION The steering link rod tht connects the steering cble to the engine must be fstened utilizing self locking nuts. These self locking nuts must never be replced with common nuts (nonlocking) s they will work loose nd vibrte off, freeing the link rod to disengge.! 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 bot control, resulting in serious injury or deth due to occupnts being thrown within or out of the bot. Alwys use required components nd follow instructions nd torque procedures. - Self locking nuts Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves fr enough wy from the opertor's position (s in ccidentl ejection from the opertor's position) to ctivte the switch. Tiller hndle outbords nd some remote control units re equipped with lnyrd stop switch. A lnyrd stop switch cn be instlled s n ccessory generlly on the dshbord or side djcent to the opertor's position. A decl ner the lnyrd stop switch is visul reminder for the opertor to ttch the lnyrd to their personl flottion device (PFD) or wrist. eng 15

26 GENERAL INFORMATION The lnyrd cord is usully cm (4 5 feet) in length when stretched out, with n element on one end mde to be inserted into the switch nd clip on the other end for ttching to the opertor's PFD or wrist. The lnyrd is coiled to mke its t rest condition s short s possible to minimize the likelihood of lnyrd entnglement with nerby objects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. b ATTACH LANYARD RUN OFF c Lnyrd cord clip b - Lnyrd decl c - Lnyrd stop switch Red the following Sfety Informtion before proceeding. Importnt Sfety Informtion: The purpose of lnyrd stop switch is to stop the engine when the opertor moves fr enough wy from the opertor's position to ctivte the switch. This would occur if the opertor ccidentlly flls overbord or moves within the bot sufficient distnce from the opertor's position. Flling overbord nd ccidentl ejections re more likely to occur in certin types of bots such s low sided infltbles, bss bots, high performnce bots, nd light, sensitive hndling fishing bots operted by hnd tiller. Flling overbord nd ccidentl ejections re lso likely to occur s result of poor operting prctices such s sitting on the bck of the set or gunwle t plning speeds, stnding t plning speeds, sitting on elevted fishing bot decks, operting t plning speeds in shllow or obstcle infested wters, relesing your grip on steering wheel or tiller hndle tht is pulling in one direction, drinking lcohol or consuming drugs, or dring high speed bot mneuvers. 16 eng

27 GENERAL INFORMATION While ctivtion of the lnyrd stop switch will stop the engine immeditely, bot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the bot will not complete full circle. While the bot is costing, it cn cuse injury to nyone in the bot's pth s seriously s the bot would when under power. We strongly recommend tht other occupnts be instructed on proper strting nd operting procedures should they be required to operte the engine in n emergency (if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the bot, stop the engine immeditely to reduce the possibility of serious injury or deth from being struck by the bot. 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 bot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Accidentl or unintended ctivtion of the switch during norml opertion is lso possibility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could be thrown forwrd due to unexpected loss of forwrd motion prticulr concern for pssengers in the front of the bot who could be ejected over the bow nd possibly struck by the gercse or propeller. Loss of power nd directionl control in hevy ses, strong current, or high winds. Loss of control when docking. KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before ech use, check to ensure the lnyrd stop switch works properly. Strt the engine nd stop it by pulling the lnyrd cord. If the engine does not stop, hve the switch repired before operting the bot. Before ech use, visully inspect the lnyrd cord to ensure it is in good working condition nd tht there re no breks, cuts, or wer to the cord. Check tht the clips on the ends of the cord re in good condition. Replce ny dmged or worn lnyrd cords. eng 17

28 Protecting People in the Wter WHILE YOU ARE CRUISING GENERAL INFORMATION It is very difficult for person in the wter to tke quick ction to void bot heding in their direction, even t slow speeds Alwys slow down nd exercise extreme cution ny time you re boting in n re where there might be people in the wter. Whenever bot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force by the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. WHILE BOAT IS STATIONARY! WARNING A spinning propeller, moving bot, or ny solid device ttched to the bot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your bot. Shift into neutrl nd shut off the engine before llowing people to swim or be in the wter ner your bot. Exhust Emissions BE ALERT TO CARBON MONOXIDE POISONING Crbon monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl combustion engines, including the engines tht propel bots, nd the genertors tht power bot ccessories. By itself, CO is odorless, colorless, nd tsteless, but if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of crbon monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse. 18 eng

29 GENERAL INFORMATION! WARNING Inhling engine exhust gses cn result in crbon monoxide poisoning, which cn led to unconsciousness, brin dmge, or deth. Avoid exposure to crbon monoxide. Sty cler from exhust res when engine is running. Keep the bot well ventilted while t rest or underwy. STAY CLEAR OF EXHAUST AREAS Engine exhust gses contin hrmful crbon monoxide. Avoid res of concentrted engine exhust gses. When engines re running, keep swimmers wy from the bot, nd do not sit, lie, or stnd on swim pltforms or bording ldders. While underwy, do not llow pssengers to be positioned immeditely behind the bot (pltform drgging, tek/body surfing). This dngerous prctice not only plces person in n re of high engine exhust concentrtion, but lso subjects them to the possibility of injury from the bot propeller. GOOD VENTILATION Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the bot: POOR VENTILATION Under certin running nd/or wind conditions, permnently enclosed or cnvs enclosed cbins or cockpits with insufficient ventiltion my drw in crbon monoxide. Instll one or more crbon monoxide detectors in your bot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry bot tht contins, or is ner, running engine my be exposed to hzrdous level of crbon monoxide. eng 19

30 GENERAL INFORMATION 1. Exmples of poor ventiltion while the bot is sttionry: b Operting the engine when the bot is moored in confined spce b - Mooring close to nother bot tht hs its engine operting 2. Exmples of poor ventiltion while the bot is moving: b Operting the bot with the trim ngle of the bow too high b - Operting the bot with no forwrd htches open (sttion wgon effect) Pssenger Sfety Messge Pontoon Bots nd Deck Bots Whenever the bot is in motion, observe the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in bot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of bot direction, could throw them over the front of the bot. Flling over the front of the bot between the two pontoons will position them to be run over by the outbord. BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the bot is in motion. Keep ll pssengers behind the front fence or enclosure. 20 eng

31 GENERAL INFORMATION Persons on the front deck could esily be thrown overbord or persons dngling their feet over the front edge could get their legs cught by wve nd pulled into the wter ! WARNING Sitting or stnding in n re of the bot not designed for pssengers t speeds bove idle cn cuse serious injury or deth. Sty bck from the front end of deck bots or rised pltforms nd remin seted while the bot is in motion. BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevted fishing sets re not intended for use when the bot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Any unexpected, sudden reduction in bot speed could result in the elevted pssenger flling over the front of the bot eng 21

32 Impct with Underwter Hzrds GENERAL INFORMATION Reduce speed nd proceed with cution whenever you drive bot in shllow wter res, or in res where you suspect underwter obstcles my exist which could be struck by the outbord or the bot bottom. The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter object is to control the bot speed. Under these conditions, bot speed should be kept to minimum plning speed of 24 to 40 km/h (15 to 25 mph) Striking floting or underwter object could result in n infinite number of situtions. Some of these situtions could result in the following: Prt of the outbord or the entire outbord could brek loose nd fly into the bot. The bot could move suddenly in new direction. Such shrp chnge in direction cn cuse occupnts to be thrown out of their sets or out of the bot. A rpid reduction in speed. This will cuse occupnts to be thrown forwrd, or even out of the bot. Impct dmge to the outbord nd/or bot. Keep in mind, the most importnt thing you cn do to help reduce injury or impct dmge during n impct is control the bot speed. Bot speed should be kept to minimum plning speed when driving in wters known to hve underwter obstcles. After striking submerged object, stop the engine s soon s possible nd inspect it for ny broken or loose prts. If dmge is present or suspected, the outbord should be tken to n uthorized deler for thorough inspection nd necessry repir. The bot should lso be checked for ny hull frctures, trnsom frctures, or wter leks. Operting dmged outbord could cuse dditionl dmge to other prts of the outbord, or could ffect control of the bot. If continued running is necessry, do so t gretly reduced speeds. 22 eng

33 GENERAL INFORMATION! WARNING Operting bot 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. Selecting Accessories for Your Outbord Genuine Mercury Precision or Quicksilver Accessories hve been specificlly designed nd tested for your outbord. These ccessories re vilble from Mercury Mrine delers. IMPORTANT: Check with your deler before instlling ccessories. The misuse of pproved ccessories or the use of nonpproved ccessories cn dmge the product. Some ccessories not mnufctured or sold by Mercury Mrine re not designed to be sfely used with your outbord or outbord operting system. Red the instlltion, opertion nd mintennce mnuls for ll your selected ccessories. Refer to Outbord Instlltion Accessories Mounted to the Trnsom Clmp Brcket for importnt informtion on mounting ccessories to the trnsom clmp brcket. Sfe Boting Recommendtions To sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl boting regultions nd restrictions nd consider the following suggestions. Know nd obey ll nuticl rules nd lws of the wterwys. We recommend tht ll powerbot opertors complete boting sfety course. In the U.S., the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil boting lw enforcement gency provide courses. For more informtion in the U.S., cll the Bot U.S. Foundtion t BOAT (2628). Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment onbord. Here re some suggestions of the types of sfety equipment to crry when boting: Approved fire extinguishers Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Tools necessry for minor repirs Anchor nd extr nchor line Mnul bilge pump nd extr drin plugs eng 23

34 Drinking wter Rdio Pddle or or Spre propeller, thrust hubs, nd n pproprite wrench First id kit nd instructions Wterproof storge continers Spre operting equipment, btteries, bulbs, nd fuses Compss nd mp or chrt of the re Personl flottion device (one per person onbord) Wtch for signs of wether chnge nd void foul wether nd rough se boting. Tell someone where you re going nd when you expect to return. Pssenger bording. Stop the engine whenever pssengers re bording, unloding, or re ner the bck (stern) of the bot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl lw requires tht there be U.S. Cost Gurd pproved life jcket (personl flottion device), correctly sized nd redily ccessible for every person onbord, plus throwble cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the bot. Prepre other bot opertors. Instruct t lest one person onbord in the bsics of strting nd operting the engine nd bot hndling in cse the driver becomes disbled or flls overbord. Do not overlod your bot. GENERAL INFORMATION Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot's cpcity plte). Know your bot's operting nd loding limittions. Know if your bot will flot if it is full of wter. When in doubt, contct your uthorized Mercury Mrine deler or the bot mnufcturer. Ensure tht everyone in the bot is properly seted. Do not llow nyone to sit or ride on ny prt of the bot tht ws not intended for such use. This includes the bcks of sets, gunwles, trnsom, bow, decks, rised fishing sets, nd ny rotting fishing set. Pssengers should not sit or ride nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of bot control, or sudden bot movement could cuse person to be thrown overbord or into the bot. Ensure tht ll pssengers hve proper set nd re in it before ny bot movement. 24 eng

35 Never operte bot while under the influence of lcohol or drugs. It is the lw. Alcohol or drugs cn impir your judgment nd gretly reduce your bility to rect quickly. Know your boting re nd void hzrdous loctions. Be lert. The opertor of the bot is responsible by lw to mintin proper lookout by sight nd hering. The opertor must hve n unobstructed view prticulrly to the front. No pssengers, lod, or fishing sets should block the opertor's view when the bot is bove idle or plning trnsition speed. Wtch out for others, the wter, nd your wke. Never drive your bot directly behind wter skier. Your bot trveling t 40 km/h (25 mph) will overtke fllen skier who is 61 m (200 ft) in front of you in five seconds. Wtch fllen skiers. When using your bot for wterskiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the bot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never bck up to the skier or nyone in the wter. Report ccidents. GENERAL INFORMATION Bot opertors re required by lw to file boting ccident report with their stte boting lw enforcement gency when their bot is involved in certin boting ccidents. A boting ccident must be reported if 1) there is loss of life or probble loss of life, 2) there is personl injury requiring medicl tretment beyond first id, 3) there is dmge to bots or other property where the dmge vlue exceeds $500.00, or 4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement. eng 25

36 Recording Seril Number GENERAL INFORMATION It is importnt to record this number for future reference. The seril number is locted on the outbord s shown. XXXXXXXXX XXXXX XXXX b - Model number b - Seril number c - Yer mnufctured c Component Identifiction l j i k g b c d e f - Top cowl b - Side cowl ltches (both sides) c - Front cowl ltch d - Auxiliry tilt switch e - Clmp/swivel brcket f - Gercse g - Cooling wter intke (loction dependent on gercse) h - Skeg i - Anode j - Anode k - Driveshft housing l - Wter pump indictor h eng

