75/90/115/115 Pro XS/125 OptiMax - Mercury

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General InformationBoater's Responsibilities............................................................ 27Before Operating Your Outboard............................................... 27Boat Horsepower Capacity........................................................ 28High‐Speed and High‐Performance Boat Operation................. 28Propeller Selection.....................................................................29Outboard Remote Control Models ............................................ 32Remote Steering Notice.............................................................32Lanyard Stop Switch.................................................................. 33Protecting People in the Water.................................................. 37Passenger Safety Message ‐ Pontoon Boats and Deck Boats................................................................................................... 38Wave and Wake Jumping.......................................................... 39Impact with Underwater Hazards...............................................40Exhaust Emissions.................................................................... 42Selecting Accessories for Your Outboard.................................. 44Safe Boating Recommendations............................................... 44Recording Serial Number.......................................................... 48Specifications.............................................................................48Component Identification........................................................... 50TransportingTrailering Boat/Outboard .......................................................... 51viii eng

MaintenanceOutboard Care........................................................................... 78EPA Emissions Regulations...................................................... 78Inspection and Maintenance Schedule...................................... 79Flushing the Cooling System .................................................... 82Top Cowl Removal and Installation........................................... 83Cleaning Care for Top Cowl...................................................... 84Flywheel Cover Removal and Installation..................................84Side Panel Removal and Installation......................................... 85Fuel System............................................................................... 86Steering Link Rod Fasteners..................................................... 89Fuse Replacement.....................................................................90Corrosion Control Anode........................................................... 91Battery Inspection ..................................................................... 92Battery Information.................................................................... 92Propellers...................................................................................93Spark Plug Inspection and Replacement...................................97Compressor Air Intake Filter...................................................... 99Alternator Belt Inspection.........................................................100Lubrication Points.................................................................... 100Checking Power Trim Fluid......................................................102Gearcase Lubrication...............................................................103StorageStorage Preparation.................................................................106Fuel System............................................................................. 106Protecting Internal Engine Components.................................. 108Protecting External Outboard Components............................. 108Gearcase................................................................................. 109Positioning Outboard for Storage............................................ 109Battery Storage........................................................................ 109x eng

Maintenance LogMaintenance Log..................................................................... 151xii eng

WARRANTY INFORMATIONWarranty Registration United States and CanadaTo be eligible for warranty coverage, the product must beregistered with Mercury Marine.At the time of sale, the selling dealer should complete thewarranty registration and immediately submit it to MercuryMarine via MercNET, e‐mail, or mail. Upon receipt of thiswarranty registration, Mercury Marine will record the registration.A copy of the warranty registration should be provided to you byyour selling dealer.NOTE: Registration lists must be maintained by Mercury Marineand any dealer of Mercury Marine products sold in the UnitedStates, should a safety recall notification under the FederalSafety Act be required.You may change your registered address at any time, includingat time of warranty claim, by calling Mercury Marine or sending aletter or fax with your name, old address, new address, andengine serial number to Mercury Marine’s warranty registrationdepartment. Your dealer can also process this change ofinformation.Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Fax +1 920 907 6663OUTSIDE UNITED STATES AND CANADAFor products purchased outside the United States and Canada,contact the distributor in your country, or the Marine PowerService Center closest to you.Transfer of Warranty United States and CanadaThe limited warranty is transferable to a subsequent purchaser,but only for the remainder of the unused portion of the limitedwarranty. This will not apply to products used for commercialapplications.eng 1

WARRANTY INFORMATIONTo transfer the warranty to the subsequent owner, send or fax acopy of the bill of sale or purchase agreement, new owner’sname, address, and engine serial number to Mercury Marine’swarranty registration department. In the United States andCanada, mail to:Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Fax +1 920 907 6663Upon processing the transfer of warranty, Mercury Marine willrecord the new owner's information.There is no charge for this service.OUTSIDE THE UNITED STATES AND CANADAFor products purchased outside the United States and Canada,contact the distributor in your country, or the Marine PowerService Center closest to you.Transfer of Mercury Product Protection (ExtendedService Coverage) Plan United States and CanadaThe remaining coverage period of the Product Protection Plan istransferable to the subsequent purchaser of the engine withinthirty (30) days from the date of sale. Contracts not transferredwithin thirty (30) days of the subsequent purchase will no longerbe valid and the product will no longer be eligible for coverageunder the terms of the contract.To transfer the plan to the subsequent owner, contact MercuryProduct Protection or an authorized dealer to receive a Requestfor Transfer form. Submit to Mercury Product Protection areceipt/bill of sale, a completed Request of Transfer form, and acheck payable to Mercury Marine in the amount of $50.00 (perengine) to cover the transfer fee.Plan coverage is not transferable from one product to anotherproduct or for noneligible applications.The certified preowned engine plans are not transferable.2 eng

WARRANTY INFORMATIONFor help or assistance, contact Mercury Product ProtectionDepartment at 1‐888‐427‐5373 from 7:30 a.m. to 4:30 p.m. CST,Monday–Friday or e‐mail mpp_support@mercmarine.com.Outboard Limited WarrantyUNITED STATES, CANADA, EUROPE, MIDDLE EAST,AFRICA, AND THE CONFEDERATION OF INDEPENDENTSTATESWHAT IS COVERED: Mercury Marine warrants its new productsto be free of defects in material and workmanship during theperiod described below.DURATION OF COVERAGE: This Limited Warranty providescoverage for three (3) years from the date the product is first soldto a recreational use retail purchaser, or the date on which theproduct is first put into service, whichever occurs first.Commercial users of these products receive warranty coverageof one (1) year from the date of first retail sale, or one (1) yearfrom the date on which the product was first put into service,whichever occurs first. Commercial use is defined as any work oremployment related use of the product, or any use of the productwhich generates income, for any part of the warranty period,even if the product is only occasionally used for such purposes.The repair or replacement of parts, or the performance of serviceunder this warranty, does not extend the life of this warrantybeyond its original expiration date. Unexpired warranty coveragecan be transferred from one recreational use customer to asubsequent recreational use customer upon proper reregistrationof the product. Unexpired warranty coverage cannot betransferred either to or from a commercial use customer.Warranty coverage may be terminated for used repossessedproduct; or product purchased at auction, from a salvage yard, orfrom an insurance company.eng 3

WARRANTY INFORMATIONCONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGE: Warranty coverage is available onlyto retail customers that purchase from a Dealer authorized byMercury Marine to distribute the product in the country in whichthe sale occurred, and then only after the Mercury Marinespecified predelivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Inaccuratewarranty registration information regarding recreational use, orsubsequent change of use from recreational to commercial(unless properly reregistered) may void the warranty at the solediscretion of Mercury Marine. Routine maintenance outlined inthe Operation and Maintenance Manual must be timelyperformed in order to maintain warranty coverage. MercuryMarine reserves the right to make warranty coverage contingentupon proof of proper maintenance.WHAT MERCURY WILL DO: Mercury's sole and exclusiveobligation under this warranty is limited to, at our option,repairing a defective part, replacing such part or parts with newor Mercury Marine certified remanufactured parts, or refundingthe purchase price of the Mercury product. Mercury reserves theright to improve or modify products from time to time withoutassuming an obligation to modify products previouslymanufactured.4 eng

WARRANTY INFORMATIONHOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repair,and reasonable access to the product for warranty service.Warranty claims shall be made by delivering the product forinspection to a Mercury dealer authorized to service the product.If purchaser cannot deliver the product to such a dealer, writtennotice must be given to Mercury. We will then arrange for theinspection and any covered repair. Purchaser, in that case, shallpay for all related transportation charges and/or travel time. If theservice provided is not covered by this warranty, purchaser shallpay for all related labor and material, and any other expensesassociated with that service. Purchaser shall not, unlessrequested by Mercury, ship the product or parts of the productdirectly to Mercury. Proof of registered ownership must bepresented to the dealer at the time warranty service is requestedin order to obtain coverage.eng 5

WARRANTY INFORMATIONWHAT IS NOT COVERED: This limited warranty does not coverroutine maintenance items, tune‐ups, adjustments, normal wearand tear, damage caused by abuse, abnormal use, use of apropeller or gear ratio that does not allow the engine to run in itsrecommended wide‐open throttle RPM range (see the Operationand Maintenance Manual), operation of the product in a mannerinconsistent with the recommended operation/duty cycle sectionof the Operation and Maintenance Manual, neglect, accident,submersion, improper installation (proper installationspecifications and techniques are set forth in the installationinstructions for the product), improper service, use of anaccessory or part not manufactured or sold by us, jet pumpimpellers and liners, operation with fuels, oils or lubricants whichare not suitable for use with the product (see the Operation andMaintenance Manual), alteration or removal of parts, waterentering the engine through the fuel intake, air intake or exhaustsystem, or damage to the product from insufficient cooling watercaused by blockage of the cooling system by a foreign body,running the engine out of water, mounting the engine too high onthe transom, or running the boat with the engine trimmed out toofar. Use of the product for racing or other competitive activity, oroperating with a racing type lower unit, at any point, even by aprior owner of the product, voids the warranty.Expenses related to haul‐out, launch, towing, storage, telephone,rental, inconvenience, slip fees, insurance coverage, loanpayments, loss of time, loss of income, or any other type ofincidental or consequential damages are not covered by thiswarranty. Also, expenses associated with the removal and/orreplacement of boat partitions or material caused by boat designfor access to the product are not covered by this warranty.No individual or entity, including Mercury Marine authorizeddealers, has been given authority by Mercury Marine to makeany affirmation, representation or warranty regarding theproduct, other than those contained in this limited warranty, andif made, shall not be enforceable against Mercury Marine.6 eng

WARRANTY INFORMATIONFor additional information regarding events and circumstancescovered by this warranty, and those that are not, see theWarranty Coverage section of the Operation and MaintenanceManual, incorporated by reference into this warranty.DISCLAIMERS AND LIMITATIONS:THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THEEXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGESARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOMESTATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOUSPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGALRIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TOCOUNTRY.3 Year Limited Warranty Against CorrosionWHAT IS COVERED: Mercury Marine warrants that each newMercury, Mariner, Mercury Racing, Sport‐Jet, M 2 Jet Drive,Tracker by Mercury Marine Outboard, Mercury MerCruiserInboard or Sterndrive Engine (Product) will not be renderedinoperative as a direct result of corrosion for the period of timedescribed below.DURATION OF COVERAGE: This limited corrosion warrantyprovides coverage for three (3) years from either the date theproduct is first sold, or the date on which the product is first putinto service, whichever occurs first. The repair or replacement ofparts, or the performance of service under this warranty, doesnot extend the life of this warranty beyond its original expirationdate. Unexpired warranty coverage can be transferred tosubsequent (noncommercial use) purchaser upon properreregistration of the product.eng 7

WARRANTY INFORMATIONCONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGE: Warranty coverage is available onlyto retail customers that purchase from a Dealer authorized byMercury Marine to distribute the product in the country in whichthe sale occurred, and then only after the Mercury Marinespecified predelivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Corrosionprevention devices specified in the Operation and MaintenanceManual must be in use on the boat, and routine maintenanceoutlined in the Operation and Maintenance Manual must betimely performed (including, without limitation, the replacement ofsacrificial anodes, use of specified lubricants, and touch‐up ofnicks and scratches) in order to maintain warranty coverage.Mercury Marine reserves the right to make warranty coveragecontingent upon proof of proper maintenance.WHAT MERCURY WILL DO: Mercury's sole and exclusiveobligation under this warranty is limited to, at our option,repairing a corroded part, replacing such part or parts with newor Mercury Marine certified remanufactured parts, or refundingthe purchase price of the Mercury product. Mercury reserves theright to improve or modify products from time to time withoutassuming an obligation to modify products previouslymanufactured.8 eng

WARRANTY INFORMATIONHOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repair,and reasonable access to the product for warranty service.Warranty claims shall be made by delivering the product forinspection to a Mercury dealer authorized to service the product.If purchaser cannot deliver the product to such a dealer, writtennotice must be given to Mercury. We will then arrange for theinspection and any covered repair. Purchaser, in that case, shallpay for all related transportation charges and/or travel time. If theservice provided is not covered by this warranty, purchaser shallpay for all related labor and material, and any other expensesassociated with that service. Purchaser shall not, unlessrequested by Mercury, ship the product or parts of the productdirectly to Mercury. Proof of registered ownership must bepresented to the dealer at the time warranty service is requestedin order to obtain coverage.WHAT IS NOT COVERED: This limited warranty does not coverelectrical system corrosion; corrosion resulting from damage,corrosion which causes purely cosmetic damage, abuse, orimproper service; corrosion to accessories, instruments, steeringsystems; corrosion to factory installed jet drive unit; damage dueto marine growth; product sold with less than a one year limitedProduct warranty; replacement parts (parts purchased bycustomer); products used in a commercial application.Commercial use is defined as any work or employment relateduse of the product, or any use of the product which generatesincome, for any part of the warranty period, even if the product isonly occasionally used for such purposes.eng 9

WARRANTY INFORMATIONCorrosion damage caused by stray electrical currents (onshorepower connections, nearby boats, submerged metal) is notcovered by this corrosion warranty and should be protectedagainst by the use of a corrosion protection system, such as theMercury Precision Parts or Quicksilver MerCathode systemand/or Galvanic Isolator. Corrosion damage caused by improperapplication of copper base antifouling paints is also not coveredby this limited warranty. If antifouling protection is required,Tri‐Butyl‐Tin‐Adipate (TBTA) base antifouling paints arerecommended on Outboard and MerCruiser boating applications.In areas where TBTA base paints are prohibited by law, copperbase paints can be used on the hull and transom. Do not applypaint to the outboard or MerCruiser product. In addition, caremust be taken to avoid an electrical interconnection between thewarranted product and the paint. For MerCruiser product, anunpainted gap of at least 38 mm (1.5 in.) should be left aroundthe transom assembly. Refer to the Operation and MaintenanceManual for additional details.For additional information regarding events and circumstancescovered by this warranty, and those that are not, see theWarranty Coverage section of the Operation and MaintenanceManual, incorporated by reference into this warranty.DISCLAIMERS AND LIMITATIONS:THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THEEXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGESARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOMESTATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOUSPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGALRIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TOCOUNTRY.10 eng

WARRANTY INFORMATIONWarranty Coverage and ExclusionsThe purpose of this section is to help eliminate some of the morecommon misunderstandings regarding warranty coverage. Thefollowing information explains some of the types of services thatare not covered by warranty. The provisions set forth followinghave been incorporated by reference into the Three Year LimitedWarranty Against Corrosion Failure, the International LimitedOutboard Warranty, and the United States and Canada LimitedOutboard Warranty.Keep in mind that warranty covers repairs that are needed withinthe warranty period because of defects in material andworkmanship. Installation errors, accidents, normal wear, and avariety of other causes that affect the product are not covered.Warranty is limited to defects in material or workmanship, butonly when the consumer sale is made in the country to whichdistribution is authorized by us.Should you have any questions concerning warranty coverage,contact your authorized dealer. They will be pleased to answerany questions that you may have.GENERAL EXCLUSIONS FROM WARRANTY1. Minor adjustments and tune‐ups, including checking,cleaning, or adjusting spark plugs, ignition components,carburetor settings, filters, belts, controls, and checkinglubrication made in connection with normal services.2. Factory installed jet drive units ‐ Specific parts excludedfrom the warranty are: the jet drive impeller and jet driveliner damaged by impact or wear, and water damageddriveshaft bearings as a result of improper maintenance.3. Damage caused by neglect, lack of maintenance, accident,abnormal operation, or improper installation or service.4. Haul‐out, launch, towing charges, removal and/orreplacement of boat partitions or material because of boatdesign for necessary access to the product, all relatedtransportation charges and/or travel time, etc. Reasonableaccess must be provided to the product for warranty service.Customer must deliver product to an authorized dealer.eng 11

WARRANTY INFORMATION5. Additional service work requested by customer other thanthat necessary to satisfy the warranty obligation.6. Labor performed by other than an authorized dealer may becovered only under the following circumstances: whenperformed on emergency basis (providing there are noauthorized dealers in the area who can perform the workrequired or have no facilities to haul‐out, etc., and priorfactory approval has been given to have the work performedat this facility).7. All incidental and/or consequential damages (storagecharges, telephone or rental charges of any type,inconvenience or loss of time or income) are the owner'sresponsibility.8. Use of other than Mercury Precision or Quicksilver partswhen making warranty repairs.9. Oils, lubricants, or fluids changed as a matter of normalmaintenance is customer's responsibility unless loss orcontamination of same is caused by product failure thatwould be eligible for warranty consideration.10.Participating in or preparing for racing or other competitiveactivity or operating with a racing type lower unit.11.Engine noise does not necessarily indicate a serious engineproblem. If diagnosis indicates a serious internal enginecondition which could result in a failure, conditionresponsible for noise should be corrected under thewarranty.12.Lower unit and/or propeller damage caused by striking asubmerged object is considered a marine hazard.13.Water entering engine through the fuel intake, air intake, orexhaust system or submersion.14.Failure of any parts caused by lack of cooling water, whichresults from starting motor out of water, foreign materialblocking inlet holes, motor being mounted too high, ortrimmed too far out.15.Use of fuels and lubricants which are not suitable for usewith or on the product. Refer to the Maintenance section.12 eng

WARRANTY INFORMATION16.Our limited warranty does not apply to any damage to ourproducts caused by the installation or use of parts andaccessories which are not manufactured or sold by us.Failures which are not related to the use of those parts oraccessories are covered under warranty if they otherwisemeet the terms of the limited warranty for that product.U.S. EPA Emissions Limited WarrantyConsistent with the obligations created by 40 CFR Part 1045,Subpart B, Mercury Marine provides a five year or 175 hours ofengine use, whichever occurs first, to the retail customer, thatthe engine is designed, built, and equipped so as to conform atthe time of sale with applicable regulations under section 213 ofthe Clean Air Act, and that the engine is free from defects inmaterials and workmanship which cause the engine to fail toconform with applicable regulations. This emission‐relatedwarranty covers all the components listed in the EmissionControl System Components.Emission Control System ComponentsThe EPA and California emission‐related warranty covers all thefollowing list of components:COMPONENTS OF THE EMISSIONS CONTROL SYSTEM:1. Fuel metering systema. Carburetor and internal parts (and/or pressure regulatoror fuel injection system)b. Cold start enrichment systemc. Intake valves2. Air induction systema. Intake manifoldb. Turbocharger or supercharger systems (whereapplicable)3. Ignition systema. Spark plugsb. Magneto or electronic ignition systemc. Spark advance/retard systemeng 13

