Operation Maintenance and Installation Manual

Transcription

1 2017 Mercury Mrine CT, 40, 60 SePro Opertion Mintennce nd Instlltion Mnul 8M eng

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3 Welcome You hve selected one of the finest mrine power pckges 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. The Opertion nd Mintennce Mnul contins specific instructions for using nd mintining your product. We suggest 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, Fond du Lc, Wisconsin, U.S.A. Nme / function: John Pfeifer, President, Mercury Mrine Red This Mnul Thoroughly IMPORTANT: If you do not understnd ny portion of this mnul, contct your deler. Your deler cn lso provide demonstrtion of ctul strting nd operting procedures. Notice Throughout this publiction, nd on your power pckge, wrnings, cutions, nd notices, ccompnied by the Interntionl Hzrd Symbol!, my be used to lert the instller nd user to specil instructions concerning prticulr service or opertion tht my be hzrdous if performed incorrectly or crelessly. Observe them crefully. These sfety lerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! 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. eng i

4 NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. IMPORTANT: Identifies informtion essentil to the successful completion of the tsk. NOTE: Indictes informtion tht helps in the understnding of prticulr step or ction. IMPORTANT: The opertor (driver) is responsible for the correct nd sfe opertion of the bot, the equipment bord, nd the sfety of ll occupnts bord. We strongly recommend tht the opertor red this Opertion nd Mintennce Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories before the bot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, birth defects or other reproductive hrm. The seril numbers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Mrine power pckge. When contcting Mercury Mrine bout service, lwys specify model nd seril numbers. Descriptions nd specifictions contined herein were in effect t the time this ws pproved for printing. Mercury Mrine, whose policies re bsed on continuous improvement, reserves the right to discontinue models t ny time or to chnge specifictions or designs without notice nd without incurring obligtion. 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 Mnul included with the product. The Wrrnty Mnul 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 importnt informtion. Mercury Mrine products re designed nd mnufctured to comply with our own high qulity stndrds, pplicble industry stndrds nd regultions, s well s certin emissions regultions. At Mercury Mrine every engine is operted nd tested before it is boxed for shipment to mke sure tht the product is redy for use. In ddition, certin Mercury Mrine products re tested in controlled nd monitored environment, for up to 10 hours of engine run time, in order to verify nd mke record of complince with pplicble stndrds nd regultions. All Mercury Mrine product, sold s new, receives the pplicble limited wrrnty coverge, whether the engine prticipted in one of the test progrms described bove or not. ii eng

5 Copyright nd Trdemrk Informtion MERCURY MARINE. All rights reserved. Reproduction in whole or in prt without permission is prohibited. Alph, Axius, Brvo One, Brvo Two, Brvo Three, GO BOLDLY., 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. Identifiction Records Plese record the following pplicble informtion: Engine Model nd Horsepower Engine Seril Number Ger Rtio Outbord Propeller Number Pitch Dimeter Hull Identifiction Number (HIN) Purchse Dte Bot Mnufcturer Bot Model Length Exhust Gs Emissions Certifiction Number (Europe Only) eng iii

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7 Generl Informtion Boter's Responsibilities... 1 Before Operting Your Outbord... 1 Bot Horsepower Cpcity... 1 High Speed nd High Performnce Bot Opertion... 2 Outbord Remote Control Models... 2 Remote Steering Notice...3 Lnyrd Stop Switch... 3 Protecting People in the Wter... 6 Pssenger Sfety Messge Pontoon Bots nd Deck Bots...6 Wve nd Wke Jumping... 8 Impct with Underwter Hzrds...8 Exhust Emissions Selecting Accessories for Your Outbord Sfe Boting Recommendtions Recording Seril Number /50/60 FourStroke Specifictions , 60 SePro Specifictions...17 Component Identifiction Trnsporttion Trilering Bot/Outbord Trnsporting Portble Fuel Tnks Fuel nd Oil Fuel Requirements Low Permetion Fuel Hose Requirement EPA Pressurized Portble Fuel Tnk Requirements Fuel Demnd Vlve (FDV) Requirement Mercury Mrine's Pressurized Portble Fuel Tnk Filling Fuel Tnk Engine Oil Recommendtions Checking nd Adding Engine Oil eng v

8 Fetures nd Controls Remote Control Fetures Wrning System Power Trim nd Tilt...30 Throttle Grip Friction Adjustment Tiller Hndle Models Steering Friction Adjustment Tiller Hndle Models Trim Tb Adjustment Opertion Importnt Dily Inspection Before Ech Use Prestrting Check List...36 Operting in Freezing Tempertures Operting in Sltwter or Polluted Wter Prestrting Instructions Engine Brek in Procedure...38 Strting the Engine Remote Control Models Strting the Engine Tiller Hndle Models Ger Shifting Stopping the Engine Emergency Strting vi eng

9 Mintennce Clening Cre Recommendtions EPA Emissions Regultions Inspection nd Mintennce Schedule Flushing the Cooling System Top Cowl Removl nd Instlltion Exterior Cre...52 Bttery Inspection Fuel System Steering Link Rod Fsteners Corrosion Control Anode Propeller Replcement Stndrd Gercse Propeller Replcement Commnd Thrust Gercse Sprk Plug Inspection nd Replcement...63 Fuse Replcement...64 Timing Belt Inspection Lubriction Points Checking Power Trim Fluid...67 Chnging Engine Oil Gercse Lubricnt Submerged Outbord Storge Storge Preprtion...74 Protecting Externl Outbord Components Protecting Internl Engine Components Gercse Positioning Outbord for Storge Bttery Storge Troubleshooting Strter Motor Will Not Crnk the Engine (Electric Strt Models) Engine Will Not Strt...76 Engine Runs Errticlly Performnce Loss...77 Bttery Will Not Hold Chrge eng vii

10 Owner Service Assistnce Service Assistnce Ordering Literture...80 Instlltion Mercury Mrine Vlidted Engine Mounting Hrdwre Accessories Mounted to the Trnsom Clmp Brcket Instlltion Informtion...86 Fuel Hose Connection Remote Control Models Electricl Connections nd Control Cble Instlltion Propeller Instlltion Trim Tb Adjustment Trim In Stop Adjustment Power Trim Models Mintennce Log Mintennce Log viii eng

11 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. Sfety nd operting informtion tht is prcticed, long with using good common sense, cn help prevent personl injury nd product dmge. This mnul s well s sfety lbels posted on the outbord use the following sfety lerts to drw your ttention to specil sfety instructions tht should be followed.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. Bot Horsepower Cpcity! WARNING Exceeding the 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 1

12 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

13 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 3

14 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. 4 eng

15 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 5

16 Protecting People in the Wter WHILE YOU ARE CRUISING GENERAL INFORMATION It is very difficult for person stnding or floting in the wter to tke quick ction to void bot heding in his/her direction, even t slow speed Alwys slow down nd exercise extreme cution ny time you re boting in n re where there might be people in the wter. Whenever bot is moving (costing) nd the outbord ger shift is in neutrl position, there is sufficient force by the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. WHILE THE 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 the outbord into neutrl nd shut off the engine before llowing people to swim or be in the wter ner your bot. 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. 6 eng

17 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 7

18 Wve nd Wke Jumping GENERAL INFORMATION Operting recretionl bots over wves nd wke is nturl prt of boting. However, when this ctivity is done with sufficient speed to force the bot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the bot enters the wter The primry concern is the bot chnging direction while in the midst of the jump. In such cse, the lnding my cuse the bot to veer violently in new direction. Such shrp chnge in direction cn cuse occupnts to be thrown out of their sets, or out of the bot.! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts being thrown within or out of the bot. Avoid wve or wke jumping whenever possible. There is nother less common hzrdous result from llowing your bot to lunch off wve or wke. If the bow of your bot pitches down fr enough while irborne, upon wter contct it my penetrte under the wter surfce nd submrine for n instnt. This will bring the bot to nerly instntneous stop nd cn send the occupnts flying forwrd. The bot my lso steer shrply to one side. Impct with Underwter Hzrds Your outbord is equipped with hydrulic trim nd tilt system tht lso contins shock bsorbing feture. This feture helps the outbord withstnd dmge in the cse of impct with n underwter object t low to moderte speeds. At higher speeds, the force of the impct my exceed the system s bility to bsorb the energy of the impct nd cuse serious product dmge. No impct protection exists while in reverse. Use extreme cution when operting in reverse to void striking underwter objects. 8 eng

19 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 tht could be struck by the outbord or the bot bottom. The most significnt ction you cn tke 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 the minimum plning speed, typiclly 24 to 40 km/h (15 to 25 mph) ! WARNING Avoid serious injury or deth from ll or prt of n outbord or drive unit coming into the bot fter striking floting or underwter object. When operting in wters where objects my be t the surfce or just under the surfce of the wter, reduce your speed nd keep vigilnt lookout. Exmples of objects tht cn cuse engine dmge re dredging pipes, bridge supports, wing dms, trees, stumps, nd rocks. Striking floting or underwter object could result in ny of n infinite number of situtions. Some of these situtions could yield 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. A shrp chnge in direction cn cuse occupnts to be thrown out of their sets or out of the bot. The bot's speed could rpidly reduce. This will cuse occupnts to be thrown forwrd or even out of the bot. The outbord or bot could sustin impct dmge. 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. If wter leks re discovered fter n impct, immeditely ctivte the bilge pump. eng 9

