Mercury 135 Verado FourStroke, 175 Verado FourStroke, 150 Verado FourStroke, 400R Verado FourStroke Maintance Manual

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Operation

and

Maintenance

Manual

135/150/175/200 Verado FourStroke

8M0125711 1216 eng

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eng

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Welcome

You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability.

With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water.

Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant!

Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:

John Pfeifer, President, Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a demonstration of actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, warnings, cautions,

and notices, accompanied by the International Hazard Symbol

, may be used to alert the installer and user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while performing the service, plus common sense operation, are major accident prevention measures.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard. We strongly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.

Warranty Message

The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.

Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.

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Identification Records

Please record the following applicable information:

Outboard

Engine Model and Horsepower

Engine Serial Number

Gear Ratio

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

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General Information

Boater's Responsibilities..................................................................................... 1

Before Operating Your Outboard........................................................................ 1

Boat Horsepower Capacity................................................................................. 1

High‑Speed and High‑Performance Boat Operation.......................................... 2

Outboard Remote Control Models ..................................................................... 2

Lanyard Stop Switch........................................................................................... 2

Protecting People in the Water........................................................................... 5

Passenger Safety Message ‑ Pontoon Boats and Deck Boats...........................5

Wave and Wake Jumping................................................................................... 7

Impact with Underwater Hazards........................................................................7

Exhaust Emissions............................................................................................. 9

Selecting Accessories for Your Outboard......................................................... 11

Safe Boating Recommendations...................................................................... 11

Recording Serial Number................................................................................. 14

135/150/175/200 Verado FourStroke Specifications........................................ 14

Component Identification.................................................................................. 16

Propeller Selection............................................................................................17

Transporting

Trailering Boat/Outboard.................................................................................. 19

Fuel and Oil

Fuel Requirements........................................................................................... 20

Fuel Additives................................................................................................... 21

Low Permeation Fuel Hose Requirement ........................................................ 21

EPA Pressurized Portable Fuel Tank Requirements........................................ 21

Fuel Demand Valve (FDV) Requirement.......................................................... 22

Mercury Marine's Pressurized Portable Fuel Tank........................................... 22

Filling Fuel Tank............................................................................................... 23

Engine Oil Recommendations.......................................................................... 24

Checking and Adding Engine Oil...................................................................... 24

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Features and Controls

Panel Mount Control Features and Operation.................................................. 27

Slim Binnacle Control Features and Operation................................................ 29

Dual‑Handle Console Control Features and Operation.................................... 35

Shadow Mode Control with CAN Trackpad Features and Operation............... 43

Warning System............................................................................................... 46

Power Trim and Tilt...........................................................................................48

Operation

Important Daily Inspection Before Each Use ................................................... 52

Prestarting Check List.......................................................................................52

Operating in Freezing Temperatures................................................................ 53

Operating in Saltwater or Polluted Water......................................................... 53

Operating at High Elevations............................................................................ 53

Effects of Elevation and Weather on Performance........................................... 53

Setting Trim Angle While Running Engine at Idle Speed................................. 54

Engine Break‑in Procedure...............................................................................54

Starting the Engine........................................................................................... 55

Gear Shifting..................................................................................................... 57

Stopping the Engine......................................................................................... 59

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Maintenance

Cleaning Care Recommendations.................................................................... 60

EPA Emissions Regulations............................................................................. 62

Inspection and Maintenance Schedule............................................................. 63

Flushing the Cooling System............................................................................ 64

Top Cowl Removal and Installation.................................................................. 65

Battery Inspection ............................................................................................ 65

Verado Engine Battery Specifications.............................................................. 66

Air Filter............................................................................................................ 67

Fuel System...................................................................................................... 71

Corrosion Control Anode.................................................................................. 74

Propeller Replacement..................................................................................... 75

Spark Plug Inspection and Replacement..........................................................77

Fuses................................................................................................................ 81

Steering Link Rod Fasteners............................................................................ 82

DTS Wiring System.......................................................................................... 83

Accessory Drive Belt Inspection....................................................................... 83

Lubrication Points............................................................................................. 83

Checking Power Trim Fluid...............................................................................86

Checking Power Steering Fluid........................................................................ 87

Changing Engine Oil......................................................................................... 88

Gearcase Lubrication........................................................................................91

Storage

Storage Preparation..........................................................................................94

Protecting External Outboard Components...................................................... 94

Protecting Internal Engine Components........................................................... 95

Gearcase.......................................................................................................... 95

Positioning Outboard for Storage..................................................................... 95

Battery Storage................................................................................................. 95

Troubleshooting

Starter Motor Will Not Crank the Engine........................................................... 96

Engine Will Not Start.........................................................................................96

Engine Starts But Will Not Shift Into Gear........................................................ 96

Engine Runs Erratically.................................................................................... 96

Performance Loss.............................................................................................97

Battery Will Not Hold Charge............................................................................ 97

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Owner Service Assistance

Local Repair Service.........................................................................................98

Service Away from Home................................................................................. 98

Parts and Accessories Inquiries....................................................................... 98

Service Assistance........................................................................................... 98

Ordering Literature..........................................................................................100

Installation Information

Mercury Marine Validated Engine Mounting Hardware.................................. 102

Accessories Mounted to the Transom Clamp Bracket.................................... 102

Fastening the Outboard to the Transom......................................................... 106

Installing Outboard..........................................................................................111

Propeller Selection..........................................................................................112

Maintenance Log

Maintenance Log............................................................................................ 113

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Boater's Responsibilities

The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard.

Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

Before Operating Your Outboard

Read this manual carefully. Learn how to operate your outboard properly. If you have any questions, contact your dealer.

Safety and operating information that is practiced, along with using good common sense, can help prevent personal injury and product damage.

This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

Boat Horsepower Capacity

WARNING

Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating.

GENERAL INFORMATION

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Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT CAPACITY

XXX

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High‑Speed and High‑Performance Boat Operation

If your outboard is to be used on a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you do not operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat/ outboard combination. For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

Outboard Remote Control Models

The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start‑in‑gear protection is provided by the remote control system.

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.

A decal near the lanyard stop switch is a visual reminder for the operator to attach the lanyard to their personal flotation device (PFD) or wrist.

GENERAL INFORMATION

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The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or tie a knot in the lanyard.

a - Lanyard cord clip b - Lanyard decal c - Lanyard stop switch

Read the following Safety Information before proceeding. Important Safety Information: The purpose of a lanyard stop switch is to stop

the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position. Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables, bass boats, high performance boats, and light, sensitive handling fishing boats operated by a hand tiller. Falling overboard and accidental ejections are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating at planing speeds in shallow or obstacle infested waters, releasing your grip on a steering wheel or tiller handle that is pulling in one direction, drinking alcohol or consuming drugs, or daring high speed boat maneuvers.

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OFF

RUN

ATTACH LANYARD

GENERAL INFORMATION

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While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (if the operator is accidentally ejected).

WARNING

If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard.

WARNING

Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.

Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller.

• Loss of power and directional control in heavy seas, strong current, or high winds.

• Loss of control when docking.

KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION

Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

Before each use, visually inspect the lanyard cord to ensure it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

GENERAL INFORMATION

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Protecting People in the Water

WHILE YOU ARE CRUISING

It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed.

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Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

Whenever a boat is moving (coasting) and the outboard gear shift is in neutral position, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.

WHILE THE BOAT IS STATIONARY

WARNING

A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat.

Passenger Safety Message ‑ Pontoon Boats and Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat. Falling over the front of the boat between the two pontoons will position them to be run over by the outboard.

BOATS HAVING AN OPEN FRONT DECK

No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure.

GENERAL INFORMATION

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Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.

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WARNING

Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

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Wave and Wake Jumping

Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.

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The primary concern is the boat changing direction while in the midst of the jump. In such case, the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

WARNING

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward. The boat may also steer sharply to one side.

Impact with Underwater Hazards

Your outboard is equipped with a hydraulic trim and tilt system that also contains a shock absorbing feature. This feature helps the outboard withstand damage in the case of impact with an underwater object at low to moderate speeds. At higher speeds, the force of the impact may exceed the system’s ability to absorb the energy of the impact and cause serious product damage.

No impact protection exists while in reverse. Use extreme caution when operating in reverse to avoid striking underwater objects.

GENERAL INFORMATION

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Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist that could be struck by the outboard or the boat bottom. The most significant

action you can take to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed. Under these conditions, boat speed should be kept to the minimum planing speed, typically 24 to 40 km/h (15 to 25 mph).

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WARNING

Avoid serious injury or death from all or part of an outboard or drive unit coming into the boat after striking a floating or underwater object. When operating in waters where objects may be at the surface or just under the surface of the water, reduce your speed and keep a vigilant lookout.

Examples of objects that can cause engine damage are dredging pipes, bridge supports, wing dams, trees, stumps, and rocks.

Striking a floating or underwater object could result in any of an infinite number of situations. Some of these situations could yield the following:

• Part of the outboard or the entire outboard could break loose and fly into the boat.

• The boat could move suddenly in a new direction. A sharp change in direction can cause occupants to be thrown out of their seats or out of the boat.

• The boat's speed could rapidly reduce. This will cause occupants to be thrown forward or even out of the boat.

• The outboard or boat could sustain impact damage.

After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts. If damage is present or suspected, the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair.

The boat should also be checked for any hull fractures, transom fractures, or water leaks. If water leaks are discovered after an impact, immediately activate the bilge pump.

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Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

WARNING

Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.

Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness, drowsiness, and nausea.

WARNING

Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide.

Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.

STAY CLEAR OF EXHAUST AREAS

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Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, 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 the boat (platform dragging, teak/body surfing). This dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the possibility of injury from the boat propeller.

GOOD VENTILATION

Ventilate the passenger area, open side curtains or forward hatches to remove fumes.

Example of desired air flow through the boat:

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POOR VENTILATION

Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide.

1. Examples of poor ventilation while the boat is stationary:

a - Operating the engine when the boat is moored in a confined space b - Mooring close to another boat that has its engine operating

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2. Examples of poor ventilation while the boat is moving:

a - Operating the boat with the trim angle of the bow too high b - Operating the boat with no forward hatches open (station wagon effect)

Selecting Accessories for Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

IMPORTANT: Check with your dealer before installing accessories. The misuse of approved accessories or the use of nonapproved accessories can damage the product.

Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Read the installation, operation and maintenance manuals for all your selected accessories.

Refer to Outboard Installation ‑ Accessories Mounted to the Transom Clamp Bracket for important information on mounting accessories to the transom clamp bracket.

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions.

Know and obey all nautical rules and laws of the waterways.

• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. 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.

• Follow a regular schedule and ensure that all repairs are properly made.

Check safety equipment onboard.

