2016 Mercury Marine. Operation Maintenance and Installation Manual. 4/5/6 FourStroke

Transcription

1 2016 Mercury Mrine Opertion Mintennce nd Instlltion Mnul 4/5/6 FourStroke 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. 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, 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. ii eng

5 Identifiction Records Plese record the following pplicble informtion: Outbord Engine Model nd Horsepower Engine Seril Number Ger Rtio 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 Lnyrd Stop Switch... 2 Protecting People in the Wter... 5 Exhust Emissions... 5 Selecting Accessories for Your Outbord... 7 Sfe Boting Recommendtions... 7 Recording Seril Number /5/6 Specifictions...10 Instlltion Instlling Outbord...12 Trnsporting Crrying, Storing, nd Trnsporting Your Outbord When Removed from Bot Trilering Your Bot 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 Engine Oil Fetures nd Controls Fetures nd Controls Tilting Outbord Shllow Wter Opertion Setting the Operting Angle of Your Outbord Engine Overspeed Protection System eng v

8 Opertion Prestrting Check List...26 Operting in Freezing Tempertures Operting in Sltwter or Polluted Wter Engine Brek in Procedure...27 Strting the Engine Ger Shifting Stopping the Engine Emergency Strting Mintennce Outbord Cre EPA Emission Regultions Inspection nd Mintennce Schedule Flushing the Cooling System Top Cowl Removl nd Instlltion Corrosion Control Anode Exterior Cre...39 Fuel System Propeller Replcement Sprk Plug Inspection nd Replcement...42 Lubriction Points Chnging Engine Oil Gercse Lubriction...46 Submerged Outbord Storge Storge Preprtion...49 Protecting Externl Outbord Components Protecting Internl Engine Components Gercse Positioning Outbord for Storge vi eng

9 Owner Service Assistnce Locl Repir Service...51 Service Awy from Home Prts nd Accessories Inquiries Service Assistnce Ordering Literture...53 Mintennce Log Mintennce Log eng vii

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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 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. 2 eng

13 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. eng 3

14 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. GENERAL INFORMATION 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. 4 eng

15 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. Exhust Emissions BE ALERT TO CARBON MONOXIDE POISONING Crbon monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl combustion engines, including the engines tht propel bots, nd the genertors tht power bot ccessories. By itself, CO is odorless, colorless, nd tsteless, but if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of crbon monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse. eng 5

16 ! 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 GENERAL INFORMATION 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. 6 eng

17 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. eng 7

18 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. 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. GENERAL INFORMATION 8 eng

19 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 eng 9

20 - 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. d Model Number XXXXXXX Seril Number XXXXX XL XX XXXX XXX HP XXX KW XXX LB XXX KG XXX Me rc ury Mrine Brunswick Corp. Mde in Jpn XX b c Model designtion b - Seril number c - Yer mnufctured d - Certified Europe Insigni (s pplicble) 4/5/6 Specifictions Models Power 2.94 kw (4 hp) 3.68 kw (5 hp) 4.41 kw (6 hp) Full throttle RPM rnge Idle speed 1100 RPM in Forwrd Ger, 1300 RPM in Neutrl Number of cylinders 1 Piston displcement Cylinder bore Piston stroke Vlve clernce (cold) Intke vlve Exhust vlve Engine oil cpcity Recommended sprk plug 123 cc (7.51 cid) 59 mm (2.32 in.) 45 mm (1.77 in.) mm ( in.) mm ( in.) 450 ml (15 fl oz) NGK DCPR6E 10 eng

21 GENERAL INFORMATION Sprk plug gp Models Gercse lubricnt cpcity 0.9 mm (0.035 in.) 195 ml (6.6 fl oz) Ger rtio 2.15:1 Recommended gsoline Emission control system Sound t drivers er (ICOMIA 39 94) bba Tiller hndle vibrtion (ICOMIA 38 94) m/s² Refer to Fuel nd Oil Engine modifiction (EM) eng 11

22 INSTALLATION Instlling Outbord BOAT TRANSOM HEIGHT REQUIREMENT Mesure the trnsom height of your bot. The nti ventiltion plte should be mm (1 2 in.) below the bottom of the bot. - Anti ventiltion plte INSTALLING OUTBOARD ON TRANSOM 1. Plce the outbord on the centerline of the trnsom Tighten the trnsom clmp hndles eng