WARRANTY INFORMATIONd. Ignition coil and/or control modulee. Ignition wires4. Lubrication system (4‐Stroke engines excluded)a. Oil pump and internal partsb. Oil injectorsc. Oil meter5. Exhaust systema. Exhaust manifoldb. Exhaust valves6. Miscellaneous items used in above systemsa. Hoses, clamps, fittings, tubing, sealing gaskets ordevices, and mounting hardwareb. Pulleys, belts, and idlersc. Vacuum, temperature, check and time sensitive valvesand switchesd. Electronic controlsThe emission‐related warranty does not cover componentswhose failure would not increase an engine's emissions on anyregulated pollutant.California Emissions Limited WarrantyThe California Air Resources Board has promulgated airemission regulations for outboard engines. The regulations applyto all outboard engines sold to retail consumers in California, andwhich were manufactured for the 2001 model year and later.Mercury Marine, in compliance with those regulations, providesthis limited warranty for the emission control systems (see thecomponents listed in the Emission Control SystemComponents), and further warrants that the outboard enginewas designed, built, and equipped to conform with all applicableregulations adopted by the California Air Resources Boardpursuant to its authority in Chapters 1 and 2, Part 5, Division 26of the Health and Safety Code. For information regarding thelimited warranty for the nonemission‐related components of theoutboard, please see the limited warranty statement for youroutboard.14 eng

WARRANTY INFORMATIONWHAT IS COVERED: Mercury Marine warrants the componentsof the emissions control systems (see the components listed inthe Emission Control System Components) of its new, 2001model year and later outboards, sold by a California dealer toretail customers residing in California, to be free from defects inmaterial or workmanship, that cause the failure of a warrantedpart to be identical in all material respects to that part asdescribed in the application of Mercury Marine for certificationfrom the California Air Resources Board, for the period of time,and under the conditions, identified below. The cost to diagnosea warranty failure is covered under the warranty (if the warrantyclaim is approved). Damage to other engine components causedby the failure of a warranted part will also be repaired underwarranty.DURATION OF COVERAGE: This limited warranty providescoverage for the components of the emissions control systems ofnew, 2001 model year and later outboards, sold to retailcustomers in California for four (4) years from either the date theproduct is first sold, or first put into service, whichever occursfirst, or the accumulation of 250 hours of engine operation (asdetermined by the engine's hour meter, if any). Emission‐relatednormal maintenance items such as spark plugs and filters, thatare on the warranted parts list, are warranted up to their firstrequired replacement interval only. Refer to Emission ControlSystem Components and Maintenance Schedule. The repair orreplacement of parts, or the performance of service under thiswarranty, does not extend the life of this warranty beyond itsoriginal expiration date. Unexpired warranty coverage can betransferred to a subsequent purchaser. (See instructions ontransfer of warranty.)eng 15

WARRANTY INFORMATIONHOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repairand reasonable access to the product for warranty service.Warranty claims shall be made by delivering the product forinspection to a Mercury dealer authorized to service the product.If purchaser cannot deliver the product to such a dealer, pleasenotify Mercury Marine and Mercury will then arrange for theinspection and any covered repair. Purchaser, in that case, shallpay for all related transportation charges and/or travel time. If theservice provided is not covered by this warranty, purchaser shallpay for all related labor and material, and any other expensesassociated with that service. Purchaser shall not, unlessrequested by Mercury, ship the product or parts of the productdirectly to Mercury.WHAT MERCURY WILL DO: Mercury Marine's sole andexclusive obligation under this warranty is limited to, at ourexpense and at our option, repairing or replacing defective partswith new or Mercury Marine certified remanufactured parts, orrefunding the purchase price of the Mercury product. Mercuryreserves the right to improve or modify products from time totime without assuming an obligation to modify productspreviously manufactured.WHAT IS NOT COVERED: This limited warranty does not coverroutine maintenance items, tune‐ups, adjustments, normal wearand tear, damage caused by abuse, abnormal use, use of apropeller or gear ratio that does not allow the engine to run in itsrecommended wide‐open throttle RPM range (see GeneralInformation ‐ Specifications), operation of the product in amanner inconsistent with the recommended operationprocedures, neglect, accident, submersion, improper installation(proper installation specifications and techniques are set forth inthe installation instructions for the product), improper service, jetpump impellers and liners, operation with fuels, oils, or lubricantswhich are not suitable for use with the product (see Fuel andOil), alteration or removal of parts.16 eng

WARRANTY INFORMATIONExpenses related to haul‐out, launch, towing, storage, telephone,rental, inconvenience, slip fees, insurance coverage, loanpayments, loss of time, loss of income, or any other type ofincidental or consequential damages are not covered by thiswarranty. Also, expenses associated with the removal and/orreplacement of boat partitions or material caused by boat designfor access to the product are not covered by this warranty.Nonwarranty maintenance, replacement, or repair of emissioncontrol devices and systems may be performed by any marineengine repair establishment or individual. The use ofnon‐Mercury parts for nonwarranty maintenance or repairs willnot be grounds for disallowing other warranty work. The use ofadd‐on (as defined at section 1900 (b)(1) and (b)(10) of Title 13of the California Code of Regulations) or modified parts notexempted by the California Air Resources Board may begrounds for disallowing a warranty claim, at the discretion ofMercury Marine. Failures of warranted parts caused by the useof a nonexempted add‐on or modified part will not be covered.DISCLAIMERS AND LIMITATIONSTHE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THEEXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGESARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOMESTATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOUSPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGALRIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TOCOUNTRY.If you have any questions regarding your warranty rights andresponsibilities, you should contact Mercury Marine at1‐920‐929‐5040.eng 17

WARRANTY INFORMATIONCalifornia Air Resources Board Explanation ofYour California Emission Control WarrantyStatementYOUR WARRANTY RIGHTS AND OBLIGATIONS: TheCalifornia Air Resources Board is pleased to explain theemission control system warranty on your 2001 model year andlater outboard engine. In California, new outboard engines mustbe designed, built, and equipped to meet the State's stringentantismog standards. Mercury Marine must warrant the emissioncontrol system on your outboard engine for the periods of timelisted below, provided there has been no abuse, neglect, orimproper maintenance of your outboard engine.Your emission control system may include parts such as thecarburetor or fuel injection system, the ignition system, andcatalytic converter. Also included may be hoses, belts,connectors, and other emission‐related assemblies.Where a warrantable condition exists, Mercury Marine will repairyour outboard engine at no cost to you, including diagnosis,parts, and labor.MANUFACTURER'S WARRANTY COVERAGE: Select emissioncontrol parts from model year 2001 and later outboard enginesare warranted for four (4) years, or for 250 hours of use,whichever occurs first. However, warranty coverage based onthe hourly period is only permitted for outboard engines andpersonal watercraft equipped with appropriate hour meters ortheir equivalent. If any emission‐related part on your engine isdefective under warranty, the part will be repaired or replaced byMercury Marine.OWNER'S WARRANTY RESPONSIBILITIES: As the outboardengine owner, you are responsible for the performance of therequired maintenance listed in the Maintenance section.Mercury Marine recommends that you retain all receipts coveringmaintenance on your outboard engine, but Mercury Marinecannot deny warranty solely for the lack of receipts or yourfailure to ensure the performance of all scheduled maintenance.18 eng

WARRANTY INFORMATIONAs the outboard engine owner, you should, however, be awarethat Mercury Marine may deny you warranty coverage if youroutboard engine or a part has failed due to abuse, neglect,improper maintenance, or unapproved modifications.You are responsible for presenting your outboard to a Mercurydealer authorized to service the product as soon as a problemexists. The warranty repairs will be completed in a reasonableamount of time, not to exceed 30 days.If you have any questions regarding your warranty rights andresponsibilities, you should contact Mercury Marine at1‐920‐929‐5040.Emission Certification Star LabelOutboards are labeled on the cowl with one of the following starlabels.The symbol for a cleaner marine engine means:Cleaner air and water ‐ for a healthier lifestyle and environment.Better fuel economy ‐ burns up to 30–40 percent less gas and oilthan conventional carbureted two‐stroke engines, saving moneyand resources.Longer emission warranty ‐ protects consumer for worry‐freeoperation.One Star ‐ Low Emission22531The One Star label identifies engines that meetthe Air Resources Board's 2001 exhaustemissions standards. Engines meeting thesestandards have 75% lower emissions thanconventional carbureted two‐stroke engines.These engines are equivalent to the U.S. EPA's2006 standards for marine engines.Two Stars ‐ Very Low Emission42537The Two Star label identifies engines that meetthe Air Resources Board's Personal Watercraftand Outboard marine engine 2004 exhaustemissions standards. Engines meeting thesestandards have 20% lower emissions than OneStar ‐ Low Emission engines.eng 19

WARRANTY INFORMATIONThree Stars ‐ Ultra Low Emission42538The Three Star label identifies engines that meetthe Air Resources Board's Personal Watercraftand Outboard marine engine 2008 exhaustemissions standards or the Sterndrive andInboard marine engine 2003‐2008 exhaustemission standards. Engines meeting thesestandards have 65% lower emissions than OneStar ‐ Low Emission engines.Four Stars ‐ Super Ultra Low Emission42539The Four Star label identifies engines that meetthe Air Resources Board's Sterndrive and Inboardmarine engine 2009 exhaust emission standards.Personal Watercraft and Outboard marine enginesmay also comply with these standards. Enginesmeeting these standards have 90% loweremissions than One Star ‐ Low Emission engines.Warranty Policy—Australia and New ZealandMERCURY/MARINER OUTBOARD LIMITED WARRANTY–AUSTRALIA AND NEW ZEALAND POLICYThis limited warranty is given by Marine Power International PtyLtd ACN 003 100 007 of 41–71 Bessemer Drive, DandenongSouth, Victoria 3175 Australia (telephone (61) (3) 9791 5822)e‐mail: merc_info@mercmarine.com.What is CoveredMercury Marine warrants its new products to be free of defects inmaterial and workmanship during the period described below.The benefits to the consumer given by the warranty are inaddition to other rights and remedies of the consumer under alaw in relation to the goods or services to which the warrantyrelates.20 eng

WARRANTY INFORMATIONGuarantees Under Australian Consumer LawOur goods come with guarantees that cannot be excluded underthe Australian Consumer Law. You are entitled to a replacementor refund for a major failure and compensation for any otherreasonably foreseeable loss or damage. You are also entitled tohave the goods repaired or replaced if the goods fail to be ofacceptable quality and the failure does not amount to a majorfailure.Warranty Period for Recreational UseThis Limited Warranty provides coverage for three (3) years fromthe date the product is first sold to a recreational use retailpurchaser, or the date on which the product is first put intoservice, whichever occurs first. Unexpired warranty coveragecan be transferred to a subsequent recreational use customerupon proper registration of the product.Warranty Period for Commercial UseCommercial users of these products receive warranty coverageunder this Limited Warranty of one (1) year from the date of firstretail sale, or one (1) year from the date on which the productwas first put into service, whichever occurs first. Commercial useis defined as any work or employment related use of the product,or any use of the product which generates income, for any partof the warranty period, even if the product is only occasionallyused for such purposes. Unexpired warranty coverage cannot betransferred either to or from a commercial use customer.eng 21

WARRANTY INFORMATIONConditions That Must Be Met to Obtain Warranty CoverageWarranty coverage under this Limited Warranty is available onlyto retail customers that purchase from a Dealer authorized byMercury Marine to distribute the product in the country in whichthe sale occurred, and then only after the Mercury Marinespecified predelivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Inaccuratewarranty registration information regarding recreational use, orsubsequent change of use from recreational to commercial(unless properly registered) may void the warranty at the solediscretion of Mercury Marine. Routine maintenance outlined inthe Operation and Maintenance Manual must be timelyperformed in order to maintain warranty coverage. MercuryMarine reserves the right to make warranty coverage contingentupon proof of proper maintenance.What Mercury Will DoMercury Marine's sole and exclusive obligation under thisLimited Warranty is limited to, at our option, repairing a defectivepart, replacing such part or parts with new or Mercury Marinecertified remanufactured parts, or refunding the purchase price ofthe Mercury Marine product. Mercury Marine reserves the rightto improve or modify products from time to time withoutassuming an obligation to modify products previouslymanufactured.22 eng

WARRANTY INFORMATIONHow to Obtain Warranty Coverage Under This Limited WarrantyThe customer must provide Mercury Marine with a reasonableopportunity to repair and reasonable access to the product forwarranty service. Warranty claims shall be made by deliveringthe product for inspection to a Mercury Marine dealer authorizedto service the product. A list of dealers and their contact details isavailable at www.mercurymarine.com.au. If the purchaser cannotdeliver the product to such a dealer, written notice must be givento Mercury Marine at the address shown above. Mercury Marinewill then arrange for the inspection and any covered repair. ThisLimited Warranty will not cover the purchaser for all relatedtransportation charges and travel time. If the service provided isnot covered by this limited warranty, the purchaser shall pay forall related labor and material and any other expenses associatedwith that service, provided that a consumer will not be obligatedto pay where the service has been carried out to remedy a failureof an acceptable quality guarantee which is binding on MercuryMarine under the Australian Consumer Law. The purchaser shallnot, unless requested by Mercury Marine, ship the product orparts of the product directly to Mercury Marine. Proof ofregistered ownership must be presented to the dealer at the timewarranty service is requested in order to obtain coverage underthis Limited Warranty.eng 23

What is Not CoveredWARRANTY INFORMATIONThis limited warranty does not cover routine maintenance items,tune‐ups, adjustments, normal wear and tear, damage causedby abuse, abnormal use, use of a propeller or gear ratio thatdoes not allow the engine to run in its recommended wide‐openthrottle RPM range (see the Operation and MaintenanceManual), operation of the product in a manner inconsistent withthe recommended operation/duty cycle section of the Operationand Maintenance Manual, neglect, accident, submersion,improper installation (proper installation specifications andtechniques are set forth in the installation instructions for theproduct), improper service, use of an accessory or part notmanufactured or sold by us, jet pump impellers and liners,operation with fuels, oils or lubricants which are not suitable foruse with the product (see the Operation and MaintenanceManual), alteration or removal of parts, water entering the enginethrough the fuel intake, air intake or exhaust system, or damageto the product from insufficient cooling water caused by blockageof the cooling system by a foreign body, running the engine outof water, mounting the engine too high on the transom, orrunning the boat with the engine trimmed out too far. Use of theproduct for racing or other competitive activity, or operating witha racing type lower unit, at any point, even by a prior owner ofthe product, voids the warranty.Expenses related to haul‐out, launch, towing, storage, telephone,rental, inconvenience, slip fees, insurance coverage, loanpayments, loss of time, loss of income, or any other type ofincidental or consequential damages are not covered by thisLimited Warranty. Also, expenses associated with the removaland/or replacement of boat partitions or material caused by boatdesign for access to the product are not covered by thiswarranty.24 eng

WARRANTY INFORMATIONNo individual or entity, including Mercury Marine authorizeddealers, has been given authority by Mercury Marine to makeany affirmation, representation or warranty regarding theproduct, other than those contained in this limited warranty, andif made, shall not be enforceable against Mercury Marine. Foradditional information regarding events and circumstancescovered by this warranty, and those that are not, see theWarranty Coverage section of the Operation and MaintenanceManual, incorporated by reference into this warranty.Expense of Claiming This Limited WarrantyThis Limited Warranty does not cover any expenses you mayincur claiming the warranty.DISCLAIMERS AND LIMITATIONS:EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS ANDREMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIANCONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THEPRODUCTS RELATE, THE IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AREEXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BEDISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATIONTO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL ANDCONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGEUNDER THIS LIMITED WARRANTY.TRANSFER OF WARRANTY—AUSTRALIA AND NEWZEALAND POLICYThe limited warranty is transferable to a subsequent purchaser,but only for the remainder of the unused portion of the limitedwarranty. This will not apply to products used for commercialapplications.To transfer the warranty to the subsequent owner, send or fax acopy of the Bill of Sale or Purchase Agreement, new owner’sname, address, and hull identification number (HIN) to MercuryMarine’s Warranty Registration Department. In Australia andNew Zealand, mail to:eng 25

Mercury MarineWARRANTY INFORMATIONAttn: Warranty Registration DepartmentBrunswick Asia Pacific GroupPrivate Bag 1420Dandenong South, Victoria 3164AustraliaUpon processing the transfer of warranty, Mercury Marine willsend registration verification to the new owner of the product bymail. There is no charge for this service.You may change your address at any time, including at the timeof the warranty claim, by calling Mercury Marine or sending aletter or fax with your name, old address, new address, and hullidentification number (HIN) to Mercury Marine’s WarrantyRegistration Department.26 eng

GENERAL INFORMATIONBoater's ResponsibilitiesThe operator (driver) is responsible for the correct and safeoperation of the boat and the safety of its occupants and generalpublic. It is strongly recommended that each operator read andunderstand this entire manual before operating the outboard.Be sure that at least one additional person onboard is instructedin the basics of starting and operating the outboard and boathandling in case the driver is unable to operate the boat.Before Operating Your OutboardRead this manual carefully. Learn how to operate your outboardproperly. If you have any questions, contact your dealer.Safety and operating information that is practiced, along withusing good common sense, can help prevent personal injury andproduct damage.This manual as well as safety labels posted on the outboard usethe following safety alerts to draw your attention to special safetyinstructions that should be followed.! DANGERIndicates a hazardous situation which, if not avoided, will resultin death or serious injury.! WARNINGIndicates a hazardous situation which, if not avoided, couldresult in death or serious injury.! CAUTIONIndicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.NOTICEIndicates a situation which, if not avoided, could result inengine or major component failure.eng 27