37 Specifictions GENERAL INFORMATION Model Cylinder configurtion Specifictions 3.0L Diesel Sprk Ignition 60 V6 Propshft horsepower 175 Propshft kilowtts Engine weight 25 in. models 240 kg (528 lb) Number of cylinders 6 Idle RPM (in ger) 625 (675) Full throttle RPM rnge Neutrl rev limit 3000 Overspeed RPM limit 6100 Engine displcement Cylinder bore Stroke Sprk plug Sprk plug gp 3032 cc (185.0 cid) mm ( in.) 76.2 mm (3.00 in.) NGK IZFR5J (fctory instlled) Refer to Sprk Plug Inspection nd Indexing Instlltion mm (0.030 in.) Firing order Mximum timing Idle timing Fuel pressure Air pressure Ger rtio Required fuel Required engine oil Gercse oil GENERAL INFORMATION Fleet Mster Not djustble; controlled by ECM 6.55 ± 0.14 br (655 ± 13.8 kp [95 ± 2 psi]) 7.58 ± 0.14 br (758 ± 13.8 kp [110 ± 2 psi]) 2.08:1 Stndrd 2.08:1 Ultr low sulfur diesel (ULSD) 15 ppm mximum Mercury Rcing Multi Fuel Plus Oil or Oil meeting Mercury Mrine Specifiction 8M T Mercury Rcing Ger Lube eng 27

38 GENERAL INFORMATION Gercse cpcity Bttery rting* Chrging system output Fleet Mster Stndrd Strting circuit required voltge Emission control system Specifictions 710 ml (24 fl oz) 970 ml (32.8 fl oz) AGM 31 series bttery 1050 mrine crnking mps 105 mp hours 60 A mximum 12 V Electronic engine control (EC) *Bttery mnufcturers my rte nd test their btteries to different stndrds. MCA, CCA, Ah, nd reserve cpcity (RC) re the rtings recognized by Mercury Mrine. Mnufcturers tht use stndrds different thn these, such s equivlent MCA, do not meet Mercury Mrine bttery requirements. Propeller Selection Select propeller tht llows the engine to operte in the upper hlf of the recommended full throttle rpm rnge with the bot normlly loded (refer to Generl Informtion Specifictions). This RPM rnge llows for better ccelertion while mintining mximum bot speed. If full throttle opertion is below the recommended rnge, the propeller must be chnged to prevent loss of performnce nd possible engine dmge. On the other hnd, operting n engine bove the recommended operting rpm rnge will cuse higher thn norml wer nd/or dmge. Generlly, there is RPM chnge between propeller pitches If chnging conditions cuse the rpm to drop below the recommended rnge (such s wrmer, more humid wether, opertion t higher elevtions, incresed bot lod, or dirty bot bottom/gercse), propeller chnge or clening my be required to mintin performnce nd ensure the outbords durbility. Check full throttle RPM, using n ccurte tchometer, with the engine trimmed out to blnced steering condition (steering effort equl in both directions) without cusing the propeller to brek loose. 28 eng

39 Trilering Bot/Outbord TRANSPORTING Triler your bot with the outbord tilted down in verticl operting position. If dditionl ground clernce is required, the outbord should be tilted up using n ccessory outbord support device. Refer to your locl deler for recommendtions. Additionl clernce my be required for rilrod crossings, drivewys nd triler bouncing. IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to mintin proper ground clernce for trilering. The outbord tilt support lever is not intended to support the outbord for trilering Shift the outbord to forwrd ger. This prevents the propeller from spinning freely. eng 29

40 FUEL AND OIL Fuel Requirements NOTICE The use of improper fuel cn cuse serious dmge to the engine. Dmge resulting from the use of improper fuel is considered engine misuse nd is not covered under the limited wrrnty. Use only the recommended fuel in the engine. Fuel Type Ultr low sulfur diesel (15 ppm sulfur or less) Oil Requirement Required Engine Oil Mercury Rcing Multi Fuel Plus Oil 9.4 L (2.5 US gl) continer L (55 US gl) continer Mercury Rcing Multi Fuel Plus Oil is higher grde oil tht provides incresed lubriction nd extr resistnce to crbon buildup when used with vrying grdes of fuel. IMPORTANT: Use only Mercury Rcing Multi Fuel Plus Oil or oil meeting Mercury Mrine Specifiction 8M T in this engine. Using ny other types of oil will void ll wrrnties. Ctstrophic filure will occur if ny other oils re used. Avoiding Fuel Flow Restrictions NOTICE Adding components to the fuel supply system cn dmge the engine. These dditions cn restrict fuel flow, stll the engine t low speeds, nd crete len fuel conditions t high speeds. Follow ll regultions for fuel system instlltion nd do not dd ny dditionl components to the fuel system. Low Permetion Fuel Hose Requirement Required for outbords mnufctured for sle, sold, or offered for sle in the United Sttes. The Environmentl Protection Agency (EPA) requires tht ny outbord mnufctured fter Jnury 1, 2009, must use low permetion fuel hose for the primry fuel hose connecting the fuel tnk to the outbord. Low permetion hose is USCG Type B1 15 or Type A1 15, defined s not exceeding 15 g/m²/24 h with CE 10 fuel t 23 C s specified in SAE J 1527 mrine fuel hose. Filling Remote Oil Tnk Remove the filler cp nd fill with the required engine oil. Oil tnk cpcity is 11.5 liters (3 gllons). Replce the filler cp nd tighten securely. 30 eng

41 FUEL AND OIL Required Engine oil Mercury Rcing Multi Fuel Plus Oil or Oil meeting Mercury Mrine Specifiction 8M T IMPORTANT: Alwys mke sure the oil tnk cps re threded on tight. An ir lek will prevent oil flow to the engine Filling Engine Mounted Oil Reservoir Tnk Remove the top cowl. Loosen the fill cp on the engine oil reservoir tnk. Run the engine until ll the ir hs been vented out of the oil reservoir tnk nd tnk is filled with oil to the point of overflow. Tighten the fill cp. Stop the engine nd replce the top cowl NOTE: Filling this tnk is only necessry if the oil level should ever drop nd the low oil wrning system is ctivted. Filling Fuel Tnk Fill fuel tnks outdoors wy from het, sprks, nd open flmes. Remove portble fuel tnks from the bot to fill them. Alwys stop engine before filling tnks. eng 31

42 FUEL AND OIL 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.! WARNING This engine requires diesel fuel. Mixing gsoline, gsohol, or lcohol nd diesel fuel cn cuse serious injury or deth due to fire or explosion. Never mix gsoline, gsohol, or lcohol with diesel fuel. 32 eng

43 FEATURES AND CONTROLS Remote Control Fetures Your bot my be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your deler for description of the functions nd opertions of the remote control. b c d c c Trim/tilt switch b - Ignition key switch OFF, ON, START c - Throttle only button d - Lnyrd stop switch Trim/tilt switch Used to trim the drive during opertion or rise the drive for trilering, lunching, beching, or shllow wter opertion. Throttle only button The throttle only button llows throttle dvncement without shifting the engine. The throttle only button disengges the shifting mechnism from the control hndle. The throttle only button cn be pressed nd held in only when the remote control hndle is in the neutrl position. While holding the throttle only button in, move the throttle hndle forwrd to ssist in strting the engine. Lnyrd stop switch (if equipped) The purpose of lnyrd stop switch is to shut down the engine when the opertor moves fr enough wy from the opertor's position to ctivte the switch. A lnyrd stop switch cn be instlled s n ccessory, generlly on the dshbord or side djcent to the opertor's position. Control hndle Opertion of the shift nd throttle is controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick firm motion to the first detent for reverse ger. Continue pulling bck to increse speed. IMPORTANT: Forcing the shift mechnism while the engine is not operting cn result in product dmge. eng 33

44 GEAR SHIFTING IMPORTANT: Observe the following: FEATURES AND CONTROLS Never shift the drive into ger unless the engine speed is t idle. Do not shift the drive into reverse when the engine is not running. Your power pckge hs three ger shift positions to provide opertion: forwrd (F), neutrl (N), nd reverse (R). When shifting, lwys stop t the neutrl position nd llow the engine speed to return to idle. Alwys shift into ger with quick motion. After shifting into ger, dvnce the lever further to increse speed. F N R Zero Effort Control Fetures b - Throttle lever b - Trim switch c - Shift lever c eng

45 Glow Plug Indictor FEATURES AND CONTROLS This engine utilizes glow plugs to id strting the engine when it is cold. When the key switch is turned to the on position, the glow plug indictor will illuminte, indicting preheting cycle hs strted. The prehet cycle usully lsts 2 40 seconds. When the glow plug indictor turns off, the engine cn be strted. The durtion of the prehet cycle depends on the temperture of the cylinder block nd cylinder hed. 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. There re two types of wrning horns to lert the opertor of n ctive problem within the engine s operting system. 1. Continuous six second beep: Indictes criticl engine condition. Depending on the condition, the Engine Gurdin system my engge nd protect the engine by limiting power. You should return to port immeditely nd contct your servicing deler. 2. Intermittent short beeps for six seconds: Indictes noncriticl engine condition. This condition does not require immedite ttention. You my continue using your bot, however, depending on the nture of the problem, the engine s power my be limited by the Engine Gurdin system (see Engine Gurdin System following) to protect the engine. You should contct your servicing deler t your erliest convenience. It is importnt to note tht in either of the bove scenrios, the horn will only sound one time. If you key the engine off nd restrt it, the horn will sound gin, one time, if the fult is still present. For visul disply of the specific engine functions nd dditionl engine dt, refer to SmrtCrft Product informtion, following. A few of the noncriticl conditions indicted by the intermittent short beeps for six seconds cn be corrected by the opertor. These opertor correctble conditions re s follows: eng 35

46 Wter in the engine mounted fuel filter. Refer to Mintennce Wter Seprting Fuel Filter. Cooling system (wter pressure or engine temperture) problem. Stop the engine nd check the wter intke holes in the lower unit for obstruction. Low engine oil level. Refer to Fuel nd Oil Filling Engine Mounted Oil Reservoir Tnk. ENGINE GUARDIAN SYSTEM The Engine Gurdin system monitors the criticl sensors on the engine for ny erly indictions of problems. Engine Gurdin is functionl whenever your engine is operting, so you never hve to be concerned bout whether or not you re protected. The system will respond to problem by sounding the wrning horn for six seconds nd/or reducing engine power in order to provide engine protection. If Engine Gurdin hs been ctivted, reduce the engine speed. The problem will need to be identified nd corrected. The system must be reset before the engine will operte t higher speeds. Moving the throttle lever bck to the idle position will reset the Engine Gurdin system. If the Engine Gurdin system hs determined the reset hs not corrected the problem, Engine Gurdin will remin ctivted, limiting the throttle. The problem must be identified nd corrected before Engine Gurdin will llow the engine to rech norml operting RPM. OVERSPEED REV LIMIT The overspeed rev limit is set t n RPM greter thn the operting rnge. In the event tht the engine is operted t n RPM greter thn or equl to the overspeed limit, the wrning horn will engge. If the engine is operted overspeed for more thn five seconds, Engine Gurdin will engge, reducing the RPM to The engine throttle RPM must drop below 5900 to disble Engine Gurdin nd the wrning horn. Refer to Specifictions to determine this engine s RPM limit. Upon reching the beginning of the rev limit, Engine Gurdin will turn off the ignition to specific cylinders. If the opertor does not reduce engine speed, Engine Gurdin will turn off the ignition to ll the cylinders. To reset the Engine Gurdin protection or wrning horn: 1. Reduce the throttle RPM below 5900 for three seconds. 2. Engge the throttle. If the engine does not respond, repet step one. SMARTCRAFT PRODUCT FEATURES AND CONTROLS A Mercury SmrtCrft System instrument pckge cn be purchsed for this outbord. A few of the functions the instrument pckge will disply re engine RPM, coolnt temperture, oil pressure, wter pressure, bttery voltge, fuel consumption, nd engine operting hours. 36 eng

47 The SmrtCrft instrument pckge will lso id in Engine Gurdin dignostics. The SmrtCrft Instrument pckge will disply criticl engine lrm dt nd potentil problems. Power Trim nd Tilt FEATURES AND CONTROLS NOTE: Outbord position cn be djusted by pressing trim switch. This rnge is used while operting your bot on plne. c b Trim switch b - Trim rnge c - Tilt rnge Pressing (DN): Moves the outbord in closer to the bot trnsom, clled trimming in or down. Pressing (UP): Moves the outbord further wy from the bot trnsom, clled trimming out or up. The term trim generlly refers to the djustment of the outbord within the first 20 rnge of trvel. The term tilt generlly refers to djusting the outbord further up out of the wter. With the engine turned off, the outbord cn be tilted out of the wter. At low idle speed, the outbord cn lso be tilted up pst the trim rnge to permit, for exmple, shllow wter opertion. POWER TRIM OPERATION With most bots, operting round the middle of the trim rnge will give stisfctory results. Trimming your outbord ll the wy in or out my improve performnce, but cuse some potentil control hzrds. eng 37