23 TRANSPORTING Crrying, Storing, nd Trnsporting Your Outbord When Removed from Bot 1. Remote fuel tnk models Disconnect the remote fuel line. Instll the protector cp over the fuel connector. b Remote fuel line b - Protector cp 2. With the outbord still in the wter, move the fuel vlve to the "OFF" (closed) position. Run the engine until it stops. This will drin fuel from the crburetor. Close the fuel tnk vent. b Fuel vlve "OFF" position b - Fuel tnk vent 3. Remove the outbord nd hold it upright until the wter is drined out. Keep the outbord in n upright position when crrying. eng 13

24 TRANSPORTING 4. Crry, trnsport, or store the outbord only in the upright position or tiller hndle down position. These positions will prevent oil from drining out of the crnkcse. NOTICE THIS SIDE UP b - Upright position b - Tiller hndle down position NOTE: Never crry, store, or trnsport the outbord in these positions. Engine dmge could result from oil drining out of the crnkcse Trilering Your Bot IMPORTANT: The tilt lock mechnism is not intended to support the outbord in the tilted up position when trilering your bot. Use of the tilt lock mechnism could llow the outbord to bounce nd drop down cusing dmge to the outbord. Your bot should be trilered with the outbord tilted down (norml operting position). If dditionl ground clernce is required, remove the outbord from the bot nd store securely. Additionl clernce my be needed for rilrod crossings, drivewys, nd triler bouncing. Set the ger shift into forwrd ger. This prevents the propeller from spinning freely eng

25 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 15

26 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. 16 eng

27 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 17

28 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. 18 eng

29 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 Engine Oil IMPORTANT: Do not overfill. Be sure tht the outbord is upright (not tilted) when checking the oil. 1. Position the outbord verticl nd remove the top cowl. 2. Remove the oil filler cp. Wipe oil off the dipstick nd screw the oil filler cp bck into the oil fill hole completely. Remove the oil filler cp nd check oil level on dipstick. Oil must be between full mrk nd dd mrk. If oil level is low, dd oil to bring level no higher thn the full mrk. NOTE: If oil level is t the dd mrk, dd 100 ml (3 oz) of oil. - Full mrk b - Add mrk b eng 19

30 FUEL AND OIL NOTE: Under certin conditions, the operting temperture of four stroke outbord engines my not get hot enough to evporte the norml fuel nd moisture tht ccumulte in the crnkcse. These conditions include operting t idle for long periods, repeted short trips, slow speed or quick stop nd go opertion, nd operting in cooler climtes. This dditionl fuel nd moisture tht collects in the crnkcse eventully ends up in the oil sump nd will dd to the totl volume of oil tht ppers on the dipstick reding. This increse in oil volume is known s oil dilution. Outbord engines cn typiclly hndle lrge mounts of oil dilution without cusing durbility problems. However, to ensure extended life of the outbord engine, Mercury recommends tht the oil be chnged regulrly following the oil chnge intervl nd using the recommended oil qulity. It is further recommended tht if your outbord is operted frequently in the conditions described bove, tht more frequent oil chnge intervls be considered. 3. Instll the oil filler cp nd tighten securely. 20 eng

31 FEATURES AND CONTROLS Fetures nd Controls Fuel shut off vlve for internl fuel tnk Turn vlve up to close or down to open. If n optionl remote fuel tnk is used, turn vlve up when using the remote fuel tnk. Turn vlve down when using the internl fuel tnk. Using internl fuel tnk Turning vlve up to "OFF" (stops fuel flow). Turning vlve down to "ON" (opens fuel flow). Using optionl remote fuel tnk Turn vlve up to the "OFF" position when using the remote fuel tnk. Disconnect the remote fuel hose when using the internl fuel tnk. c b Fuel shut off vlve b - "ON" (open) position c - "OFF" (closed) position Choke knob Pull completely out when strting cold engine. Push hlfwy in s engine is wrming up. Push in completely fter engine is wrmed up. Oil pressure indictor If oil pressure drops too low, the oil pressure indictor light will turn on. If the oil pressure indictor light turns on while the engine is running, stop the engine s soon s possible. Check oil level nd dd oil s needed. If the oil pressure indictor light should sty on when the oil level is correct, consult your deler. Engine stop switch/lnyrd stop switch Push in or pull lnyrd to stop engine. The engine will not strt unless the lnyrd is engged with the stop switch. eng 21

32 FEATURES AND CONTROLS Remote the fuel tnk connector For optionl remote fuel tnk. b c d - Choke knob b - Oil pressure indictor light c - Lnyrd stop switch d - Remote fuel connector e - Lnyrd e Throttle grip friction knob Turn the friction knob to set nd mintin the throttle t desired speed. Turn the knob clockwise to tighten friction or turn the knob counterclockwise to loosen friction. - Throttle grip friction knob b - Loosen friction (counterclockwise) c - Tighten friction (clockwise) c b 45614! 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 or steering wheel is relesed. Steering friction djustment Adjust this knob to chieve the desired steering friction (drg) on the tiller hndle. Turn knob clockwise to tighten friction nd counterclockwise to loosen friction. b - Loosen friction (counterclockwise) b - Tighten friction (clockwise) c - Steering friction knob c eng