• Here are some suggestions of the types of safety equipment to carry when boating:

Approved fire extinguishers

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Signal devices: flashlight, rockets or flares, flag, and whistle or horn

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

Watch for signs of weather change and avoid foul weather and rough‑sea boating.

Tell someone where you are going and when you expect to return.

Passenger boarding.

• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

Use personal flotation devices.

• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver 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 if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

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• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

Never operate a boat while under the influence of alcohol or drugs. It is the law.

• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

Be alert.

• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.

Never drive your boat directly behind a water skier.

• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.

Watch fallen skiers.

• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

Report accidents.

• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.

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Recording Serial Number

It is important to record this number for future reference. The serial number is located on the outboard, as shown.

a - Model designation b - Serial number c - Certified Europe Insignia (as applicable)

135/150/175/200 Verado FourStroke Specifications

Models

135 150 175 200 Horsepower 135 150 175 200 Kilowatts 99.3 110 129 147 Full throttle RPM range 5200–6400 5800–6400 Idle speed in neutral

gear

650 RPM

Number of cylinders 4 Piston displacement 1,731 cc (105.6 cid) Cylinder bore 82 mm (3.23 in.) Stroke 82 mm (3.23 in.) Valve clearance (cold) Intake valve 0.150–0.230 mm (0.0059–0.009 in.) Exhaust valve 0.350–0.430 mm (0.0137–0.0169 in.) Recommended spark

plug

NGK ILFR6G‑E

Spark plug gap 0.8 mm (0.0315 in.) Spark plug hex size 16 mm Gear ratio 2.08:1

XXXXXXXXX

XXXXXXXX

XXXX

62548

1. With engine fully warmed up.

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Models 135 150 175 200

Recommended gasoline

Refer to Fuel and Oil

Recommended oil

Refer to Fuel and Oil

Right‑hand rotation gearcase lubricant capacity

970 mL (32.8 fl oz)

Left‑hand rotation gearcase lubricant capacity

900 mL (30.4 fl oz)

Engine oil capacity with oil filter replacement

6.0 liter (6.3 US qt)

Required battery type 12 volt AGM (absorbed glass mat) battery

Required USA (SAE) starting battery rating

800 minimum marine cranking amps (MCA) with a

minimum reserve capacity of 135 minutes RC25

rating

Required International (EN) starting battery rating

975 minimum cold cranking amps (CCA) with a

minimum of 65 amp hours (Ah)

Emission control system

Electronic engine control (EC)

Sound at drivers ear (ICOMIA 39‑94) dBA

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Component Identification

a - Engine flush b - Auxiliary tilt switch c - Top cowl d - Bottom cowl e - Engine oil drain f - Anti‑ventilation plate g - Gearcase h - Cooling water intake holes i - Transom brackets j - Tilt lock level

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Propeller Selection

The propeller on your outboard is one of the most important components in the propulsion system. An improper propeller choice can significantly affect the performance of your boat and could result in damage to the outboard engine.

When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer.

SELECTING THE CORRECT PROPELLER

An accurate tachometer for measuring engine speed is important in choosing the correct propeller.

Choose a propeller for your boating application that will allow the engine to operate within the specified full throttle operating range. When operating the boat at full throttle under normal load conditions, the engine RPM should be in the upper half of the recommended full throttle RPM range. Refer to Specifications. If engine RPM is above that range, select a propeller of increased pitch in order to reduce engine RPM. If engine RPM is below the recommended range, select a propeller of reduced pitch to increase engine RPM.

IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware.

Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. The first number represents the diameter of the propeller and the second number represents the pitch. For example, 14x19 represents a propeller with a 14 inch diameter and 19 inches of pitch.

a - Diameter b - Pitch ‑ Travel during one revolution

22669

GENERAL INFORMATION

eng 17

Page 28

The following are some propeller basics that will help you determine the correct propeller for your boating application.

Diameter ‑ The diameter is the distance across the imaginary circle that is made when the propeller rotates. The correct diameter for each propeller has been predetermined for the design of your outboard. However, when more than one diameter is available for the same pitch, use a larger diameter for heavy boat applications and a smaller diameter for lighter applications.

Pitch ‑ The pitch is the theoretical distance, in inches, that a propeller travels forward during one revolution. Pitch can be thought of similar to gears in a car. The lower the gear, the faster the car will accelerate, but with lower overall top speed. Likewise, a lower pitch propeller will accelerate quickly, but top‑end speed will be reduced. The higher the propeller pitch the faster the boat will usually go; though typically slowing acceleration.

Determining the correct pitch size ‑ First, check the full throttle RPM under normal load condition. If the full throttle RPM is within the recommended range, select a replacement or upgrade propeller with the same pitch as the current propeller.

• Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200

• Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200

• Upgrading from a 3‑blade propeller to a 4‑blade propeller will generally decrease full throttle RPM by 50 to 100

IMPORTANT: Avoid damage to the engine. Never use a propeller that allows the engine to exceed the recommended full throttle RPM range when under normal full throttle operation.

PROPELLER MATERIAL

Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats. Stainless steel is over five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies. Stainless steel propellers also come in a larger variety of sizes and styles that allow you to dial in the ultimate performance for your boat.

3 BLADE VS. 4 BLADE

Available in many sizes of both aluminum and stainless, 3 and 4‑blade propellers have unique performance characteristics. In general, 3‑blade propellers offer good all around performance and higher top speed than 4‑blade propellers. However, 4‑blade propellers are usually faster to plane and more efficient at cruising speeds, but lack the top end speed of a 3‑blade propeller.