20 Operting dmged outbord could cuse dditionl dmge to other prts of the outbord or could ffect control of the bot. If continued running is necessry, do so t gretly reduced speeds.! WARNING 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or crgo should occupy the re directly in front of the outbord while the bot is in motion. If n underwter obstcle is struck, the outbord will tilt up nd could seriously injure nyone occupying this re. Models with Clmp Screws: Some outbords come with trnsom brcket clmp screws. The use of clmp brcket screws lone, is insufficient to properly nd sfely secure the outbord to the trnsom. Proper instlltion of the outbord includes bolting the engine to the bot through the trnsom. Refer to Instlltion Instlling Outbord for more complete instlltion informtion.! WARNING Filure to correctly fsten the outbord could result in the outbord propelling off the bot trnsom resulting in property dmge, serious injury, or deth. Before opertion, the outbord must be correctly instlled with the required mounting hrdwre. If n obstcle is struck t plning speed nd the outbord is not securely fstened to the trnsom, it is possible the outbord could lift off the trnsom nd lnd in the bot. Exhust Emissions GENERAL INFORMATION 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. 10 eng

21 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 co co co co co co co co co co co co co co co co co co co co 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 11

22 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) 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. Acquire nd red the instlltion, opertion nd mintennce mnuls for ll your selected ccessories. 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. 12 eng

23 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 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. GENERAL INFORMATION 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. eng 13

24 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. 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. 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 14 eng

25 - 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. 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. Model Number XXXXXXX Seril Number XXXXX XL XX XXXX XXX HP XXX KW XXX LB XXX KG XXX H Me PL rc ury Mrine Brunswick Corp. Mde in Jpn B c b Seril number b - Model designtion c - Certified Europe Insigni (s pplicble) 40/50/60 FourStroke Specifictions Models Horsepower Kilowtts Full throttle RPM rnge RPM Number of cylinders 4 Idle speed in forwrd ger Piston displcement Cylinder bore Stroke Recommended sprk plug Sprk plug gp Controlled by ECM 995 cc (60.8 in³) 65 mm (2.559 in.) 75 mm (2.953 in.) Chmpion RA8HC 1.0 mm (0.040 in.) eng 15

26 GENERAL INFORMATION Models Ger rtio Gercse lubricnt cpcity Stndrd gercse Commnd Thrust gercse Stndrd gercse Recommended gsoline Recommended oil Engine oil cpcity Bttery rting* Emission control system Commnd Thrust gercse Opertion bove 0 C (32 F) Opertion below 0 C (32 F) Sound t drivers er (ICOMIA 39 94) dba Tiller hndle vibrtion (ICOMIA 38 94) m/s² 1.83:1 2.33:1 340 ml (11.5 fl oz) 710 ml (24.0 fl oz) Refer to Fuel nd Oil Refer to Fuel nd Oil 3.0 liter (3 US qt) 465 mrine crnking mps (MCA), 350 cold crnking mps (CCA), 70 mp hour (Ah) 1000 mrine crnking mps (MCA), 750 cold crnking mps (CCA), 100 mp hour (Ah) Electronic engine control (EC) 81.1 *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 eng

27 40, 60 SePro Specifictions Models Horsepower Kilowtts Full throttle RPM rnge RPM Number of cylinders 4 Idle speed in forwrd ger Piston displcement Cylinder bore Stroke Recommended sprk plug Sprk plug gp Controlled by ECM 995 cc (60.8 in³) 65 mm (2.559 in.) 75 mm (2.953 in.) Chmpion RA8HC 1.0 mm (0.040 in.) Ger rtio 2.33:1 Gercse lubricnt cpcity Recommended gsoline Recommended oil Engine oil cpcity Bttery rting* Opertion bove 0 C (32 F) Opertion below 0 C (32 F) Emission control system Sound t drivers er (ICOMIA 39 94) dba Tiller hndle vibrtion (ICOMIA 38 94) m/s² GENERAL INFORMATION 710 ml (24.0 fl oz) Refer to Fuel nd Oil Refer to Fuel nd Oil 3.0 liter (3 US qt) 465 mrine crnking mps (MCA), 350 cold crnking mps (CCA), 70 mp hour (Ah) 1000 mrine crnking mps (MCA), 750 cold crnking mps (CCA), 100 mp hour (Ah) Electronic engine control (EC) 81.1 *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. 3.3 eng 17

28 Component Identifiction GENERAL INFORMATION b c d e f l k j i h g m n o p q Auxiliry tilt switch b - Tilt support knob c - Trnsom brckets d - Oil drin plug e - Primry cooling wter intke f - Gercse g - Trim tb h - Anti ventiltion plte i - Driveshft housing j - Wter pump indictor hole k - Bottom cowl l - Top cowl m - Shift hndle n - Engine stop switch o - Throttle friction djustment knob p - Lnyrd stop switch q - Steering friction djustment lever (tiller hndle models) 18 eng

29 Trilering Bot/Outbord TRANSPORTATION 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. Trnsporting Portble Fuel Tnks! WARNING Avoid serious injury or deth from gsoline fire or explosion. Follow the trnsporting instructions supplied with the portble fuel tnk. Trnsport the fuel tnk in well ventilted re wy from open flme or sprks. MANUAL VENTING TYPE FUEL TANK Close the fuel tnk ir vent when trnsporting tnk. This will prevent escpe of fuel or vpors from tnk eng 19

30 AUTO-VENTING TYPE FUEL TANK TRANSPORTATION 1. Disconnect the remote fuel line from tnk. This will close the ir vent nd prevent escpe of fuel or vpors from tnk. 2. Instll tether cp over the fuel line connector stem. This will protect the connector stem from being ccidentlly pushed in, llowing fuel or vpor to escpe. - Connector stem b - Tether cp F b eng

31 Fuel Requirements IMPORTANT: Use of improper gsoline cn dmge your engine. Engine dmge resulting from the use of improper gsoline is considered misuse of the engine nd will not be covered under the limited wrrnty. FUEL RATINGS Mercury outbord engines will operte stisfctorily with ny mjor brnd of unleded gsoline tht meets the following specifictions: USA nd Cnd A posted pump octne rting of 87 (R+M)/2, minimum, for most models. Premium gsoline 91 (R+M)/2 octne is lso cceptble for most models. Do not use leded gsoline. Outside USA nd Cnd A posted pump octne rting of 91 RON, minimum, for most models. Premium gsoline (95 RON) is lso cceptble for ll models. Do not use leded gsoline. USING REFORMULATED (OXYGENATED) GASOLINE (USA ONLY) Reformulted gsoline is required in certin res of the USA nd is cceptble for use in your Mercury Mrine engine. The only oxygente currently in use in the USA is lcohol (ethnol, methnol, or butnol). GASOLINE CONTAINING ALCOHOL Bu16 Butnol Fuel Blends Fuel blends of up to 16.1% butnol (Bu16) tht meet the published Mercury Mrine fuel rting requirements re n cceptble substitute for unleded gsoline. Contct your bot mnufcturer for specific recommendtions on your bot's fuel system components (fuel tnks, fuel lines, nd fittings). Methnol nd Ethnol Fuel Blends IMPORTANT: The fuel system components on your Mercury Mrine engine will withstnd up to 10% lcohol (methnol or ethnol) content in the gsoline. Your bot's fuel system my not be cpble of withstnding the sme percentge of lcohol. Contct your bot mnufcturer for specific recommendtions on your bot's fuel system components (fuel tnks, fuel lines, nd fittings). Be wre tht gsoline contining methnol or ethnol my cuse incresed: Corrosion of metl prts FUEL AND OIL Deteriortion of rubber or plstic prts Fuel permetion through the rubber fuel lines Likelihood of phse seprtion (wter nd lcohol seprting from the gsoline in the fuel tnk) eng 21

32 FUEL AND OIL! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement before further engine opertion. IMPORTANT: If you use gsoline tht contins or might contin methnol or ethnol, you must increse the frequency of inspection for leks nd bnormlities. IMPORTANT: When operting Mercury Mrine engine on gsoline contining methnol or ethnol, do not store the gsoline in the fuel tnk for long periods. Crs normlly consume these blended fuels before they cn bsorb enough moisture to cuse trouble; bots often sit idle long enough for phse seprtion to tke plce. Internl corrosion my occur during storge if lcohol hs wshed protective oil films from internl components. 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. EPA Pressurized Portble Fuel Tnk 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 Demnd Vlve (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. 22 eng

33 FUEL AND OIL 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. 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 Mercury Mrine's Pressurized Portble Fuel Tnk Mercury Mrine hs creted new portble pressurized fuel tnk tht meets the preceding EPA requirements. These fuel tnks re vilble s n ccessory or re provided with certin portble outbord models. SPECIAL FEATURES OF THE PORTABLE FUEL TANK The fuel tnk hs two wy vlve which llows ir to enter the tnk s the fuel is drwn to the engine, nd lso opens to vent to the tmosphere if internl pressure in the tnk exceeds 34.4 kp (5.0 psi). A hissing noise my be herd s the tnk vents to the tmosphere. This is norml. The fuel tnk includes fuel demnd vlve tht prevents pressurized fuel from entering the engine nd cusing fuel system overflow or possible fuel spillge. When instlling the fuel tnk cp, turn the cp to the right until you her click. This signls tht the fuel cp is fully seted. A built in device prevents overtightening. The fuel tnk hs mnul vent screw which should be closed for trnsporttion nd open for opertion nd cp removl. Since seled fuel tnks re not vented, they will expnd nd contrct s the fuel expnds nd contrcts during heting nd cooling cycles of the outside ir. This is norml. REMOVING THE FUEL CAP b - Fuel cp b - Mnul vent screw c - Tb lock IMPORTANT: Contents my be under pressure. Rotte the fuel cp 1/4 turn to relieve pressure before opening. c eng 23