48 ! WARNING Trimming the outbord beyond neutrl steering condition my result in pull on the steering wheel or tiller hndle nd loss of bot control. Mintin control of the bot if trimming beyond neutrl steering condition. Consider the following lists crefully. Trimming in or down cn: Lower the bow of the bot. Result in quicker plning off. Generlly improve the ride in choppy wter. Increse steering torque or pull to the right (with the norml right hnd rottion propeller). In excess, lower the bow to point t which the bot begins to plow with the bow in the wter while on plne. This cn result in n unexpected turn in either direction clled bow steering or over steering if ny turn is ttempted, or if significnt wve is encountered. LIMITING TRIM IN FEATURES AND CONTROLS In rre circumstnces, the owner my decide to limit the trim in to void unsfe hndling or steering conditions t plning speeds.! WARNING Operting the bot t high speeds with the outbord trimmed too fr under cn crete excessive bow steer, resulting in the opertor losing control of the bot. Instll the trim limit pin in position tht prevents excessive trim under nd operte the bot in sfe mnner.! WARNING On some bots, incresed trim in rnge cn cuse hndling problems t high speeds, resulting in personl injury or deth. We recommend tht only qulified personnel djust the trim in limit inserts nd test the bot for hndling problems. IMPORTANT: Some bot/engine combintions not using trim ngle djustment device, or trimmed to the full trim in position, my not exhibit ny undesireble or unsfe hndling or steering conditions. In these cses, trim limiting device my not be dventgeous to ccellertion or plning. Alwys perform wter test to determine if these chrcteristics pply to prticulr bot/engine combintion. To limit trim in on models with three rm trim system, purchse stinless steel tilt pin from your deler nd insert it in whichever djustment hole is desired. 38 eng

49 FEATURES AND CONTROLS To limit trim in on models with single rm trim system, use the cdmium plted bolt shipped with the engine. b Stinless steel tilt pin (Three Rm trim system) b - Bolt shipped with engine (Single Rm trim system) Trimming out or up cn: Lift the bow higher out of the wter. Generlly increse top speed. Gin clernce over submerged objects or shllow bottom. Increse steering torque or pull to the left t norml instlltion height (with the norml right hnd rottion propeller). In excess, cuse bot porpoising (bouncing) or propeller ventiltion. Cuse engine overheting if ny cooling wter intke holes re bove the wter line. POWER TILT OPERATION (THREE-RAM TRIM SYSTEMS) To tilt the outbord, shut off the engine nd press the trim/tilt switch or the uxiliry tilt switch (locted on the cowl) to the up position. The outbord tilts up until the switch is relesed or it reches the mximum tilt position. eng 39

50 FEATURES AND CONTROLS 1. Engge the tilt support lever by pushing the metl stop nd rotting the knob to bring the support lever upwrd. b c Tilt support lever b - Metl stop c - Knob 2. Lower the outbord to rest on the tilt support lever. 3. Disengge the tilt support lever by rising the outbord off the support lever nd rotting the lever until it locks. Lower the outbord. MANUAL TILT OPERATION If the outbord cnnot be tilted using the power trim/tilt switch, the outbord cn be tilted mnully. 40 eng

51 FEATURES AND CONTROLS 1. Turn out the mnul tilt relese vlve three turns (counterclockwise). This llows mnul tilting of the outbord Tilt the outbord to the desired position nd tighten the mnul tilt relese vlve. NOTE: The mnul tilt relese vlve must be tightened before operting the outbord to prevent the outbord from tilting up during reverse opertion. AUXILIARY TILT SWITCH This switch cn be used to tilt the outbord up or down using the power trim system. - Auxiliry tilt switch 2745 eng 41

52 OPERATION Importnt Informtion IMPORTANT DAILY INSPECTION BEFORE EACH USE Any outbord mounted on the bot must hve the mounting hrdwre inspected nd checked to ensure tht the hrdwre hs not become loose. A decl on the trnsom brcket reminds the owner to check the fsteners securing the outbord to the trnsom before ech use. BEFORE STARTING THE ENGINE Decl on the trnsom brcket NOTICE Lck of oil pressure in the system cn cuse severe internl engine dmge during strt up. Prime the oil injection pump on new or rebuilt engines or fter performing mintennce on the oiling system. Refer to Priming the Oil Injection Pump for instructions. OIL REQUIREMENT Required Engine Oil Mercury Rcing Multi Fuel Plus Oil 9.4 L (2.5 US gl) continer L (55 US gl) continer Mercury Rcing Multi Fuel Plus Oil is higher grde oil tht provides incresed lubriction nd extr resistnce to crbon buildup when used with vrying grdes of fuel. IMPORTANT: Use only Mercury Rcing Multi Fuel Plus Oil or oil meeting Mercury Mrine Specifiction 8M T in this engine. Using ny other types of oil will void ll wrrnties. Ctstrophic filure will occur if ny other oils re used. 42 eng

53 Engine Brek in IMPORTANT: Filure to follow the engine brek in procedures cn result in poor performnce throughout the life of the engine nd cn cuse engine dmge. Alwys follow brek in procedures. Brek in Procedure Vry throttle settings during brek in. Use the following suggestions. First Hour Allow the engine to wrm up for three minutes. Do not idle for more thn five minutes when wrm. Run the engine the mjority of the time between RPM (pproximtely three qurter throttle). Short bursts of wide open throttle for 10 seconds or less re cceptble. Chnge the engine speed pproximtely every two minutes. Avoid trimming the outbord out (up) beyond verticl trim position during opertion. Avoid using hydrulic jck plte to rise the engine during the brek in cycle. Next Three Hours: Chnge the engine speed every 10 minutes. Engine Brek in Fuel Mixture The propulsion control module (PCM) controls oil nd fuel mixture during engine brek in. Prestrting Check List Engine lowered to run position with ll wter intke holes submerged Fuel tnk vent cp open or fuel drin vlve on Fuel supply OK Lnyrd stop switch in "RUN" position nd cord connected Remote control in neutrl Top cowl ltches secure OPERATION Mke inspection checks listed in the Inspection nd Mintennce Schedule. Refer to Mintennce section. Operting in Freezing Tempertures When using your outbord or hving your outbord moored in freezing or ner freezing tempertures, keep the outbord tilted down t ll times so the gercse is submerged. This prevents the trpped wter in the gercse from freezing nd cusing possible dmge to the wter pump nd other components. eng 43

54 If there is chnce of ice forming on the wter, the outbord should be removed nd drined completely of wter. If ice should form t the wter level inside the outbord driveshft housing, it will block wter flow to the engine cusing possible dmge. Operting in Sltwter or Polluted Wter We recommend tht you flush the internl wter pssges of your outbord with fresh wter fter ech use in slt or polluted wter. This will prevent buildup of deposits from clogging the wter pssges. Refer to Mintennce Flushing the Cooling System. If you keep your bot moored in the wter, lwys tilt the outbord so the gercse is completely out of wter (except in freezing tempertures) when not in use. Wsh the outbord exterior nd flush out the exhust outlet of the propeller nd gercse with fresh wter fter ech use. Ech month, spry Mercury Precision or Quicksilver Corrosion Gurd on externl metl surfces. Do not spry on corrosion control nodes s this will reduce the effectiveness of the nodes. Operting t High Elevtions Your engine utomticlly compenstes for high elevtion chnges. A different pitch propeller my help reduce some norml performnce loss resulting from reduced oxygen in the ir. Consult your deler. Effects of Elevtion nd Wether on Performnce The following conditions lower engine performnce nd cnnot be compensted by the engine fuel or electronic mngement systems: Above se level elevtions High temperture Low brometric pressure High humidity These conditions bove reduce ir density to the engine, which in turn lowers the following: Boost pressure on superchrged engines Horsepower nd torque throughout the RPM rnge Pek RPM Crnking compression EXAMPLE: An engine running t n elevtion of 8,000 feet will hve over 30% power loss while loss of engine power on hot nd humid dy could be s much s 14%. These losses pply to normlly spirted nd superchrged engines. Compensting for power robbing conditions: Switch to lower pitch propeller. Chnge ger rtio. OPERATION 44 eng

55 OPERATION Some bot performnce cn be improved by dropping to lower pitch propeller, but engine performnce will still remin lower. In some cses, ger rtio reduction my be more beneficil. To optimize engine performnce, prop the engine to llow it to operte t or ner the top end of the recommended mximum RPM rnge t wide open throttle with norml bot lod. Other dvntges to propeller or ger rtio chnges: Reduces the possibility of detontion Enhnces overll relibility nd durbility of the engine Setting Trim Angle While Running Engine t Idle Speed Submerging the exhust relief hole on the outbord cn hppen on some bots if you trim full in while running t idle speed, resulting in, exhust restriction, rough idle, excessive smoke, nd fouled sprk plugs. If this condition exists, trim outbord up until exhust relief hole is out of the wter. b - Relief hole submerged (wrong) b - Relief hole bove wterline (correct) Operting in Shllow Wter When operting your bot in shllow wter, you cn tilt the outbord beyond the mximum trim rnge to prevent hitting bottom. NOTICE Operting the engine with the outbord in the tilt rnge cn dmge the engine or the trnsom. If operting the engine in the tilt rnge, such s in shllow wter, do not exceed 2000 RPM. 1. Reduce the engine speed below 2000 RPM. 2. Tilt the outbord up. Mke sure ll the cooling wter intke holes sty submerged t ll times. 3. Operte the engine t slow speed only. Models with three rm trim system: If engine speed exceeds 2000 RPM, the outbord will utomticlly return down to the mximum trim rnge. Models with single rm trim system: The outbord will remin t the selected tilt position, regrdless of engine RPM eng 45

56 OPERATION Strting the Engine NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. INITIAL STARTING PROCEDURE NOTE: For initil strt up of new engine, or for n engine tht rn out of fuel or ws drined of fuel, the fuel system should be filled ccording to the following procedure. 1. Squeeze the fuel line primer bulb until it feels firm. 2. Turn the ignition key switch to the on position for three seconds. This opertes the electric fuel pump. 3. Turn the ignition key switch bck to the off position, nd squeeze the primer bulb gin until it feels firm. Turn the ignition key switch to the on position gin for three seconds. Continue this procedure until the fuel line primer bulb stys firm. Before strting, red the Prestrting Check List. COLD ENGINE STARTING PROCEDURE 1. Tilt the engine down to verticl operting position. Verify the cooling wter intke holes re submerged Open the fuel tnk filler cp vent screw (mnul venting fuel tnks) eng

57 OPERATION 3. Squeeze the fuel line primer bulb severl times until it feels firm Set the lnyrd stop switch to the run position. Red the Lnyrd Stop Switch sfety explntion nd wrning in the Generl Informtion section Shift the remote control into the neutrl position. N F R Do not dvnce the neutrl fst idle speed feture on the remote control for strting (if equipped). eng 47

58 OPERATION 7. Turn the key to the on position. The glow plug indictor should turn on Glow plug indictor IMPORTANT: Attempting to strt the engine before the glow plug indictor turns off, will require longer engine crnking time nd my cuse the sprk plugs to foul. IMPORTANT: The glow plug indictor durtion is engine temperture dependent. A cold engine will require more time before the indictor turns off. 8. When the glow plug indictor turns off, turn the ignition key to the strt position. Relese the key when the engine strts. If the engine fils to strt within ten seconds, return the key to the off position. Turn the key to the on position nd wit for the glow plug indictor to turn off before ttempting to strt. If the glow plug indictor does not illuminte, ttempt to strt the engine Check for wter coming out of the wter pump indictor hole Allow the engine to rech the operting temperture of 43 C (110 F) before shifting into ger. NOTE: Attempting to ccelerte before the engine hs reched sufficient operting temperture will significntly increse the risk of sprk plug fouling. The engine my lso run rough, similr to running out of fuel. 48 eng

59 NOTICE Operting the engine while overheted cn cuse engine dmge. If no wter exits the wter pump indictor hole, stop the engine nd check the cooling wter intke holes for obstruction. No obstruction my indicte wter pump filure or blockge in the cooling system, which cn overhet the engine. Hve n uthorized Mercury Mrine deler check the system. STARTING A WARM ENGINE Strt the engine following the procedure explined previously in Cold Engine Strting Procedure. If the engine is ner the operting temperture, the engine cn be shifted nd the RPM incresed immeditely fter strting. Mximum Idle Durtion When idling n engine tht hs reched the recommended operting temperture: Do not idle continuously for more thn 60 minutes. Between periods of continuous idle, ccelerte the bot on plne to minimum of 4000 RPM for minimum of 10 minutes. The sprk plugs will rech self clening temperture, burning the ccumulted deposits on the sprk plug. Running the engine t higher RPMs will reduce the time required to clen the sprk plugs. Ger Shifting OPERATION IMPORTANT: Never shift into ger unless the engine is t idle. Never shift into reverse without the engine running. Your outbord hs three ger shift positions to provide opertion: forwrd, neutrl (out of ger), nd reverse. F N R When shifting, lwys stop t neutrl position nd llow the engine speed to return to idle. Alwys shift into ger with quick motion. After shifting into ger, dvnce the lever further to increse speed. eng 49