GENERAL INFORMATION

18 eng

Page 29

Trailering Boat/Outboard

Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up

using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing.

14825

IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailering.

Shift the outboard to forward gear. This prevents the propeller from spinning freely.

TRANSPORTING

eng 19

Page 30

Fuel Requirements

IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine and will not be covered under the limited warranty.

FUEL RATINGS

Mercury outboard engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following specifications:

USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for most models. Premium gasoline 91 (R+M)/2 octane is also acceptable for most models. Do not use leaded gasoline.

Outside USA and Canada ‑ A posted pump octane rating of 91 RON, minimum, for most models. Premium gasoline (95 RON) is also acceptable for all models. Do not use leaded gasoline.

USING REFORMULATED (OXYGENATED) GASOLINE (USA ONLY)

Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).

GASOLINE CONTAINING ALCOHOL

Bu16 Butanol Fuel Blends

Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

Methanol and Ethanol Fuel Blends

IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

Be aware that gasoline containing methanol or ethanol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through the rubber fuel lines

• Likelihood of phase separation (water and alcohol separating from the gasoline in the fuel tank)

FUEL AND OIL

20 eng

Page 31

WARNING

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation.

IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of inspection for leaks and abnormalities.

IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble; boats often sit idle long enough for phase separation to take place. Internal corrosion may occur during storage if alcohol has washed protective oil films from internal components.

Fuel Additives

To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container.

Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered for sale in the United States.

• The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.

• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15 g/m²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑ marine fuel hose.

EPA Pressurized Portable Fuel Tank Requirements

The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following:

• An air inlet that opens to allow air to enter as the fuel is drawn out of the tank.

• An air outlet that opens (vents) to the atmosphere if pressure exceeds

34.4 kPa (5.0 psi).

FUEL AND OIL

eng 21

Page 32

Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and the engine. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve.

a - Fuel demand valve ‑ installed in the

fuel hose between the fuel tank and

the engine

b - Manual release c - Vent/water drain holes

Mercury Marine's Pressurized Portable Fuel Tank

Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

SPECIAL FEATURES OF THE PORTABLE FUEL TANK

• The fuel tank has a two‑way valve which allows air to enter the tank as the fuel is drawn to the engine, and also opens to vent to the atmosphere if internal pressure in the tank exceeds 34.4 kPa (5.0 psi). A hissing noise may be heard as the tank vents to the atmosphere. This is normal.

• The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

• When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening.

• The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal.

Since sealed fuel tanks are not vented, they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air. This is normal.

46273

FUEL AND OIL

22 eng

Page 33

REMOVING THE FUEL CAP

a - Fuel cap b - Manual vent screw c - Tab lock

IMPORTANT: Contents may be under pressure. Rotate the fuel cap 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 to relieve the pressure.

4. Press down on the tab lock again and remove the cap.

DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK

1. When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening.

2. Open the manual vent screw on top of the cap for operation and cap removal. Close the manual vent screw for transportation.

3. For fuel hoses that have quick disconnects, disconnect the fuel line from the engine or fuel tank when not in use.

Follow Filling Fuel Tank instructions for fueling.

Filling Fuel Tank

WARNING

Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

Fill the fuel tanks outdoors away from heat, sparks, and open flames. Remove the portable fuel tanks from the boat to fill them. Always stop the engine before filling the tanks. Do not completely fill the fuel tanks. Leave approximately 10% of the tank

volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled.

46290

FUEL AND OIL

eng 23

Page 34

PORTABLE FUEL TANK PLACEMENT IN THE BOAT

Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions.

Engine Oil Recommendations

Mercury Verado NMMA FC‑W certified SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil is recommended for general, all‑temperature use. As an optional choice, Mercury or Quicksilver NMMA FC‑W certified 25W‑40 Mineral Marine 4‑Stroke Engine Oil may be used. If the recommended Mercury or Quicksilver NMMA FC‑W certified oils are not available, a major outboard manufacturer's brand of NMMA FC‑W certified 4‑Stroke Outboard Oil of similar viscosity may be used.

IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives are not recommended.

+100

+80 +60 +40 +20

+38

+120

+49

+27 +16 +4

-7

-18

SAE 25W - 40

54654

Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump. Tilt outboard to vertical (not tilted) position when checking engine oil. For accurate readings, check oil only when engine is cold or after engine has not run for at least an hour.

1. Before starting (cold engine) tilt outboard out/up past vertical to allow trapped oil to drain back to the oil sump. Allow outboard to remain tilted for approximately one minute.

2. Tilt outboard to vertical operating position.

Remove the top cowl. Refer to Maintenance ‑ Top Cowl Removal and Installation.

4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way.

FUEL AND OIL

24 eng

Page 35

5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region).

IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil level is correct as long as it appears in the operating range (cross hatched region).

a - Oil level operating range

6. If the oil level is below the operating range (cross hatched region), remove the oil filler cap and add approximately 500 ml (16 oz.) of specified outboard motor oil. Allow a few minutes for the added oil to drain to the oil sump and check the dipstick. Repeat the process until oil level is on the operating range (cross hatched region). Do not try to fill to the upper end of the operation range (cross hatched region).

14770

IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.