34 1. Open the mnul vent screw on top of the fuel cp. 2. Turn the fuel cp until it contcts the tb lock. 3. Press down on the tb lock. Rotte the fuel cp 1/4 turn to relieve the pressure. 4. Press down on the tb lock gin nd remove the cp. DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. When instlling the fuel tnk cp, turn the cp to the right until you her click. This signls tht the fuel cp is fully seted. A built in device prevents overtightening. 2. Open the mnul vent screw on top of the cp for opertion nd cp removl. Close the mnul vent screw for trnsporttion. 3. For fuel hoses tht hve quick disconnects, disconnect the fuel line from the engine or fuel tnk when not in use. 4. Follow Filling Fuel Tnk instructions for fueling. Filling Fuel Tnk! WARNING Avoid serious injury or deth from gsoline fire or explosion. Use cution when filling fuel tnks. Alwys stop the engine nd do not smoke or llow open flmes or sprks in the re while filling fuel tnks. Fill the fuel tnks outdoors wy from het, sprks, nd open flmes. Remove the portble fuel tnks from the bot to fill them. Alwys stop the engine before filling the tnks. Do not completely fill the fuel tnks. Leve pproximtely 10% of the tnk volume unfilled. Fuel will expnd in volume s its temperture rises nd cn lek under pressure if the tnk is completely filled. PORTABLE FUEL TANK PLACEMENT IN THE BOAT Plce the fuel tnk in the bot so the vent is higher thn the fuel level under norml bot operting conditions. Engine Oil Recommendtions FUEL AND OIL Mercury or Quicksilver NMMA FC W certified SAE 10W 30 4 Stroke Mrine Engine Oil is recommended for generl, ll temperture use. If NMMA certified synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W 40 Synthetic Blend Mrine 4 Stroke Engine Oil. If the recommended Mercury or Quicksilver NMMA FC W certified outbord oils re not vilble, mjor FC W certified 4 stroke outbord oil my be used. 24 eng

35 FUEL AND OIL IMPORTANT: The use of nondetergent oils, multi viscosity oils (other thn Mercury or Quicksilver NMMA FC W certified oil or mjor brnd NMMA FC W certified oil), synthetic oils, low qulity or oils tht contin solid dditives re not recommended. F C b Recommended SAE viscosity for engine oil - Mercury or Quicksilver SAE 25W 40 Synthetic Blend Mrine 4 Stroke Engine Oil my be used t tempertures bove 4 C (40 F) b - Mercury or Quicksilver SAE 10W 30 4 Stroke Mrine Engine Oil is recommended for use in ll tempertures Checking nd Adding Engine Oil IMPORTANT: Do not overfill. Be sure tht the outbord is upright (not tilted) when checking oil. 1. Turn the engine off. Hve the outbord in level operting position. Remove the top cowl. 2. Flip the hndle up nd pull out the dipstick. Wipe it with clen rg or towel nd push it bck in ll the wy. 3. Pull the dipstick bck out gin nd observe the oil level. If the oil level is low, remove the oil filler cp nd fill to (but not over) the upper oil level with the recommended oil. IMPORTANT: Inspect oil for signs of contmintion. Oil contminted with wter will hve milky color to it; oil contminted with fuel will hve strong fuel smell. If contminted oil is noticed, hve the engine checked by your deler. eng 25

36 FUEL AND OIL 4. Push the dipstick bck in ll the wy, then flip the hndle down to lock the dipstick in plce. Reinstll the oil filler cp nd hnd tighten securely. c d b Full mrk b - Add mrk c - Dipstick d - Oil filler cp 26 eng

37 FEATURES AND CONTROLS Remote Control Fetures Your bot my be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your deler for description of the functions nd opertions of the remote control. f c b c h g b i i c e d d e f g f Control hndle forwrd, neutrl, reverse b - Neutrl relese lever c - Trim/tilt switch (if equipped) Refer to Fetures nd Controls Power Trim nd Tilt d - Lnyrd stop switch Refer to Generl Informtion Lnyrd Stop Switch e - Lnyrd Refer to Generl Informtion Lnyrd Stop Switch f - Throttle friction djustment Console controls require cover removl for djustment g - Ignition key switch "OFF," "ON," START" h - Fst idle lever Refer to Opertion Strting the Engine i - Throttle only button Refer to Opertion Strting the Engine eng 27

38 Wrning System WARNING HORN SIGNALS FEATURES AND CONTROLS The outbord wrning system incorportes wrning horn inside the bot. Remote control models will hve the wrning horn locted inside the remote control or connected to the ignition key switch. Tiller hndle models will hve the wrning horn locted in the ignition key pnel. b c Horn inside remote control b - Horn connected to ignition key switch c - Horn in ignition key pnel 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 its 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. The opertor is ble to correct couple engine problems indicted by the wrning horn. These conditions re s follows: Cooling system (wter pressure or engine temperture) problem. The wrning horn will sound Intermittent short beeps for six seconds. Stop the engine nd check the wter intke holes in the gercse for obstruction. Low oil pressure problem. The wrning horn will sound continuous six second beep. Stop the engine nd check for low engine oil level. Refer to Fuel nd Oil Checking nd Adding Engine Oil. 28 eng

39 FEATURES AND CONTROLS 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 the Gurdin System hs been ctivted, reduce throttle speed. The problem will need to be identified nd corrected, if possible. 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 system. SMARTCRAFT PRODUCT 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. The SmrtCrft instrument pckge will lso id in Engine Gurdin dignostics. The SmrtCrft Instrument pckge will disply criticl engine lrm dt nd potentil problems. eng 29

40 Power Trim nd Tilt Your outbord hs trim/tilt control clled power trim. This enbles the opertor to esily djust the position of the outbord by pressing the trim switch. Moving the outbord in closer to the bot trnsom is clled trimming in or down. Moving the outbord further wy from the bot trnsom is clled trimming out or up. The term trim generlly refers to the djustment of the outbord within the first 20 rnge of trvel. This is the rnge used while operting your bot on plne. The term tilt is generlly used when referring 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. b FEATURES AND CONTROLS - Remote control trim switch b - Pnel mount trim switch c - Tilt rnge of trvel d - Trim rnge of trvel POWER TRIM OPERATION With most bots, operting round the middle of the trim rnge will give stisfctory results. However, to tke full dvntge of the trimming cpbility there my be times when you choose to trim your outbord ll the wy in or out. Along with n improvement in some performnce spects comes greter responsibility for the opertor, nd this is being wre of some potentil control hzrds. The most significnt control hzrd is pull or torque tht is felt on the steering wheel or tiller hndle. This steering torque results from the outbord trimmed so tht the propeller shft is not prllel to the wter surfce.! 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. c d eng

41 Trimming in or down cn: Lower the bow Result in quicker plning off, especilly with hevy lod or stern hevy bot Generlly improve the ride in choppy wter Increse steering torque or pull to the right (with the norml right hnd rottion propeller) In excess, cn lower the bow of some bots to point where they begin to plow with their bow in the wter while on plne. This cn result in n unexpected turn in either direction (clled bow steering or oversteering) if ny turn is ttempted, or if significnt wve is encountered.! 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. In rre circumstnces, the owner my decide to limit the trim in. This is ccomplished by repositioning the tilt stop pins into the desired djustment holes in the trnsom brckets. Trimming out or up cn: Lift the bow higher out of the wter Generlly increse top speed Increse clernce over submerged objects or shllow bottom Increse steering torque or pull to the left t norml instlltion height (with the norml right hnd rottion propeller) In excess, cn cuse bot porpoising (bouncing) or propeller ventiltion Cuse engine overheting if ny cooling wter intke holes re bove the wterline TILTING OPERATION FEATURES AND CONTROLS To tilt outbord, shut off the engine nd press the trim/tilt switch or uxiliry tilt switch to the up position. The outbord will tilt up until the switch is relesed or it reches its mximum tilt position. 1. Press the knob in nd rotte it to engge the tilt support lever. 2. Lower outbord to rest on the tilt support lever. eng 31

42 FEATURES AND CONTROLS 3. To disengge the tilt support lever, rise the outbord off the support lever nd rotte the lever down. Lower the outbord. - Tilt support lever b - Knob b MANUAL TILTING If the outbord cnnot be tilted using the power trim/tilt switch, the outbord cn be mnully tilted. 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 The uxiliry tilt switch cn be used to tilt the outbord up or down using the power trim system. - Auxiliry tilt switch eng

43 FEATURES AND CONTROLS SHALLOW WATER OPERATION When operting the bot in shllow wter, the outbord cn be tilted beyond the mximum trim rnge to prevent hitting bottom. 1. Reduce engine speed below 2000 RPM Tilt outbord up, keeping the wter intke holes submerged t ll times. 3. Operte the engine t slow speed only. If engine speed exceeds 2000 RPM, the outbord will utomticlly return down to the mximum trim rnge. Throttle Grip Friction Adjustment Tiller Hndle Models Throttle grip friction knob Turn friction knob to set nd mintin the throttle t desired speed. Turn knob clockwise to tighten friction nd turn knob counterclockwise to loosen friction. b - Loosen friction b - Tighten friction Steering Friction Adjustment Tiller Hndle Models NOTE: Steering friction djustment is only provided on models with tiller hndles. Adjust this lever to chieve the desired steering friction (drg) on the tiller hndle. Move lever to the left to tighten friction or move to the right to loosen friction. eng 33

44 FEATURES AND CONTROLS NOTE: To mintin proper djustment, the locknut locted on top of the steering friction lever pivot shft cn be tightened. - Tighten friction b - Loosen friction c - Locknut c b 26811! WARNING Insufficient friction djustment cn cuse serious injury or deth due to loss of bot control. When setting the friction djustment, mintin sufficient steering friction to prevent the outbord from steering into full turn if the tiller hndle is relesed. Trim Tb Adjustment Propeller steering torque will cuse your bot to pull in one direction. This steering torque is norml result from your outbord not trimmed with the propeller shft prllel to the wter surfce. The trim tb cn help to compenste for this steering torque in mny cses nd cn be djusted within limits to reduce ny unequl steering effort NOTE: Trim tb djustment will hve little effect reducing steering torque if the outbord is instlled with the nti ventiltion plte pproximtely 50 mm (2 in.) or more bove the bot bottom. MODELS WITHOUT POWER TRIM Operte your bot t norml cruising speed trimmed to desired position by instlling the tilt pin in the desired tilt pin hole. Turn your bot left nd right nd note the direction the bot turns more esily. 34 eng