60 Stopping the Engine OPERATION Reduce the engine speed nd shift the outbord to neutrl position. Turn the ignition key to "OFF" position eng

61 Power Pckge Cre! WARNING Neglect or improper mintennce, repirs, or inspections of the power pckge cn result in product dmge or serious injury or deth. Perform ll procedures s described in this mnul. If you re not fmilir with proper mintennce or service procedures, consign the work to n uthorized Mercury Mrine deler. To ensure sfety nd retin dependbility, keep your power pckge in the best operting condition by performing the periodic inspections nd mintennce listed in the Inspection nd Mintennce Schedule. Record mintennce performed in the Mintennce Log t the bck of this book. Sve ll mintennce work orders nd receipts. Submerged Power Pckge A submerged power pckge requires prompt service by n uthorized deler fter recovery. This immedite ttention is necessry once the engine is exposed to the tmosphere to minimize internl corrosion dmge to the engine. Replcement Prts for Your Power Pckge Mercury recommends using originl Mercury Precision replcement prts nd lubricnts. Inspection nd Mintennce Schedule PRIOR TO EVERY USE MAINTENANCE Check tht the lnyrd stop switch stops the engine. Check the oil nd overhet udio wrning system. Check the oil level in the reservoir. Inspect the fuel system for deteriortion or leks. Check the outbord for tightness on the trnsom. Check the steering system for binding or loose components. Check the steering link rod fsteners for proper tightness. Check the propeller bldes for dmge. Inspect ll hoses, clmps, fittings, tubing, seling gskets, nd mounting hrdwre for wer. AFTER EACH SALTWATER OR POLLUTED WATER USE Flush ll internl pssges with fresh wter. Wsh the power pckge exterior (cowl, midsection, nd gercse) with fresh wter. Flush the propeller nd gercse exhust outlet with fresh wter. eng 51

62 Remove the cowl nd wipe off ny sltwter spry with dmp cloth. AFTER THE FIRST 20 HOURS OF USE Check the wter seprting fuel filter for wter or contminnts. Drin nd replce the gercse lubricnt. Inspect the bttery. Check the control cble djustments. Lubricte ll lubriction points. MAINTENANCE Check the tightness of ll bolts, nuts, nd other fsteners. Remove the propeller. Clen nd lubricte the propeller shft with Extreme Grese. Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M Tighten the propeller retining nut to the correct torque specifictions. Refer to Replcing the Propeller. Spry the powerhed nd the undercowl components with Corrosion Gurd. Tube Ref No. Description Where Used Prt No. 120 Corrosion Gurd Powerhed EVERY 50 HOURS OR ONCE A MONTH, WHICHEVER OCCURS FIRST Inspect the front nd side cowl ltches for tightness. Tighten if necessry. Inspect the fuel nd oil systems for deteriortion or leks. Check the steering link rod fsteners for wer. Check ll ttchment hrdwre for proper tightness. Inspect the wter seprting fuel filter for wter or contminnts. Replce if necessry. Lubricte ll components listed in Lubriction Points. Lubricte the splines on the propeller shft. Check the level nd condition of the gercse lubricnt. Inspect the bttery. Check the corrosion control nodes. Check more frequently when operting in sltwter. Refer to Corrosion Control Anode. Check the tightness of ll bolts, nut, nd other fsteners. Lubricte the strter motor shft with light mchine oil or silicone spry. Do not overlubricte. Spry the powerhed nd ll externl, unpinted metl surfces (except nodes) with Corrosion Gurd. 52 eng

63 MAINTENANCE Tube Ref No. 120 Corrosion Gurd Description Where Used Prt No. Powerhed nd ll externl unpinted metl surfces (except nodes) Inspect ll belts, pulleys, nd idler pulleys for deteriortion. Check the fuel pressure EVERY 100 HOURS OR ONCE A YEAR, WHICHEVER OCCURS FIRST Replce the sprk plugs. Inspect the sprk plug leds for dmge or deteriortion. Replce if necessry. Drin nd replce the gercse lubricnt. Check the power trim fluid. Check the control cble djustments. Lubricte the entire length of the driveshft, the driveshft splines, nd the surfce under the wter pump impeller with Extreme Grese. Tube Ref No. Description Where Used Prt No. Extreme Grese Driveshft, driveshft splines, surfce under the wter pump impeller 8M EVERY 300 HOURS OR ONCE A YEAR, WHICHEVER OCCURS FIRST Replce the wter pump impeller (more often if overheting occurs or reduced wter pressure is noted). Remove the bering crrier. Lubricte the bering crrier nd crrier nut with 2 4 C with PTFE if the outbord is used in sltwter environment. Refer to the service mnul for instructions. Tube Ref No. Description Where Used Prt No C with PTFE Bering crrier nd crrier nut A 1 Clen the entire unit, including ccessible powerhed prts. Touch up ny pint nicks. Clen nd pint corroded res. If corrosion is severe, try to isolte the cuse of corrosion nd correct. Check the entire outbord for loose, dmged, or missing prts. Tighten or replce s required. Inspect the fuel lines for dmge or deteriortion nd service the fuel filters. Inspect the oil pump lines to mke sure they hve not become hrd or brittle. Replce if necessry. Remove nd inspect the propeller. Trim propeller blde nicks nd burrs with file. Inspect for crcks or bent bldes. Clen nd lubricte the propeller shft with Extreme Grese. eng 53

64 MAINTENANCE Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M Check the remote controls nd steering. Ensure tht ll connections nd fittings re tight nd properly secured nd djusted. Inspect the crbon fiber reeds for chipping or crcks. BEFORE PERIODS OF STORAGE Refer to Storge. Flushing the Cooling System (Powerhed) Flush the internl wter pssges of the engine with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent buildup of deposits from clogging the internl wter pssges. b Plug locted on fitting b - Wter hose 1. Remove the plug from fitting in the bottom cowl. 2. Attch wter hose to the fitting. Turn on the wter nd flush for three to five minutes. NOTE: The engine cn be stopped or operted t idle speed when flushing the cooling system. Do not flush engine using wter system tht exceeds 310 kp (45 psi). 54 eng

65 MAINTENANCE Flushing the Cooling System (Lower Unit)! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the bot 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. Plce block of wood between the propeller blde nd the nti ventiltion plte. b - Fleet Mster gercse b - Flushing ttchments c - Wter hose c or Remove the propeller. Refer to Replcing the Propeller. 2. Instll the pproprite flushing ttchment so the rubber cups fit tightly over the strut intke holes. Attch the dul wter flush sel over the nose inlets. 3. Attch wter hose to the flushing ttchment. Turn on the wter nd djust the flow so wter is leking round the rubber cups to ensure the engine receives n dequte supply of cooling wter. 4. Strt the engine nd run it t idle RPM in neutrl. 5. Adjust wter flow so excess wter continues leking out from round the rubber cups to ensure the engine is receiving n dequte supply of cooling wter. 6. Check for wter coming out of the wter pump indictor hole. Continue flushing for three to five minutes, crefully monitoring wter supply t ll times. 7. Stop the engine, turn off the wter, nd remove the flushing ttchments. Instll the propeller. eng 55

66 MAINTENANCE Top Cowl Removl nd Instlltion REMOVAL Relese the front nd side cowl ltches. Lift the top cowl from the outbord INSTALLATION Position the top cowl over the engine. Mke sure the bottom rubber sel fits properly nd lock the front nd side ltches. Clening Cre for Top Cowl IMPORTANT: Dry wiping (wiping the plstic surfce when it is dry) will result in minor surfce scrtches. Alwys wet the surfce before clening. Follow the clening nd wxing procedure. CLEANING AND WAXING PROCEDURE 1. Before wshing, rinse the top cowl with clen wter to remove the dirt nd dust tht my scrtch the surfce. 2. Wsh the top cowl with clen wter nd mild nonbrsive sop. Use soft, clen cloth when wshing. 3. Dry thoroughly with soft, clen cloth. 4. Wx the surfce using nonbrsive utomotive polish (polish designed for cler cot finishes). Remove the pplied wx by hnd using soft, clen cloth. Fuel System FUEL SYSTEM SERVICE INFORMATION! WARNING Fuel is flmmble nd explosive. Ensure tht 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 before ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. 56 eng

67 IMPORTANT: Use n pproved continer to collect nd store fuel. Wipe up ny spillge immeditely. Mteril used to contin spillge must be disposed of in n pproved receptcle. Before servicing ny prt of the fuel system: Stop engine nd disconnect the bttery. Drin the fuel system completely. Perform fuel system service in well ventilted re. Inspect ny completed service work for sign of fuel lekge. FUEL LINE INSPECTION MAINTENANCE Visully inspect the fuel line nd primer bulb for crcks, swelling, leks, hrdness, or other signs of deteriortion or dmge. If ny of these conditions re found, the fuel line or primer bulb must be replced. WATER SEPARATING FUEL FILTER This filter removes moisture nd debris from the fuel. If the filter becomes filled with wter, the wter cn be removed. If the filter becomes plugged with debris, replce the filter. The wrning system engges when wter in the fuel filter reches the full level. Refer to Wrning System in Fetures nd Controls. Refer to the Inspection nd Mintennce Schedule for the proper mintennce intervl. eng 57

68 MAINTENANCE Removl - O ring sels b - Filter c - Rised bosses 1. Disconnect the link rod. 2. Use the shft of screwdriver between the filter cp bosses nd unscrew the filter. Instlltion 1. Lubricte the O ring sels with oil. 2. Instll the fuel filter nd tighten securely. 3. Connect the link rod. IMPORTANT: Visully inspect for fuel lekge from the filter while squeezing the primer bulb until firm, forcing fuel into the filter. 58 eng

69 MAINTENANCE DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If sufficient mount of wter ccumultes in the fuel filter chmber, the engine's wrning system lerts the opertor with the wrning horn. Some SmrtCrft guges re cpble of lerting the opertor of this nd other operting conditions/fults. Refer to Wrning System in the Fetures nd Controls section of this mnul for more informtion. If the wrning system lerts you to this condition, drin the wter from the fuel filter chmber. b c Drin hose b - Aft hose fitting c - Filter drin screw 1. Remove the drin hose from the ft hose fitting (right side of the chmber). Hold the unttched end of the hose over suitble continer. 2. Loosen the filter drin screw (left side of the chmber) nd llow the contents to drin. NOTE: If little or no liquid drins from the hose, loosen the red filter to vent the chmber. 3. Tighten the drin screw nd ttch the hose. IMPORTANT: Visully inspect for fuel lekge from the drin screw by squeezing the primer bulb until firm, forcing fuel into the chmber. If you experience multiple issues with wter in the fuel system over short period of time, see your uthorized Mercury deler. eng 59

70 Steering Link Rod Fsteners MAINTENANCE IMPORTANT: The steering link rod tht connects the steering cble to the engine must be fstened using specil wsher hed bolt (P/N ) nd self locking nylon insert locknuts (P/N ). Never replce locknuts with common nuts (nonlocking) s they will work loose nd vibrte off, freeing the link rod to disengge.! 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 bot control, resulting in serious injury or deth due to occupnts being thrown within or out of the bot. Alwys use required components nd follow instructions nd torque procedures.! WARNING Worn, loose, or seized steering components cn led to loss of bot control. Inspect ll steering ttchment components for wer, lubricte ll ttchment hrdwre, nd check ll fsteners for proper tightness in ccordnce with the inspection nd mintennce schedule. c d b Specil wsher hed bolt (P/N ) b - Nylon insert locknut (P/N ) used on hed bolt c - Flt wsher (2) d - Nylon insert locknut (P/N ) used on cble coupler 1. Assemble steering link rod to steering cble coupler with two flt wshers "c" nd self locking nylon insert locknut "d." Tighten the locknut until it sets, then loosen ¼ turn. 2. Assemble the steering link rod to the engine with the specil wsher hed bolt "" nd self locking nylon insert locknut "b." 3. Torque the hed bolt, then the locknut to specifictions. 60 eng