GENERAL INFORMATIONBoat Horsepower Capacity! WARNINGExceeding the boat's maximum horsepower rating can causeserious injury or death. Overpowering the boat can affect boatcontrol and flotation characteristics or break the transom. Donot install an engine that exceeds the boat's maximum powerrating.Do not overpower or overload your boat. Most boats will carry arequired capacity plate indicating the maximum acceptablepower and load as determined by the manufacturer followingcertain federal guidelines. If in doubt, contact your dealer or theboat manufacturer.U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSONCAPACITY (POUNDS)MAXIMUM WEIGHTCAPACITYXXXXXX26777High‐Speed and High‐Performance Boat OperationIf your outboard is to be used on a high‐speed orhigh‐performance boat with which you are unfamiliar, werecommend that you never operate it at its high speed capabilitywithout first requesting an initial orientation and familiarizationdemonstration ride with your dealer or an operator experiencedwith your boat/outboard combination. For additional information,obtain a copy of our Hi‐Performance Boat Operation bookletfrom your dealer, distributor, or Mercury Marine.28 eng

GENERAL INFORMATIONPropeller SelectionThe propeller on your outboard is one of the most importantcomponents in the propulsion system. An improper propellerchoice can significantly affect the performance of your boat andcould result in damage to the outboard engine.When choosing a propeller, a full selection of aluminum andstainless steel propellers specifically designed for your outboardare available through Mercury Marine. To view the entire productoffering and find the correct propeller that is best suited for yourapplication, visit www.mercmarinepropellers.com or see yourlocal authorized Mercury dealer.SELECTING THE CORRECT PROPELLERAn accurate tachometer for measuring engine speed is importantin choosing the correct propeller.Choose a propeller for your boating application that will allow theengine to operate within the specified full throttle operatingrange. When operating the boat at full throttle under normal loadconditions, the engine RPM should be in the upper half of therecommended full throttle RPM range. Refer to Specifications.If engine RPM is above that range, select a propeller ofincreased pitch in order to reduce engine RPM. If engine RPM isbelow the recommended range, select a propeller of reducedpitch to increase engine RPM.IMPORTANT: To ensure proper fit, and performance, MercuryMarine recommends the use of Mercury or Quicksilver brandedpropellers and mounting hardware.eng 29

GENERAL INFORMATIONPropellers are designated by the diameter, pitch, number ofblades, and material. The diameter and pitch are stamped (cast)into the side or the end of the propeller hub. The first numberrepresents the diameter of the propeller and the second numberrepresents the pitch. For example, 14x19 represents a propellerwith a 14 inch diameter and 19 inches of pitch.ab22669a - Diameterb - Pitch ‐ Travel during one revolutionThe following are some propeller basics that will help youdetermine the correct propeller for your boating application.Diameter ‐ The diameter is the distance across the imaginarycircle that is made when the propeller rotates. The correctdiameter for each propeller has been predetermined for thedesign of your outboard. However, when more than onediameter is available for the same pitch, use a larger diameter forheavy boat applications and a smaller diameter for lighterapplications.Pitch ‐ The pitch is the theoretical distance, in inches, that apropeller travels forward during one revolution. Pitch can bethought of similar to gears in a car. The lower the gear, the fasterthe car will accelerate, but with lower overall top speed.Likewise, a lower pitch propeller will accelerate quickly, buttop‐end speed will be reduced. The higher the propeller pitch thefaster the boat will usually go; though typically slowingacceleration.30 eng

GENERAL INFORMATIONDetermining the correct pitch size ‐ First, check the full throttleRPM under normal load condition. If the full throttle RPM iswithin the recommended range, select a replacement or upgradepropeller with the same pitch as the current propeller.• Adding 1 inch of pitch will reduce the full throttle RPM by150 to 200• Subtracting 1 inch of pitch will increase full throttle RPM by150 to 200• Upgrading from a 3‐blade propeller to a 4‐blade propellerwill generally decrease full throttle RPM by 50 to 100IMPORTANT: Avoid damage to the engine. Never use apropeller which allows the engine to exceed the recommendedfull throttle RPM range when under normal full throttle operation.PROPELLER MATERIALMost propellers manufactured by Mercury Marine are made fromeither aluminum or stainless steel. Aluminum is suitable forgeneral purpose use and is standard equipment on many newboats. Stainless steel is over five times more durable thanaluminum and typically provides performance gains inacceleration and top end speed due to design efficiencies.Stainless steel propellers also come in a larger variety of sizesand styles that allow you to dial in the ultimate performance foryour boat.3 BLADE VS. 4 BLADEAvailable in many sizes of both aluminum and stainless, 3 and4‐blade propellers have unique performance characteristics. Ingeneral, 3‐blade propellers offer good all around performanceand higher top speed than 4‐blade propellers. However, 4‐bladepropellers are usually faster to plane and more efficient atcruising speeds, but lack the top end speed of a 3‐bladepropeller.eng 31

GENERAL INFORMATIONOutboard Remote Control ModelsThe remote control connected to your outboard must beequipped with a start in neutral only protection device. Thisprevents the engine from starting when the shift is actuated inany position other than neutral.! WARNINGStarting the engine with the drive in gear can cause seriousinjury or death. Never operate a boat that does not have aneutral‐safety‐protection device.N26838Remote Steering NoticeThe steering link rod that connects the steering cable to theengine must be fastened utilizing self‐locking nuts. Theseself‐locking nuts must never be replaced with common nuts(nonlocking) as they will work loose and vibrate off, freeing thelink rod to disengage.32 eng

GENERAL INFORMATION! WARNINGImproper fasteners or improper installation procedures canresult in loosening or disengagement of the steering link rod.This can cause a sudden, unexpected loss of boat control,resulting in serious injury or death due to occupants beingthrown within or out of the boat. Always use requiredcomponents and follow instructions and torque procedures.a - Self‐locking nutsaa27740Lanyard Stop SwitchThe purpose of a lanyard stop switch is to turn off the enginewhen the operator moves far enough away from the operator'sposition (as in accidental ejection from the operator's position) toactivate the switch. Tiller handle outboards and some remotecontrol units are equipped with a lanyard stop switch. A lanyardstop switch can be installed as an accessory ‐ generally on thedashboard or side adjacent to the operator's position.eng 33

GENERAL INFORMATIONThe lanyard is a cord usually 122–152 cm (4–5 feet) in lengthwhen stretched out, with an element on one end made to beinserted into the switch and a snap on the other end for attachingto the operator. The lanyard is coiled to make its at‐rest conditionas short as possible to minimize the likelihood of lanyardentanglement with nearby objects. Its stretched‐out length ismade to minimize the likelihood of accidental activation shouldthe operator choose to move around in an area close to thenormal operator's position. If it is desired to have a shorterlanyard, wrap the lanyard around the operator's wrist or leg, ortie a knot in the lanyard.ab21629a - Lanyard cordb - Lanyard stop switchRead the following Safety Information before proceeding.34 eng

GENERAL INFORMATIONImportant Safety Information: The purpose of a lanyard stopswitch is to stop the engine when the operator moves far enoughaway from the operator's position to activate the switch. Thiswould occur if the operator accidentally falls overboard or moveswithin the boat a sufficient distance from the operator's position.Falling overboard and accidental ejections are more likely tooccur in certain types of boats such as low sided inflatables,bass boats, high performance boats, and light, sensitive handlingfishing boats operated by a hand tiller. Falling overboard andaccidental ejections are also likely to occur as a result of pooroperating practices such as sitting on the back of the seat orgunwale at planing speeds, standing at planing speeds, sittingon elevated fishing boat decks, operating at planing speeds inshallow or obstacle infested waters, releasing your grip on asteering wheel or tiller handle that is pulling in one direction,drinking alcohol or consuming drugs, or daring high speed boatmaneuvers.While activation of the lanyard stop switch will stop the engineimmediately, a boat will continue to coast for some distancedepending upon the velocity and degree of any turn at shutdown. However, the boat will not complete a full circle. While theboat is coasting, it can cause injury to anyone in the boat's pathas seriously as the boat would when under power.We strongly recommend that other occupants be instructed onproper starting and operating procedures should they berequired to operate the engine in an emergency (if the operatoris accidentally ejected).! WARNINGIf the operator falls out of the boat, stop the engine immediatelyto reduce the possibility of serious injury or death from beingstruck by the boat. Always properly connect the operator to thestop switch using a lanyard.eng 35

GENERAL INFORMATION! WARNINGAvoid serious injury or death from deceleration forces resultingfrom accidental or unintended stop switch activation. The boatoperator should never leave the operator's station without firstdisconnecting the stop switch lanyard from the operator.Accidental or unintended activation of the switch during normaloperation is also a possibility. This could cause any, or all, of thefollowing potentially hazardous situations:• Occupants could be thrown forward due to unexpected lossof forward motion ‐ a particular concern for passengers inthe front of the boat who could be ejected over the bow andpossibly struck by the gearcase or propeller.• Loss of power and directional control in heavy seas, strongcurrent, or high winds.• Loss of control when docking.KEEP THE LANYARD STOP SWITCH AND LANYARDCORD IN GOOD OPERATING CONDITIONBefore each use, check to ensure the lanyard stop switch worksproperly. Start the engine and stop it by pulling the lanyard cord.If the engine does not stop, have the switch repaired beforeoperating the boat.Before each use, visually inspect the lanyard cord to ensure it isin good working condition and that there are no breaks, cuts, orwear to the cord. Check that the clips on the ends of the cord arein good condition. Replace any damaged or worn lanyard cords.36 eng

GENERAL INFORMATIONProtecting People in the WaterWHILE YOU ARE CRUISINGIt is very difficult for a person standing or floating in the water totake quick action to avoid a boat heading in his/her direction,even at slow speed.21604Always slow down and exercise extreme caution any time youare boating in an area where there might be people in the water.Whenever a boat is moving (coasting) and the outboard gearshift is in neutral position, there is sufficient force by the water onthe propeller to cause the propeller to rotate. This neutralpropeller rotation can cause serious injury.WHILE THE BOAT IS STATIONARY! WARNINGA spinning propeller, a moving boat, or any solid deviceattached to the boat can cause serious injury or death toswimmers. Stop the engine immediately whenever anyone inthe water is near your boat.Shift the outboard into neutral and shut off the engine beforeallowing people to swim or be in the water near your boat.eng 37

GENERAL INFORMATIONPassenger Safety Message ‐ Pontoon Boats andDeck BoatsWhenever the boat is in motion, observe the location of allpassengers. Do not allow any passengers to stand or use seatsother than those designated for traveling faster than idle speed.A sudden reduction in boat speed, such as plunging into a largewave or wake, a sudden throttle reduction, or a sharp change ofboat direction, could throw them over the front of the boat.Falling over the front of the boat between the two pontoons willposition them to be run over by the outboard.BOATS HAVING AN OPEN FRONT DECKNo one should ever be on the deck in front of the fence while theboat is in motion. Keep all passengers behind the front fence orenclosure.Persons on the front deck could easily be thrown overboard orpersons dangling their feet over the front edge could get theirlegs caught by a wave and pulled into the water.26782! WARNINGSitting or standing in an area of the boat not designed forpassengers at speeds above idle can cause serious injury ordeath. Stay back from the front end of deck boats or raisedplatforms and remain seated while the boat is in motion.38 eng

GENERAL INFORMATIONBOATS WITH FRONT MOUNTED, RAISED PEDESTALFISHING SEATSElevated fishing seats are not intended for use when the boat istraveling faster than idle or trolling speed. Sit only in seatsdesignated for traveling at faster speeds.Any unexpected, sudden reduction in boat speed could result inthe elevated passenger falling over the front of the boat.26783Wave and Wake JumpingOperating recreational boats over waves and wake is a naturalpart of boating. However, when this activity is done with sufficientspeed to force the boat hull partially or completely out of thewater, certain hazards arise, particularly when the boat entersthe water.26784The primary concern is the boat changing direction while in themidst of the jump. In such case, the landing may cause the boatto veer violently in a new direction. Such a sharp change indirection can cause occupants to be thrown out of their seats, orout of the boat.eng 39

GENERAL INFORMATION! WARNINGWave or wake jumping can cause serious injury or death fromoccupants being thrown within or out of the boat. Avoid waveor wake jumping whenever possible.There is another less common hazardous result from allowingyour boat to launch off a wave or wake. If the bow of your boatpitches down far enough while airborne, upon water contact itmay penetrate under the water surface and submarine for aninstant. This will bring the boat to a nearly instantaneous stopand can send the occupants flying forward. The boat may alsosteer sharply to one side.Impact with Underwater HazardsReduce speed and proceed with caution whenever you drive aboat in shallow water areas, or in areas where you suspectunderwater obstacles may exist which could be struck by theoutboard or the boat bottom. The most important thing you cando to help reduce injury or impact damage from striking a floatingor underwater object is to control the boat speed. Under theseconditions, boat speed should be kept to a minimum planingspeed of 24 to 40 km/h (15 to 25 mph).26785Striking a floating or underwater object could result in an infinitenumber of situations. Some of these situations could result in thefollowing:• Part of the outboard or the entire outboard could break looseand fly into the boat.40 eng

GENERAL INFORMATION• The boat could move suddenly in a new direction. Such asharp change in direction can cause occupants to be thrownout of their seats or out of the boat.• A rapid reduction in speed. This will cause occupants to bethrown forward, or even out of the boat.• Impact damage to the outboard and/or boat.Keep in mind, the most important thing you can do to helpreduce injury or impact damage during an impact is control theboat speed. Boat speed should be kept to a minimum planingspeed when driving in waters known to have underwaterobstacles.After striking a submerged object, stop the engine as soon aspossible and inspect it for any broken or loose parts. If damageis present or suspected, the outboard should be taken to anauthorized dealer for a thorough inspection and necessaryrepair.The boat should also be checked for any hull fractures, transomfractures, or water leaks.Operating a damaged outboard could cause additional damageto other parts of the outboard, or could affect control of the boat.If continued running is necessary, do so at greatly reducedspeeds.! WARNINGOperating a boat or engine with impact damage can result inproduct damage, serious injury, or death. If the vesselexperiences any form of impact, have an authorized MercuryMarine dealer inspect and repair the vessel or power package.eng 41

Exhaust EmissionsGENERAL INFORMATIONBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide (CO) is a deadly gas that is present in theexhaust fumes of all internal combustion engines, including theengines that propel boats, and the generators that power boataccessories. By itself, CO is odorless, colorless, and tasteless,but if you can smell or taste engine exhaust, you are inhalingCO.Early symptoms of carbon monoxide poisoning, which are similarto the symptoms of seasickness and intoxication, includeheadache, dizziness, drowsiness, and nausea.! WARNINGInhaling engine exhaust gases can result in carbon monoxidepoisoning, which can lead to unconsciousness, brain damage,or death. Avoid exposure to carbon monoxide.Stay clear from exhaust areas when engine is running. Keepthe boat well‐ventilated while at rest or underway.STAY CLEAR OF EXHAUST AREAS41127Engine exhaust gases contain harmful carbon monoxide. Avoidareas of concentrated engine exhaust gases. When engines arerunning, keep swimmers away from the boat, and do not sit, lie,or stand on swim platforms or boarding ladders. While underway,do not allow passengers to be positioned immediately behind theboat (platform dragging, teak/body surfing). This dangerouspractice not only places a person in an area of high engineexhaust concentration, but also subjects them to the possibility ofinjury from the boat propeller.42 eng

GENERAL INFORMATIONGOOD VENTILATIONVentilate the passenger area, open side curtains or forwardhatches to remove fumes.Example of desired air flow through the boat:21622POOR VENTILATIONUnder certain running and/or wind conditions, permanentlyenclosed or canvas enclosed cabins or cockpits with insufficientventilation may draw in carbon monoxide. Install one or morecarbon monoxide detectors in your boat.Although the occurrence is rare, on a very calm day, swimmersand passengers in an open area of a stationary boat thatcontains, or is near, a running engine may be exposed to ahazardous level of carbon monoxide.1. Examples of poor ventilation while the boat is stationary:ab21626a - Operating the engine when the boat is moored in aconfined spaceb - Mooring close to another boat that has its engineoperatingeng 43

GENERAL INFORMATION2. Examples of poor ventilation while the boat is moving:ab21628a - Operating the boat with the trim angle of the bow too highb - Operating the boat with no forward hatches open (stationwagon effect)Selecting Accessories for Your OutboardGenuine Mercury Precision or Quicksilver Accessories havebeen specifically designed and tested for your outboard. Theseaccessories are available from Mercury Marine dealers.IMPORTANT: Check with your dealer before installingaccessories. The misuse of approved accessories or the use ofnonapproved accessories can damage the product.Some accessories not manufactured or sold by Mercury Marineare not designed to be safely used with your outboard oroutboard operating system. Acquire and read the installation,operation and maintenance manuals for all your selectedaccessories.Safe Boating RecommendationsTo safely enjoy the waterways, familiarize yourself with local andall other governmental boating regulations and restrictions andconsider the following suggestions.Know and obey all nautical rules and laws of the waterways.• We recommend that all powerboat operators complete aboating safety course. In the U.S., the U.S. Coast GuardAuxiliary, the Power Squadron, the Red Cross, and yourstate or provincial boating law enforcement agency providecourses. For more information in the U.S., call the Boat U.S.Foundation at 1‐800‐336‐BOAT (2628).Perform safety checks and required maintenance.44 eng

GENERAL INFORMATION• Follow a regular schedule and ensure that all repairs areproperly made.Check safety equipment onboard.• Here are some suggestions of the types of safety equipmentto carry when boating:Approved fire extinguishersSignal devices: flashlight, rockets or flares, flag, andwhistle or hornTools necessary for minor repairsAnchor and extra anchor lineManual bilge pump and extra drain plugsDrinking waterRadioPaddle or oarSpare propeller, thrust hubs, and an appropriate wrenchFirst aid kit and instructionsWaterproof storage containersSpare operating equipment, batteries, bulbs, and fusesCompass and map or chart of the areaPersonal flotation device (one per person onboard)Watch for signs of weather change and avoid foul weatherand rough‐sea boating.Tell someone where you are going and when you expect toreturn.Passenger boarding.• Stop the engine whenever passengers are boarding,unloading, or are near the back (stern) of the boat. Shiftingthe drive unit into neutral is not sufficient.Use personal flotation devices.eng 45