45 FEATURES AND CONTROLS If djustment is necessry, loosen trim tb bolt nd mke smll djustments t time. If the bot turns more esily to the left, move the triling edge of trim tb to the left. If the bot turns more esily to the right, move the triling edge of trim tb to the right. Retighten bolt nd retest. MODELS WITH POWER TRIM Operte your bot t norml cruising speed, trimmed to desired position. Turn your bot left nd right nd note the direction the bot turns more esily. If djustment is necessry, loosen trim tb bolt nd mke smll djustments t time. If the bot turns more esily to the left, move the triling edge of trim tb to the left. If the bot turns more esily to the right, move the triling edge of trim tb to the right. Retighten bolt nd retest. eng 35

46 OPERATION Importnt Dily Inspection Before Ech 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. Prestrting Check List Decl on the trnsom brcket Opertor knows sfe nvigtion, boting, nd operting procedures. An pproved personl flottion device of suitble size for ech person bord nd redily ccessible (it is the lw). A ring type life buoy or buoynt cushion designed to be thrown to person in the wter. Know your bots' mximum lod cpcity. Look t the bot cpcity plte. Fuel supply OK. Arrnge pssengers nd lod in the bot so the weight is distributed evenly nd everyone is seted in proper set. Tell someone where you re going nd when you expect to return. It is illegl to operte bot while under the influence of lcohol or drugs. Know the wters nd re you will be boting; tides, currents, snd brs, rocks, nd other hzrds. Mke inspection checks listed in Mintennce Inspection nd Mintennce Schedule. 36 eng

47 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. 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. Prestrting Instructions 1. Check the engine oil level. OPERATION Mke sure the cooling wter intke is submerged. eng 37

48 OPERATION 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 Engine Brek in Procedure 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. 1. For the first hour of opertion, run the engine t vried throttle settings up to 3500 RPM or t pproximtely hlf throttle. 2. For the second hour of opertion, run the engine t vried throttle settings up to 4500 RPM or t three qurter throttle, nd during this period of time, run it t full throttle for pproximtely one minute every ten minutes. 3. For the next eight hours of opertion, void continuous opertion t full throttle for more thn five minutes t time. Strting the Engine Remote Control Models Before strting, red the Prestrting Check List, specil operting instructions, nd Engine Brek in Procedure in the Opertion section. 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. 1. Open fuel tnk vent screw (in filler cp) on mnul venting type fuel tnks eng

49 OPERATION 2. Position the fuel line primer bulb so the rrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb severl times until it feels firm Set the lnyrd stop switch to "RUN" position. Refer to Generl Informtion Lnyrd Stop Switch Shift outbord to neutrl ("N") position. N eng 39

50 OPERATION 5. Move the throttle only lever to the fully closed position or press the throttle only button. b b Fully closed position b - Mximum fst idle speed position 6. Strting flooded engine Advnce the throttle only lever or control hndle to the mximum throttle only position nd continue to crnk the engine for strting. Immeditely reduce engine speed fter engine strts. 7. Turn ignition key to the "START" position. If the engine fils to strt in ten seconds, return the key to the "ON" position, wit 30 seconds nd try gin After engine strts, check for stedy strem of wter flowing out of the wter pump indictor hole IMPORTANT: If no wter is coming out of the wter pump indictor hole, stop engine nd check cooling wter intke for obstruction. No obstruction my indicte wter pump filure or blockge in the cooling system. These conditions will cuse the engine to overhet. Hve the outbord checked by your deler. Operting the engine while overheted will cuse engine dmge. 40 eng

51 WARMING UP ENGINE OPERATION Before beginning opertion, llow the engine to wrm up t idling speed for three minutes. Strting the Engine Tiller Hndle Models Before strting, red the Prestrting Check List, specil operting instructions, nd Engine Brek in Procedure in the Opertion section. 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. 1. Open fuel tnk vent screw (in filler cp) on mnul venting type fuel tnks Connect the remote fuel line to the outbord. Mke sure the connector is snpped into plce Position the fuel line primer bulb so the rrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb severl times until it feels firm eng 41

52 OPERATION 4. Set the lnyrd stop switch to "RUN" position. Refer to Generl Informtion Lnyrd Stop Switch Shift outbord to neutrl ("N") position. N 6. Set the throttle grip to strt position Strting flooded engine Set the throttle grip to hlf wy position. 0%100 b 0%100 START START START START Strt position b - Hlf wy position 8. Turn the ignition key to the "START" position. If the engine fils to strt in ten seconds, return the key to the "ON" position, wit 30 seconds nd try gin eng

53 OPERATION! WARNING Rpid ccelertion cn result in serious injury or deth from being thrown within or out of the bot. Decrese engine speed before shifting into ger. 9. Check for stedy strem of wter flowing out of the wter pump indictor hole IMPORTANT: If no wter is coming out of the wter pump indictor hole, stop engine nd check cooling wter intke for obstruction. No obstruction my indicte wter pump filure or blockge in the cooling system. These conditions will cuse the engine to overhet. Hve the outbord checked by your deler. Operting the engine while overheted my cuse serious engine dmge. WARMING UP ENGINE Before beginning opertion, llow the engine to wrm up t idling speed for three minutes. Ger Shifting IMPORTANT: Observe the following: Never shift the outbord into or out of ger unless the engine speed is t idle. Shifting t higher thn engine idle speed could cuse dmge to the gercse. Do not shift the outbord into reverse when the forwrd motion of the bot is greter thn no wke speed. Shifting into reverse t higher bot speeds could cuse the engine to stll, nd in some situtions, this could cuse wter to be drwn into the cylinders, resulting in severe engine dmge. Do not shift the outbord into reverse when the engine is not running. Dmge to the shift linkge could occur. eng 43

54 START Your outbord hs three ger shift positions to provide opertion: forwrd, neutrl (out of ger), nd reverse. F N R OPERATION R N F Remote control models When shifting, lwys stop t the neutrl position nd llow the engine speed to return to idle Tiller hndle models Reduce the engine speed to idle before shifting Alwys shift the outbord into ger with quick motion. After shifting the outbord into ger, dvnce the remote control lever or rotte the throttle grip (tiller hndle) to increse speed. Stopping the Engine 1. Remote control models Reduce the engine speed nd shift the outbord to neutrl position. Turn the ignition key to "OFF" position. OFF ON eng

55 OPERATION 2. Tiller hndle models Reduce the engine speed nd shift the outbord to neutrl position. Push in the engine stop button or turn the ignition key to "OFF" position Emergency Strting If the strter system fils, use the spre strter rope (provided) nd follow procedure. NOTE: EFI models Engine must hve fully chrged bttery to strt the engine. 1. Remove flywheel cover or mnul strter ssembly Shift outbord to neutrl ("N") position. N N 28528! WARNING The neutrl speed protection device is inopertive when strting the engine with the emergency strter rope. Set the engine speed t idle nd the ger shift in neutrl to prevent the outbord from strting in ger. eng 45

56 OPERATION 3. Electric strt models Turn the ignition key to "ON" position ! WARNING High voltge is present ny time the key is turned on, especilly when strting or operting the engine. Do not touch ignition components or metl test probes nd sty cler of sprk plug leds when performing live tests.! WARNING The exposed moving flywheel cn cuse serious injury. Keep your hnds, hir, clothing, tools, nd other objects wy from engine when strting or running the engine. Do not ttempt to reinstll the flywheel cover or top cowl when engine is running. 4. Plce the strter rope knot into the flywheel notch nd wind the rope clockwise round the flywheel. 5. Pull the strter rope to strt the engine eng

57 Clening Cre Recommendtions OUTBOARD CARE To keep your outbord in the best operting condition, it is importnt tht your outbord receive the periodic inspections nd mintennce listed in the Inspection nd Mintennce Schedule. We urge you to keep it mintined properly to ensure the sfety of you nd your pssengers, nd retin its dependbility. Record mintennce performed in the Mintennce Log t the bck of this book. Sve ll mintennce work orders nd receipts. Selecting Replcement Prts For Your Outbord We recommend using originl Mercury Precision or Quicksilver replcement prts nd Genuine Lubricnts. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use custic clening chemicls on the outbord power pckge. Some clening products contin strong custic gents such s hull cleners with hydrochloric cid. These cleners cn degrde some of the components they come in contct with including criticl steering fsteners. Dmge to steering fsteners my not be obvious during visul inspection nd this dmge my led to ctstrophic filure. Some custic clening chemicls my cuse or ccelerte corrosion. Exercise cution when using clening chemicls round the engine nd follow the recommendtions on the pckging of the clening product. CLEANING GAUGES IMPORTANT: Never use high pressure wter to clen guges. Routine clening of the guges is recommended to prevent buildup of slt nd other environmentl debris. Crystlized slt cn scrtch the guge disply lens when using dry or dmp cloth. Ensure tht the cloth hs sufficient mount of fresh wter to dissolve nd remove slt or minerl deposits. Do not pply ggressive pressure on the disply lens while clening. When wter mrks cnnot be removed with dmp cloth, mix 50/50 solution of wrm wter nd isopropyl lcohol to clen the disply lens. Do not use cetone, minerl spirits, turpentine type solvents, or mmoni bsed clening products. The use of strong solvents or detergents my dmge the coting, the plstics, or the rubber keys on the guges. If the guge hs sun cover vilble, it is recommended tht the cover be instlled when the unit is not in use to prevent UV dmge to the plstic bezels nd rubber keys. CLEANING REMOTE CONTROLS MAINTENANCE IMPORTANT: Never use high pressure wter to clen remote controls. eng 47