71 Description Nm lb in. lb ft Cble coupler nylon insert locknut "d" Tighten locknut until it sets, then loosen ¼ turn. Hed bolt nylon insert locknut "b" Specil wsher hed bolt Fuses MAINTENANCE IMPORTANT: Alwys crry spre ATC 2, 5, nd 20 mp fuses. Never use ATO type fuses. The electricl wiring circuits on the engine re protected from overlod by fuses in the wiring. If fuse is blown, try to locte nd correct the cuse of the overlod before replcing the fuse. If the cuse is not found, the fuse my blow gin. 1. There re two fuse holders on this engine. Open the fuse holder nd inspect the silver colored bnd inside the fuse. If the bnd is broken, replce the fuse. 2. Replce the fuse with new fuse with the sme rting. eng 61

72 MAINTENANCE The fuses nd circuits re identified s follows: b c h g d f e i Fuse loction nd identifiction - SmrtCrft b - Dignostic circuit 2 mp c - Glow plug light 2 mp d - Ignition coil circuit 20 mp e - Fuel injector/direct injector/pcm nd electric fuel pump circuits 20 mp f - Helm min power rely 20 mp g - Spre fuse slot h - Good fuse i - Blown fuse Corrosion Control Anode NOTICE Anodes mde of insufficiently pure luminum lloys my not dequtely protect criticl drive components from corrosion. We recommend using nodes sold through Mercury Precision Prts only. Anodes help protect the power pckge ginst glvnic corrosion by scrificing its metl to be slowly eroded insted of other metls. 62 eng

73 MAINTENANCE This model hs three corrosion control nodes two bove nd one below the nti ventiltion plte. A fourth node is locted on the bottom of the clmp/ swivel brcket ssembly. - Corrosion control nodes (three on gercse) b - Corrosion control node (one on clmp/swivel brcket) All nodes require periodic inspection, especilly in sltwter (refer to the Inspection nd Mintennce Schedule). Replce ny nodes before they re 50% corroded. Never pint or pply protective coting on the node, s effectiveness of the node will be reduced. Sprk Plug Inspection nd Indexing Instlltion! WARNING Dmged sprk plug boots my emit sprks tht cn ignite fuel vpors under the engine cowl, resulting in serious injury or deth from fire or explosion. To void dmging the sprk plug boots, do not use ny shrp object or metl tool to remove the sprk plug boots. 1. Remove the sprk plug leds by twisting the rubber boots while pulling them off the sprk plugs Remove the sprk plugs. Replce the sprk plug if the electrode is worn; the insultor is rough, crcked, broken, or blistered; or if the precious metl is not visible on the sprk plug electrode. eng 63

74 MAINTENANCE IMPORTANT: The color of the plug my not ccurtely reflect its condition. To ccurtely dignose fulty plug, inspect the precious metl on the plug's electrode. If no precious metl is visible, replce the plug Precious metl 3. Set the sprk plug gp. Refer to Specifictions All of the sprk plugs should hve the gp checked nd corrected s necessry before instlltion. b. Mesure the gp with feeler guge or pin guge. Never use wedge type gp checking tool to inspect or to djust the gp. c. If n djustment is necessry, do not pry or pply ny force on the center electrode. This is criticl with ny type of sprk plug tht hs wer surfce, such s pltinum or iridium dded to either the ground electrode or the center electrode. d. When it is necessry to widen the gp, use sprk gp tool tht only pulls bck on the ground electrode without touching the center electrode, the porcelin, or the wer portion of the ground electrode. e. When it is necessry to close the gp, gently tp the plug ground electrode on hrd surfce. 4. If the sprk plug condition is cceptble to use, instll the sprk plug in the sme loction it ws removed from. 64 eng

75 MAINTENANCE 5. Mrk the sprk plug insultor with permnent mrker in line with the sprk plug gp Mrk on sprk plug insultor ligned with sprk plug gp 6. Lubricte the threds nd seling ring of the sprk plug with Anti Corrosion Grese nd instll finger tight. Tube Ref No. 94 Description Where Used Prt No. Anti-Corrosion Grese Sprk plug threds nd seling ring Obtin Loclly 7. Set the torque wrench to 20.3 Nm (179.7 lb in.). This is the minimum torque tht should be pplied. 8. Align the torque wrench hndle with the index mrk on the sprk plug. Tighten the sprk plug while ttempting to lign the torque wrench hndle within 45 left or right of the ir injector center. If the index mrk is before the left side of the trget window, set the torque wrench to 33.9 Nm (25 lb ft) nd tighten the sprk plug while ttempting to lign index mrk with the ir injector. NEW SPARK PLUG INDEXING INSTALLATION IMPORTANT: All of the sprk plugs must be indexed properly. The open gp of the sprk plug must be within 45, left or right of the ir injector center fter the sprk plug hs been tightened to the specified torque. This 90 window is where the sprk plug gp must be for this engine to perform within design limits. eng 65

76 MAINTENANCE The following digrm shows the 90 window where the sprk plug gp must be for this engine to perform within design limits, the re where the sprk plug gp must be fter it is instlled finger tight with socket, nd the re where you must try different sprk plug. b c Sprk plug index mrk trget - Air injector b - 90 window where the sprk plug gp must be fter tightening to the specified torque c - Are where the sprk plug gp must be fter it is instlled finger tight with socket d - Do not instll. Try different sprk plug. d Mrk the sprk plug insultor with permnent mrker in line with the sprk plug gp. IMPORTANT: The mrk on the sprk plug insultor must be ligned with the center of the ir injector for optimum performnce. The mrk on the sprk plug cnnot be more thn 45 to the left or right of the ir injector center for this engine to perform within design limits Mrk on sprk plug insultor ligned with sprk plug gp 2. Clen the sprk plug set re of debris. 3. Lubricte the sprk plug threds nd seling ring with Anti Corrosion Grese. 66 eng

77 MAINTENANCE Tube Ref No. 94 Description Where Used Prt No. Anti-Corrosion Grese Sprk plug threds nd seling ring Obtin Loclly NOTE: Test fit the sprk plug instlltion prior to lubricting the sprk plug threds nd seling ring with Anti Corrosion Grese. 4. Instll the sprk plug nd tighten finger tight. 5. Inspect where the mrk on the sprk plug insultor is in reltion to the ir injector. b - 90 window where the sprk plug gp must be fter tightening to the specified torque b - Are where the sprk plug gp must be fter it is instlled finger tight with socket eng 67

78 MAINTENANCE Exmple of when to try different sprk plug fter instlled finger-tight with socket 6. Set the torque wrench to 20.3 Nm (179.7 lb in.). This is the minimum torque tht must be pplied. 7. Align the torque wrench hndle with the mrk on the sprk plug. Tighten the sprk plug to the set torque vlue. 8. If the torque wrench hndle is not within the 45 window, left of the ir injector, set the torque wrench to 33.9 Nm (25 lb ft). This is the mximum torque tht should be pplied. 68 eng

79 MAINTENANCE 9. Align the torque wrench hndle with the mrk on the sprk plug. Tighten the sprk plug while ttempting to lign the mrk on the insultor (torque wrench hndle) with the ir injector. Bttery Inspection Exmple of n optiml ligned sprk plug The bttery should be inspected t periodic intervls to ensure proper engine strting cpbility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your bttery. 1. Turn off the engine before servicing the bttery. 2. Ensure the bttery is secure ginst movement. 3. Bttery cble terminls should be clen, tight, nd correctly instlled. Positive to positive nd negtive to negtive. 4. Ensure the bttery is equipped with nonconductive shield to prevent ccidentl shorting of bttery terminls. eng 69

80 Fusible Link MAINTENANCE This model hs two fusible links; one is between the lterntor nd the +12 volt stud nd the other is between the glow plug rely nd the min power rely. These fusible links protect the components from dmge due to ccidentl reverse bttery connection. If the bttery cbles re reversed, the fusible link cretes n open circuit, protecting the component. With the fusible link open, the engine cn be strted; however, the glow plugs will not het up, cusing difficult cold engine strting, or the run time is limited, becuse the lterntor is not chrging the bot bttery. If the fusible link circuit becomes open, contct your uthorized Mercury Mrine deler Replcing the Propeller! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the bot 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. Plce block of wood between the propeller blde nd the nti ventiltion plte. REMOVING THE PROPELLER NOTE: If propeller is seized to the shft nd cnnot be removed, consult your uthorized Mercury deler. 1. Shift the outbord to neutrl. 2. Remove the keys from the ignition nd engge the sfety stop switch. 3. Strighten the bent tbs on the propeller nut retiner (if pplicble). 70 eng

81 MAINTENANCE 4. Plce block of wood between the gercse nd the propeller to hold the propeller nd remove the propeller nut Remove the propeller nd ssocited hrdwre from the propeller shft. INSTALLING THE PROPELLER NOTICE Operting the engine with the wrong propeller instlled cn limit power, increse fuel consumption, overhet the engine, or cuse internl powerhed dmge. Choose propeller tht llows the engine to operte t the specified wide open throttle RPM. Mercury Rcing pplictions use 19 spline propeller shfts nd require instlltion of the Hevy Duty Propeller Hub kit, included with most Mercury Rcing propellers. IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft, especilly in slt wter, lwys pply cot of Extreme Grese to the entire propeller shft t the recommended mintennce intervls nd lso ech time the propeller is removed. 1. Lubricte the propeller shft splines with Extreme Grese. eng 71

82 MAINTENANCE 2. Instll the propeller hub ssembly, propeller, wsher, Belleville wsher, wsher, nd propeller nut onto the propeller shft. d e - Propeller hub ssembly b - Propeller c - Wsher d - Belleville wsher e - Wsher f - Propeller nut c f b 2693 Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft splines 8M Plce block of wood between the gercse nd propeller nd torque the propeller nut Description Nm lb. in. lb. ft. Propeller nut Disengge the sfety stop switch by plcing it in the "RUN" position nd return the keys to the ignition switch. 72 eng

83 Lubriction Points MAINTENANCE Lubricte the following with Extreme Grese nd 2 4 C with PTFE Tube Ref No. Description Where Used Prt No. Extreme Grese Trim rod bll ends, propeller shft 8M C with PTFE Swivel brcket, tilt support lever, tilt tube A 1 NOTE: Turn the bll ends to work the lubricnt into the bll sockets. Lubricte through fittings. eng 73

84 MAINTENANCE! WARNING Incorrect cble lubriction cn cuse hydrulic lock, leding to serious injury or deth from loss of bot control. Completely retrct the end of the steering cble before pplying lubricnt. Lubricte the steering link with lightweight oil. Lubricte the belt tensioner pulley nd steering cble with 2 4 C with PTFE Tube Ref No C with PTFE Description Where Used Prt No. Steering cble, grese fitting on belt tensioner pulley Checking Power Trim Fluid (Three Rm Trim Systems) A 1 1. Tilt outbord to the full up position nd engge the tilt support lock. 114 or Tilt support lock 74 eng

85 Tube Ref. No. Description Where Used Prt Number 114 Power Trim nd Steering Fluid Fill hole A1 2. Remove fill cp nd check fluid level. The fluid level should be even with the bottom of the fill hole. Add fluid if required. Gercse Lubricnt MAINTENANCE CHECKING/FILLING GEARCASE LUBRICANT b c e d Fleet Mster gercse (verticl operting position) b - Vent hole c - Vent plug nd seling wsher d - Fill/drin hole e - Fill/drin plug Tube Ref No. Description Where Used Prt No. SAE 85W90 Mercury Rcing Ger Oil Gercse 8M Plce the outbord in verticl operting position. 2. Remove the vent plug (upper plug) nd seling wsher. 3. Remove the fill/drin plug (lower plug). 4. Quickly plce the lubricnt tube into the fill hole. 5. Slowly dd lubricnt until it flows from the (upper) vent hole. 6. Stop dding lubricnt. Instll the (upper) vent plug nd seling wsher before removing the lubricnt tube. IMPORTANT: Replce the seling wshers if dmged. eng 75

86 NOTE: Exmine the mgnetic fill/drin plug for metl prticles. A smll mount of metl filings or fine metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) should be checked by n uthorized deler. 7. Remove lubricnt tube nd instll clened (lower) fill/drin plug nd seling wsher. Wter in ger lubricnt my: Settle to the bottom nd drin out with the lubricnt Be mixed with the lubricnt giving milky color to the lubricnt Wter in ger lubricnt will: Result in premture bering filure In freezing tempertures, turn to ice nd dmge the gercse DRAINING THE GEARCASE MAINTENANCE c b - Fleet Mster gercse (verticl operting position) b - Vent plug nd seling wsher c - Fill/drin plug nd seling wsher d - Drin pn d Plce the outbord in verticl operting position. 2. Plce drin pn below the outbord. 3. Remove the vent plug (upper plug) nd seling wsher. 4. Remove the fill/drin plug (lower plug) nd seling wsher nd drin the lubricnt. GEARCASE LUBRICANT CAPACITY Gercse lubricnt cpcity is pproximtely 710 ml (24 oz). 122 mm (4.8 in.) Dimeter Gercse DRAINING GEARCASE 1. Plce outbord in verticl operting position. 2. Remove propeller. Refer to Propeller Replcement. 3. Plce drin pn below outbord. 76 eng