33 FEATURES AND CONTROLS Shift hndle Controls the ger shift. N R F Shift hndle Tilting Outbord TILTING TO FULL UP POSITION 1. Stop the engine. Shift the outbord into forwrd ger. 2. Tke hold of the top cowl grip nd rise the outbord to the full up position The spring loded tilt lock lever will engge utomticlly nd lock the outbord in full up position. LOWERING TO RUN POSITION Rise the outbord nd pull up on the tilt relese lever. Gently lower the outbord down. - Tilt relese lever b - Tilt lock lever b eng 23

34 Shllow Wter Opertion FEATURES AND CONTROLS This outbord hs shllow wter drive position. This will llow you to tilt the outbord to higher position to prevent hitting bottom. ENGAGING SHALLOW WATER DRIVE 1. Reduce the engine speed to idle in forwrd ger. Tke hold of the top cowl grip nd rise outbord to the higher tilt position. The spring loded tilt lock lever will engge utomticlly nd lock the outbord in the shllow wter drive position Ensure the cooling wter intke is submerged IMPORTANT: Operte outbord t slow speed for shllow wter opertion nd keep the cooling wter intke submerged. 3. To relese outbord bck down to run position, tilt outbord up slightly nd pull up on the tilt relese lever. Gently lower the outbord down. - Tilt relese lever b - Tilt lock lever b eng

35 FEATURES AND CONTROLS Setting the Operting Angle of Your Outbord The verticl operting ngle of your outbord is djusted by chnging the position of the tilt pin in the djustment holes provided. Proper djustment llows the bot to chieve optimum performnce, stbility, nd minimize steering effort. The tilt pin should be djusted so the outbord is positioned to run perpendiculr to the wter when the bot is running t full speed. This llows the bot to be driven prllel to the wter. Arrnge pssengers nd lod in the bot so the weight is distributed evenly. - Tilt pin IMPORTANT: Do not operte the outbord with the tilt pin removed. Engine Overspeed Protection System The engine overspeed protection system is ctivted if the engine speed should exceed the mximum llowble limit. This will protect the engine from mechnicl dmge. Anytime the engine overspeed protection system is ctivted, the engine speed is utomticlly reduced to within the llowble limit. If engine overspeed continues, hve the outbord checked by your deler. NOTE: Your engine speed should never rech the mximum limit to ctivte the system unless the propeller is ventilting, n incorrect propeller is being used, or the propeller is fulty. eng 25

36 Prestrting Check List 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. OPERATION Arrnge pssengers nd lod in the bot so the weight is distributed evenly nd everyone is seted in proper set. Tell someone where you re going nd when you expect to return. It is illegl to operte bot while under the influence of lcohol or drugs. Know the wters nd re you will be boting; tides, currents, snd brs, rocks, nd other hzrds. Mke inspection checks listed in Mintennce Inspection nd Mintennce Schedule. Operting in Freezing Tempertures When using your outbord or hving your outbord moored in freezing or ner freezing tempertures, keep the outbord tilted down t ll times so the gercse is submerged. This prevents 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. 26 eng

37 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 2000 RPM or t pproximtely hlf throttle. 2. For the second hour of opertion, run the engine t vried throttle settings up to 3000 RPM or t three qurter throttle, nd t full throttle for pproximtely one minute every ten minutes. 3. For the next eight hours of opertion, void continuous opertion t full throttle for more thn five minutes t time. Strting the Engine OPERATION Before strting, red the Pre Strting 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. Ensure the cooling wter intke is submerged. 2. Check the engine oil level eng 27

38 OPERATION 3. Shift the outbord to neutrl (N) position. N R F NOTE: The engine will not strt unless the lnyrd is engged with the stop switch. 4. Attch the lnyrd to the stop switch. Refer to Generl Informtion Lnyrd Stop Switch. - Lnyrd b - Stop switch b Strting procedure when using the internl fuel tnk for fuel:. Open the fuel cp vent on the internl fuel tnk. b. Move the fuel vlve to the "ON" (open) position. b Fuel vlve "ON" (open) position b - Fuel tnk vent 6. Strting procedure when using optionl remote fuel tnk: 28 eng