58 Routine clening of the remote control externl surfces is recommended to prevent buildup of slt nd other environmentl debris. Use cloth towel which hs sufficient mount of fresh wter to dissolve nd remove slt or minerl deposits. When wter mrks cnnot be removed with dmp cloth, mix 50/50 solution of wrm wter nd isopropyl lcohol to clen the remote control. Do not use cetone, minerl spirits, turpentine type solvents, or mmoni bsed clening products. The use of strong solvents or detergents my dmge the coting, the plstics, or the rubber components on the remote control. CLEANING CARE FOR TOP AND BOTTOM COWLS IMPORTANT: Dry wiping (wiping the plstic surfce when it is dry) will result in minor surfce scrtches. Alwys wet the surfce before clening. Do not use detergents contining hydrochloric cid. Follow the clening nd wxing procedure. Clening nd Wxing Procedure 1. Before wshing, rinse the cowls with clen wter to remove dirt nd dust tht my scrtch the surfce. 2. Wsh the cowls with clen wter nd mild nonbrsive sop. Use soft clen cloth when wshing. 3. Dry thoroughly with soft clen cloth. MAINTENANCE 4. Wx the surfce using nonbrsive utomotive polish (polish designed for cler cot finishes). Remove the pplied wx by hnd using clen soft cloth. 5. To remove minor scrtches, use Mercury Mrine Cowl Finishing Compound ( K 1). CLEANING CARE FOR THE POWERHEAD (SALTWATER USE) If the outbord is operted in sltwter, remove the top cowl nd flywheel cover. Inspect the powerhed nd powerhed components for slt buildup. Wsh off ny slt buildup from the powerhed nd powerhed components with fresh wter. Keep wter spry out of the ir filter/intke nd lterntor. After wshing, llow the powerhed nd components to dry. Apply Quicksilver or Mercury Precision Lubricnts Corrosion Gurd spry on the externl metl surfces of the powerhed nd powerhed components. Do not llow the Corrosion Gurd spry to come in contct with the lterntor drive belt or belt pulleys. IMPORTANT: Do not llow lubricnt or Corrosion Gurd spry to come in contct with the lterntor drive belt or the belt pulleys. The lterntor drive belt could slip nd be dmged if it becomes coted with ny lubricnt or Corrosion Gurd spry. 48 eng

59 MAINTENANCE Tube Ref No. 120 Corrosion Gurd Description Where Used Prt No. EPA Emissions Regultions Externl metl surfces of the powerhed nd powerhed components All new outbords mnufctured by Mercury Mrine re certified to the United Sttes Environmentl Protection Agency, s conforming to the requirements of the regultions for the control of ir pollution from new outbord motors. This certifiction is contingent on certin djustments set to fctory stndrds. For this reson, the fctory procedure for servicing the product must be strictly followed nd, wherever prcticble, returned to the originl intent of the design. Mintennce, replcement, or repir of the emission control devices nd systems my be performed by ny mrine sprk ignition (SI) engine repir estblishment or individul. EMISSION CERTIFICATION LABEL An emission certifiction lbel, showing emission levels nd engine specifictions directly relted to emissions, is plced on the engine t the time of mnufcture. b c d e SPARK PLUG: GAP: EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in ger): hp kw L LOW PERM/HIGH PERM: FAMILY: HC+NOx:FEL: CO FEL: g/kwh g/kwh f g h i j Idle speed b - Engine horsepower c - Piston displcement d - Engine power kilowtts e - Dte of mnufcture f - US EPA engine fmily nme g - Regulted emission limit for the engine fmily h - Regulted emission limit for the engine fmily i - Recommended sprk plug nd gp j - Percent of fuel line permetion OWNER RESPONSIBILITY The owner/opertor is required to hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. eng 49

60 The owner/opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow emission levels to exceed their predetermined fctory specifictions. Inspection nd Mintennce Schedule DAILY CHECKS Check the engine oil level Check the lnyrd stop switch Inspect the fuel system for leks Inspect the engine tightness on the trnsom Check the steering system for binding Check the propeller for dmge Inspect the hydrulic steering fittings nd hoses for leks or signs of dmge, if equipped Check the hydrulic steering fluid level, if equipped AFTER EACH USE Wsh the power pckge exterior with fresh wter Flush the outbord cooling system, sltwter or brckish wter only ANNUALLY OR 100 HOURS Grese the engine, if pplicble Chnge the engine oil nd filter, if equipped Inspect the thermostt, sltwter or brckish wter only Add Quickleen to the fuel tnk, once per yer, per engine Apply ntiseize to the sprk plug threds Replce the ger lubricnt Inspect the corrosion control nodes Lubricte the propeller shft splines Replce ll filters on the suction side of the fuel system deler item Lubricte the driveshft splines deler item Check the tightness on ll the fsteners deler item Check the torque of the outbord mounting hrdwre deler item Check the bttery condition nd tightness of the bttery cble connection, if equipped deler item THREE YEARS OR 300 HOURS Replce the sprk plugs MAINTENANCE Replce the wter pump impeller deler item Inspect the crbon fiber reeds, if equipped deler item Inspect the wire hrness connectors deler item 50 eng

61 Check the remote control cble djustment, if equipped deler item Replce the high pressure fuel filter, if equipped deler item Replce the ccessory drive belt, if equipped deler item Check the power trim fluid level, if equipped deler item Inspect the engine motor mounts deler item Flushing the Cooling System MAINTENANCE Flush the internl wter pssges of the outbord with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent buildup of deposits from clogging the internl wter pssges. IMPORTANT: The engine must be run during flushing in order to open the thermostt nd circulte wter through the wter pssges.! 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. 1. Plce the outbord in either the operting position (verticl) or in tilted position. 2. Remove the propeller. Refer to Propeller Replcement. 3. Thred wter hose into the rer fitting. Prtilly open the wter tp (1/2 mximum). Do not open the wter tp ll the wy s this llows high pressure flow of wter. IMPORTANT: Do not run engine bove idle when flushing. 4. Shift the outbord into neutrl. Strt the engine nd flush the cooling system for t lest five minutes. Keep the engine speed t idle. 5. Stop the engine. Turn off the wter nd remove the hose. Reinstll the propeller eng 51

62 MAINTENANCE Top Cowl Removl nd Instlltion REMOVAL Pull out the rer lock lever nd remove the top cowl INSTALLATION 1. Lower the top cowl over the engine. 2. Bring the front of the cowl down first nd engge the front hook. Lower the cowl into its seted position nd pply downwrd pressure to the bck of the cowl to lock it in plce. Gently pull up on the bck of cowl to mke sure it is securely fstened Exterior Cre Your outbord is protected with durble bked enmel finish. Clen nd wx often using mrine cleners nd wxes. Bttery Inspection The bttery should be inspected t periodic intervls to ensure proper engine strting cpbility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your bttery. 1. Turn off the engine before servicing the bttery. 52 eng

63 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. Fuel System! 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. Before servicing ny prt of the fuel system, stop the engine nd disconnect the bttery. Drin the fuel system completely. Use n pproved continer to collect nd store the fuel. Wipe up ny spillge immeditely. Mteril used to contin spillge must be disposed of in n pproved receptcle. Any fuel system service must be performed in well ventilted re. Inspect ny completed service work for sign of fuel lekge. FUEL LINE INSPECTION Visully inspect the fuel line nd primer bulb for crcks, swelling, leks, hrdness, or other signs of deteriortion or dmge. If ny of these conditions re found, the fuel line or primer bulb must be replced. ENGINE FUEL FILTER Check the fuel filter for wter ccumultion or sediment. If wter is in the fuel, remove the sight bowl nd drin the wter. If the filter ppers to be contminted, remove nd replce. REMOVAL MAINTENANCE 1. Red the preceding fuel system servicing informtion nd wrning. 2. Pull out the filter ssembly from the mount. Hold onto the cover to prevent it from turning nd remove the sight bowl. Empty contents into n pproved continer. eng 53

64 MAINTENANCE 3. Inspect the filter element. If replcement is necessry, replce the filter ssembly. b c d Cover b - Filter element c - O ring sel d - Sight bowl INSTALLATION IMPORTANT: Visully inspect for fuel lekge from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. 1. Push the filter element into the cover. 2. Plce the O ring sel into its proper position on the sight bowl nd screw the sight bowl hnd tight into the cover. 3. Push the filter ssembly bck into the mount. 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 ("e" Prt Number ) nd self locking nylon insert locknuts ("b" nd "d" Prt Number ). These locknuts must never be replced with common nuts (nonlocking) s they will work loose nd vibrte off, freeing the link rod to disengge. 54 eng

65 MAINTENANCE! 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. b c d e Spcer ( ) b - Nylon insert locknut ( ) c - Flt wsher (2) d - Nylon insert locknut ( ) e - Specil wsher hed bolt ( ) Description Nm lb in. lb ft Nylon insert locknut "b" Nylon insert locknut "d" Tighten until it sets, then bck off 1/4 turn Specil wsher hed bolt Assemble steering link rod to steering cble with two flt wshers nd nylon insert locknut. Tighten locknut until it sets, then bck nut off 1/4 turn. Assemble steering link rod to engine with specil wsher hed bolt, locknut, nd spcer. First torque bolt, then locknut to specifiction. Corrosion Control Anode The outbord hs corrosion control nodes t different loctions. An node helps protect the outbord ginst glvnic corrosion by scrificing its metl to be slowly corroded insted of the outbord metls. eng 55