87 MAINTENANCE 4. Remove vent plug nd fill/drin plug nd drin lubricnt. b Vent plug b - Fill/drin plug GEARCASE LUBRICANT CAPACITY Gercse lubricnt cpcity is pproximtely 970 ml (32.8 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performnce Ger Lubricnt. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Plce outbord in verticl operting position. 2. Remove vent plug/seling wsher. 3. Remove fill/drin plug. Plce lubricnt tube into the fill hole nd dd lubricnt until it ppers t the vent hole. b Vent hole b - Fill hole IMPORTANT: Replce seling wshers if dmged. 4. Stop dding lubricnt. Instll the vent plug nd seling wsher before removing the lubricnt tube. eng 77

88 MAINTENANCE 5. Remove lubricnt tube nd reinstll clened fill/drin plug nd seling wsher. 78 eng

89 STORAGE Protecting Externl Outbord Components Lubricte ll outbord components listed in Mintennce Inspection nd Mintennce Schedule. Touch up ny pint nicks. See your deler for touch up pint. Spry Quicksilver or Mercury Precision Lubricnts Corrosion Gurd on externl metl surfces (except corrosion control nodes). Tube Ref No. Description Where Used Prt No. 120 Corrosion Gurd Externl metl surfces Gercse Drin nd refill the gercse lubricnt. Refer to Gercse Lubricnt. Positioning Outbord for Storge Store outbord in n upright (verticl) position to llow wter to drin out of the outbord. NOTICE Storing the outbord in tilted position cn dmge the outbord. Wter trpped in the cooling pssges or rin wter collected in the propeller exhust outlet in the gercse cn freeze. Store the outbord in the full down position. Bttery Storge Follow the bttery mnufcturer's instructions for storge nd chrging. Remove the bttery from the bot nd check wter level. Chrge if necessry. Store the bttery in cool, dry plce. Periodiclly check the wter level nd chrge the bttery during storge. eng 79

90 TROUBLESHOOTING Strter Motor Will Not Crnk the Engine POSSIBLE CAUSES Blown 20 mp fuse in the strting circuit. Refer to Mintennce. Outbord is not shifted to neutrl position. Wek bttery or bttery 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 Lnyrd stop switch not in "RUN" position. Bttery not fully chrged. Incorrect strting procedure. Refer to Opertion section. Old or contminted fuel. Fuel is not reching the engine. Fuel tnk is empty. Fuel tnk vent not open or restricted. Fuel line is disconnected or kinked. Primer bulb not squeezed. Primer bulb check vlve is fulty. Fuel filter is obstructed. Refer to Mintennce section. Fuel pump filure. Fuel tnk filter obstructed. Open 20 mp fuse. Check fuses, refer to Mintennce section. Threded connection of n ir hose is loose. Ignition system component filure. Sprk plugs fouled or defective. Refer to Mintennce section. Engine Runs Errticlly POSSIBLE CAUSES Sprk plugs fouled or defective. Refer to Mintennce section. Incorrect setup nd djustments. Fuel is being restricted to the engine.. Engine fuel filter is obstructed. Refer to Mintennce section. b. Fuel tnk filter obstructed. c. Stuck ntisiphon vlve on built in fuel tnk. 80 eng

91 d. Fuel line is kinked or pinched. e. Injector plugged. Threded connection of n ir hose is loose. Fuel pump filure. Ignition system component filure. Performnce Loss POSSIBLE CAUSES Throttle not opening fully. Dmged propeller or improper propeller size. Bot overloded or lod improperly distributed. Excessive wter in bilge. Bot bottom is dirty or dmged. Wrning horn filure. Engine block pressure sensor or coolnt temperture sensor filure (Gurdin is ctivted). Wrning Horn Activtes (With Power Loss) POSSIBLE CAUSES Intermittent horn sound: The oil level in the engine mounted oil reservoir tnk is low. Refill the reservoir tnk nd the remote oil tnk. Refer to Fuel nd Oil for detils. Bttery voltge is out of limits. Throttle position sensor filure. Continuous horn sound: The oil level in the engine mounted oil reservoir tnk is criticlly low. Refill the reservoir tnk nd the remote oil tnk. Refer to Fuel nd Oil for detils. The oil pump hs filed, hlting the oil supply to the engine. Engine speed exceeds the mximum llowble RPM. The system limits the engine to within the llowble rnge. If the overspeed condition continues, Engine Gurdin plces the engine into power reduction. Overspeed my be cused by incorrect propeller pitch, engine height, trim ngle, etc. High engine temperture or low block wter pressure. Cooling system clogged. TROUBLESHOOTING Incorrect trnsom height (wter pickups not getting dequte wter supply). eng 81

92 Wrning Horn Activtes (No Power Loss) POSSIBLE CAUSES Wrning horn ctivtes on strt up. This is norml opertion. Wter is detected in the wter seprting fuel filter. Refer to Mintennce for procedures on removing wter from the filter. Thermostt opertion fult. Inspect the thermostt for debris nd tht it opertes within the opening nd closing temperture specifictions. Bttery Will Not Hold Chrge POSSIBLE CAUSES Bttery connections re loose or corroded. Low electrolyte level in bttery. Worn out or inefficient bttery. TROUBLESHOOTING Excessive use of electricl ccessories. Defective rectifier, lterntor, or voltge regultor. 82 eng

93 OWNER SERVICE ASSISTANCE Service Assistnce LOCAL REPAIR SERVICE If you need service for your Mercury outbord powered bot, tke it to your uthorized deler. Only uthorized delers specilize in Mercury products nd hve fctory trined mechnics, specil tools nd equipment, nd genuine Quicksilver prts nd ccessories to properly service your engine. NOTE: Quicksilver prts nd ccessories re engineered nd built by Mercury Mrine specificlly for your power pckge. SERVICE AWAY FROM HOME If you re wy from your locl deler nd the need rises for service, contct the nerest uthorized deler. If, for ny reson, you cnnot obtin service, contct the nerest Regionl Service Center. Outside the United Sttes nd Cnd, contct the nerest Mrine Power Interntionl Service Center. STOLEN POWER PACKAGE If your power pckge is stolen, immeditely dvise the locl uthorities nd Mercury Mrine of the model nd seril numbers nd to whom the recovery is to be reported. This informtion is mintined in dtbse t Mercury Mrine to id uthorities nd delers in the recovery of stolen power pckges. ATTENTION REQUIRED AFTER SUBMERSION 1. Before recovery, contct n uthorized Mercury deler. 2. After recovery, immedite service by n uthorized Mercury deler is required to reduce the possibility of serious engine dmge. REPLACEMENT SERVICE PARTS! WARNING Avoid fire or explosion hzrd. Electricl, ignition, nd fuel system components on Mercury Mrine products comply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replcement electricl or fuel system components tht do not comply with these stndrds. When servicing the electricl nd fuel systems, properly instll nd tighten ll components. Mrine engines re expected to operte t or ner full throttle for most of their lives. They re lso expected to operte in both fresh nd sltwter environments. These conditions require numerous specil prts. PARTS AND ACCESSORIES INQUIRIES Direct ny inquiries concerning genuine Mercury Precision Prts or Quicksilver Mrine Prts nd Accessories to locl uthorized deler. Delers hve the proper systems to order prts nd ccessories, if they re not in stock. Engine model nd seril number re required to order correct prts. eng 83

94 RESOLVING A PROBLEM Stisfction with your Mercury product is importnt to your deler nd to us. If you ever hve problem, question or concern bout your power pckge, contct your deler or ny uthorized Mercury delership. If you need dditionl ssistnce: 1. Tlk with the delership's sles mnger or service mnger. 2. If your question, concern, or problem cnnot be resolved by your delership, plese contct the Mercury Mrine Service Office for ssistnce. Mercury Mrine will work with you nd your delership to resolve ll problems. The following informtion will be needed by the Customer Service: Your nme nd ddress Your dytime telephone number The model nd seril numbers of your power pckge The nme nd ddress of your delership The nture of the problem OWNER SERVICE ASSISTANCE CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For ssistnce, cll, fx, or write to the geogrphic office in your re. Plese include your dytime telephone number with mil nd fx correspondence. United Sttes, Cnd Telephone Fx Website English Frnçis English Frnçis Mercury Mrine W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Austrli, Pcific Telephone Fx Brunswick Asi Pcific Group Bessemer Drive Dndenong South, Victori 3175 Austrli Europe, Middle Est, Afric Telephone Fx Brunswick Mrine Europe Prc Industriel de Petit-Rechin B-4800 Verviers, Belgium 84 eng

95 Mexico, Centrl Americ, South Americ, Cribben Telephone Fx Mercury Mrine Interchnge Circle North Mirmr, FL U.S.A. Jpn Telephone Kisk Co., Ltd. Fx Knnbecho, Ski ku Ski shi, Osk , Jpn Asi, Singpore OWNER SERVICE ASSISTANCE Telephone Fx Brunswick Asi Pcific Group T/A Mercury Mrine Singpore Pte Ltd 29 Loyng Drive Singpore, Ordering Literture Before ordering literture, hve the following informtion bout your power pckge vilble: Model Horsepower Seril Number Yer UNITED STATES AND CANADA For dditionl literture for your Mercury Mrine power pckge, contct your nerest Mercury Mrine deler or contct: Mercury Mrine Telephone Fx Mil (920) (USA only) (920) (USA only) OUTSIDE THE UNITED STATES AND CANADA Mercury Mrine Attn: Publictions Deprtment P.O. Box 1939 Fond du Lc, WI Contct your nerest Mercury Mrine uthorized service center to order dditionl literture tht is vilble for your prticulr power pckge. eng 85

96 OWNER SERVICE ASSISTANCE Submit the following order form with pyment to: Mercury Mrine Attn: Publictions Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Ship To: (Copy this form nd print or type This is your shipping lbel) Nme Address City, Stte, Province ZIP or postl code Country Quntity Item Stock Number Price Totl Totl Due. 86 eng

97 OUTBOARD INSTALLATION Mercury Mrine Vlidted Engine Mounting Hrdwre IMPORTANT: Mercury Mrine provides vlidted fsteners nd instlltion instructions, including torque specifictions, with ll of our outbords so they cn be properly secured to bot trnsoms. Improper instlltion of the outbord cn cuse performnce nd relibility issues tht cn led to sfety concerns. Follow ll of the instructions relting to the outbord instlltion. DO NOT mount ny other ccessory onto the bot with the fsteners provided with the outbord. For exmple, do not mount tow sport brs or bording ldders onto the bot using the mounting hrdwre included with the outbord. Instlling other products onto the bot tht utilize the outbord mounting hrdwre will compromise the bility of tht hrdwre to properly nd sfely secure the outbord to the trnsom. Outbords tht require vlidted mounting hrdwre will hve the following decl on the trnsom clmp Accessories Mounted to the Trnsom Clmp Brcket Mercury Mrine hs been mde wre tht certin ftermrket mrine ccessories, such s emergency bording ldders, shllow wter nchors, trnsom wedge kits, nd tow sport ttching devices, hve been mounted to the bot by use of the sme fsteners tht secure the outbord to the trnsom or jck plte. Using the sme fstener to secure both n ccessory nd the engine to the bot compromises the bility of the fsteners to mintin the proper clmp lod. A bot with loose engine mounting fsteners cretes the possibility of performnce, durbility, nd sfety issues. eng 87

98 OUTBOARD INSTALLATION! WARNING Avoid serious injury or deth resulting from loss of bot control. Loose engine fsteners could cuse the trnsom brcket to fil, resulting in loss of the driver's bility to control the bot. Alwys ensure tht the engine fsteners re tightened to the specified torque. ACCEPTABLE ACCESSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the trnsom or jck plte in ccordnce with the engine instlltion instructions, it is cceptble to ttch n ccessory to the bot by use of the unused bolt holes in the trnsom clmp brcket s shown in Figure 1. The following list provides dditionl guidelines for mounting ccessories to the trnsom clmp brcket. The ccessory fsteners must pss through the bot trnsom or jck plte. 88 eng

99 OUTBOARD INSTALLATION The instlltion must not crete interference issues, s would n ccessory mounting plte resting in the rdius of the trnsom clmp brcket. Refer to Figure 1. f e c b d Figure 1 - Minimum clernce mm (0.125 in.) b - Edge of ccessory brcket c - Trnsom clmp brcket wll d - Rdius e - Engine supplied mounting fsteners f - Fsteners supplied by the ccessory mnufcturer instlled through unused engine mounting brcket holes eng 89