39 OPERATION. Close the fuel cp vent on the internl fuel tnk. b. Move the fuel vlve to the "OFF" (closed) position. b Fuel vlve "OFF" (closed) position b - Fuel cp vent c. Connect the remote fuel line to the outbord. d. 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. b Remote fuel hose b - Primer blub e. Open the fuel tnk vent on mnul venting type tnks. 7. Position the throttle grip s follows: Cold engine Move to the START position. eng 29

40 OPERATION Wrm engine Move to the RE START position. RE-START START b - Wrm engine strt b - Cold engine strt If engine is cold, completely pull out the choke. Push in the choke hlfwy s the engine is wrming up. Push in completely fter engine is wrmed up. - Choke NOTE: Strting flooded engine Push in the choke knob. Wit 30 seconds, then continue to crnk engine for strting. 9. Pull the strter rope slowly until you feel the strter engge, then pull rpidly to crnk the engine. Allow rope to return slowly. Repet until engine strts. - Strter rope Check for stedy strem of wter flowing out of the wter pump indictor hole. 30 eng

41 OPERATION 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 Ger Shifting Your outbord hs three ger shift positions to provide opertion: Forwrd (F), Neutrl (N), nd Reverse (R). Reduce the throttle speed to idle speed. Alwys shift the outbord into ger with quick motion. N R F eng 31

42 Stopping the Engine OPERATION Reduce the engine speed nd push in the stop switch or pull the lnyrd. - Lnyrd b - Stop switch b Emergency Strting If the strter rope should brek or the rewind strter fils, use the spre strter rope (provided) nd follow this procedure. 1. Shift the outbord to neutrl position. N 45629! 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. 32 eng

43 OPERATION 2. Disconnect the linkge from the rewind strter ssembly. b Rewind strter ssembly b - Linkge 3. Remove the three 10 mm bolts nd rewind strter ssembly mm wrench provided with outbord 45631! 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 rewind strter ssembly or top cowl when engine is running. 4. Plce the strter rope knot into the strter cup notch nd wind the rope clockwise round the cup. eng 33

44 OPERATION 5. Pull the strter rope to strt the engine. - Strter rope provided with outbord eng

45 Outbord Cre 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 REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using originl Mercury Precision or Quicksilver replcement prts nd Genuine Lubricnts. EPA Emission Regultions MAINTENANCE 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. eng 35

46 EMISSION CERTIFICATION LABEL MAINTENANCE An emission certifiction lbel, showing emission levels nd engine specifictions directly relted to emissions, is plced on the engine t time of mnufcture. b c d 2008 JAN FEB MAR APR MAY JUN EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2010 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES. REFER TO OWNER S MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. PLEASE PERFORM THE ENGINE MAINTENANCE CORRECTLY. DISPLACEMENT : FAMILY : FEL : HC+NOx= CO= HP : LOW-PERM/HIGH-PERM : MAXIMUM POWER : TIMING : IDLE SPEED (IN GEAR) : MERCURY MARINE 2008 JUL AUG SEP OCT NOV DEC e f g h Piston displcement b - Mximum emission output for the engine fmily c - Percent of fuel line permetion d - Timing specifiction e - Fmily number f - Engine fmily description g - Engine power kilowtts h - Idle speed OWNER RESPONSIBILITY The owner/opertor is required to hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. 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 36 eng

47 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 nti seize to the sprk plug threds Replce the ger lubricnt Inspect the corrosion control nodes Replce ll filters on the suction side of the fuel system deler item Lubricte the driveshft splines deler item Lubricte the propeller shft 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 deler item THREE YEARS OR 300 HOURS Replce the sprk plugs Replce the wter pump impeller deler item Inspect the crbon fiber reeds deler item Inspect the wire hrness connectors deler item Check the remote control cble djustment, if pplicble deler item Replce the high pressure fuel filter deler item Replce the ccessory drive belt deler item Check the power trim fluid level deler item Inspect the engine motor mounts deler item Flushing the Cooling System Flush the internl wter pssges of the outbord with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent buildup of deposits from clogging the internl wter pssges. Use Mercury Precision or Quicksilver ccessory (or equivlent) flushing ttchment. NOTE: Do not run the engine while flushing the cooling system. 1. Remove the plug nd gsket. MAINTENANCE eng 37