66 MAINTENANCE Ech node requires periodic inspection, especilly in sltwter which will ccelerte the erosion. To mintin this corrosion protection, lwys replce the node before it is completely eroded. Never pint or pply protective coting on the node, s this will reduce effectiveness of the node. This model hs n node instlled on ech side of the gercse nd one on the bottom of the trnsom brcket ssembly. b Anode on trnsom brcket ssembly b - Gercse nodes Propeller Replcement Stndrd Gercse! WARNING Rotting the propeller shft my cuse the engine to crnk over nd strt. To prevent this type of ccidentl engine strting nd possible serious injury cused from being struck by rotting propeller, lwys turn the ignition key or lnyrd stop switch to the "OFF" position nd remove the sprk plug leds from the sprk plugs while servicing. 1. Shift the outbord to the neutrl ("N") position. N N eng

67 MAINTENANCE 2. Remove the sprk plug leds to prevent the engine from strting Strighten the bent tbs on the propeller nut retiner Plce block of wood between the gercse nd propeller to keep the propeller from turning. Remove the propeller nut. 5. Pull the propeller stright off the shft. If the propeller is seized to the shft nd cnnot be removed, hve the propeller removed by n uthorized deler eng 57

68 MAINTENANCE 6. Apply to the propeller shft Quicksilver or Mercury Precision Lubricnts Extreme Grese or 2 4 C with PTFE Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M C with PTFE Propeller shft A 1 IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft (especilly in sltwter), lwys pply cot of the recommended lubricnt to the entire propeller shft t the recommended mintennce intervls, nd ech time the propeller is removed. 7. Flo Torq I drive hub propellers Instll the forwrd thrust hub, propeller, propeller nut retiner, nd propeller nut onto the shft. b - Propeller nut b - Propeller nut retiner c - Propeller d - Forwrd thrust hub c d Flo Torq II drive hub propellers Instll the forwrd thrust hub, propeller, replceble drive sleeve, rer thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Rer thrust hub d - Replceble drive sleeve e - Propeller f - Forwrd thrust hub 58 eng

69 MAINTENANCE 9. Plce the propeller nut retiner over the pins. Plce block of wood between the gercse nd the propeller nd tighten the propeller nut to the specified torque. Description Nm lb in. lb ft Propeller nut Align the flt sides of the propeller nut with the tbs on the propeller nut retiner. Secure the propeller nut by bending the tbs up nd ginst the flts on the propeller nut. b - Pins b - Tbs 11. Instll the sprk plug leds. Propeller Replcement Commnd Thrust Gercse! WARNING Rotting the propeller shft my cuse the engine to crnk over nd strt. To prevent this type of ccidentl engine strting nd possible serious injury cused from being struck by rotting propeller, lwys turn the ignition key or lnyrd stop switch to the "OFF" position nd remove the sprk plug leds from the sprk plugs while servicing. 1. Shift the outbord to the neutrl ("N") position. N b N eng 59

70 MAINTENANCE 2. Remove the sprk plug leds to prevent the engine from strting Strighten the bent tbs on the propeller nut retiner Plce block of wood between the gercse nd propeller to keep the propeller from turning. Remove the propeller nut. 5. Pull the propeller stright off the shft. If the propeller is seized to the shft nd cnnot be removed, hve the propeller removed by n uthorized deler eng

71 MAINTENANCE 6. Apply to the propeller shft Quicksilver or Mercury Precision Lubricnts Extreme Grese or 2 4 C with PTFE Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M C with PTFE Propeller shft A 1 IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft (especilly in sltwter), lwys pply cot of the recommended lubricnt to the entire propeller shft t the recommended mintennce intervls, nd ech time the propeller is removed. 7. Flo Torq I drive hub propellers Instll the thrust wsher, propeller, continuity wsher, thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Thrust hub d - Continuity wsher e - Propeller f - Thrust wsher 8. Flo Torq II drive hub propellers Instll the forwrd thrust hub, replceble drive sleeve, propeller, thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Thrust hub d - Propeller e - Replceble drive sleeve f - Forwrd thrust hub eng 61

72 MAINTENANCE NOTE: We recommend the instlltion of Flo Torq III drive hub propeller for stinless steel pplictions. 9. Flo Torq III drive hub propellers Instll the forwrd thrust hub, replceble drive sleeve, propeller, rer thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Rer thrust hub d - Propeller e - Replceble drive sleeve f - Forwrd thrust hub 10. Plce block of wood between the gercse nd propeller nd tighten the propeller nut to the specified torque. Description Nm lb in. lb ft Propeller nut Secure the propeller nut by bending three of the tbs into the thrust hub grooves eng

73 MAINTENANCE Sprk Plug Inspection nd Replcement! 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 boots. Twist the rubber boots slightly nd pull off Remove the sprk plugs to inspect. Replce sprk plug if electrode is worn or the insultor is rough, crcked, broken, blistered, or fouled. 3. Set the sprk plug gp to specifiction Sprk Plug Sprk plug gp 1.0 mm (0.040 in.) 4. Before instlling sprk plugs, clen off ny dirt on the sprk plug sets. Instll plugs finger tight, nd then tighten 1/4 turn or tighten to the specified torque. Description Nm lb in. lb ft Sprk plug eng 63

74 Fuse Replcement IMPORTANT: Alwys crry spre fuses. MAINTENANCE The electricl wiring circuits on the outbord re protected from overlod by fuses in the wiring. If fuse is blown, try to locte nd correct the cuse of the overlod. If the cuse is not found, the fuse my blow gin. Open the fuse holder nd look t the silver colored bnd inside the fuse. If the bnd is broken, replce the fuse. Replce the fuse with new fuse of the sme rting. f b g d e c Ignition coil circuit 20 mp b - Fuel pump/idle ir control/fuel injector circuits 20 mp c - Voltge regultor 25 mp d - Min power rely/ccessories/remote control 15 mp e - Spre 20 mp f - Good fuse g - Blown fuse Timing Belt Inspection Inspect the timing belt nd hve it replced by n uthorized deler if ny of the following conditions re found. Crcks in the bck of the belt or in the bse of the belt teeth. 64 eng

75 MAINTENANCE Excessive wer t the roots of the cogs. Rubber portion swollen by oil. Belt surfces roughened. Signs of wer on edges or outer surfces of belt Lubriction Points 1. Lubricte the following with Quicksilver or Mercury Precision Lubricnts Extreme Grese or 2 4 C with PTFE. Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M C with PTFE Propeller shft A 1 2. Lubricte the following with Quicksilver or Mercury Precision Lubricnt 2 4 C with PTFE. Tube Ref No C with PTFE Description Where Used Prt No. Tilt support lever, swivel brcket, tilt tube, co-pilot shft (tiller hndle models), steering cble grese fitting A 1 Tilt support lever Lubricte through fitting. eng 65

76 MAINTENANCE Swivel brcket Lubricte through fitting. - Tilt support lever b - Swivel brcket b Tilt tube Lubricte through fitting Co pilot shft (tiller hndle models) Lubricte through fitting. Move the steering friction lever bck nd forth while lubricting ! 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. 66 eng

77 MAINTENANCE Steering cble grese fitting (if equipped) Rotte steering wheel to fully retrct the steering cble end into the outbord tilt tube. Lubricte through fitting. b Fitting b - Steering cble end 3. Lubricte the following with lightweight oil. Steering link rod pivot points Lubricte points Checking Power Trim Fluid 1. Tilt the outbord to the full up position nd engge the tilt support lock eng 67

78 MAINTENANCE 2. Remove the fill cp nd check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricnts Power Trim nd Steering Fluid. If not vilble, use utomotive utomtic trnsmission fluid (ATF) Tube Ref No. 114 Description Where Used Prt No. Power Trim nd Steering Fluid Power trim reservoir K01 Chnging Engine Oil ENGINE OIL CAPACITY Engine oil Cpcity 3.0 Liter (3 U.S. Qurts) Fluid Type Mercury or Quicksilver SAE 25W 40 Synthetic Blend Mrine 4 Stroke Engine Oil Mercury or Quicksilver SAE 10W 30 4 Stroke Mrine Engine Oil OIL CHANGING PROCEDURE 1. Tilt the outbord up to the triler position. 68 eng

79 MAINTENANCE 2. Turn the outbord so the drin hole is fcing downwrd. Remove the drin plug nd drin the engine oil into n pproprite continer. Lubricte the sel on the drin plug with oil nd reinstll. b Drin plug b - Drin hole CHANGING OIL FILTER 1. Plce rg or towel below the oil filter to bsorb ny spilled oil. 2. Unscrew the old filter by turning the filter to the left. 3. Clen the mounting bse. Apply film of clen oil to the filter gsket. Do not use grese. Screw the new filter on until the gsket contcts the bse, then tighten 3/4 to 1 turn OIL FILLING 1. Remove the oil fill cp nd dd oil to the proper operting level. eng 69

80 MAINTENANCE 2. Idle the engine for five minutes nd check for leks. Stop the engine nd check the oil level on the dipstick. Add oil if necessry. - Oil fill cp Gercse Lubricnt STANDARD GEARCASE LUBRICATION When dding or chnging gercse lubricnt, visully check for the presence of wter in the lubricnt. If wter is present, it my hve settled to the bottom nd will drin out prior to the lubricnt, or it my be mixed with the lubricnt, giving it milky colored ppernce. If wter is noticed, hve the gercse checked by your deler. Wter in the lubricnt my result in premture bering filure or, in freezing tempertures, will turn to ice nd dmge the gercse. Exmine the drined gercse lubricnt for metl prticles. A smll mount of fine metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte bnorml ger wer nd should be checked by n uthorized deler. Drining Gercse Plce the outbord in verticl operting position. 2. Plce drin pn below the outbord. 3. Remove the vent plug nd fill/drin plug nd drin the lubricnt. - Vent plug b - Fill/drin plug b eng