GENERAL INFORMATION• Federal law requires that there be a U.S. CoastGuard‐approved life jacket (personal flotation device),correctly sized and readily accessible for every persononboard, plus a throwable cushion or ring. We stronglyadvise that everyone wear a life jacket at all times while inthe boat.Prepare other boat operators.• Instruct at least one person onboard in the basics of startingand operating the engine and boat handling in case thedriver becomes disabled or falls overboard.Do not overload your boat.• Most boats are rated and certified for maximum load(weight) capacities (refer to your boat's capacity plate).Know your boat's operating and loading limitations. Know ifyour boat will float if it is full of water. When in doubt, contactyour authorized Mercury Marine dealer or the boatmanufacturer.Ensure that everyone in the boat is properly seated.• Do not allow anyone to sit or ride on any part of the boat thatwas not intended for such use. This includes the backs ofseats, gunwales, transom, bow, decks, raised fishing seats,and any rotating fishing seat. Passengers should not sit orride anywhere that sudden unexpected acceleration, suddenstopping, unexpected loss of boat control, or sudden boatmovement could cause a person to be thrown overboard orinto the boat. Ensure that all passengers have a proper seatand are in it before any boat movement.Never operate a boat while under the influence of alcohol ordrugs. It is the law.• Alcohol or drugs can impair your judgment and greatlyreduce your ability to react quickly.Know your boating area and avoid hazardous locations.Be alert.46 eng

GENERAL INFORMATION• The operator of the boat is responsible by law to maintain aproper lookout by sight and hearing. The operator musthave an unobstructed view particularly to the front. Nopassengers, load, or fishing seats should block theoperator's view when the boat is above idle or planingtransition speed. Watch out for others, the water, and yourwake.Never drive your boat directly behind a water skier.• Your boat traveling at 40 km/h (25 mph) will overtake afallen skier who is 61 m (200 ft) in front of you in fiveseconds.Watch fallen skiers.• When using your boat for waterskiing or similar activities,always keep a fallen or down skier on the operator's side ofthe boat while returning to attend to the skier. The operatorshould always have the down skier in sight and never backup to the skier or anyone in the water.Report accidents.• Boat operators are required by law to file a boating accidentreport with their state boating law enforcement agency whentheir boat is involved in certain boating accidents. A boatingaccident must be reported if 1) there is loss of life orprobable loss of life, 2) there is personal injury requiringmedical treatment beyond first aid, 3) there is damage toboats or other property where the damage value exceeds$500.00, or 4) there is complete loss of the boat. Seekfurther assistance from local law enforcement.eng 47

-GENERAL INFORMATIONRecording Serial NumberIt is important to record this number for future reference. Theserial number is located on the outboard as shown.adModel Number- - - . - - -XXXXXXXSerial NumberXXXXX XL XXXXXX XXXHP XXX KW XXXLB XXX KG XXXMe rc ury MarineBrunswick Corp.Made in JapanXXbcHPLB23884a - Serial numberb - Model designationc - Year manufacturedd - Certified Europe Insignia (as applicable)SpecificationsModels 75 90115/115 ProXS125Horsepower 75 90 115 125Kilowatts 55.2 66.2 84.6 91.3Full throttleRPM rangeIdle speed inforward gearNumber ofcylindersPistondisplacementCylinder borePiston strokeRecommendedspark plugSpark plug gap5000–5750 RPM625–675 RPM31523.5 cc (92.9 in³)92.11 mm (3.63 in.)76.2 mm (3.0 in.)IZFR5J0.80 mm (0.030 in.)48 eng

GENERAL INFORMATIONModels 75 90115/115 ProXSGear ratio 2.33:1 2.07:1RecommendedgasolineRecommendedoilOil tankcapacityGearcaselubricantcapacityBattery ratingChargingsystem outputEmissioncontrol systemSound atdrivers ear(ICOMIA 39‐94)dBARefer to Fuel and OilRefer to Fuel and Oil4.72 liter (5 US qt)665 ml (22.5 fl oz)1251000 marine cranking amps (MCA) or 800 cold crankingamps (CCA)60 AElectronic engine control (EC)82.0eng 49

GENERAL INFORMATIONComponent Identificationgaihjbdca - Top cowlb - Auxiliary tilt switchc - Transom bracketsd - Gearcasee - Cooling waterintake holesf - Trim tabg - Anti‐ventilationplateh - Driveshaft housingi - Water pumpindicator holej - Bottom cowlfe2946150 eng

TRANSPORTINGTrailering Boat/OutboardTrailer your boat with the outboard tilted down in a verticaloperating position.If additional ground clearance is required, the outboard shouldbe tilted up using an accessory outboard support device. Referto your local dealer for recommendations. Additional clearancemay be required for railroad crossings, driveways, and trailerbouncing.28419IMPORTANT: Do not rely on the power trim/tilt system or tiltsupport lever to maintain proper ground clearance for trailering.The outboard tilt support lever is not intended to support theoutboard for trailering.Shift the outboard to forward gear. This prevents the propellerfrom spinning freely.eng 51

Fuel RecommendationsFUEL AND OILIMPORTANT: Use of improper gasoline can damage yourengine. Engine damage resulting from the use of impropergasoline is considered misuse of the engine, and damagecaused thereby will not be covered under the limitedwarranty.FUEL RATINGSMercury Marine engines will operate satisfactorily when using amajor brand of unleaded gasoline meeting the followingspecifications:USA and Canada ‐ having a posted pump octane rating of 87 (R+M)/2 minimum. Premium gasoline (92 [R+M]/2 octane) is alsoacceptable. Do not use leaded gasoline.Outside USA and Canada ‐ having a posted pump octanerating of 90 RON minimum. Premium gasoline (98 RON) is alsoacceptable. If unleaded gasoline is not available, use a majorbrand of leaded gasoline.USING REFORMULATED (OXYGENATED) GASOLINES(USA ONLY)This type of gasoline is required in certain areas of the USA. Thetwo types of oxygenates used in these fuels are alcohol (ethanol)or ether (MTBE or ETBE). If ethanol is the oxygenate that isused in the gasoline in your area, refer to Gasolines ContainingAlcohol.These reformulated gasolines are acceptable for use in yourMercury Marine engine.GASOLINES CONTAINING ALCOHOLIf the gasoline in your area contains either methanol (methylalcohol) or ethanol (ethyl alcohol), you should be aware ofcertain adverse effects that can occur. These adverse effects aremore severe with methanol. Increasing the percentage of alcoholin the fuel can also worsen these adverse effects.Some of these adverse effects are caused because the alcoholin the gasoline can absorb moisture from the air, resulting in aseparation of the water/alcohol from the gasoline in the fuel tank.52 eng

FUEL AND OILThe fuel system components on your Mercury Marine engine willwithstand up to 10% alcohol content in the gasoline. We do notknow what percentage your boat's fuel system will withstand.Contact your boat manufacturer for specific recommendations onthe boat's fuel system components (fuel tanks, fuel lines, andfittings). Be aware that gasolines containing alcohol may causeincreased:• Corrosion of metal parts• Deterioration of rubber or plastic parts• Fuel permeation through rubber fuel lines• Starting and operating difficulties! WARNINGFuel leakage is a fire or explosion hazard, which can causeserious injury or death. Periodically inspect all fuel systemcomponents for leaks, softening, hardening, swelling, orcorrosion, particularly after storage. Any sign of leakage ordeterioration requires replacement before further engineoperation.Because of possible adverse effects of alcohol in gasoline, it isrecommended that only alcohol‐free gasoline be used wherepossible. If only fuel containing alcohol is available, or if thepresence of alcohol is unknown, increased inspection frequencyfor leaks and abnormalities is required.IMPORTANT: When operating a Mercury Marine engine ongasoline containing alcohol, storage of gasoline in the fuel tankfor long periods should be avoided. Long periods of storage,common to boats, create unique problems. In cars, alcohol‐blendfuels normally are consumed before they can absorb enoughmoisture to cause trouble, but boats often sit idle long enough forphase separation to take place. In addition, internal corrosionmay take place during storage if alcohol has washed protectiveoil films from internal components.eng 53

Fuel RequirementsFUEL AND OILDo not use premixed gas and oil in this engine. The engineautomatically receives extra oil during engine break‐in. Use afresh supply of the recommended gasoline during enginebreak‐in and after engine break‐in.Fuel AdditivesTo minimize carbon deposit buildup in the engine, it isrecommended to add Mercury or Quicksilver Quickleen EngineTreatment additive to the engine's fuel at each tank fillthroughout the boating season. Use additive as directed oncontainer.Avoiding Fuel Flow RestrictionIMPORTANT: Adding components to the fuel supply system(filters, valves, fittings, etc.) may restrict the fuel flow. This maycause engine stalling at low speed, and/or a lean fuel conditionat high RPM that could cause engine damage.Low Permeation Fuel Hose RequirementRequired for outboards manufactured for sale, sold, or offeredfor sale in the United States.• The Environmental Protection Agency (EPA) requires thatany outboard manufactured after January 1, 2009, must uselow permeation fuel hose for the primary fuel hoseconnecting the fuel tank to the outboard.• Low permeation hose is USCG Type B1‐15 or Type A1‐15,defined as not exceeding 15/gm²/24 h with CE 10 fuel at23 °C as specified in SAE J 1527 ‐ marine fuel hose.EPA Pressurized Portable Fuel TankRequirementsThe Environmental Protection Agency (EPA) requires portablefuel systems that are produced after January 1, 2011, for usewith outboard engines to remain fully sealed (pressurized) up to34.4 kPa (5.0 psi). These tanks may contain the following:54 eng

FUEL AND OIL• An air inlet that opens to allow air to enter as the fuel isdrawn out of the tank.• An air outlet that opens (vents) to the atmosphere ifpressure exceeds 34.4 kPa (5.0 psi).Fuel Demand Valve (FDV) RequirementWhenever a pressurized fuel tank is used, a fuel demand valveis required to be installed in the fuel hose between the fuel tankand primer bulb. The fuel demand valve prevents pressurizedfuel from entering the engine and causing a fuel system overflowor possible fuel spillage.The fuel demand valve has a manual release. The manualrelease can be used (pushed in) to open (bypass) the valve incase of a fuel blockage in the valve.acb46273a - Fuel demand valve ‐ installedin the fuel hose between thefuel tank and primer bulbb - Manual releasec - Vent/water drain holesMercury Marine's Pressurized Portable Fuel TankMercury Marine has created a new portable pressurized fuel tankthat meets the preceding EPA requirements. These fuel tanksare available as an accessory or are provided with certainportable outboard models.SPECIAL FEATURES OF THE PORTABLE FUEL TANK• The fuel tank has a two‐way valve which allows air to enterthe tank as the fuel is drawn to the engine, and also opensto vent to the atmosphere if internal pressure in the tankexceeds 34.4 kPa (5.0 psi). A hissing noise may be heardas the tank vents to the atmosphere. This is normal.• The fuel tank includes a fuel demand valve that preventspressurized fuel from entering the engine and causing a fuelsystem overflow or possible fuel spillage.eng 55

FUEL AND OIL• When installing the fuel tank cap, turn the cap to the rightuntil you hear a click. This signals that the fuel cap is fullyseated. A built‐in device prevents overtightening.• The fuel tank has a manual vent screw which should beclosed for transportation and open for operation and capremoval.Since sealed fuel tanks are not vented, they will expand andcontract as the fuel expands and contracts during heating andcooling cycles of the outside air. This is normal.REMOVING THE FUEL CAPaba - Fuel capb - Manual vent screwc - Tab lockIMPORTANT: Contents may be under pressure. Rotate the fuelcap 1/4 turn to relieve pressure before opening.1. Open the manual vent screw on top of the fuel cap.2. Turn the fuel cap until it contacts the tab lock.3. Press down on the tab lock. Rotate the fuel cap 1/4 turn torelieve the pressure.4. Press down on the tab lock again and remove the cap.DIRECTIONS FOR USING THE PRESSURIZED PORTABLEFUEL TANK1. When installing the fuel tank cap, turn the cap to the rightuntil you hear a click. This signals that the fuel cap is fullyseated. A built‐in device prevents overtightening.2. Open the manual vent screw on top of the cap for operationand cap removal. Close the manual vent screw fortransportation.3. For fuel hoses that have quick disconnects, disconnect thefuel line from the engine or fuel tank when not in use.c4629056 eng

FUEL AND OIL4. Follow Filling Fuel Tank instructions for fueling.Oil RecommendationRecommended OilOptiMax Oil or Premium Plus 2‐Cycle TCW 3Outboard OilMercury OptiMax/DFI or Quicksilver DFI 2‐Cycle Engine Oil isrecommended for your engine. If Mercury OptiMax/DFI orQuicksilver DFI 2‐Cycle Engine Oil is not available, werecommend using Mercury or Quicksilver TC‐W3 Premium Plus2‐Cycle Oil. Severe engine damage may result from use of aninferior oil.Filling Oil Injection System1. Place the outboard in a vertical operating position.2. Remove the cowl cover.3. Remove the oil filler cap.ab 37147a - Cowl coverb - Oil filler capeng 57

FUEL AND OIL4. Oil filler caps with a dipstick ‐ Check the oil level on thedipstick. The first set of holes indicates 0.94 liters (1 US qt)low. The second set of holes indicates 1.89 liters (2 US qt)low. The third set of holes indicates 2.83 liters (3 US qt) low.abc37143a - Add 0.94 liters (1 US qt)b - Add 1.89 liters (2 US qt)c - Add 2.83 liters (3 US qt)5. Oil filler caps with a chain ‐ Check the oil level on the chain.The first ball marker indicates 0.94 liters (1 US qt) low. Thesecond ball marker indicates 1.89 liters (2 US qt) low.ab37146a - Add 0.94 liters (1 US qt)b - Add 1.89 liters (2 US qt)6. Slowly fill the oil tank with the specified oil. Do not overfill.Add only enough oil to bring the oil level up to the bottom ofthe fill neck.58 eng

FUEL AND OILCapacityFluid TypeOil tank 4.72 liters (5 US qt) OptiMax/DFI 2‐Cycle Engine Oil294657. Install the oil filler cap and tighten securely. Install the cowlcover.29466Filling Fuel Tank! WARNINGAvoid serious injury or death from a gasoline fire or explosion.Use caution when filling fuel tanks. Always stop the engine anddo not smoke or allow open flames or sparks in the area whilefilling fuel tanks.Fill the fuel tanks outdoors away from heat, sparks, and openflames.Remove portable fuel tanks from the boat to refill them.Always stop engine engine before filling the tanks.eng 59

FUEL AND OILDo not completely fill the fuel tanks. Leave approximately 10% ofthe tank volume unfilled. Fuel will expand in volume as itstemperature rises and can leak under pressure if the tank iscompletely filled.60 eng

FEATURES AND CONTROLSRemote Control FeaturesYour boat may be equipped with one of the Mercury Precision orQuicksilver remote controls shown. If not, consult your dealer fora description of the functions and operations of the remotecontrol.cccfabahgbiaieddefgf26800a - Control handle – forward, neutral, reverseb - Neutral release leverc - Trim/tilt switch (if equipped) – Refer to Features andControls – Power Trim and Tiltd - Lanyard stop switch – Refer to General Information –Lanyard Stop Switche - Lanyard – Refer to General Information – Lanyard StopSwitchf - Throttle friction adjustment – Console controls requirecover removal for adjustmentg - Ignition key switch – "OFF," "ON," START"h - Fast idle lever – Refer to Operation – Starting the Enginei - Throttle only button – Refer to Operation – Starting theEngineeng 61

Warning SystemFEATURES AND CONTROLSWARNING HORN SIGNALSWhen the key switch is turned to the "ON" position, the horn willturn on for a moment as a test to indicate the horn is working.There are two types of warning horns to alert the operator of anactive problem within the engine’s operating system.1. Continuous six second beep: Indicates a critical enginecondition. Depending on the condition, the Engine Guardiansystem may engage and protect the engine by limiting it’spower. You should return to port immediately and contactyour servicing dealer.2. Intermittent short beeps for six seconds: Indicates anoncritical engine condition. This condition does not requireimmediate attention. You may continue using your boat,however, depending on the nature of the problem, theengine’s power may be limited by the Engine Guardiansystem (see Engine Guardian System following) to protectthe engine. You should contact your servicing dealer at yourearliest convenience.It is important to note that in either of the above scenarios, thehorn will only sound one time. If you key the engine off andrestart it, the horn will sound again, one time, if the fault is stillpresent. For visual display of the specific engine functions andadditional engine data, refer to SmartCraft Product information,following.A few of the noncritical conditions indicated by the intermittentshort beeps for six seconds can be corrected by the operator.These operator correctable conditions are as follows:• Water in the engine mounted fuel filter. Refer toMaintenance – Water Separating Fuel Filter.• Cooling system (water pressure or engine temperature)problem. Stop the engine and check the water intake holesin the lower unit for obstruction.• Low engine oil level. Refer to Fuel and Oil – Checking andAdding Engine Oil.62 eng

FEATURES AND CONTROLSENGINE GUARDIAN SYSTEMThe Engine Guardian system monitors the critical sensors on theengine for any early indications of problems. Engine Guardian isfunctional whenever your engine is operating, so you never haveto be concerned about whether or not you are protected. Thesystem will respond to a problem by sounding the warning hornfor six seconds and/or reducing engine power in order to provideengine protection.If Engine Guardian has been activated, reduce the enginespeed. The problem will need to be identified and corrected. Thesystem must be reset before the engine will operate at higherspeeds. Moving the throttle lever back to the idle position willreset the Engine Guardian system. If the Engine Guardiansystem has determined the reset has not corrected the problem,Engine Guardian will remain activated, limiting the throttle. Theproblem must be identified and corrected before EngineGuardian will allow the engine to reach a normal operating RPM.OVERSPEED REV LIMITThe overspeed rev limit is set at an RPM greater than theoperating range. In the event that the engine is operated at anRPM greater than or equal to the overspeed limit, the PCM doesnot allow the engine to maintain the power requested by theoperator. Refer to Specifications to determine this engine’sRPM limit.Upon reaching the beginning of the rev limit, Engine Guardianwill cut‐out the ignition to specific cylinders. If the operator doesnot reduce engine speed, Engine Guardian will cut‐out theignition to all the cylinders. There is no audible warning whileEngine Guardian overspeed limit is active.To reset the Engine Guardian protection:1. Completely reduce the throttle for three seconds.2. Engage the throttle. If the engine does not respond, repeatstep one.eng 63