100 OUTBOARD INSTALLATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fsteners tht secure the engine to the bot (either the trnsom or the jck plte) for ny purpose other thn securing the engine to the bot. 1. Do not mount n ccessory to the trnsom clmp brcket in n unsupported condition. Refer to Figure 2. Figure Do not ttch n ccessory to the bot by use of the engine mounting hrdwre. Refer to Figure 3. b c Figure 3 - Engine supplied mounting fsteners b - Trnsom clmp brcket c - Accessory eng

101 OUTBOARD INSTALLATION 3. Do not instll wedges or pltes between the trnsom clmp brckets nd the trnsom (or jck plte). Refer to Figure 4. b Figure 4 - Bot trnsom or jck plte b - Trnsom clmp brcket c - Wedge/plte c Bot Horsepower Cpcity! WARNING Exceeding the bot's mximum horsepower rting cn cuse serious injury or deth. Overpowering the bot cn ffect bot control nd flottion chrcteristics or brek the trnsom. Do not instll n engine tht exceeds the bot's mximum power rting. Do not overpower or overlod your bot. Most bots will crry required cpcity plte indicting the mximum cceptble power nd lod s determined by the mnufcturer following certin federl guidelines. If in doubt, contct your deler or the bot mnufcturer. U.S. COAST GUARD CAP ACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY XXX XXX Strt in Ger Protection! WARNING Strting the engine with the drive in ger cn cuse serious injury or deth. Never operte bot tht does not hve neutrl sfety protection device. eng 91

102 The remote control connected to the outbord must be equipped with strt in neutrl only protection device. This prevents the engine from strting in ger. Selecting Accessories for Your Outbord Genuine Mercury Precision or Quicksilver Accessories hve been specificlly designed nd tested for this outbord. Some ccessories not mnufctured or sold by Mercury Mrine re not designed to be sfely used with this outbord or outbord operting system. Acquire nd red the instlltion, opertion, nd mintennce mnuls for ll selected ccessories. Fuel System 3.0L DIESEL FUEL DECAL OUTBOARD INSTALLATION This engine is mnufctured for diesel fuel use only. A decl supplied with this engine, must be plced ner the fuel fill re. The re where the decl will be plced, must be clen nd dry for the decl to properly dhere to the surfce. Use solvent or sop tht will not leve residue when dry. CAUTION Avoid engine dmge from improper fuel. Use only ultr low sulphur diesel fuel. 8M AVOIDING FUEL FLOW RESTRICTION IMPORTANT: Adding components to the fuel supply system (filters, vlves, fittings, etc.) my restrict the fuel flow. This my cuse engine stlling t low speed, nd/or len fuel condition t high RPM tht could cuse engine dmge. ELECTRIC FUEL PUMP The fuel pressure must not exceed 28 kp (4 psi). If necessry, instll pressure regultor. LOW PERMEATION FUEL HOSE REQUIREMENT Required for outbords mnufctured for sle, sold, or offered for sle in the United Sttes. 92 eng

103 OUTBOARD INSTALLATION The Environmentl Protection Agency (EPA) requires tht ny outbord mnufctured fter Jnury 1, 2009, must use low permetion fuel hose for the primry fuel hose connecting the fuel tnk to the outbord. Low permetion hose is USCG Type B1 15 or Type A1 15, defined s not exceeding 15 g/m²/24 h with CE 10 fuel t 23 C s specified in SAE J 1527 mrine fuel hose. EPA PRESSURIZED PORTABLE FUEL TANK REQUIREMENTS The Environmentl Protection Agency (EPA) requires portble fuel systems tht re produced fter Jnury 1, 2011, for use with outbord engines to remin fully seled (pressurized) up to 34.4 kp (5.0 psi). These tnks my contin the following: An ir inlet tht opens to llow ir to enter s the fuel is drwn out of the tnk. An ir outlet tht opens (vents) to the tmosphere if pressure exceeds 34.4 kp (5.0 psi). FUEL DEMAND VALVE (FDV) REQUIREMENT Whenever pressurized fuel tnk is used, fuel demnd vlve is required to be instlled in the fuel hose between the fuel tnk nd primer bulb. The fuel demnd vlve prevents pressurized fuel from entering the engine nd cusing fuel system overflow or possible fuel spillge. The fuel demnd vlve hs mnul relese. The mnul relese cn be used (pushed in) to open (bypss) the vlve in cse of fuel blockge in the vlve. FUEL TANKS c b Fuel demnd vlve instlled in the fuel hose between the fuel tnk nd primer bulb b - Mnul relese c - Vent/wter drin holes Portble Fuel Tnk Select suitble loction in the bot within the engine fuel line length limittions nd secure the tnk in plce. Permnent Fuel Tnk Permnent fuel tnks should be instlled in ccordnce with industry nd federl sfety stndrds, which include recommendtions pplicble to grounding, nti siphon protection, ventiltion, etc. FILLING THE FUEL SYSTEM For the initil strt of new engine, or for n engine tht rn out of fuel or ws drined of fuel, the fuel system should be filled s follows: 1. Squeeze the fuel line primer bulb until it feels firm. eng 93

104 2. Turn the ignition key switch to the "ON" position for three seconds. This opertes the electric fuel pump. 3. Turn the ignition key switch bck to the "OFF" position, nd squeeze the primer bulb gin until it feels firm. Turn the ignition key switch to the "ON" position gin for three seconds. Continue this procedure until the fuel line primer bulb stys firm. Instlltion Specifictions OUTBOARD INSTALLATION b Minimum trnsom opening b - Engine centerline for dul engine 66.0 cm (26 in.) Minimum Trnsom Opening Single engine Dul engine 84.8 cm (33 3/8 in.) cm (59 3/4 in.) Lifting the Outbord! WARNING Improperly supporting n engine during lifting cn result in the engine flling, cusing serious injury or deth. Before lifting the engine, verify tht the lifting ring is threded into the flywheel for minimum of five turns nd tht the hoist hs the correct lifting cpcity for the engine weight. To lift the outbord: 1. Remove the cowl from the outbord. 94 eng

105 OUTBOARD INSTALLATION 2. Thred the lifting eye into the flywheel hub for minimum of five turns. - Lifting eye Connect hoist to the lifting eye. 4. Lift the outbord nd plce it on the bot trnsom. Lifting Eye Threds into the flywheel to remove the powerhed ssembly from the driveshft housing, or to lift entire engine for removl/instlltion. Steering Cble Strbord Side Routed Cble 1. Lubricte the O ring sel nd the entire cble end Tube Ref No. Description Where Used Prt No C with PTFE O-ring sel nd entire cble end A 1 eng 95

106 OUTBOARD INSTALLATION 2. Insert the steering cble into the tilt tube Tighten the nut to the specified torque Description Nm lb in. lb ft Nut Steering Link Rod Fsteners IMPORTANT: The steering link rod tht connects the steering cble to the engine must be fstened using specil wsher hed bolt (P/N ) nd self locking nylon insert locknuts (P/N ). Never replce locknuts with common nuts (nonlocking) s they will work loose nd vibrte off, freeing the link rod to disengge.! 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 bot control, resulting in serious injury or deth due to occupnts being thrown within or out of the bot. Alwys use required components nd follow instructions nd torque procedures. 96 eng

107 OUTBOARD INSTALLATION! WARNING Worn, loose, or seized steering components cn led to loss of bot control. Inspect ll steering ttchment components for wer, lubricte ll ttchment hrdwre, nd check ll fsteners for proper tightness in ccordnce with the inspection nd mintennce schedule. c d b Specil wsher hed bolt (P/N ) b - Nylon insert locknut (P/N ) used on hed bolt c - Flt wsher (2) d - Nylon insert locknut (P/N ) used on cble coupler 1. Assemble steering link rod to steering cble coupler with two flt wshers "c" nd self locking nylon insert locknut "d." Tighten the locknut until it sets, then loosen ¼ turn. 2. Assemble the steering link rod to the engine with the specil wsher hed bolt "" nd self locking nylon insert locknut "b." 3. Torque the hed bolt, then the locknut to specifictions. Description Nm lb in. lb ft Cble coupler nylon insert locknut "d" Tighten locknut until it sets, then loosen ¼ turn. Hed bolt nylon insert locknut "b" Specil wsher hed bolt eng 97

108 OUTBOARD INSTALLATION Recommended Mounting Height DETERMINING OUTBOARD MOUNTING HEIGHT FOR A STANDARD GEAR HOUSING 63.5 cm (25 in.) e 60.9 cm (24 in.) 58.4 cm (23 in.) c b 56.0 cm (22 in.) 53.3 cm (21 in.) e 50.8 cm (20 in.) 48.2 cm (19 in.) d Stndrd 20-inch (L) mounting brcket grph - The solid line is recommended to determine the outbord mounting height. b - The broken lines represent the extremes of known successful outbord mounting height dimensions. c - This line my be preferred to determine outbord mounting height dimension, if mximum speed is the only objective. d - This line my be preferred to determine outbord mounting height dimension for dul outbord instlltion. e - Outbord mounting height (height of outbord mounting brckets from bottom of bot trnsom). For heights over 56.0 cm (22 in.), propeller tht is designed for piercing the wter surfce is usully preferred. f - Mximum bot speed nticipted. f eng

109 NOTICE 1. The outbord should be mounted high enough on the trnsom so tht the exhust relief hole will sty t lest 25.4 mm (1 in.) bove the wterline when the engine is running t idle speed. Hving the exhust relief hole bove 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 outbord mounting heights. 3. The mounting height of the outbord must not exceed 63.5 cm (25 in.) for L models, 76 cm (30 in.) for XL models. Mounting the outbord higher my cuse dmge to the gercse components. Incresing the mounting height will usully: Reduce steering torque Increse top speed Increse bot stbility OUTBOARD INSTALLATION Cuse the propeller to brek loose during plning Drilling Outbord Mounting Holes IMPORTANT: Before drilling ny mounting holes, crefully red Determining Recommended Outbord Mounting Height nd instll outbord to the nerest recommended mounting height. 1. Mrk four mounting holes on the trnsom using the trnsom drilling fixture. b - Drill guide holes b - Trnsom drilling fixture c - Trnsom centerline c 2757 eng 99

110 OUTBOARD INSTALLATION Trnsom Drilling Fixture A2 Aids in engine instlltion by cting s templte for engine mounting holes Drill four 13.5 mm (17/32 in.) mounting holes Fstening the Outbord to the Trnsom MOUNTING BOLTS Outbord Trnsom Mounting Hrdwre Supplied with Outbord Prt Number Prt Nme Description 8M Outbord mounting bolt ½ 20 x 5.00 in. long (3.25 in. thred) Nylon insert locknut ½ Flt wsher 1.50 in. dimeter Flt wsher in. dimeter Avilble Outbord Mounting Bolts Prt Number Description ½ 20 x 2.50 in. long (1.25 in. thred) ½ 20 x 3.50 in. long (1.25 in. thred) ½ 20 x 4.00 in. long (2.25 in. thred) ½ 20 x 4.50 in. long (2.25 in. thred) 8M ½ 20 x 5.00 in. long (3.25 in. thred) 8M ½ 20 x 5.50 in. long (3.25 in. thred) ½ 20 x 6.50 in. long (2.75 in. thred) 8M ½ 20 x 7.50 in. long (2.75 in. thred) 100 eng

111 OUTBOARD INSTALLATION Prt Number 8M Avilble Outbord Mounting Bolts Description ½ 20 x 8.00 in. long (2.75 in. thred) CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the bot trnsom. The outbord mounting locknuts nd bolts should be ble to hold 75 Nm (55 lb ft) of torque without the bot trnsom yielding or crcking. If the bot trnsom yields or crcks under this torque, the construction of the trnsom my not be dequte. The bot trnsom must be strengthened or the lod crrying re incresed. b Trnsom yielding under bolt torque b - Trnsom crcking under bolt torque Use dil torque wrench to determine trnsom strength. If the bolt 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 be incresed by using lrger wsher or trnsom reinforcement plte. b Lrge trnsom wsher b - Trnsom reinforcement plte eng 101

112 OUTBOARD INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The trnsom mounting surfce must be flt within 3.17 mm (0.125 in.). No step in the trnsom mounting surfce is llowed. The inside trnsom mounting bolt wsher surfce must be flt within 3.17 mm (0.125 in.). b Step (not llowed) b - Gp between trnsom clmp nd bot trnsom (not llowed) 102 eng

113 OUTBOARD INSTALLATION IMPORTANT: Clernce must be mintined between the vessel trnsom nd the outbord trnsom brcket relief rdius re. Filure to mintin clernce my dmge the trnsom brcket nd cuse the trnsom brcket to fil. Adjustments to the position of the Mercury Mrine trnsom drilling fixture my be required to ensure proper clernce of the trnsom brcket relief rdius re Instlltion 1. Apply mrine seler to the shnks of the bolts, not to the threds. 2. Fsten the outbord with the correct mounting hrdwre. Tighten the locknuts to the specified torque. IMPORTANT: Ensure tht minimum of two full threds of the mounting bolts extend beyond the locknut fter tightening. The locknut must be drwn tight while still engging the bolt threds nd not contcting the shnk of the bolt. eng 103