81 Gercse Lubricnt Cpcity Gercse lubricnt cpcity is pproximtely 340 ml (11.5 fl oz). Checking Gercse Lubricnt Level nd Filling Gercse 1. Plce the outbord in verticl operting position. 2. Remove the vent plug. MAINTENANCE 3. Plce the lubricnt tube into the fill hole nd dd lubricnt until it ppers t the vent hole. IMPORTANT: Replce seling wshers if dmged. 4. Stop dding lubricnt. Instll the vent plug nd seling wsher before removing the lubricnt tube. 5. Remove the lubricnt tube nd instll clened fill/drin plug nd seling wsher. b c Vent hole b - Vent plug c - Fill/drin plug COMMAND THRUST GEARCASE LUBRICATION When dding or chnging gercse lubricnt, visully check for the presence of wter in the lubricnt. If wter is present, it my hve settled to the bottom nd will drin out prior to the lubricnt, or it my be mixed with the lubricnt, giving it milky colored ppernce. If wter is noticed, hve the gercse checked by your deler. Wter in the lubricnt my result in premture bering filure or, in freezing tempertures, will turn to ice nd dmge the gercse. Exmine the drined gercse lubricnt for metl prticles. A smll mount of fine metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte bnorml ger wer nd should be checked by n uthorized deler. Drining Gercse 1. Plce the outbord in verticl operting position. 2. Plce drin pn below the outbord. eng 71

82 MAINTENANCE 3. Remove the vent plugs nd fill/drin plug nd drin the lubricnt. - Vent plugs b - Fill/drin plug Gercse Lubricnt Cpcity Gercse lubricnt cpcity is pproximtely 710 ml (24 fl oz). Checking Lubricnt Level nd Filling Gercse 1. Plce the outbord in verticl operting position. 2. Remove the front vent plug nd rer vent plug. b Plce the lubricnt tube into the fill hole nd dd lubricnt until it ppers t the front vent hole. At this time instll the front vent plug nd seling wsher. 4. Continue dding lubricnt until it ppers t the rer vent hole. 5. Stop dding lubricnt. Instll the rer vent plug nd seling wsher before removing the lubricnt tube. 6. Remove the lubricnt tube nd instll clened fill/drin plug nd seling wsher. c b d e - Front vent plug b - Front vent hole c - Rer vent hole d - Rer vent plug e - Fill/drin plug nd seling wsher 72 eng

83 Submerged Outbord MAINTENANCE A submerged outbord will require service within few hours by n uthorized deler once the outbord is recovered from the wter. This immedite ttention by servicing deler is necessry once the engine is exposed to the tmosphere to minimize internl corrosion dmge to the engine. eng 73

84 Storge Preprtion The mjor considertion in prepring your outbord for storge is to protect it from rust, corrosion, nd dmge cused by freezing of trpped wter. The following storge procedures should be followed to prepre your outbord for out of seson storge or prolonged storge (two months or longer). 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. FUEL SYSTEM STORAGE IMPORTANT: Gsoline contining lcohol (ethnol or methnol) cn cuse formtion of cid during storge nd cn dmge the fuel system. If the gsoline being used contins lcohol, it is dvisble to drin s much of the remining gsoline s possible from the fuel tnk, remote fuel line, nd engine fuel system. Fill the fuel tnk nd engine fuel system with treted (stbilized) fuel to help prevent formtion of vrnish nd gum. Proceed with the following instructions. Portble fuel tnk Pour the required mount of gsoline stbilizer (follow instructions on continer) into the fuel tnk. Tip fuel tnk bck nd forth to mix stbilizer with the fuel. Permnently instlled fuel tnk Pour the required mount of gsoline stbilizer (follow instructions on continer) into seprte continer nd mix with pproximtely one liter (one qurt) of gsoline. Pour this mixture into the fuel tnk. Remove the fuel filter sight bowl nd empty contents in suitble continer. Refer to Mintennce Fuel System for removl nd instlltion of filter. Add 3 cc (1/2 tsp.) of gsoline stbilizer into the fuel filter sight bowl nd instll. Plce the outbord in wter or connect flushing ttchment for circulting cooling wter. Run the engine t idle RPM for 15 minutes to fill the engine fuel system with stbilized fuel. 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). 74 eng

85 STORAGE Tube Ref No. Description Where Used Prt No. 120 Corrosion Gurd Externl metl surfces Protecting Internl Engine Components Remove the sprk plugs nd dd pproximtely 30 ml (1 oz) of engine oil or inject five second spry of storge sel into ech sprk plug hole. Rotte the flywheel mnully severl times to distribute the oil in the cylinders. Reinstll sprk plugs. Chnge the engine oil. 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 75

86 Strter Motor Will Not Crnk the Engine (Electric Strt Models) POSSIBLE CAUSES Blown fuse in the strting circuit. Refer to Mintennce section. 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 or strter solenoid filure. Engine Will Not Strt POSSIBLE CAUSES Lnyrd stop switch not in "RUN" position. Incorrect strting procedure. Refer to Opertion section. Old or contminted gsoline. Engine flooded. Refer to Opertion section. Fuel is not reching the engine.. Fuel tnk is empty. b. Fuel tnk vent not open or restricted. c. Fuel line is disconnected or kinked. d. Primer bulb not squeezed. e. Primer bulb check vlve is fulty. f. Fuel filter is obstructed. Refer to Mintennce section. g. Fuel pump filure. h. Fuel tnk filter obstructed. Blown fuse. Refer to Mintennce section. Ignition system component filure. Sprk plugs fouled or defective. Refer to Mintennce section. Engine Runs Errticlly POSSIBLE CAUSES Gurdin System ctivted. Refer to Fetures nd Controls Wrning System. 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. TROUBLESHOOTING 76 eng

87 c. Stuck ntisiphon vlve locted on permnently built in type fuel tnks. d. Fuel line is kinked or pinched. Fuel pump filure. Ignition system component filure. Fuel injection component filure (EFI models). Performnce Loss POSSIBLE CAUSES Engine Gurdin System ctivted. Refer to Fetures nd Controls Wrning System. Throttle not fully open. Dmged or improper size propeller. Incorrect engine timing, djustments, or setup. Bot overloded or lod improperly distributed. Excessive wter in bilge. Bot bottom is dirty or dmged. 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. eng 77

88 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 OWNER SERVICE ASSISTANCE 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. 78 eng

89 OWNER SERVICE ASSISTANCE PARTS AND ACCESSORIES INQUIRIES Direct ny inquiries concerning Quicksilver replcement prts nd ccessories to your locl uthorized deler. The deler hs the necessry informtion to order prts nd ccessories for you if they re not in stock. Only uthorized delers cn purchse genuine Quicksilver prts nd ccessories from the fctory. Mercury Mrine does not sell to unuthorized delers or retil customers. When inquiring bout prts nd ccessories, the deler requires the engine model nd seril numbers to order the correct prts. 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. Contct the owner of the delership if the sles mnger nd service mnger hve been unble to resolve the problem. 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 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 eng 79

90 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 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 Telephone Fx Brunswick Asi Pcific Group T/A Mercury Mrine Singpore Pte Ltd 29 Loyng Drive Singpore, Ordering Literture OWNER SERVICE ASSISTANCE 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: 80 eng

91 OWNER SERVICE ASSISTANCE 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. 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. eng 81

92 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. 82 eng

93 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. eng 83

94 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 84 eng

95 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 85

96 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 Instlltion Informtion BOAT HORSEPOWER CAPACITY! 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 eng

97 START IN GEAR 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. 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. LOW PERMEATION 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. ELECTRIC FUEL PUMP INSTALLATION If n electric fuel pump is used, the fuel pressure must not exceed kp (4 psi) t the engine. If necessry, instll pressure regultor to regulte the pressure. INSTALLATION SPECIFICATIONS A A B Minimum trnsom opening b - Engine centerline for dul engines Minimum Trnsom Opening Single engine (remote) Single engine (tiller) 48.3 cm (19 in.) 76.2 cm (30 in.) eng 87

98 INSTALLATION Minimum Trnsom Opening Dul engines Engine Centerline Minimum cm (40 in.) 66 cm (26 in.) LIFTING OUTBOARD Use the lifting eye on the engine eng

99 INSTALLATION INSTALLING OUTBOARD Drilling Outbord Mounting Holes 1. Mrk four mounting holes on the trnsom using the trnsom drill fixture. b - Drill guide holes b - Trnsom drilling fixture c - Trnsom centerline c 2757 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 eng 89

100 FASTENING THE OUTBOARD TO THE TRANSOM 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 Prt Number Avilble Outbord Mounting Bolts 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 M ½ 20 x 5.00 in. long (3.25 in. thred) ½ 20 x 5.50 in. long (3.25 in. thred) ½ 20 x 6.50 in. long (2.75 in. thred) 8M M Checking Bot Trnsom Construction INSTALLATION ½ 20 x 7.50 in. long (2.75 in. thred) ½ 20 x 8.00 in. long (2.75 in. thred) 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 90 eng

101 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. INSTALLATION b Lrge trnsom wsher b - Trnsom reinforcement plte Fstening the Outbord to the Trnsom 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.). - Step (not llowed) b - Gp between trnsom clmp nd bot trnsom (not llowed) eng 91

102 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. 92 eng

103 INSTALLATION NOTE: For more ccurte torque reding, tighten the mounting locknuts rther thn the outbord mounting bolts 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 93

104 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 STEERING CABLE - STARBOARD SIDE ROUTED CABLE 1. Lubricte the entire cble end Tube Ref No. Description Where Used Prt No C with PTFE Steering cble end A 1 2. Insert the steering cble into the tilt tube eng