FEATURES AND CONTROLSSMARTCRAFT PRODUCTA Mercury SmartCraft System instrument package can bepurchased for this outboard. A few of the functions theinstrument package will display are engine RPM, coolanttemperature, battery voltage, fuel consumption, and engineoperating hours.The SmartCraft instrument package will also aid in EngineGuardian diagnostics. The SmartCraft instrument package willdisplay critical engine alarm data and potential problems.Power Trim and TiltYour outboard has a trim/tilt control called power trim. Thisenables the operator to easily adjust the position of the outboardby pressing the trim switch. Moving the outboard in closer to theboat transom is called trimming in or down. Moving the outboardfurther away from the boat transom is called trimming out or up.The term trim generally refers to the adjustment of the outboardwithin the first 20° range of travel. This is the range used whileoperating your boat on plane. The term tilt is generally usedwhen referring to adjusting the outboard further up out of thewater. With the engine turned off, the outboard can be tilted outof the water. At low idle speed, the outboard can also be tilted uppast the trim range to permit, for example, shallow wateroperation.abc27761a - Trim switchb - Tilt range oftravelc - Trim range oftravelPOWER TRIM OPERATIONNOTE: When traveling at slow speeds, a slight drop in engineRPM may be noticed on occasion when engaging power trim.This condition is normal and has no adverse affect on theoutboard.64 eng

FEATURES AND CONTROLSWith most boats, operating around the middle of the trim rangewill give satisfactory results. However, to take full advantage ofthe trimming capability there may be times when you choose totrim your outboard all the way in or out. Along with animprovement in some performance aspects comes a greaterresponsibility for the operator, and this is being aware of somepotential control hazards.The most significant control hazard is a pull or torque that can befelt on the steering wheel or tiller handle. This steering torqueresults from the outboard being trimmed so that the propellershaft is not parallel to the water surface.! WARNINGTrimming the outboard beyond a neutral steering conditionmay result in a pull on the steering wheel or tiller handle andloss of boat control. Maintain control of the boat if trimmingbeyond a neutral steering condition.Consider the following lists carefully.1. Trimming in or down can:• Lower the bow.• Result in quicker planing off, especially with a heavy loador a stern heavy boat.• Generally improve the ride in choppy water.• Increase steering torque or pull to the right (with thenormal right‐hand rotation propeller).• In excess, can lower the bow of some boats to a pointwhere they begin to plow with their bow in the water whileon plane. This can result in an unexpected turn in eitherdirection (called bow steering or oversteering) if any turnis attempted, or if a significant wave is encountered.eng 65

FEATURES AND CONTROLS! WARNINGOperating the boat at high speeds with the outboard trimmedtoo far under can create excessive bow steer, resulting in theoperator losing control of the boat. Install the trim limit pin in aposition that prevents excessive trim under and operate theboat in a safe manner.• In rare circumstances, the owner may decide to limit thetrim in. This can be accomplished by purchasing astainless steel tilt pin from your dealer and inserting it inwhatever adjustment hole in the transom brackets isdesired. The nonstainless steel shipping bolt should notbe used in this application.2. Trimming out or up can:• Lift the bow higher out of the water.• Generally increase top speed.• Increase clearance over submerged objects or a shallowbottom.• Increase steering torque or pull to the left at a normalinstallation height (with the normal right‐hand rotationpropeller).• In excess, can cause boat porpoising (bouncing) orpropeller ventilation.• Cause engine overheating if any cooling water intakeholes are above the waterline.TILTING OPERATIONTo tilt the outboard, shut off the engine and press the trim/tiltswitch or auxiliary tilt switch to the up position. The outboard willtilt up until the switch is released or it reaches its maximum tiltposition.1. Engage the tilt support lever by rotating the knob to bring thesupport lever upward.2. Lower the outboard to rest on the tilt support lever.66 eng

FEATURES AND CONTROLS3. Disengage the tilt support lever by raising the outboard offthe support lever and rotating the lever down. Lower theoutboard.aa - Tilt support leverb - Knobb27778MANUAL TILTINGIf the outboard cannot be tilted using the power trim/tilt switch,the outboard can be manually tilted.NOTE: The manual tilt release valve must be tightened beforeoperating the outboard to prevent the outboard from tilting upduring reverse operation.Turn out the manual tilt release valve three turnscounterclockwise. This allows manual tilting of the outboard. Tiltthe outboard to the desired position and tighten the manual tiltrelease valve.22362SHALLOW WATER OPERATIONWhen operating your boat in shallow water, you can tilt theoutboard beyond the maximum trim range to prevent hittingbottom.1. Reduce engine speed below 2000 RPM.2. Tilt outboard up. Make sure all the water intake holes staysubmerged at all times.eng 67

FEATURES AND CONTROLS3. Operate the engine at slow speed only. If engine speedexceeds 2000 RPM, the outboard will automatically returndown to the maximum trim range.AUXILIARY TILT SWITCHThe auxiliary tilt switch can be used to tilt the outboard up ordown using the power trim system.a - Auxiliary tilt switcha27779Trim Tab AdjustmentPropeller steering torque will cause your boat to pull in onedirection. This steering torque is a normal thing that results fromyour outboard not being trimmed so the propeller shaft is parallelto the water surface. The trim tab can help compensate for thissteering torque in many cases and can be adjusted within limitsto reduce any unequal steering effort.26816NOTE: Trim tab adjustment will have little effect reducingsteering torque if the outboard is installed with the anti‐ventilationplate approximately 50 mm (2 inches) or more above the boatbottom.Operate your boat at normal cruising speed, trimmed to thedesired position. Turn your boat left and right and note thedirection the boat turns more easily.68 eng

FEATURES AND CONTROLSIf adjustment is necessary, loosen trim tab bolt and make smalladjustments at a time. If the boat turns more easily to the left,move the trailing edge of trim tab to the left. If the boat turnsmore easily to the right, move the trailing edge of trim tab to theright. Tighten bolt and retest.eng 69

OPERATIONImportant Daily Inspection Before Each UseAny outboard mounted on the boat must have the mountinghardware inspected and checked to ensure that the hardwarehas not become loose. A decal on the transom bracket remindsthe owner to check the fasteners securing the outboard to thetransom before each use.Prestarting Check List51985Decal on the transom bracketOperator knows safe navigation, boating, and operatingprocedures.An approved personal flotation device of suitable size foreach person aboard and readily accessible. It is the law.A ring‐type life buoy or buoyant cushion designed to bethrown to a person in the water.Know the boat's maximum load capacity. Look at the boatcapacity plate.Fuel supply OK.Oil supply (oil injection) OK.Arrange passengers and load in the boat so the weight isdistributed evenly and everyone is seated in a proper seat.Tell someone where you are going and when you expect toreturn.70 eng

OPERATIONIt is illegal to operate a boat while under the influence ofalcohol or drugs.Know the waters and area you will be boating; tides,currents, sand bars, rocks, and other hazards.Make the inspection checks listed in Maintenance ‐Inspection and Maintenance Schedule.Operating in Freezing TemperaturesWhen using your outboard or having your outboard moored infreezing or near freezing temperatures, keep the outboard tilteddown at all times so the gearcase is submerged. This preventsthe trapped water in the gearcase from freezing and causingpossible damage to the water pump and other components.If there is a chance of ice forming on the water, the outboardshould be removed and drained completely of water. If iceshould form at the water level inside the outboard driveshafthousing, it will block water flow to the engine causing possibledamage.Operating in Saltwater or Polluted WaterWe recommend that you flush the internal water passages ofyour outboard with fresh water after each use in salt or pollutedwater. This will prevent a buildup of deposits from clogging thewater passages. Refer to Maintenance ‐ Flushing the CoolingSystem.If you keep your boat moored in the water, always tilt theoutboard so the gearcase is completely out of water (except infreezing temperatures) when not in use.Wash the outboard exterior and flush out the exhaust outlet ofthe propeller and gearcase with fresh water after each use. Eachmonth, spray Mercury Precision or Quicksilver Corrosion Guardon external metal surfaces. Do not spray on corrosion controlanodes as this will reduce the effectiveness of the anodes.eng 71

OPERATIONOperating at High ElevationsYour engine automatically compensates for high elevationchanges. A different pitch propeller may help reduce somenormal performance loss resulting from reduced oxygen in theair. Consult your dealer.Setting Trim Angle While Running Engine at IdleSpeedThe exhaust relief hole on the outboard may become submergedif the outboard is trimmed full‐in while running at idle speed. Thiswill cause exhaust restriction, rough idle, excessive smoke, andfouled spark plugs. If this condition exists, trim the outboard upuntil the exhaust relief hole is out of the water. The outboardshould be lowered for accelerating from a standing start or fromidle speed.28423Engine Break‐inIMPORTANT: Failure to follow the engine break‐in procedurescan result in poor performance throughout the life of the engineand can cause engine damage. Always follow break‐inprocedures.Break‐in ProcedureVary throttle settings during break‐in. Use the following suggestions.First Hour• Allow the engine to warm‐up for 30–60 seconds.72 eng

OPERATIONBreak‐in Procedure• Do not idle for more than five minutes.• Run the engine the majority of the time between 4000–5400 RPM(approximately three‐quarter throttle).• Short bursts of wide‐open throttle for 10 seconds or less are acceptable.• Change the engine speed approximately every two minutes.• Avoid trimming the outboard out (up) beyond a vertical trim positionduring operation.• Avoid using a hydraulic jack plate to raise the engine during the break‐incycle.Next Three Hours: Change the engine speed every 10 minutes.Starting the EngineBefore starting, read the prestarting check list, special operatinginstructions, and engine break‐in procedure in the Operationsection.NOTICEWithout sufficient cooling water, the engine, the water pump,and other components will overheat and suffer damage.Provide a sufficient supply of water to the water inlets duringoperation.1. Lower the outboard to the vertical operating position. Makesure all cooling water intake holes are submerged.26837eng 73

OPERATION2. Open the fuel tank vent screw, located in the filler cap, onmanual venting type fuel tanks.197483. Position the fuel line primer bulb so the arrow on the side ofthe bulb is pointing up. Squeeze the fuel line primer bulbseveral times until it feels firm.273484. Set the lanyard stop switch to "RUN" position. Refer toGeneral Information ‐ Lanyard Stop Switch.197915. Shift outboard to neutral ("N") position.N2683874 eng

OPERATION6. For the initial start of a new engine, or for an engine that ranout of fuel or was drained of fuel, the fuel system should befilled as follows:a. Squeeze the fuel line primer bulb until it feels firm.b. Turn the ignition key switch to the "ON" position for threeseconds. This operates the electric fuel pump.c. Turn the ignition key switch back to the "OFF" position,and squeeze the primer bulb again until it feels firm. Turnthe ignition key switch to the "ON" position again for threeseconds. Continue this procedure until the fuel line primerbulb stays firm.7. Do not advance the neutral fast idle speed feature on theremote control for starting.272428. Turn the ignition key to "START" position. Release the keywhen engine starts. If engine fails to start in 10 seconds,return the key to "OFF" position, wait one second and tryagain.19804NOTE: The electronic starting system will automatically prime(choke) the engine and increase idle speed for starting.9. Check for a steady stream of water flowing out of the waterpump indicator hole.eng 75

OPERATIONIMPORTANT: If no water is coming out of the water pumpindicator hole, stop the engine and check cooling water intakeholes for obstruction. No obstruction may indicate a water pumpfailure or blockage in the cooling system. This condition willcause the engine to overheat. Have the outboard checked byyour dealer. Operating the engine while overheated will causeengine damage.19805Gear ShiftingIMPORTANT: Observe the following:• Never shift the outboard into gear unless the engine speedis at idle.• Do not shift the outboard into reverse when the engine is notrunning.• Your outboard has three gear shift positions to provideoperation: forward (F), neutral (N), and reverse (R).• When shifting, always stop at neutral position and allow theengine speed to return to idle.• Always shift the outboard into gear with a quick motion.• After shifting the outboard into gear, advance the leverfurther to increase speed.FNR2723776 eng

Stopping the EngineOPERATIONReduce engine speed and shift outboard to neutral position. Turnignition key to "OFF" position.26843eng 77

Outboard CareMAINTENANCETo keep your outboard in the best operating condition, it isimportant that your outboard receive the periodic inspections andmaintenance listed in the Inspection and MaintenanceSchedule. We urge you to keep it maintained properly to ensurethe safety of you and your passengers, and retain itsdependability.Record maintenance performed in the Maintenance Log at theback of this book. Save all maintenance work orders andreceipts.SELECTING REPLACEMENT PARTS FOR YOUROUTBOARDWe recommend using original Mercury Precision or Quicksilverreplacement parts and Genuine Lubricants.EPA Emissions RegulationsAll new outboards manufactured by Mercury Marine are certifiedto the United States Environmental Protection Agency, asconforming to the requirements of the regulations for the controlof air pollution from new outboard motors. This certification iscontingent on certain adjustments set to factory standards. Forthis reason, the factory procedure for servicing the product mustbe strictly followed and, wherever practicable, returned to theoriginal intent of the design. Maintenance, replacement, or repairof the emission control devices and systems may be performedby any marine spark ignition (SI) engine repair establishment orindividual.78 eng

MAINTENANCEEMISSION CERTIFICATION LABELAn emission certification label, showing emission levels andengine specifications directly related to emissions, is placed onthe engine at the time of manufacture.abcdeSPARK PLUG:GAP:EMISSION CONTROLINFORMATIONTHIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPAEMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINESREFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,SPECIFICATIONS, AND ADJUSTMENTSIDLE SPEED (in gear):hpkwLLOW PERM/HIGH PERM:FAMILY:HC+NOx:FEL:CO FEL:g/kWhg/kWhfghij43210a - Idle speedb - Engine horsepowerc - Piston displacementd - Engine power ‐ kilowattse - Date of manufacturef - Family numberg - Regulated emission limit for the engine familyh - Regulated emission limit for the engine familyi - Recommended spark plug and gapj - Percent of fuel line permeationOWNER RESPONSIBILITYThe owner/operator is required to have routine enginemaintenance performed to maintain emission levels withinprescribed certification standards.The owner/operator is not to modify the engine in any mannerthat would alter the horsepower or allow emission levels toexceed their predetermined factory specifications.Inspection and Maintenance SchedulePRIOR TO EVERY USE• Check that the lanyard stop switch stops the engine.• Check the steering system for binding or loose components.eng 79

MAINTENANCE• Verify the outboard is securely attached to the boat transom.If the outboard or any of its fasteners are loose, tighten themto the specified torque. When checking to verify theoutboard is securely fastened, look for loss of outboardtransom bracket material or paint caused by movementbetween the outboard mounting fasteners and the outboardtransom brackets. Also look for signs of movement betweenthe outboard transom brackets and the boat transom or liftplate/setback bracket.Description Nm lb‐in. lb‐ftOutboard mounting locknuts andbolts – standard boat transomOutboard mounting locknuts andbolts – metal lift plates and setbackbrackets75 – 55122 – 90• Check the propeller blades for damage.• Inspect all hoses, clamps, fittings, tubing, sealing gaskets,and mounting hardware for wear.AFTER EACH SALTWATER OR POLLUTED WATER USE• Flush all internal passages with fresh water.• Wash the power package exterior (cowl, midsection, andgearcase) with fresh water.• Flush the propeller and gearcase exhaust outlet with freshwater.• Remove the cowl and wipe off any saltwater spray with adamp cloth.EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATEROR POLLUTED WATER USE• Spray the powerhead and all external, unpainted metalsurfaces (except anodes) with Corrosion Guard.TubeRef No.120Description Where Used Part No.CorrosionGuardPowerhead and all external,unpainted metal surfaces(except anodes)92-802878 5580 eng

MAINTENANCEEVERY 25 HOURS OR EVERY 30 DAYS, WHICHEVEROCCURS FIRST• Verify the front and side cowl latches are tight. Tighten themif necessary.• Inspect the fuel and oil systems for deterioration or leaks.• Inspect the hydraulic steering hoses for deterioration orleaks.• Inspect the steering link rod fasteners for wear. Lubricate allof the specified components. Check all attachment hardwareto ensure proper torque.• Check the level and condition of the gearcase lubricant.• Check the alternator belt tension.EVERY 50 HOURS OR ONCE A YEAR, WHICHEVEROCCURS FIRST• Lubricate all of the lubrication points listed in the manual.• Lubricate the splines on the driveshaft. 1.• Lubricate the length of driveshaft with Extreme Grease.TubeRef No.Description Where Used Part No.ExtremeGreaseLength of driveshaft• Lubricate the splines on the propeller shaft.• Drain and replace the gearcase lubricant.8M0071842• Inspect all belts, pulleys, and idler pulleys for deterioration.• Check the fuel pressure. 1.• Check the control cable adjustments.• Inspect the battery.• Check the corrosion control anodes.• Check the tightness of all fasteners.• Check the power trim fluid.• Use Quicksilver products to remove engine deposits. Seeyour dealer for an explanation of which products to use.1. These items should be serviced by an authorized dealer.eng 81