14784

FUEL AND OIL

eng 25

Page 36

7. Push the dipstick back in all the way.

8. Install the oil fill cap hand tight.

9. Install the top cowl.

FUEL AND OIL

26 eng

Page 37

Panel Mount Control Features and Operation

1. Operation of the shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling back to increase speed.

3413

2. Shift lock ‑ Pressing the shift lock allows the engine to shift. The shift lock must always be pressed when moving the control handle out of the neutral position.

3428

3. Trim switch (if equipped) ‑ Pressing the trim switch will trim the engine up or down.

5152

FEATURES AND CONTROLS

eng 27

Page 38

4. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn indicates throttle only is engaged. Advance throttle to increase engine RPM. To disengage, return the control handle to the neutral position. Engine RPM is limited to prevent engine damage.

3416

5. Stop/start button ‑ Allows the boat operator to start or stop the engine without using the ignition key. The ignition key must be in the "ON" position to start the engine.

3414

6. Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.

a - Lanyard stop switch

22964

FEATURES AND CONTROLS

28 eng

Page 39

7. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

8. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.

a - Detent tension adjustment screw b - Control handle tension adjustment

screw

Slim Binnacle Control Features and Operation

DTS SLIM BINNACLE SINGLE HANDLE CONSOLE FEATURES AND OPERATION

1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pushing back to increase speed.

5171

FEATURES AND CONTROLS

eng 29

Page 40

2. Trim Switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The PCM closes the ground circuit to the up or down trim relay.

a - Forward b - Neutral c - Reverse d - Trim switch

3. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions. Turning screw clockwise will increase tension. Adjust to tension desired.

4. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

a - Caps (2) b - Detent tension

adjustment

c - Control handle

tension adjustment

NOTE: The control handle tension and detent tension screws may require periodic maintenance adjustment.

abc

52360

abc

52313

FEATURES AND CONTROLS

30 eng

Page 41

Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers.

STOP/ START

THROTTLE - ONLY

DOCK TRANSFER

bcd

52365

Slim binnacle ERC

Item Control Function

Trim control (handle)

Raises and lowers the engine for best efficiency, or for conditions such as shallow water, trailering, etc.

b "Stop/Start"

Allows the operator to start or stop the engine without the use of the key switch. The key switch must be in the run position for the start/stop switch to function.

c "Transfer"

Allows boat control to be transferred to a different helm.

d "Throttle‑only"

Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into gear.

e "+"

Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.

f "–"

Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.

g "Dock"

Reduces control lever operation throttle capacity to approximately 50% of normal control lever throttle demand.

h Neutral light

Illuminates when the drive is in the neutral gear position. The lights flash when the engine is in throttle only mode.

FEATURES AND CONTROLS

eng 31

Page 42

HELM TRANSFER

Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to another helm.

WARNING

Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.

The helm transfer function allows the boat operator to select which helm is in control of the vessel. Before a transfer can be initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position.

NOTE: If you attempt to transfer helm control when the ERC levers are not in neutral, a beep will sound and the helm transfer will not succeed until the levers at the helms are moved to neutral and transfer is requested again.

Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the helm transfer procedure. Ensure that other control and navigation inputs are performed after helm transfer is complete to avoid setting fault codes.

NOTICE

The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects nearby resulting in damage. Keep an adequate look out while performing the helm transfer.

To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items or when near other vessels.

REQUESTING HELM TRANSFER

NOTE: Any movement of the ERC levers after pressing the transfer button terminates the helm transfer request. A single beep sounds and the transfer button light turns off signaling the end of the transfer request.

To request the transfer of vessel control from one helm to another:

FEATURES AND CONTROLS

32 eng

Page 43

1. At the helm you are requesting be made active and with the ERC levers in neutral, press the transfer button one time. After the transfer button is pressed, the transfer button light turns on and one beep will sound confirming the impending transfer.

THROTTLE - ONLY

DOCK TRANSFER

52367

"Transfer" button

NOTE:

If the ERC levers at the helms are not in neutral, the neutral lights will

flash. Move all the ERC levers to neutral and the neutral light will stop flashing.

2. With the transfer button light and neutral light on, press the transfer button a second time to complete the helm transfer.

3. When the helm transfer is complete, another beep sounds and the transfer button light turns off.

NOTE: If the helm transfer is not completed in 10 seconds, the request is automatically cancelled, a double beep sounds and control will remain at the existing active helm. Press the transfer button again to start the helm transfer.

4. The helm where the transfer request was initiated, is now active and controls the vessel.

THROTTLE-ONLY

Throttle‑only allows the operator to increase the engine RPM for warm‑up without shifting the engine into gear. To engage throttle‑only mode:

THROTTLE - ONLY

DOCK

TRANSFER

52373

"Throttle-Only" button

1. Place the ERC lever in neutral.

2. Press the "Throttle‑Only" button. The button light will turn on and the neutral lights will blink.

FEATURES AND CONTROLS

eng 33

Page 44

3. Place either ERC lever into gear. The warning horn will beep each time the lever is moved in and out of gear while in throttle only, but will remain in neutral.

4. The RPM of the engines can be increased.

NOTE: Pressing the "Throttle‑Only" button while the ERC lever is not in the neutral position, turns the button light off and remains in throttle‑only mode. You must place the ERC lever into the neutral position to disengage throttle‑only mode.

To disengage throttle‑only mode:

1. Place the ERC lever into neutral. Throttle‑only will not disengage unless the ERC lever is in neutral.

2. Press the "Throttle‑Only" button. The button light will turn off.

3. The neutral lights stop flashing and remain illuminated.

DOCK

Dock mode reduces throttle capacity to approximately 50% of normal throttle demand, allowing finer control of engine power in close quarter situations. If more power is needed for vessel maneuvering when environmental conditions require more thrust, disable dock mode to return the engine control to full thrust capability.