105 INSTALLATION 3. Tighten the nut to the specified torque Description Nm lb in. lb ft Nut STEERING CABLE SEAL 1. Mrk tilt tube 6.4 mm (0.25 in.) from end. Instll sel components. 2. Thred cp to the mrk. b c d mm (1/4 in.) b - Plstic spcer c - O ring sel d - Cp STEERING LINK ROD FASTENERS 8041 IMPORTANT: The steering link rod tht connects the steering cble to the engine must be fstened using specil wsher hed bolt ("" Prt Number ) nd self locking nylon insert locknuts ("b" nd "e" Prt Number ). These locknuts must never be replced with common nuts (nonlocking) s they will work loose nd vibrte off, freeing the link rod to disengge. eng 95

106 INSTALLATION! WARNING Improper fsteners or improper instlltion procedures cn result in loosening or disenggement of the steering link rod. This cn cuse sudden, unexpected loss of 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. f b c e d Specil wsher hed bolt ( ) b - Nylon insert locknut ( ) c - Spcer ( ) d - Flt wsher (2) e - Nylon insert locknut ( ) f - Use middle hole steer outbord to the side to gin hole ccess Description Nm lb in. lb ft Specil wsher hed bolt Nylon insert locknut "b" Nylon insert locknut "e" Tighten until it sets, then bck off 1/4 turn 96 eng

107 Assemble steering link rod to steering cble with two flt wshers nd nylon insert locknut. Tighten locknut until it sets, then bck nut off 1/4 turn. Assemble steering link rod to engine with specil wsher hed bolt, locknut nd spcer. First torque bolt, then torque locknut to specifictions. Fuel Hose Connection Remote Control Models REMOTE FUEL HOSE SIZE Minimum fuel hose inside dimeter (ID) is 8 mm (5/16 in.). Use seprte fuel hose/fuel tnk pickup for ech engine. FUEL HOSE CONNECTION INSTALLATION Fsten the remote fuel hose to the fitting with metl hose clmp or the plstic type hose clmp tht is provided with the outbord. b - Hose clmp b - Remote fuel hose eng 97

108 INSTALLATION Electricl Connections nd Control Cble Instlltion REMOTE WIRING HARNESS Remove the ccess cover Access cover Route the remote wiring hrness through the rubber grommet. 98 eng

109 INSTALLATION Connect the 14 pin connector to the engine hrness nd fsten the hrness with the retiner. b c Remote wiring hrness b - Retiner c - 14 pin connector BATTERY CABLE CONNECTIONS Single Outbord (+) - Red sleeve Positive (+) b - Blck sleeve Negtive ( ) c - Crnking bttery b (-) c eng 99

110 Dul Outbords INSTALLATION Connect common ground cble (wire size sme s engine bttery cbles) between negtive ( ) terminls on strting btteries. b (-) d b c (-) d Red sleeve Positive (+) b - Blck sleeve Negtive ( ) c - Ground cble d - Crnking bttery SHIFT CABLE INSTALLATION Instll the cbles into the remote control following the instructions provided with the remote control. 1. Locte the center point of the slck or lost motion tht exists in the shift cble s follows:. Move the remote control hndle from neutrl into forwrd nd dvnce the hndle to full speed position. Slowly return the hndle bck to neutrl. Plce mrk ("") on the cble next to the cble end guide. b. Move the remote control hndle from neutrl into reverse nd dvnce the hndle to full speed position. Slowly return the hndle bck to neutrl. Plce mrk ("b") on the cble next to the cble end guide. 100 eng

111 INSTALLATION c. Mke center mrk ("c"), midwy between mrks ("" nd "b"). Align the cble end guide with this center mrk when instlling cble to the engine. b c Mnully shift the outbord into neutrl. The propeller will rotte freely. 3. Position the remote control hndle into neutrl. N Fit the shift cble through the rubber grommet. - Rubber grommet b - Shift cble b Attch the shift cble to the shift lever with bow tie clip retiner. eng 101

112 INSTALLATION 6. Adjust the cble brrel so the center mrk on the cble is ligned with the end guide when the cble brrel is plced in the brrel receptcle. b c e d Cble end guide b - Bow tie clip retiner c - Center mrk d - Cble brrel e - Brrel ltch 7. Plce the cble brrel into the brrel receptcle. 8. Lock brrel in plce with the brrel ltch. - Brrel ltch Check shift cble djustments s follows:. Shift remote control into forwrd. The propeller shft should be locked in ger. If not, djust the brrel closer to the cble end guide. b. Shift remote control into reverse while turning propeller. The propeller shft should be locked in ger. If not, djust the brrel wy from the cble end guide. Repet steps through c. 102 eng

113 INSTALLATION c. Shift remote control bck to neutrl. The propeller shft should turn freely without drg. If not, djust the brrel closer to the cble end guide. Repet steps through c. THROTTLE CABLE INSTALLATION Instll the cbles into the remote control following the instructions provided with the remote control. 1. Position the remote control into neutrl. N Fit the throttle cble through the rubber grommet. - Rubber grommet b - Throttle cble b Attch the throttle cble to the throttle lever with bow tie clip retiner. 4. Adjust cble brrel until the brrel slips onto the mounting stud. eng 103

114 INSTALLATION 5. Fsten the throttle cble to the mounting stud with flt wsher nd locknut. Tighten the locknut to the specified torque. b c e d Cble end guide b - Bow tie clip retiner c - Flt wsher d - Locknut e - Cble brrel Description Nm lb in. lb ft Throttle cble locknut eng

115 INSTALLATION 6. Instll the ccess cover with two bolts. Tighten the bolts to the specified torque Access cover Description Nm lb in. lb ft Access cover bolt Propeller Instlltion PROPELLER INSTALLATION STANDARD GEARCASE! 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. eng 105

116 INSTALLATION 1. Cot the propeller shft with Quicksilver or Mercury Precision Lubricnts Extreme Grese or 2 4 C with PTFE Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M C with PTFE Propeller shft A 1 IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft (especilly in sltwter), lwys pply cot of the recommended lubricnt to the entire propeller shft t the recommended mintennce intervls, nd lso ech time the propeller is removed. 2. Flo Torq I drive hub propellers Instll forwrd thrust hub, propeller, propeller nut retiner, nd propeller nut onto the shft. b - Propeller nut b - Propeller nut retiner c - Propeller d - Forwrd thrust hub c d Flo Torq II drive hub propellers Instll forwrd thrust hub, propeller, replceble drive sleeve, rer thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Rer thrust hub d - Replceble drive sleeve e - Propeller f - Forwrd thrust hub 106 eng

117 INSTALLATION 4. Plce propeller nut retiner over pins. Plce block of wood between the gercse nd propeller nd tighten the propeller nut to the specified torque. Description Nm lb in. lb ft Propeller nut Align flt sides of the propeller nut with tbs on the propeller nut retiner. Secure propeller nut by bending tbs up nd ginst the flts on the propeller nut. b - Pins b - Tbs b Instll the sprk plug leds. PROPELLER INSTALLATION COMMAND THRUST GEARCASE! 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. 1. Apply to the propeller shft Quicksilver or Mercury Precision Lubricnts Extreme Grese or 2 4 C with PTFE Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M eng 107

118 INSTALLATION Tube Ref No. Description Where Used Prt No C with PTFE Propeller shft A 1 IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft (especilly in sltwter), lwys pply the recommended lubricnt to the entire propeller shft t the recommended mintennce intervls, nd lso ech time the propeller is removed. 2. Flo Torq I drive hub propellers Instll thrust wsher, propeller, continuity wsher, thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Thrust hub d - Continuity wsher e - Propeller f - Thrust wsher 3. Flo Torq II drive hub propellers Instll forwrd thrust hub, replceble drive sleeve, propeller, thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Thrust hub d - Propeller e - Replceble drive sleeve f - Forwrd thrust hub NOTE: Stinless steel pplictions Instlltion of Flo Torq III drive hub propeller is recommended. 108 eng

119 INSTALLATION 4. Flo Torq III drive hub propellers Instll forwrd thrust hub, replceble drive sleeve, propeller, rer thrust hub, propeller nut retiner, nd propeller nut onto the shft. b c d e f Propeller nut b - Propeller nut retiner c - Rer thrust hub d - Propeller e - Replceble drive sleeve f - Forwrd thrust hub 5. Plce block of wood between the gercse nd propeller nd tighten the propeller nut to the specified torque. Description Nm lb in. lb ft Propeller nut Secure propeller nut by bending three of the tbs into the thrust hub grooves eng 109

120 Trim Tb Adjustment INSTALLATION Propeller steering torque will cuse your bot to pull in one direction. This steering torque is norml thing tht results from your outbord not being trimmed so the propeller shft is prllel to the wter surfce. The trim tb cn help compenste for this steering torque in mny cses nd cn be djusted within limits to reduce ny unequl steering effort NOTE: Trim tb djustment will hve little effect reducing steering torque if the outbord is instlled with the nti ventiltion plte pproximtely 50 mm (2 inches) or more bove the bot bottom. Operte your bot t norml cruising speed, trimmed to the desired position. Turn your bot left nd right nd note the direction the bot turns more esily. If djustment is necessry, loosen trim tb bolt nd mke smll djustments t time. If the bot turns more esily to the left, move the triling edge of trim tb to the left. If the bot turns more esily to the right, move the triling edge of trim tb to the right. Tighten bolt nd retest. Trim In Stop Adjustment Power Trim Models If n djustment is required to the trim in stop, reposition the tilt stop pins in the desired holes. Tighten the tilt stop pins to the specified torque. - Tilt stop pins Description Nm lb in. lb ft Tilt stop pins eng