MAINTENANCEEVERY 100 HOURS OR ONCE A YEAR, WHICHEVEROCCURS FIRST• Tighten the fasteners that secure the outboard to the boattransom to the specified torque. 1.Description Nm lb‐in. lb‐ftOutboard mounting locknuts andbolts – standard boat transomOutboard mounting locknuts andbolts – metal lift plates and setbackbrackets75 – 55122 – 90• Replace the water pump impeller (more often if overheatingoccurs or reduced water pressure is noted). 1.• Replace the spark plugs after the first 100 hours or firstyear. After that, inspect the spark plugs every 100 hours oronce yearly. Replace the spark plugs as needed.• Replace the water separating fuel filter.• Use Quickleen in the fuel.• Verify that the cowl seals are intact and not damaged.• Check that the internal cowl sound reduction foam (ifequipped) is intact and not deteriorating.• Ensure that the intake silencer (if equipped) is in place.• Ensure that the idle relief muffler (if equipped) is in place.• Check for loose hose clamps and rubber boots (if equipped)on the air intake assembly.EVERY 100 HOURS OF OPERATION• Inspect the carbon fiber reeds for chipping or cracks.BEFORE PERIODS OF STORAGE• Refer to Storage section.Flushing the Cooling SystemFlush the internal water passages of the outboard with freshwater after each use in salt, polluted, or muddy water. This willhelp prevent a buildup of deposits from clogging the internalwater passages.82 eng

MAINTENANCENOTE: The engine can be stopped, or running at idle speed inneutral, when flushing the cooling system. Do not flush theengine using a water source that exceeds 310 kPa (45 psi).1. Unscrew the cover from the end of the hose adapter.2. Attach a water hose to the hose adapter.3. Turn on the water and flush the cooling system for aminimum of three minutes.IMPORTANT: Do not run engine above idle speed whenflushing.4. Turn off the water and remove the water hose from the hoseadapter. Reinstall the cover into the hose adapter.abc22703a - Hose adapterb - Sealing washerc - CoverTop Cowl Removal and InstallationREMOVAL1. Unlock the rear latch by pushing lever up.2. Lift rear of cowl and disengage front hook.29468eng 83

INSTALLATIONMAINTENANCE1. Engage the front hook and push cowl back over the cowlseal.2. Push cowl down and move the rear latch lever down to lock.Cleaning Care for Top CowlIMPORTANT: Dry wiping (wiping the plastic surface when it isdry) will result in minor surface scratches. Always wet thesurface before cleaning. Follow the cleaning and waxingprocedure.CLEANING AND WAXING PROCEDURE1. Before washing, rinse the top cowl with clean water toremove the dirt and dust that may scratch the surface.2. Wash the top cowl with clean water and a mild nonabrasivesoap. Use a soft, clean cloth when washing.3. Dry thoroughly with a soft, clean cloth.4. Wax the surface using a nonabrasive automotive polish(polish designed for clear coat finishes). Remove the appliedwax by hand using a soft, clean cloth.Flywheel Cover Removal and InstallationREMOVALLift the cover off the three mounting pins.84 eng

INSTALLATIONMAINTENANCEPosition the cover onto the three mounting pins. Insert the tabsinto the slots in the side panel and push the cover down onto themounting pins.abc23754a - Flywheel coverb - Mounting pinsc - TabsSide Panel Removal and InstallationREMOVALPull the side panel off the three mounting pins.eng 85

INSTALLATIONMAINTENANCEPosition the side panel onto the three mounting pins. Insert thetabs on the flywheel cover into the upper slots and push the sidepanel onto the mounting pins.bca23765a - Side panelb - Upper slotsc - Mounting pinsFuel System! WARNINGFuel is flammable and explosive. Ensure that the key switch isoff and the lanyard is positioned so that the engine cannotstart. Do not smoke or allow sources of spark or open flame inthe area while servicing. Keep the work area well ventilatedand avoid prolonged exposure to vapors. Always check forleaks before attempting to start the engine, and wipe up anyspilled fuel immediately.86 eng

MAINTENANCEBefore servicing any part of the fuel system, stop the engine anddisconnect the battery. Drain the fuel system completely. Use anapproved container to collect and store fuel. Wipe up anyspillage immediately. Material used to contain spillage must bedisposed of in an approved receptacle. Any fuel system servicemust be performed in a well‐ventilated area. Inspect anycompleted service work for sign of fuel leakage.FUEL LINE INSPECTIONVisually inspect the fuel line and primer bulb for cracks, swelling,leaks, hardness, or other signs of deterioration or damage. If anyof these conditions are found, the fuel line or primer bulb must bereplaced.FUEL FILTER REPLACEMENTRemovalUse fuel filter tool 91‐896661, or the shaft of a screwdriver,between the lugs on the filter cap and unscrew the filter.ab29594a - Filterb - O‐ringsFuel Filter Removal/Installation Tool 91‐89666124896Aids in the removal andinstallation of the fuel filter capassembly.eng 87

InstallationMAINTENANCE1. Lubricate the O‐ring seals with oil.2. Install the fuel filter and tighten securely.3. Squeeze the primer bulb until firm and inspect for fuelleakage at the filter.DRAINING WATER FROM THE FUEL FILTER CHAMBERNOTE: If a sufficient amount of water has accumulated in thefuel filter chamber, the warning system will turn on. Draining thewater from the fuel filter chamber is required.1. Pull the drain hose off the right side fitting. Hold the openend of the hose over a container.2. Use a 1/8 in. hex wrench and loosen the drain screw anddrain the fuel filter chamber.abc23743a - Drain hoseb - Right side fittingc - Drain screw3. Tighten the drain screw and attach the hose.IMPORTANT: Visually inspect for fuel leakage from the drainscrew by squeezing the primer bulb until firm, forcing fuel into thechamber.88 eng

MAINTENANCESteering Link Rod FastenersIMPORTANT: The steering link rod that connects the steeringcable to the engine must be fastened using a special washerhead bolt ("a" ‐ Part Number 10‐849838) and self‐locking nyloninsert locknuts ("c" and "d" ‐ Part Number 11‐826709113). Theselocknuts must never be replaced with common nuts (nonlocking)as they will work loose and vibrate off, freeing the link rod todisengage.! WARNINGImproper fasteners or improper installation procedures canresult in loosening or disengagement of the steering link rod.This can cause a sudden, unexpected loss of boat control,resulting in serious injury or death due to occupants beingthrown within or out of the boat. Always use requiredcomponents and follow instructions and torque procedures.abcd27843a - Special washer head bolt (10‐849838)b - Flat washer (2)c - Nylon insert locknut (11‐826709113)d - Nylon insert locknut (11‐826709113)Description Nm lb‐in. lb‐ftSpecial washer head bolt 27 – 20Nylon insert locknut "d" 27 – 20eng 89

MAINTENANCEDescription Nm lb‐in. lb‐ftNylon insert locknut "c"Tighten until it seats, then back off 1/4turnAssemble steering link rod to steering cable with two flatwashers and self‐locking nylon insert locknut. Tighten locknutuntil it seats, then back nut off 1/4 turn.Assemble steering link rod to engine with special washer headbolt and self‐locking nylon insert locknut. First torque bolt, thentorque locknut to specifications.Fuse ReplacementIMPORTANT: Always carry spare 5 and 20‐amp fuses.The electrical wiring circuits on the outboard are protected fromoverload by fuses in the wiring. If a fuse is blown, try to locateand correct the cause of the overload. If the cause is not found,the fuse may blow again.90 eng

MAINTENANCEOpen the fuse holder and look at the silver colored band insidethe fuse. If the band is broken, replace the fuse. Replace fusewith a new fuse with the same rating.abch20201520gdfe2523793a - Good fuseb - Blown fusec - 14 pin remote control harness/cowl trim switch/main powerrelay ‐ 15‐amp fused - Ignition coil circuit ‐ 20‐amp fusee - SmartCraft data bus circuit ‐ 5‐amp fusef - Diagnostics terminal ‐ 2‐amp fuseg - Spare fuse ‐ 20‐amp fuseh - Fuel injectors/direct injectors/oil pump/PCM ‐ 20‐amp fuseCorrosion Control AnodeYour outboard has corrosion control anodes at differentlocations. An anode helps protect the outboard against galvaniccorrosion by sacrificing its metal to be slowly corroded instead ofthe outboard metals.eng 91

MAINTENANCEEach anode requires periodic inspection, especially in saltwaterwhich will accelerate the erosion. To maintain this corrosionprotection, always replace the anode before it is completelyeroded. Never paint or apply a protective coating on the anodeas this will reduce effectiveness of the anode.The gearcase has two corrosion control anodes, one on eachside. A third anode is installed on the bottom of the transombracket assembly.ab27844a - Anode (2) oneach side ofgearcaseb - Anode ontransom bracketassemblyBattery InspectionThe battery should be inspected at periodic intervals to ensureproper engine starting capability.IMPORTANT: Read the safety and maintenance instructionswhich accompany your battery.1. Turn off the engine before servicing the battery.2. Ensure the battery is secure against movement.3. Battery cable terminals should be clean, tight, and correctlyinstalled. Positive to positive and negative to negative.4. Ensure the battery is equipped with a nonconductive shieldto prevent accidental shorting of battery terminals.Battery Information! WARNINGFailure to properly secure the battery leads can result in a lossof power to the Digital Throttle and Shift (DTS) system, leadingto serious injury or death due to loss of boat control. Securethe battery leads to the battery posts with hex nuts to avoidloose connections.92 eng

MAINTENANCE• Do not use deep‐cycle batteries. Engines must use a marinestarting battery with 1000 MCA, 800 CCA, or 180 Ah.• When connecting the engine battery, hex nuts must be usedto secure battery leads to battery posts. Torque nuts tospecification.Description Nm lb‐in. lb‐ftHex nuts 13.5 120The decal needs to be placed on or near the battery box forfuture service reference. One 5/16 in. and one 3/8 in. hex nut issupplied per battery for wing nut replacement. Metric hex nutsare not supplied.NOTICE - DTS & OptiMax EnginesDO NOT USE DEEP CYCLE BATTERIES!DTS (Digital Throttle and Shift) applications andOptiMax engines must use a marine startingbattery with 1000 MCA, 800 CCA, or 180 Ah. rating.13.5Nm (120 lbs. in.)DO NOTUSE WINGNUTSIMPORTANT:Battery cable size and length is critical. Refer toengine installation manual for size requirements.37-895387Place decal on or near battery box for future servicereference. 5/16” and 3/8” hex nuts supplied for wingnut replacement. Metric hex nuts not supplied.3486PropellersREMOVALIMPORTANT: Propellers used on this product require theMercury Marine Flo‐Torq III type hub or equivalent.eng 93

MAINTENANCE! WARNINGRotating propellers can cause serious injury or death. Neveroperate the boat out of the water with a propeller installed.Before installing or removing a propeller, place the drive unit inneutral and engage the lanyard stop switch to prevent theengine from starting. Place a block of wood between thepropeller blade and the anti‐ventilation plate.1. Shift the outboard to the neutral ("N") position.N26838IMPORTANT: Refer to Spark Plug Inspection and Replacementfor removing spark plug leads.2. Remove the spark plug leads to prevent the engine fromstarting.268993. Straighten the bent tabs on the propeller nut retainer.2690094 eng

MAINTENANCE4. Place a block of wood between the gearcase and propellerand remove the propeller nut.269015. Pull the propeller straight off the shaft. If the propeller isseized to the shaft and cannot be removed, have thepropeller removed by an authorized dealer.INSTALLATIONIMPORTANT: To prevent the propeller hub from corroding andseizing to the propeller shaft (especially in saltwater), alwaysapply a coat of the recommended lubricant to the entire propellershaft at the recommended maintenance intervals and also eachtime the propeller is removed.1. Coat the propeller shaft with Extreme Grease or 2‐4‐C withPTFE.26902TubeRef No.Description Where Used Part No.ExtremeGreasePropeller shaft8M0071842eng 95

MAINTENANCETubeRef No.95Description Where Used Part No.2-4-C withPTFEPropeller shaft 92-802859A 1NOTE: The Flo‐Torq lll propeller drive hubs are designed tohave a small amount of free play when installed. This free playallows the propeller to slide back and forth on the rear thrusthub (up to 3.17 mm [1/8 in.]) and rotate up to 10 degrees.2. Flo‐Torq III drive hub propellers ‐ Install the forward thrusthub, replaceable drive sleeve, propeller, thrust hub,propeller nut retainer, and propeller nut onto the shaft.a b c d e f3223a - Propeller nutb - Propeller nut retainerc - Rear thrust hubd - Propellere - Replaceable drive sleevef - Forward thrust hub3. Place a block of wood between the gearcase and propeller.Torque the propeller nut to specification.Description Nm lb‐in. lb‐ftPropeller nut 75 – 5596 eng

MAINTENANCE4. Secure the propeller nut by bending three of the tabs intothe thrust hub grooves.26945Spark Plug Inspection and Replacement! WARNINGDamaged spark plug boots may emit sparks that can ignite fuelvapors under the engine cowl, resulting in serious injury ordeath from a fire or explosion. To avoid damaging the sparkplug boots, do not use any sharp object or metal tool to removethe spark plug boots.1. Remove the spark plug leads by twisting the rubber bootswhile pulling them off the spark plugs.268992. Remove the spark plugs. Replace the spark plug if theelectrode is worn; the insulator is rough, cracked, broken, orblistered; or if the precious metal is not visible on the sparkplug electrode.eng 97

MAINTENANCEIMPORTANT: The color of the plug may not accurately reflectits condition. To accurately diagnose a faulty plug, inspect theprecious metal on the plug's electrode. If no precious metal isvisible, replace the plug.a9381a - Precious metal3. Set the spark plug gap. Refer to Specifications.27848a. All of the spark plugs should have the gap checked andcorrected as necessary before installation.b. Measure the gap with a feeler gauge or pin gauge. Neveruse a wedge‐type gap checking tool to inspect or toadjust the gap.c. If an adjustment is necessary, do not pry or apply anyforce on the center electrode. This is critical with any typeof spark plug that has a wear surface, such as platinumor iridium added to either the ground electrode or thecenter electrode.98 eng

MAINTENANCEd. When it is necessary to widen the gap, use a tool thatonly pulls back on the ground electrode without touchingthe center electrode, the porcelain, or the wear portion ofthe ground electrode.e. When it is necessary to close the gap, gently tap the plugground electrode on a hard surface.4. Before installing spark plugs, clean off any dirt on the sparkplug seats. Install the plugs finger‐tight and then tighten anadditional 1/4 turn or tighten to the specified torque.Description Nm lb‐in. lb‐ftSpark plug 27 – 20Compressor Air Intake FilterThe filter should be changed every 100 hours of operation, oronce a season.IMPORTANT: Never run the engine without the air filter.REMOVAL1. Remove three screws and filter cover from engine.2. Remove filter from the cover.ba - Coverb - Filtera29476INSTALLATION1. Install filter into cover.2. Fasten filter cover with three screws.eng 99

Alternator Belt InspectionMAINTENANCE! WARNINGInspecting the belts with the engine running may cause seriousinjury or death. Turn off the engine and remove the ignition keybefore adjusting tension or inspecting belts.Inspect the alternator belt and have it replaced by an authorizeddealer if any of the following conditions are found.• Cracks or deterioration in the rubber portion of the belt.• Belt surfaces rough or uneven.• Signs of wear on edges or outer surfaces of belt.29477Lubrication Points1. Lubricate the following with Extreme Grease or 2‐4‐C withPTFE.TubeRef No.95Description Where Used Part No.ExtremeGrease2-4-C withPTFEPropeller shaft8M0071842Propeller shaft 92-802859A 1100 eng

MAINTENANCE• Propeller shaft ‐ Refer to Propeller Replacement forremoval and installation of the propeller. Coat the entirepropeller shaft with lubricant to prevent the propeller hubfrom corroding and seizing to the shaft.269022. Lubricate the following with 2‐4‐C with PTFE.TubeRef No.95Description Where Used Part No.2-4-C withPTFESwivel bracket, tilt supportlever, tilt tube, steering cablegrease fitting92-802859A 1• Swivel bracket ‐ Lubricate through fitting.• Tilt support lever ‐ Lubricate through fitting.aa - Swivel bracketb - Tilt support leverb27873• Tilt tube ‐ Lubricate through fitting.29478• Steering cable grease fitting (if equipped) ‐ Rotatesteering wheel to fully retract the steering cable end intothe outboard tilt tube. Lubricate through fitting.eng 101

MAINTENANCE! WARNINGIncorrect cable lubrication can cause hydraulic lock, leadingto serious injury or death from loss of boat control.Completely retract the end of the steering cable beforeapplying lubricant.aba - Fittingb - Steering cable end294793. Lubricate the following with lightweight oil.• Steering link rod pivot points ‐ Lubricate pivot points.29480Checking Power Trim Fluid1. Tilt outboard to the full up position and engage the tiltsupport lever.27877102 eng

MAINTENANCE2. Remove fill cap and check fluid level. The fluid level shouldbe even with the bottom of the fill hole. Add Quicksilver orMercury Precision Lubricants Power Trim and SteeringFluid. If not available, use automotive automatictransmission fluid (ATF).TubeRef No.114Description Where Used Part No.Power Trimand SteeringFluidPower trim reservoir 92-858074K0127884Gearcase LubricationWhen adding or changing gearcase lubricant, visually check forthe presence of water in the lubricant. If water is present, it mayhave settled to the bottom and will drain out prior to the lubricant,or it may be mixed with the lubricant, giving it a milky coloredappearance. If water is noticed, have the gearcase checked byyour dealer. Water in the lubricant may result in prematurebearing failure or, in freezing temperatures, will turn to ice anddamage the gearcase.Examine the drained gearcase lubricant for metal particles. Asmall amount of metal particles indicates normal gear wear. Anexcessive amount of metal filings or larger particles (chips) mayindicate abnormal gear wear and should be checked by anauthorized dealer.DRAINING GEARCASE1. Place outboard in a vertical operating position.2. Place a drain pan below outboard.eng 103

MAINTENANCE3. Remove vent plugs and fill/drain plug and drain lubricant.a - Vent plugsb - Fill/drain plugGEARCASE LUBRICANT CAPACITYab26977Gearcase lubricant capacity is approximately 665 ml (22.5 fl oz).GEARCASE LUBRICANT RECOMMENDATIONMercury or Quicksilver Premium or High Performance GearLubricant.CHECKING LUBRICANT LEVEL AND FILLING GEARCASE1. Place outboard in a vertical operating position.2. Remove the front vent plug and rear vent plug.104 eng