48 MAINTENANCE 2. Instll the hose coupling into the plug opening. 3. Attch wter hose to the hose coupling. Turn on the wter gently nd flush the cooling system for 3 5 minutes. 4. Remove the hose coupling nd instll the plug nd gsket. b Plug nd gsket b - Hose coupling Top Cowl Removl nd Instlltion REMOVAL 1. Relese the rer ltch. 2. Lift up the rer of the cowl nd push it towrds the front of the engine to cler the front hook INSTALLATION 1. Engge the front hook nd position the cowl over the engine. 2. Lock the rer ltch. Corrosion Control Anode Your outbord hs corrosion control node instlled on the gercse. An node helps protect the outbord ginst glvnic corrosion by scrificing its metl to be slowly corroded insted of the outbord metls. 38 eng

49 MAINTENANCE The 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 Exterior Cre Your outbord is protected with durble bked enmel finish. Clen nd wx often using mrine cleners nd wxes. 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 the 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 signs of fuel lekge. eng 39

50 FUEL LINE FILTER MAINTENANCE Inspect the fuel line filter. If the filter ppers to be contminted, remove nd replce IMPORTANT: Visully inspect for fuel lekge from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. 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. Propeller Replcement! 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. Remove the sprk plug led to prevent engine from strting eng

51 MAINTENANCE 2. Move the ger shift lever into neutrl. N 3. Strighten nd remove the cotter pin Plce block of wood between the gercse nd the propeller to hold the propeller nd remove the propeller nut. 5. Pull propeller stright off the shft. If propeller is seized to the shft nd cnnot be removed, hve the propeller removed by n uthorized deler. IMPORTANT: To prevent the propeller hub from corroding nd seizing to the propeller shft (especilly in 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. 6. Cot the propeller shft with 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 7. Instll front thrust wsher, propeller, rer thrust hub, nd propeller nut onto the shft. eng 41

52 MAINTENANCE 8. Plce block of wood between the gercse nd the propeller nd tighten the propeller nut. Secure the propeller nut to the shft with cotter pin. - Cotter pin b - Propeller nut c - Rer thrust hub d - Propeller e - Front thrust wsher b c e d 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 boot. Twist the rubber boot slightly nd pull off Remove the sprk plug to inspect. Replce sprk plug if electrode is worn or the insultor is rough, crcked, broken, blistered, or fouled eng

53 MAINTENANCE 3. Set the sprk plug gp to specifiction Sprk Plug Sprk plug gp 0.9 mm (0.035 in.) 4. Before instlling sprk plug, clen off ny dirt on the sprk plug set. Instll plug finger tight, nd then tighten 1/4 turn or torque to specifictions. Description Nm lb in. lb ft Sprk plug Lubriction Points 1. Lubricte the following with 2 4 C with PTFE or Extreme Grese. Tube Ref No C with PTFE Description Where Used Prt No. Extreme Grese Co-pilot, swivel brcket, trnsom clmp screws, tiller hndle bushing, shift hndle detent Co-pilot, swivel brcket, trnsom clmp screws, tiller hndle bushing, shift hndle detent A 1 8M Co pilot lubricte threds. Swivel brcket lubricte through fittings. - Swivel brcket lubriction fittings b - Co pilot b eng 43

54 MAINTENANCE Trnsom clmp screws lubricte threds. - Trnsom clmp screws NOTE: Lubricting the tiller hndle bushing nd shift detent shft requires disssembly of the product. These points should be lubricted t lest once yer by n uthorized deler. Tiller hndle rubber bushing lubricte internl dimeter. - Tiller hndle rubber bushing Shift detent lubricte detent shft. - Shift detent eng

55 MAINTENANCE 2. Lubricte the tilt pivot points with lightweight oil. - Tilt pivot points Lubricte the following with 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 Propeller shft refer to Propeller Replcement for removl nd instlltion of the propeller. Cot the entire propeller shft with lubricnt to prevent the propeller hub from corroding to the shft Chnging Engine Oil ENGINE OIL CAPACITY Engine oil cpcity is pproximtely 450 ml (15 fl oz). OIL CHANGING PROCEDURE 1. Plce the outbord in n upright (not tilted) position. 2. Turn the outbord to gin ccess to the drin plug. Remove the drin plug nd drin the engine oil into n pproprite continer. Lubricte the sel on the drin plug with oil nd instll. eng 45

56 MAINTENANCE 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. - Drin plug OIL FILLING IMPORTANT: Do not overfill. Be sure tht the outbord is upright (not tilted) when checking oil. Remove the oil fill cp nd refill with 450 ml (15 fl oz) of oil. Instll the oil fill cp. Idle engine for five minutes nd check for leks. Stop engine nd check the oil level on the dipstick. Add oil if necessry. Gercse Lubriction 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 metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte bnorml ger wer nd should be checked by n uthorized deler. DRAINING GEARCASE Tilt the outbord so tht the oil drin plug is t the lowest point. 2. Plce the drin pn below the outbord. 46 eng