THROTTLE - ONLY

DOCK TRANSFER

52372

"DOCK" button

FEATURES AND CONTROLS

34 eng

Page 45

Dual‑Handle Console Control Features and Operation

DUAL-HANDLE ELECTRONIC REMOTE CONTROL (ERC)— OPERATION AND ADJUSTMENT

Operation

The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling the handle back to increase speed in reverse.

a - Forward b - Neutral c - Reverse

The amount of force needed to move the handles and to move the handles through the detents is adjustable to help prevent unwanted motion.

Adjustment

NOTE: The control handle tension and detent tension may require periodic maintenance using the adjustment screws.

To adjust the handle detent tension:

1. Remove the side cover plugs of the handle that needs adjustment.

2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.

3. Adjust to the tension desired.

abc

51902

FEATURES AND CONTROLS

eng 35

Page 46

To adjust handle tension:

1. Remove the side cover plugs of the handle that needs adjustment.

2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.

3. Adjust to the tension desired.

a - Detent tension

adjustment screw

b - Handle tension

adjustment screw

51901

FEATURES AND CONTROLS

36 eng

Page 47

SPECIAL DIGITAL THROTTLE AND SHIFT (DTS) FEATURES

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously.

55232

Dual engine ERC

Item Control Function

Trim control (handle)

Raises and lowers the engines for best efficiency, or for conditions such as shallow water, trailering, etc.

NEUTRAL lights

Illuminate when the drive is in the neutral gear position. The lights flash when the engine is in throttle only mode.

c TRANSFER

Allows boat control to be transferred to a different helm. Refer to Helm Transfer.

d DOCK

Control lever operation reduces throttle capacity to approximately 50% of normal control lever throttle demand.

e +

Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.

THROTTLE ONLY

Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into gear.

g –

Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.

FEATURES AND CONTROLS

eng 37

Page 48

Item Control Function

h 1 LEVER

Enables the throttle and shift functions of both engines to be controlled by the port lever.

i SYNC

Turns off or on the auto‑synchronization feature. Refer to Sync.

NOTE: Not all functions may be active.

Dock

Dock mode reduces throttle capacity to approximately 50% of normal throttle demand, allowing finer control of engine power in close quarter situations.

51854

DOCK button

Throttle Only

NOTE: Throttle only mode should be used if the captain is not in command at the helm. Placing the ERC in throttle only mode will avoid unintended gear engagement. The engines will turn using the steering wheel and the RPM of the engines can be increased while in the throttle only mode, but the gear position will remain in neutral.

51855

THROTTLE ONLY button

To engage throttle only mode:

1. Place both ERC levers in neutral.

FEATURES AND CONTROLS

38 eng

Page 49

2. Press the THROTTLE ONLY button. The button light will turn on and the neutral lights will blink.

3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in throttle only, but will remain in neutral.

4. The RPM of the engines can be increased.

NOTE: Pressing the THROTTLE ONLY button while the ERC levers are not in the neutral position, turns the button light off and remains in throttle only mode. You must place the ERC levers into the neutral position to disengage throttle only mode.

To disengage throttle only mode:

1. Place both ERC levers into neutral. Throttle only will not disengage unless the ERC levers are in neutral.

2. Press the THROTTLE ONLY button. The button light will turn off.

3. The neutral lights stop flashing and remain illuminated.

1 Lever

This feature commands both engines with a single lever on a dual engine application. This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both engines simultaneously. It is not the same as the system feature called Sync.

51856

1 LEVER button

To engage 1 Lever mode:

1. Place both ERC levers in neutral.

2. Press the 1 LEVER button. The button light will turn on.

3. Place the starboard ERC lever into gear.

4. When the handle is moved, the engines RPM and gear position is synchronized.

To disengage 1 Lever mode:

1. Place both ERC levers in neutral.

2. Press the 1 LEVER button. The button light turns off.

FEATURES AND CONTROLS

eng 39

Page 50

Sync

Sync is an automatic engine synchronization feature that is always on unless it is turned off. Sync monitors the position of both ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM. The SmartCraft system will automatically disengage sync after 95% of throttle position range to allow each engine the ability to reach maximum available RPM. Sync cannot engage until the engines are at a minimum speed.

The indicator light on the SYNC button is on when both engines are on. The light is yellow at idle and 95% of throttle and when the engines are not synchronized. The light turns red when the engines are synchronized.

51857

SYNC button

The RPM display of VesselView also shows an orange icon under the RPM numbers if the engines RPMs differ more than 10% of each other, and the icon turns red when they are synchronized.

To disengage sync mode:

1. Place the ERC levers in any detent.

2. Press the SYNC button. The button light turns off.

To engage Sync mode, press the SYNC button at any time.

FEATURES AND CONTROLS

40 eng

Page 51

Transfer (Boats equipped with dual helms)

The TRANSFER button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer.

51858

TRANSFER button

HELM TRANSFER

WARNING

FEATURES AND CONTROLS

eng 41

Page 52

NOTICE

To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items or when near other vessels.

REQUESTING HELM TRANSFER

NOTE: Any movement of the ERC levers after pressing the TRANSFER button terminates the helm transfer request. A single beep sounds and the transfer button light turns off signaling the end of the transfer request.