MAINTENANCE3. Remove fill/drain plug. Place lubricant tube into the fill/drainplug hole and add lubricant until it appears at the front venthole. At this time install the front vent plug and sealingwasher.cbad27001ea - Front vent plugb - Front vent holec - Rear vent holed - Rear vent pluge - Fill/drain plug4. Continue adding lubricant until it appears at the rear venthole.5. Stop adding lubricant. Install the rear vent plug and sealingwasher before removing lubricant tube.6. Remove lubricant tube and reinstall cleaned fill/drain plugand sealing washer.SUBMERGED OUTBOARDA submerged outboard will require service within a few hours byan authorized dealer once the outboard is recovered from thewater. This immediate attention by a servicing dealer isnecessary once the engine is exposed to the atmosphere tominimize internal corrosion damage to the engine.eng 105

Storage PreparationSTORAGEThe major consideration in preparing your outboard for storage isto protect it from rust, corrosion, and damage caused by freezingof trapped water.The following storage procedures should be followed to prepareyour outboard for out of season storage or prolonged storage(two months or longer).NOTICEWithout sufficient cooling water, the engine, the water pump,and other components will overheat and suffer damage.Provide a sufficient supply of water to the water inlets duringoperation.Fuel SystemIMPORTANT: Gasoline containing alcohol (ethanol or methanol)can cause a formation of acid during storage and can damagethe fuel system. If the gasoline being used contains alcohol, it isadvisable to drain as much of the remaining gasoline as possiblefrom the fuel tank, remote fuel line, and engine fuel system.The most effective method of storage preparation is to add therecommended amount of Mercury Precision Fuel Stabilizer andMercury Precision Quickleen products as described on thecontainers to the fuel tank before the last operation of the boat.Adding fuel stabilizer will help prevent the formation of varnishand gum in the gasoline. The Mercury Precision Quickleenproduct will help clean and lubricate the fuel injectors.1. Portable fuel tank ‐ Pour the required amount of gasolinestabilizer and Quickleen (follow instructions on containers)into fuel tank. Tip fuel tank back and forth to mix stabilizerand Quickleen with the fuel.2. Permanently installed fuel tank ‐ Pour the required amountof gasoline stabilizer and Quickleen (follow instructions oncontainers) into a separate container and mix withapproximately 1 liter (1 US qt) of gasoline. Pour this mixtureinto fuel tank.106 eng

STORAGE3. Pull the drain hose off the right side fitting. Hold the openend of the hose over a container.4. Loosen drain screw and drain the fuel filter chamber.a - Drain screwb - Drain hosec - Right side fittingacb237515. Tighten the drain screw and attach the hose.6. Pull the drain hose off the left side fitting. Hold the open endof the hose over a container.7. Loosen the drain screw and drain the float chamber.a - Left side fittingb - Drain screwc - Drain hoseabc237528. Tighten the drain screw and attach the hose.9. Premix the following in a container:a. 8 cc (0.27 oz) or 2 teaspoons of Mercury PrecisionQuickleen lubricant.b. 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision FuelStabilizer.eng 107

STORAGE10.Remove the fuel filter. See Maintenance ‐ Fuel System forprocedure.11.Pour this mixture into the fuel filter opening. Install the fuelfilter.12.Prime the fuel system. See Operation ‐ Starting TheEngine.13.Place the outboard in water or use the flush hose or flushingdevice or for circulating cooling water. Start the engine andrun at idle speed for five minutes to allow the treated fuel tofill the fuel system.Flushing Device 91‐44357Q 2Attaches to the water intakes;provides a fresh waterconnection when flushing thecooling system or operatingthe engine.9192Protecting Internal Engine ComponentsNOTE: Make sure the fuel system has been prepared forstorage. Refer to Fuel System, preceding.IMPORTANT: Refer to Spark Plug Inspection andReplacement for correct procedure for removing spark plugleads.1. Remove the spark plugs. Add approximately 30 ml (1 oz) ofengine oil or inject a five second spray of storage seal intoeach spark plug hole.2. Rotate the flywheel manually several times to distribute theoil or storage seal in the cylinders.3. Install the spark plugs.Protecting External Outboard Components• Lubricate all outboard components listed in Maintenance ‐Inspection and Maintenance Schedule.108 eng

STORAGE• Touch up any paint nicks. See your dealer for touch‐uppaint.• Spray Quicksilver or Mercury Precision Lubricants CorrosionGuard on external metal surfaces (except corrosion controlanodes).TubeRef No.120Description Where Used Part No.CorrosionGuardExternal metal surfaces 92-802878 55Gearcase• Drain and refill the gearcase lubricant (refer to GearcaseLubrication).Positioning Outboard for StorageStore outboard in an upright (vertical) position to allow water todrain out of the outboard.NOTICEStoring the outboard in a tilted position can damage theoutboard. Water trapped in the cooling passages or rain watercollected in the propeller exhaust outlet in the gearcase canfreeze. Store the outboard in the full down position.Battery Storage• Follow the battery manufacturer's instructions for storageand charging.• Remove the battery from the boat and check water level.Charge if necessary.• Store the battery in a cool, dry place.• Periodically check the water level and charge the batteryduring storage.eng 109

OWNER SERVICE ASSISTANCELocal Repair ServiceAlways return your outboard to your local authorized dealershould the need for service arise. Only he has the factory trainedmechanics, knowledge, special tools, equipment, and genuineparts and accessories to properly service your engine should theneed occur. He knows your engine best.Service Away from HomeIf you are away from your local dealer and the need arises forservice, contact the nearest authorized dealer. Refer to theYellow Pages of the telephone directory. If, for any reason, youcannot obtain service, contact the nearest Mercury MarineService Office.Parts and Accessories InquiriesAll inquiries concerning genuine replacement parts andaccessories should be directed to your local authorized dealer.The dealer has the necessary information to order parts andaccessories for you. When inquiring about parts andaccessories, the dealer requires the model and serial number toorder the correct parts.Service AssistanceLOCAL REPAIR SERVICEIf you need service for your Mercury‐outboard‐powered boat,take it to your authorized dealer. Only authorized dealersspecialize in Mercury products and have factory‐trainedmechanics, special tools and equipment, and genuineQuicksilver parts and accessories to properly service yourengine.NOTE: Quicksilver parts and accessories are engineered andbuilt by Mercury Marine specifically for your power package.110 eng

OWNER SERVICE ASSISTANCESERVICE AWAY FROM HOMEIf you are away from your local dealer and the need arises forservice, contact the nearest authorized dealer. If, for any reason,you cannot obtain service, contact the nearest Regional ServiceCenter. Outside the United States and Canada, contact thenearest Marine Power International Service Center.STOLEN POWER PACKAGEIf your power package is stolen, immediately advise the localauthorities and Mercury Marine of the model and serial numbersand to whom the recovery is to be reported. This information ismaintained in a database at Mercury Marine to aid authoritiesand dealers in the recovery of stolen power packages.ATTENTION REQUIRED AFTER SUBMERSION1. Before recovery, contact an authorized Mercury dealer.2. After recovery, immediate service by an authorized Mercurydealer is required to reduce the possibility of serious enginedamage.REPLACEMENT SERVICE PARTS! WARNINGAvoid fire or explosion hazard. Electrical, ignition, and fuelsystem components on Mercury Marine products comply withfederal and international standards to minimize risk of fire orexplosion. Do not use replacement electrical or fuel systemcomponents that do not comply with these standards. Whenservicing the electrical and fuel systems, properly install andtighten all components.Marine engines are expected to operate at or near full throttle formost of their lives. They are also expected to operate in bothfresh and saltwater environments. These conditions requirenumerous special parts.eng 111

OWNER SERVICE ASSISTANCEPARTS AND ACCESSORIES INQUIRIESDirect any inquiries concerning Quicksilver replacement partsand accessories to your local authorized dealer. The dealer hasthe necessary information to order parts and accessories for youif they are not in stock. Only authorized dealers can purchasegenuine Quicksilver parts and accessories from the factory.Mercury Marine does not sell to unauthorized dealers or retailcustomers. When inquiring about parts and accessories, thedealer requires the engine model and serial numbers to orderthe correct parts.RESOLVING A PROBLEMSatisfaction with your Mercury product is important to your dealerand to us. If you ever have a problem, question or concern aboutyour power package, contact your dealer or any authorizedMercury dealership. If you need additional assistance:1. Talk with the dealership's sales manager or servicemanager. Contact the owner of the dealership if the salesmanager and service manager have been unable to resolvethe problem.2. If your question, concern, or problem cannot be resolved byyour dealership, please contact the Mercury Marine ServiceOffice for assistance. Mercury Marine will work with you andyour dealership to resolve all problems.The following information will be needed by the CustomerService:• Your name and address• Your daytime telephone number• The model and serial numbers of your power package• The name and address of your dealership• The nature of the problemCONTACT INFORMATION FOR MERCURY MARINECUSTOMER SERVICEFor assistance, call, fax, or write to the geographic office in yourarea. Please include your daytime telephone number with mailand fax correspondence.112 eng

OWNER SERVICE ASSISTANCEUnited States, CanadaTelephoneFaxWebsiteEnglish +1 920 929 5040Français +1 905 636 4751English +1 920 929 5893Français +1 905 636 1704www.mercurymarine.comMercury MarineW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939Australia, PacificTelephone +61 3 9791 5822 Brunswick Asia Pacific Group41–71 Bessemer DriveFax +61 3 9706 7228 Dandenong South, Victoria 3175AustraliaEurope, Middle East, AfricaTelephone +32 87 32 32 11 Brunswick Marine EuropeParc Industriel de Petit-RechainFax +32 87 31 19 65 B-4800 Verviers,BelgiumMexico, Central America, South America, CaribbeanTelephone +1 954 744 3500 Mercury Marine11650 Interchange Circle NorthFax +1 954 744 3535 Miramar, FL 33025U.S.A.JapanTelephone +81 72 233 8888 Kisaka Co., Ltd.4‐130 Kannabecho, Sakai‐kuFax +81 72 233 8833 Sakai‐shi, Osaka 590‐0984, JapanAsia, SingaporeTelephone +65 65466160 Brunswick Asia Pacific GroupT/A Mercury Marine Singapore Pte LtdFax +65 65467789 29 Loyang DriveSingapore, 508944Ordering LiteratureBefore ordering literature, have the following information aboutyour power package available:eng 113

OWNER SERVICE ASSISTANCEModelHorsepowerSerial NumberYearUNITED STATES AND CANADAFor additional literature for your Mercury Marine power package,contact your nearest Mercury Marine dealer or contact:Mercury MarineTelephone Fax Mail(920) 929‐5110(USA only)(920) 929‐4894(USA only)Mercury MarineAttn: Publications DepartmentP.O. Box 1939Fond du Lac, WI 54935-1939OUTSIDE THE UNITED STATES AND CANADAContact your nearest Mercury Marine authorized service centerto order additional literature that is available for your particularpower package.Submit the followingorder form with paymentto:Mercury MarineAttn: Publications DepartmentW6250 West Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939Ship To: (Copy this form and print or type–This is your shipping label)NameAddressCity, State, ProvinceZIP or postal codeCountryQuantity Item Stock Number Price Total. .. .. .. .. .Total Due .114 eng

TROUBLESHOOTINGStarter Motor Will Not Crank the EnginePOSSIBLE CAUSES• Blown 20‐amp fuse in the starting circuit. Refer toMaintenance.• Outboard is not shifted to neutral position.• Weak battery or battery connections are loose or corroded.• Ignition key switch failure.• Wiring or electrical connection faulty.• Starter motor solenoid or slave solenoid failure.Engine Will Not StartPOSSIBLE CAUSES• Lanyard stop switch not in "RUN" position.• Battery not fully charged.• Incorrect starting procedure. Refer to Operation section.• Old or contaminated fuel.• Fuel is not reaching the engine.• Fuel tank is empty.• Fuel tank vent not open or restricted.• Fuel line is disconnected or kinked.• Primer bulb not squeezed.• Primer bulb check valve is faulty.• Fuel filter is obstructed. Refer to Maintenance section.• Fuel pump failure.• Fuel tank filter obstructed.• Open 20‐amp fuse. Check fuses, refer to Maintenancesection.• Threaded connection of an air hose is loose.• Ignition system component failure.• Spark plugs fouled or defective. Refer to Maintenancesection.eng 115

Engine Runs ErraticallyPOSSIBLE CAUSESTROUBLESHOOTING• Spark plugs fouled or defective. Refer to Maintenancesection.• Incorrect setup and adjustments.• Fuel is being restricted to the engine.a. Engine fuel filter is obstructed. Refer to Maintenancesection.b. Fuel tank filter obstructed.c. Stuck antisiphon valve on built‐in fuel tank.d. Fuel line is kinked or pinched.e. Injector plugged.• Threaded connection of an air hose is loose.• Fuel pump failure.• Ignition system component failure.Performance LossPOSSIBLE CAUSES• Throttle not fully open.• Damaged propeller or improper propeller size.• Boat overloaded or load improperly distributed.• Excessive water in bilge.• Boat bottom is dirty or damaged.Battery Will Not Hold ChargePOSSIBLE CAUSES• Battery connections are loose or corroded.• Low electrolyte level in battery.• Worn out or inefficient battery.• Excessive use of electrical accessories.• Defective rectifier, alternator, or voltage regulator.• Open circuit in the alternator output wire (fused link).116 eng

OUTBOARD INSTALLATIONMercury Marine Validated Engine MountingHardwareIMPORTANT: Mercury Marine provides validated fasteners andinstallation instructions, including torque specifications, with all ofour outboards so they can be properly secured to boat transoms.Improper installation of the outboard can cause performance andreliability issues that can lead to safety concerns. Follow all ofthe instructions relating to the outboard installation. DO NOTmount any other accessory onto the boat with the fastenersprovided with the outboard. For example, do not mount a towsport bars or boarding ladders onto the boat using the mountinghardware included with the outboard. Installing other productsonto the boat that utilize the outboard mounting hardware willcompromise the ability of that hardware to properly and safelysecure the outboard to the transom.Outboards that require validated mounting hardware will havethe following decal on the transom clamp.51965eng 117

Important InformationOUTBOARD INSTALLATIONRigging boats, which includes proper engine installation, hasbecome more complex over the years. As a result, werecommend our engines be installed only by Mercury authorizeddealers. If you intend to disregard this recommendation andinstall the engine yourself, please make sure to read and complywith these instructions. Failure to comply with these installationinstructions could lead to serious injury or death.Boat Horsepower Capacity! WARNINGExceeding the boat's maximum horsepower rating can causeserious injury or death. Overpowering the boat can affect boatcontrol and flotation characteristics or break the transom. Donot install an engine that exceeds the boat's maximum powerrating.Do not overpower or overload your boat. Most boats will carry arequired capacity plate indicating the maximum acceptablepower and load as determined by the manufacturer followingcertain federal guidelines. If in doubt, contact your dealer or theboat manufacturer.U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSONCAPACITY (POUNDS)MAXIMUM WEIGHTCAPACITYXXXXXX26777118 eng

OUTBOARD INSTALLATIONStart in Gear Protection! WARNINGStarting the engine with the drive in gear can cause seriousinjury or death. Never operate a boat that does not have aneutral‐safety‐protection device.The remote control connected to the outboard must be equippedwith a start in neutral only protection device. This prevents theengine from starting in gear.Selecting Accessories for Your OutboardGenuine Mercury Precision or Quicksilver Accessories havebeen specifically designed and tested for this outboard.Some accessories not manufactured or sold by Mercury Marineare not designed to be safely used with this outboard or outboardoperating system. Acquire and read the installation, operation,and maintenance manuals for all selected accessories.Fuel SystemAVOIDING FUEL FLOW RESTRICTIONIMPORTANT: Adding components to the fuel supply system(filters, valves, fittings, etc.) may restrict the fuel flow. This maycause engine stalling at low speed, and/or a lean fuel conditionat high RPM that could cause engine damage.ELECTRIC FUEL PUMPThe fuel pressure must not exceed 28 kPa (4 psi). If necessary,install a pressure regulator.LOW PERMEATION FUEL HOSE REQUIREMENTRequired for outboards manufactured for sale, sold, or offeredfor sale in the United States.• The Environmental Protection Agency (EPA) requires thatany outboard manufactured after January 1, 2009, must uselow permeation fuel hose for the primary fuel hoseconnecting the fuel tank to the outboard.eng 119

OUTBOARD INSTALLATION• Low permeation hose is USCG Type B1‐15 or Type A1‐15,defined as not exceeding 15/gm²/24 h with CE 10 fuel at23 °C as specified in SAE J 1527 ‐ marine fuel hose.EPA PRESSURIZED PORTABLE FUEL TANKREQUIREMENTSThe Environmental Protection Agency (EPA) requires portablefuel systems that are produced after January 1, 2011, for usewith outboard engines to remain fully sealed (pressurized) up to34.4 kPa (5.0 psi). These tanks may contain the following:• An air inlet that opens to allow air to enter as the fuel isdrawn out of the tank.• An air outlet that opens (vents) to the atmosphere ifpressure exceeds 34.4 kPa (5.0 psi).FUEL DEMAND VALVE (FDV) REQUIREMENTWhenever a pressurized fuel tank is used, a fuel demand valveis required to be installed in the fuel hose between the fuel tankand primer bulb. The fuel demand valve prevents pressurizedfuel from entering the engine and causing a fuel system overflowor possible fuel spillage.The fuel demand valve has a manual release. The manualrelease can be used (pushed in) to open (bypass) the valve incase of a fuel blockage in the valve.acb46273a - Fuel demand valve ‐ installedin the fuel hose between thefuel tank and primer bulbb - Manual releasec - Vent/water drain holesFUEL TANKSPortable Fuel TankSelect a suitable location in the boat within the engine fuel linelength limitations and secure the tank in place.120 eng