114 OUTBOARD INSTALLATION NOTE: For more ccurte torque reding, tighten the mounting locknuts rther thn the outbord mounting bolts. d c e c b d in. dimeter outbord mounting bolt (4) b in. flt wsher (4) c - Nylon insert locknut (4) d in. flt wsher (4) e - Mrine seler pply to the shnk of the bolts, not the threds Description Nm lb in. lb ft Outbord mounting locknuts nd bolts stndrd bot trnsom Outbord mounting locknuts nd bolts metl lift pltes nd setbck brckets eng

115 OUTBOARD INSTALLATION A decl on the trnsom brcket reminds the owner to check the fsteners securing the outbord to the trnsom before ech use Decl on the trnsom brcket Electricl, Hoses, Control Cbles, nd Front Clmp REMOTE WIRING HARNESS Route the remote 14 pin bot hrness through the front clmp opening in the bottom cowl. Connect remote hrness to the 14 pin connector on the engine hrness pin connector BATTERY INFORMATION (DIESEL SPARK IGNITION MODEL) Do not use deep cycle btteries. This engine must use n AGM 31 series strting bttery with 1050 mrine crnking mps nd reserve cpcity of 105 mp hour rting. eng 105

116 OUTBOARD INSTALLATION When connecting the engine bttery, use hex nuts to secure the bttery leds to the bttery posts. Tighten the nuts to the specified torque. Description Nm lb in. lb ft Hex nuts A decl dvising ginst using deep cycle btteries nd wing nuts should be plced on or ner the bttery box for future service reference. One 5/16 in. nd one 3/8 in. hex nut is supplied per bttery for wing nut replcement. Metric hex nuts re not supplied. NOTICE DO NOT USE DEEP CYCLE BATTERIES! 13.5Nm (120 lb-in.) DO NOT USE WINGNUTS IMPORTANT: Refer to the outbord owner s mnul for bttery requirements. Bttery cble size nd length is criticl. Refer to engine instlltion mnul for size requirements. 8M Plce decl on or ner bttery box for future service reference. Included with the engine rigging components re 5/16" nd 3/8 hex nuts to be used for bttery terminl wing nut replcement. Metric hex nuts must be obtined loclly BATTERY CABLES IMPORTANT: This outbord requires the use of bttery cbles specified in the following tble. The bttery cble ends must be crimped onto the cble to ensure power trnsfer from the bttery to the engine. The vessel mnufcturer or instlling technicin is responsible for determining the bttery cble length nd prepring the bttery cble termintion t the engine side nd bttery side. AWG Required Bttery Cble Specifictions Mrine Wire Per SAE J378 nd J1127 Dimeter Turns of wire mm inch per cm per inch 00 (2/0)* * The closest metric equivlence is 70 mm eng

117 Bttery Cble Drwings OUTBOARD INSTALLATION b c d e Positive cble engine side - Ring terminl 2/0 guge, tin plted copper b - Eyelet 8 mm (0.313 in.) c - Red het shrink dhesive lined, 38 mm (1.5 in.), dielectric strength 700v/mil d - Red bttery cble e - 24 mm (0.95 in.) minimum b c d e Negtive cble engine side - Ring terminl 2/0 guge, tin plted copper b - Eyelet 8 mm (0.313 in.) c - Blck het shrink dhesive lined, 38 mm (1.5 in.), temperture rting 40 to 54 C ( 40 to 130 F) d - Blck bttery cble e - 24 mm (0.95 in.) minimum eng 107

118 Bttery Cble Preprtion OUTBOARD INSTALLATION 1. Remove the insultion from the end of the cble Instll the terminl protection boot on the positive bttery cble. 3. Slide shrink tubing over the cble. 4. Instll the cble ring terminl Ring terminl 5. Secure the ring terminl to the cble with the recommended crimp tool. NOTE: The crimp tool cn be purchsed loclly. 108 eng

119 OUTBOARD INSTALLATION IMPORTANT: The ring terminl must be secured to the cble with two crimps tht re offset. Crimping tool Correct crimp eng 109

120 OUTBOARD INSTALLATION 6. Slide the shrink tubing over the crimped re nd pply het to sel the crimp re nd prevent corrosion Shrink tubing BATTERY CABLE CONNECTIONS 1. Verify the terminl protection boot is instlled onto the positive (+) bttery cble. 2. Connect the positive (+) bttery cble to the engine power stud nd secure with lockwsher nd 8M nut. Tighten the nut to the specified torque. - Positive (+) bttery cble secured to the engine power stud b - Terminl protection boot b Description Nm lb in. lb ft M8 nut Apply Liquid Neoprene to the connection to prevent corrosion. 110 eng

121 OUTBOARD INSTALLATION Tube Ref No. 25 Liquid Neoprene Description Where Used Prt No. Bttery cble connections on power hed Allow the Liquid Neoprene to dry. Cover the connection with the terminl protection boot. 5. Instll the negtive bttery cble to the stud on the lower strter mount. Secure the bttery cble with wsher nd 8M flnge nut. Tighten the nut to the specified torque. Apply Liquid Neoprene to the connection to prevent corrosion. b Negtive bttery cble connection loction - Wsher b - 8M flnge nut Description Nm lb in. lb ft 8M nut Connecting the Bttery Route the bttery cbles through the rigging hose (if equipped) nd the cowl fitting. eng 111

122 OUTBOARD INSTALLATION NOTE: The rigging hose is removed from the following illustrtion for prt descriptions only. Mercury Mrine recommends routing ll wires, hoses, nd control cbles through rigging hose from the engine to the bot s gunnel or motor well. This helps protect components from wter contmintion. Follow the instructions included with the rigging hose kit to instll the rigging hose Bttery cbles Single Outbord (+) - Red sleeve positive (+) b - Blck sleeve negtive ( ) c - Crnking bttery b (-) c eng

123 Dul Outbords OUTBOARD INSTALLATION Connect common ground cble (wire size sme s engine bttery cbles) between the negtive ( ) terminls on strting btteries. b (-) d b c (-) d Red sleeve positive (+) b - Blck sleeve negtive ( ) c - Ground cble d - Crnking bttery HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside dimeter (I.D.) is 8 mm (5/16 in.), with seprte fuel line/fuel tnk pickup for ech engine. Fsten the remote fuel hose to the fitting with hose clmp. Oil Hoses Connect the remote oil hoses to the engine hose connections. Fsten hose connections with cble ties. Wter Pressure nd Speedometer Hose or Tubing NOTE: This pplies to models without SmrtCrft guges. eng 113

124 OUTBOARD INSTALLATION This outbord hs speedometer wter pickup locted in the leding edge of the gercse. If you wnt to use this wter pickup for the speedometer, disconnect the wter pickup tubing from the speedometer sensor nd route tubing out of the cowl. Instll the coupler provided with the outbord on the end of the tubing. Mke the wter pressure guge hose connection to the tubing s shown. c b j k l e d g f h i j k Wter pressure tube b - Speedometer wter pickup tube (if required) c - Coupler d - Plug e - Brb hose fitting f - Speedometer hose or tubing g - Wter pressure tube h - Remote fuel hose i - Hose clmp j - Oil hose with blue stripe k - Oil hose without blue stripe l - Cble tie INSTALLING THE SHIFT CABLE IMPORTANT: The shift cble is the first cble to move when the remote control hndle is moved out of neutrl, so instll/connect it to the engine first. 114 eng

125 OUTBOARD INSTALLATION Locting the Center Point of the Shift Cble IMPORTANT: Locte the center point of the slck or lost motion tht exists in the shift cble for proper djustment of the shift cble. 1. Mrk the forwrd position s follows:. Move the remote control hndle from neutrl into forwrd nd dvnce the hndle to the full speed position. Ensure the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the hndle bck to the neutrl detent position. c. Plce mrk on the shift cble ginst the cble end guide Forwrd position mrk 2. Mrk the reverse position s follows:. Move the remote control hndle into reverse nd dvnce the hndle to the full speed position. Ensure the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the hndle bck to the neutrl detent position. c. Plce mrk on the shift cble ginst the cble end guide Reverse position mrk eng 115

126 OUTBOARD INSTALLATION 3. Mrk the center on the shift cble midwy between the forwrd nd reverse mrks Center mrk 4. Align the cble end guide ginst this center mrk when instlling the cble to the engine. 5. Position the remote control nd outbord into neutrl position. 6. Slide the nchor pin forwrd until resistnce is felt, then slide the nchor pin towrd the rer until resistnce is felt. 7. Center the nchor pin between these resistnce points. - Anchor pin Adjusting the Shift Cble Align the shift cble end guide with the center mrk s instructed in Locting the Center Point of the Shift Cble Center mrk 2. Plce the shift cble end guide on the nchor pin nd djust the cble brrel so tht it slips freely into the brrel holder. 116 eng

127 OUTBOARD INSTALLATION 3. Secure the shift cble to the nchor pin with the retiner clip. c b Cble brrel b - Shift cble retiner c - Retiner clip 4. Check the shift cble djustments s follows:. Shift the remote control to forwrd while turning the propeller shft. If the propeller shft does not lock in ger, djust the cble brrel closer to the cble end guide. b. Shift the remote control into neutrl. If the propeller shft does not turn freely without drg, djust the brrel wy from the cble end guide. Repet steps nd b. c. Shift the remote control into reverse while turning the propeller shft. If the propeller shft does not lock solidly in ger, djust the brrel wy from the cble end guide. Repet steps through c. d. Return the remote control hndle to neutrl. If the propeller shft does not turn freely without drg, djust the brrel closer to the cble end guide. Repet steps through d. INSTALLING THE THROTTLE CABLE IMPORTANT: Attch the shift cble to the engine prior to ttching the throttle cble. 1. Shift the remote control into the neutrl position. 2. Attch the throttle cble to the throttle lever. Secure with wsher nd locknut. Tighten the locknut to the specified vlue. b - Nylon wsher b - Locknut 2678 eng 117

128 Description Nm lb in. lb ft Throttle cble locknut "b" OUTBOARD INSTALLATION Tighten, then loosen 1/4 turn 3. Adjust the cble brrel so the instlled throttle cble will hold the idle stop screw ginst the stop. c b Brrel sleeve b - Cble brrel c - Idle stop screw 4. Check the throttle cble djustment s follows:. Shift the outbord into ger few times to ctivte the throttle linkge. Rotte the propeller shft while shifting into reverse. b. Return the remote control to neutrl. c. Plce thin piece of pper between the idle djustment screw nd the idle stop. The djustment is correct when the pper cn be removed without tering, but hs some drg on it. IMPORTANT: The idle stop screw must be touching the stop. b - Idle stop screw b - Idle stop 2680 d. Adjust the cble brrel if necessry. 118 eng

129 OUTBOARD INSTALLATION 5. Lock the brrel holder in plce with the cble ltch BOTTOM COWL RIGGING TUBE Observe the following guidelines when instlling the rigging hose nd ssembling the bottom cowl: Follow the instructions in the rigging hose kit. Position the trnsom housing hed of the engine to crete sufficient slck in the wires, hoses, nd control cbles routed through the rigging hose. Position the rigging hose to llow lrge, sweeping bends during steering. Ensure enough slck exists throughout the full trim nd steering rnges. Choose n unobstructed pth for the wires, hoses, nd control cbles. Mke the pth s stright s possible with no shrp bends. 1. Route ll wires, hoses, nd control cbles through the rigging hose nd cowl coupler. 2. Attch the cowl coupler to the bottom cowl s follows: eng 119

130 OUTBOARD INSTALLATION. With one hnd supporting the rigging hose, tilt the cowl coupler up t 30 ngle s shown. b - Cowl coupler tilted up b - One hnd supports the rigging hose 2708 NOTE: If necessry, loosen the rigging hose from the coupler to lign the coupler with the cowl. 120 eng

131 OUTBOARD INSTALLATION b. Align the tb on the coupler with the notch on the cowl. Tilt the coupler down nd ttch the coupler to the cowl. Ensure the tb engges with the notch in the cowl nd tht the coupler is flush with the bottom cowl. b - Coupler tb nd cowl notches engged b - Coupler flush with bottom cowl 2709 c. Lower the rigging brcket over the wires, hoses, nd control cbles. eng 121

132 OUTBOARD INSTALLATION d. Instll the brcket between the slots on the coupler nd lign the mounting holes. c d b Rigging brcket b - Mounting holes c - Slots d - Cowl coupling e. Secure the brcket with three mounting screws. Tighten the screws securely. b - Screws (3) b - Brcket c - Cowl coupler c eng