To request the transfer of vessel control from one helm to another:

1. At the helm you are requesting be made active and with the ERC levers in neutral, press the TRANSFER button one time. After the TRANSFER button is pressed, the transfer button light turns on and one beep will sound confirming the impending transfer.

51858

TRANSFER button

NOTE: If the ERC levers at the helms are not in neutral, the neutral lights will flash. Move all the ERC levers to neutral and the neutral light will stop flashing.

2. With the TRANSFER button light and neutral light on, press the TRANSFER button a second time to complete the helm transfer.

3. When the helm transfer is complete, another beep sounds and the transfer button light turns off.

NOTE: If the helm transfer is not completed in 10 seconds, the request is automatically cancelled and a double beep sounds. Control will remain at the existing active helm. Press the TRANSFER button again to restart helm transfer.

4. The helm where the transfer request was initiated is now active and controls the vessel.

FEATURES AND CONTROLS

42 eng

Page 53

Shadow Mode Control with CAN Trackpad Features and Operation

TRIPLE ENGINE THROTTLE AND SHIFT OPERATION

Movement of the handles on the remote control allows the boat operator to control the engine throttle speed and gear shift positions of all three engines.

The throttle and shift function is dependant on what engines are running. Refer to the following table.

Port Engine

Center Engine

Starboard

Engine

Control Handle Function

Running Running Running

Port engine throttle and shift = controlled by port control handle

Starboard engine throttle and shift = controlled by starboard control handle

Center engine throttle = average of port and starboard engines

Center engine shift = neutral unless both engines are in the same gear

Running Running Off

Port and center engine throttle and shift = controlled by port control handle

Off Running Running

Starboard and center engine throttle and shift = controlled by starboard control handle

Running Off Running

Port engine throttle and shift = controlled by port control handle

Starboard engine throttle and shift = controlled by starboard control handle

Running Off Off

Port engine throttle and shift = controlled by port control handle

Off Off Running

Starboard engine throttle and shift = controlled by starboard control handle

Off (ignition key switch turned on)

Running

Off (ignition key switch turned on)

Center engine throttle and shift = neutral/idle unless both control handles are in the same gear

FEATURES AND CONTROLS

eng 43

Page 54

Turning off one of the outer engines while underway will cause the center engine to go into forced neutral/idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral position and then engaging. The center engine speed and gear shift will then be controlled by the functioning outer engine.

Turning off the center engine while underway will have no effect on the operation of the outer engines.

If a failure should occur while underway which causes one of the outer engines into forced neutral/idle condition, the center engine will also be forced to neutral/idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral and then engaging.

QUAD ENGINE THROTTLE AND SHIFT OPERATION

Movement of the handles on the remote control allows the boat operator to control the engine throttle speed and gear shift positions of all four engines.

The throttle and shift function is dependent on what engines are running. The following table represents the most common quad engine vessel personality for shadow operation.

IMPORTANT: Quad engine vessel personalities may vary on which engines are configured to be the master engines. It is possible to have the center engines as the master and the outer engines configured as the shadow engines. Therefore, the following table does not represent this type of vessel personality.

Port Outer

Engine

Port

Inner

Engine

Starboard

Inner

Engine

Starboard

Outer Engine

Control Handle Function

Running Running Running Running

Port inner and outer engines throttle and shift = controlled by port control handle

Starboard inner and outer engines throttle and shift = controlled by starboard control handle

Running Running Off Off

Port inner and outer engines throttle and shift = controlled by port control handle

Off Off Running Running

Starboard inner and outer engines throttle and shift = controlled by starboard control handle

FEATURES AND CONTROLS

44 eng

Page 55

Port Outer

Engine

Port

Inner

Engine

Starboard

Inner

Engine

Starboard

Outer Engine

Control Handle Function

Off (ignition key switch turned on)

Running Running Running

Port inner engine throttle and shift = controlled by port control handle

Running Running Running

Off (ignition key switch turned on)

Starboard inner engine throttle and shift = controlled by starboard control handle

Off (ignition key switch turned off)

Running Running Running

Port inner engine throttle and shift = controlled by starboard control handle

Running Running Running

Off (ignition key switch turned off)

Starboard inner engine throttle and shift = controlled by port control handle

Running Off Off Running

Port outer engine throttle and shift = controlled by port control handle

Starboard outer engine throttle and shift = controlled by starboard control handle

Off (ignition key switch turned on)

Running Running

Off (ignition key switch turned on)

Port inner engine throttle and shift = controlled by port control handle

Starboard inner engine throttle and shift = controlled by starboard control handle

Turning off the starboard outer engine while underway will cause the starboard inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then into gear. The inner engine speed and gear shift will then be controlled by the starboard control handle.

Turning off the port outer engine while underway will cause the port inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the port outer engine ignition key to the on position and moving the port control handle back into neutral position and then into gear. The inner engine speed and gear shift will then be controlled by the port control handle.

FEATURES AND CONTROLS

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Page 56

Turning off one of the inner engines while underway will have no effect on the operation of the outer engines.

If a failure should occur while underway which causes the starboard outer engine into forced neutral/idle condition, the inner starboard engine will also be forced to neutral/idle. Operation to the inner engine can be restored by moving the starboard control handle back into neutral and then into gear.

If a failure should occur while underway which causes the port outer engine into forced neutral/idle condition, the inner port engine will also be forced to neutral/ idle. Operation to the inner engine can be restored by moving the port control handle back into neutral and then into gear.