OUTBOARD INSTALLATIONPermanent Fuel TankPermanent fuel tanks should be installed in accordance withindustry and federal safety standards, which includerecommendations applicable to grounding, anti‐siphonprotection, ventilation, etc.FILLING THE FUEL SYSTEMWhen starting an engine for the first time, or starting an enginethat ran out of fuel or was drained of fuel, fill and prime the fuelsystem.To fill and prime the fuel system:1. Squeeze the fuel line primer bulb until it feels firm.2. Turn the key switch to the "ON" position for three seconds.This operates the electric fuel pump.3. Turn the key switch back to the "OFF" position and squeezethe primer bulb again until it feels firm.4. Turn the key switch to the "ON" position again for threeseconds.5. Continue this procedure until the fuel line primer bulb staysfirm.Installation Specificationsaab18552a - Minimum transom openingb - Engine centerline for dual engine ‐ 66.0 cm (26 in.)eng 121

Minimum Transom OpeningOUTBOARD INSTALLATIONSingle engineDual engine84.2 cm (33 in.)149.9 cm (59 in.)Lifting the Outboard! WARNINGImproperly supporting an engine during lifting can result in theengine falling, causing serious injury or death. Before lifting theengine, verify that the lifting ring is threaded into the flywheelfor a minimum of five turns and that the hoist has the correctlifting capacity for the engine weight.To lift the outboard:1. Remove the cowl from the outboard.2. Thread the lifting eye into the flywheel hub for a minimum offive turns.15363Lifting Eye 91‐90455‐‐12756Threads into the flywheel toremove the powerheadassembly from the driveshafthousing, or to lift entire enginefor removal/installation.3. Connect a hoist to the lifting eye.4. Lift the outboard and place it on the boat transom.122 eng

OUTBOARD INSTALLATIONSteering Cable ‐ Starboard Side Routed Cable1. Lubricate the O‐ring seal and the entire cable end.953724TubeRef No.95Description Where Used Part No.2-4-C withPTFEO-ring seal and entire cableend2. Insert the steering cable into the tilt tube.92-802859A 13725eng 123

OUTBOARD INSTALLATION3. Tighten the nut to the specified torque.3727Description Nm lb‐in. lb‐ftNut 47.5 – 35124 eng

OUTBOARD INSTALLATIONDetermining Recommended Outboard MountingHeight63.5 cm(25 in.)e60.9 cm(24 in.)58.4 cm(23 in.)cb56.0 cm(22 in.)53.3 cm(21 in.)ae50.8 cm(20 in.)48.2 cm(19 in.)d10 20 30 40 50 60 70 80a - The solid line is recommended to determine the outboardmounting heightb - The broken lines represent the extremes of knownsuccessful outboard mounting height dimensionsc - This line may be preferred to determine outboardmounting height dimension, if maximum speed is the onlyobjectived - This line may be preferred to determine outboardmounting height dimension for dual outboard installatione - Outboard mounting height (height of outboard mountingbrackets from bottom of boat transom). For heights over56.0 cm (22 in.), a propeller that is designed for surfacingoperation is usually preferred.f - Maximum boat speed (MPH) anticipatedf18562eng 125

OUTBOARD INSTALLATIONNOTICE1. The outboard should be mounted high enough on the transom so theexhaust relief hole will stay at least 25.4 mm (1 in.) above the waterlinewhen the engine is running at idle speed. Having the exhaust relief holeabove the waterline will prevent exhaust restrictions. Exhaust restrictionswill result in poor performance at idle.2. Add 12.7 cm (5 in.) for XL models to the listed outboard mountingheights.3. The mounting height of the outboard must not exceed 63.5 cm (25 in.)for L models, 76 cm (30 in.) for XL models. Mounting the outboard highermay cause damage to the gearcase components.Increasing the mounting height will usually:• Reduce steering torque• Increase top speed• Increase boat stability• Cause propeller to break loose during planingDrilling Outboard Mounting HolesIMPORTANT: Before drilling any mounting holes, carefully readDetermining Recommended Outboard Mounting Height andinstall outboard to the nearest recommended mounting height.1. Mark four mounting holes on the transom using the transomdrilling fixture.aba - Drill guide holesb - Transom drilling fixturec - Transom centerlineac2757126 eng

OUTBOARD INSTALLATIONTransom Drilling Fixture 91‐98234A254892. Drill four 13.5 mm (17/32 in.) mounting holes.Aids in engine installation byacting as a template for enginemounting holes.3973Fastening the Outboard to the TransomMOUNTING BOLTSOutboard Transom Mounting Hardware ‐ Supplied with OutboardPart Number Part Name Description8M0033366 Outboard mounting bolt ½‐20 x 5.00 in. long (3.25 in. thread)826711‐17 Nylon insert locknut ½‐2028421 Flat washer 1.50 in. diameter54012 Flat washer 0.875 in. diameterAvailable Outboard Mounting BoltsPart NumberDescription67755005 ½‐20 x 2.50 in. long (1.25 in. thread)67755006 ½‐20 x 3.50 in. long (1.25 in. thread)814259 ½‐20 x 4.00 in. long (2.25 in. thread)67755‐1 ½‐20 x 4.50 in. long (2.25 in. thread)8M0033366½‐20 x 5.00 in. long (3.25 in. thread)eng 127

OUTBOARD INSTALLATIONPart NumberAvailable Outboard Mounting BoltsDescription67755‐003 ½‐20 x 5.50 in. long (3.25 in. thread)67755‐2 ½‐20 x 6.50 in. long (2.75 in. thread)8M00280808M0032860½‐20 x 7.50 in. long (2.75 in. thread)½‐20 x 8.00 in. long (2.75 in. thread)CHECKING BOAT TRANSOM CONSTRUCTIONIMPORTANT: Determine the strength of the boat transom. Theoutboard mounting locknuts and bolts should be able to hold75 Nm (55 lb‐ft) of torque without the boat transom yielding orcracking. If the boat transom yields or cracks under this torque,the construction of the transom may not be adequate. The boattransom must be strengthened or the load carrying areaincreased.ab18961a - Transom yielding under bolt torqueb - Transom cracking under bolt torque128 eng

OUTBOARD INSTALLATIONUse a dial torque wrench to determine transom strength. If thebolt or nut continues to turn without the torque reading on thedial increasing, it is an indication that the transom is yielding. Theload area can be increased by using a larger washer or atransom reinforcement plate.aba - Large transom washerb - Transom reinforcement plate33962eng 129

OUTBOARD INSTALLATIONFASTENING THE OUTBOARD TO THE TRANSOMIMPORTANT: The transom mounting surface must be flat within3.17 mm (0.125 in.). No step in the transom mounting surface isallowed. The inside transom mounting bolt washer surface mustbe flat within 3.17 mm (0.125 in.).ab51817a - Step (not allowed)b - Gap between transom clamp and boat transom (notallowed)130 eng

OUTBOARD INSTALLATIONIMPORTANT: Clearance must be maintained between thevessel transom and the outboard transom bracket relief radiusarea. Failure to maintain clearance may damage the transombracket and cause the transom bracket to fail. Adjustments to theposition of the Mercury Marine transom drilling fixture may berequired to ensure proper clearance of the transom bracket reliefradius area.51867Installation1. Apply marine sealer to the shanks of the bolts, not to thethreads.2. Fasten the outboard with the correct mounting hardware.Tighten the locknuts to the specified torque.IMPORTANT: Ensure that a minimum of two full threads of themounting bolts extend beyond the locknut after tightening. Thelocknut must be drawn tight while still engaging the bolt threadsand not contacting the shank of the bolt.eng 131

OUTBOARD INSTALLATIONNOTE: For a more accurate torque reading, tighten themounting locknuts rather than the outboard mounting bolts.adcecbda40952a - 0.500 in. diameter outboard mounting bolt (4)b - 0.875 in. flat washer (4)c - Nylon insert locknut (4)d - 1.500 in. flat washer (4)e - Marine sealer – apply to the shank of the bolts, not thethreadsDescription Nm lb‐in. lb‐ftOutboard mounting locknuts andbolts – standard boat transomOutboard mounting locknuts andbolts – metal lift plates and setbackbrackets75 – 55122 – 90132 eng

OUTBOARD INSTALLATIONA decal on the transom bracket reminds the owner to check thefasteners securing the outboard to the transom before each use.51985Decal on the transom bracketElectrical, Fuel Hose, Flush Hose, and ControlCablesFRONT COWL GROMMETNOTE: Sufficient slack must exist in wiring, battery cables, andhoses that are routed between the grommet and engineattachment points to relieve stress and prevent hoses from beingkinked or pinched.eng 133

OUTBOARD INSTALLATION1. Pull up the cowl seal. Remove the access cover from thebottom cowl.ba23714a - Access coverb - Screws2. Insert the lower alignment pin on the grommet into the holein the lower cover. Ensure the lettered side of the grommetis facing out.3. Route the hoses, wiring, and cables through the correctopening in the grommet, as shown.134 eng

OUTBOARD INSTALLATION4. Install the flush hose after removing the knockouts. Refer toFlush Hose Routing.adecfFTHSHWBgkhijb23638a - Flush hoseb - Grommetc - Remote boat harnessd - Not usede - Throttle cablef - Fuel hoseg - Upper alignment pinh - SmartCraft harness or additional harness openingi - Water pressure tubej - Battery cablesk - Lower alignment pin5. Install the access cover with two screws. Tighten the screwsto the specified torque.Description Nm lb‐in. lb‐ftAccess cover screws 7.3 65 –eng 135

OUTBOARD INSTALLATION6. Attach two cable ties around the grommet tube. Reattachthe cowl seal.a23639a - Cable tieFLUSH HOSE ROUTINGIf desired, the flush hose can be routed outside the cowling asfollows:1. Using a needle‐nose pliers, break out the semi‐circularknockouts in the access cover and lower cover. Smooth theedges of the knockout with sandpaper or a small knife.2. Route the flush hose through this opening.ab23642a - Knockoutb - Flush hose136 eng

OUTBOARD INSTALLATIONREMOTE BOAT HARNESSRoute the remote boat harness through the grommet. Connectthe remote harness to the 14 pin connector on the engineharness.a23699a - Remote 14 pin boat harnessBATTERY INFORMATION! WARNINGFailure to properly secure the battery leads can result in a lossof power to the Digital Throttle and Shift (DTS) system, leadingto serious injury or death due to loss of boat control. Securethe battery leads to the battery posts with hex nuts to avoidloose connections.• Do not use deep‐cycle batteries. Engines must use a marinestarting battery with 1000 MCA, 800 CCA, or 180 Ah.• When connecting the engine battery, hex nuts must be usedto secure battery leads to battery posts. Torque nuts tospecification.eng 137

OUTBOARD INSTALLATIONDescription Nm lb‐in. lb‐ftHex nuts 13.5 120 –IMPORTANT: Battery cable size and length is critical. Refer toengine installation manual for size requirements.The decal needs to be placed on or near the battery box forfuture service reference. One 5/16 in. and one 3/8 in. hex nut issupplied per battery for wing nut replacement. Metric hex nutsare not supplied.NOTICE - DTS & OptiMax EnginesDO NOT USE DEEP CYCLE BATTERIES!DTS (Digital Throttle and Shift) applications andOptiMax engines must use a marine startingbattery with 1000 MCA, 800 CCA, or 180 Ah. rating.13.5Nm (120 lbs. in.)DO NOTUSE WINGNUTSIMPORTANT:Battery cable size and length is critical. Refer toengine installation manual for size requirements.37-895387Place decal on or near battery box for future servicereference. 5/16” and 3/8” hex nuts supplied for wingnut replacement. Metric hex nuts not supplied.3486BATTERY CABLE CONNECTIONSSingle Outboardba(+)ca - Red sleeve ‐positive (+)b - Black sleeve ‐negative (–)c - Cranking battery(-)15496138 eng

Dual OutboardsOUTBOARD INSTALLATIONConnect a common ground cable (wire size same as enginebattery cables) between negative (–) terminals on startingbatteries.aba(-)dbc(-)d15497a - Red sleeve ‐ positive (+)b - Black sleeve ‐ negative (–)c - Ground cabled - Cranking batteryeng 139

OUTBOARD INSTALLATIONSMARTCRAFT HARNESS CONNECTIONIf SmartCraft gauges are being used with the outboard, route theSmartCraft wiring harness through the grommet and connect it tothe SmartCraft harness connector on the engine.a23700a - SmartCraft harness connectorWATER PRESSURE TUBE CONNECTIONIf a water connection to the engine is required for a waterpressure gauge, make the connection as follows:140 eng

OUTBOARD INSTALLATION1. The water pressure tube is coiled and attached on the sideof the engine. Cut the cable tie and route the water pressuretube out through the grommet.aa - Water pressure tube23702eng 141

OUTBOARD INSTALLATION2. Remove the plug from the coupler and make the connection.A barb fitting (22‐859731) can be installed for largerdiameter hose connection.acb23708a - Plugb - Couplerc - Barb fitting (22‐859731)FUEL HOSE CONNECTIONRemote Fuel Hose SizeMinimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) withseparate fuel hose/fuel tank pickup for each engine.142 eng

OUTBOARD INSTALLATIONFuel Hose ConnectionFasten the remote fuel hose to the fitting with a hose clamp.ab23709a - Hose clampb - Remote fuel hoseSHIFT CABLE INSTALLATIONNOTE: Install the shift cable to the engine first. The shift cable isthe first cable to move when the remote control handle is movedout of neutral.Install cables into the remote control following the instructionsprovided with the remote control.1. Position remote control into neutral.N2. Shift outboard into neutral.26838eng 143

OUTBOARD INSTALLATION3. Measure the distance between pin and center of barrelpocket.acbFN R23720a - Distance between pin and center of lower holeb - Pinc - Barrel pocket144 eng

OUTBOARD INSTALLATION4. Push in on the shift cable end until resistance is felt. Adjustthe cable barrel to attain distance measured in Step 3.ba23721a - Shift cable endb - Cable barrel5. Place the cable barrel into the pocket. Fasten the cable withlocknut and flat washer.abc7736a - Cable barrelb - Locknutc - Flat washer6. Check shift cable adjustments as follows:a. Shift the remote control into forward. The propeller shaftshould be locked in gear. If not, adjust the barrel closer tothe cable end.eng 145

OUTBOARD INSTALLATIONb. Shift the remote control into neutral. The propeller shaftshould turn freely without drag. If not, adjust the barrelaway from the cable end. Repeat steps a and b.c. Shift the remote control into reverse while turningpropeller. The propeller shaft should be locked in gear. Ifnot, adjust the barrel away from the cable end. Repeatsteps a through c.d. Shift the remote control back to neutral. The propellershaft should turn freely without drag. If not, adjust thebarrel closer to the cable end. Repeat steps a through d.THROTTLE CABLE INSTALLATIONInstall cables into the remote control following the instructionsprovided with the remote control.1. Position remote control into neutral.N268382. Install the throttle cable to the throttle arm with a flat washerand locknut. Tighten the locknut, then back off the locknut1/4 turn.3. Adjust the cable barrel so that the installed throttle cable willhold the throttle arm against the idle stop.4. Place the cable barrel into the barrel retainer.146 eng

OUTBOARD INSTALLATION5. Lock the retainer and cables in place with the cable latch.cdeab15317a - Flat washerb - Locknutc - Barrel retainerd - Cable barrele - Cable latchOil Injection Set‐UpFILLING OIL INJECTION SYSTEM1. Fill the oil tank with the specified oil. Refer to Filling OilInjection System. Add only enough oil to bring the oil levelup to the bottom of the fill neck.29465eng 147

OUTBOARD INSTALLATIONAll Models Capacity Fluid TypeOil tank 4.72 liters (5 US qt) OptiMax/DFI 2‐Cycle Engine OilPRIMING THE OIL INJECTION PUMPBefore starting engine for the first time, prime the oil injectionpump. Priming will remove any air that may be in the pump, oilsupply hose, or internal passages.aa - Oil injection pumpb - Oil supply hosebIMPORTANT: Fill the engine fuel system with fuel before primingthe oil injection pump. Otherwise, the fuel pump will run withoutfuel during the priming process and may be damaged.Prime the oil injection pump as follows:1. Fill the engine fuel tank with fuel.7912NOTE: Use the primer bulb located in the fuel hose to theengine to draw fuel from the tank to fill the engine fuel system.2. Position the fuel hose primer bulb so that the arrow on theside of the bulb is pointing up. Squeeze the fuel hose primerbulb until it feels firm.27348148 eng

OUTBOARD INSTALLATION3. Turn the ignition key switch to the "ON" position.268464. Within the first 10 seconds after the key switch has beenturned on, move the remote control handle from neutral intoforward gear 3–5 times. This will automatically start thepriming process.NOTE: It may take a few minutes for the pump to complete thepriming process.Trim In Pin! WARNINGOperating the boat at high speeds with the outboard trimmedtoo far under can create excessive bow steer, resulting in theoperator losing control of the boat. Install the trim limit pin in aposition that prevents excessive trim under and operate theboat in a safe manner.Some boats, particularly some bass boats, are built with agreater than normal transom angle, which will allow the outboardto be trimmed further in or under. This greater trim undercapability is desirable to improve acceleration, reduce the angleand time spent in a bow high boat during planing off, and insome cases, may be necessary to plane off a boat with aftlivewells, given the variety of available propellers and heightrange of engine installations.eng 149

OUTBOARD INSTALLATIONHowever, once on plane, the engine should be trimmed to amore intermediate position to avoid a bow‐down planingcondition called plowing. Plowing can cause bow steering oroversteering and inefficiently consumes horsepower.a - Tilt pin (not included with engine)a2688Stainless Steel Tilt Pin 17‐49930A 12749Limits the down trim angle of thepower trim equipped engines, oraids in determining the trim outangle on non‐power trimengines.The owner may decide to limit the trim in. This can beaccomplished by purchasing a stainless steel tilt pin from yourdealer and insert it in whatever adjustment hole in the transombrackets is desired. A nonstainless steel shipping bolt should notbe used in this application other than on a temporary basis.150 eng

Maintenance LogMAINTENANCE LOGRecord all maintenance performed on your outboard here. Besure to save all work orders and receipts.Date Maintenance Performed Engine Hourseng 151