Warning System

WARNING HORN SIGNALS

When the key switch is turned to the "ON" position, the horn will turn 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 an active problem within the engine’s operating system.

Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian system may engage and protect the engine by limiting power. You should return to port immediately and contact your servicing dealer.

Intermittent short beeps for six seconds: Indicates a noncritical engine condition. This condition does not require immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s power may be limited by the Engine Guardian system (see Engine Guardian System following) to protect the engine. You should contact your servicing dealer at your earliest convenience.

It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present. For visual display of the specific engine functions and additional engine data, refer to SmartCraft Product information, following.

A few of the noncritical conditions indicated by the intermittent short 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 to Maintenance – Water Separating Fuel Filter.

• Cooling system (water pressure or engine temperature) problem. Stop the engine and check the water intake holes in the lower unit for obstruction.

•

Low engine oil level. Refer to Fuel and Oil – Checking and Adding Engine Oil.

FEATURES AND CONTROLS

46 eng

Page 57

ENGINE GUARDIAN SYSTEM

The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected. The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to provide engine protection.

If Engine Guardian has been activated, reduce the engine speed. The problem will need to be identified and corrected. The system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will reset the Engine Guardian system. If the Engine Guardian system has determined the reset has not corrected the problem, Engine Guardian will remain activated, limiting the throttle. The problem must be identified and corrected before Engine Guardian will allow the engine to reach a normal operating RPM.

OVERSPEED REV LIMIT

The overspeed rev limit is set at an RPM greater than the operating range. In the event that the engine is operated at an RPM greater than or equal to the overspeed limit, the PCM does not allow the engine to maintain the power requested by the operator. Refer to Specifications to determine this engine’s RPM limit.

Upon reaching the beginning of the rev limit, Engine Guardian will cut‑out the ignition to specific cylinders. If the operator does not reduce engine speed, Engine Guardian will cut‑out the ignition to all the cylinders. There is no audible warning while Engine 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, repeat step one.

SMARTCRAFT PRODUCT

A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.

The SmartCraft instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems.

FEATURES AND CONTROLS

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Page 58

Power Trim and Tilt

The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the outboard within the first 20° range of travel. This is the range used while operating the boat on plane. The term tilt is generally used when referring to adjusting the outboard further up out of the water. With the engine turned off and ignition switch turned on, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up past the trim range to permit, for example, shallow water operation.

a - Trim switch b - Trim range c - Tilt range

POWER TRIM OPERATION

With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.

The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface.

14834

FEATURES AND CONTROLS

48 eng

Page 59

WARNING

Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond 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 load or a stern heavy boat.

• Generally improve the ride in choppy water.

• Increase steering torque or pull to the right (with the normal right‑hand rotation propeller.)

• In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is attempted, or if a significant wave is encountered.

WARNING

Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.

• In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The nonstainless steel shipping bolt should not be used in this application other than on a temporary basis.

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 shallow bottom.

• Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller.)

• In excess, can cause boat porpoising (bouncing) or propeller ventilation.

• Cause engine overheating if any cooling water intake holes are above the waterline.

FEATURES AND CONTROLS

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Page 60

TRIM WITHOUT KEY

Trim without key is a method of allowing trim operation after the ignition key switch is turned off. The command module and PCM remain powered and are able to process trim requests for up to 15 minutes after the key switch is turned off. The command module does not process any requests other than trim during this period. Once the 15 minute period expires, the command module sends a command through the CAN lines to shut down the PCM. On multi‑engine applications, the timeout is managed separately for each engine.

The trim without key period may be ended at any time by moving the control handle to wide‑open throttle reverse (WOTR) with the key off. To end the 15 minute period for the center engine in a shadow mode application, ensure all ignition key switches are in the "OFF" position and both remote control handles are in the wide‑open throttle reverse (WOTR) position.

TILTING TO FULL UP POSITION

Tilt at Helm

NOTE: The trim/tilt switch will remain active for 15 minutes after the ignition key switch has been turned off.

1. If the ignition key switch has been turned off for over 15 minutes, turn it to the "ON" position.

2. Press the trim/tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position.

Tilt at Engine

The cowl mounted auxiliary tilt switch can be used to tilt the outboard with the key switch in the "OFF" position.

Tilt Support Lever

1. Engage the tilt support lever, by rotating knob to bring the support lever upward.

2. Lower outboard to rest on the tilt support lever.

3. Disengage the tilt support lever, by raising the outboard off the support lever and rotating the tilt support lever down. Lower the outboard.

a - Tilt support lever b - Knob

27778

FEATURES AND CONTROLS

50 eng

Page 61

MANUAL TILTING

If 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 before operating the outboard to prevent the outboard from tilting up during reverse operation.

Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve.

22362

AUXILIARY TILT SWITCH

NOTE: This model allows the auxiliary tilt switch to be mounted on either the port side (shown) or on the starboard side.

This switch can be used to tilt the outboard up or down using the power trim system.

a - Auxiliary tilt switch (port side)

SHALLOW WATER OPERATION

When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

1. Reduce the engine speed below 2000 RPM.

2. Tilt the outboard up. Make sure all the water intake holes stay submerged at all times.

3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range.

14831

FEATURES AND CONTROLS

eng 51

Page 62

Important Daily Inspection Before Each Use

Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

51985

Decal on the transom bracket

Prestarting Check List

• Operator knows safe navigation, boating, and operating procedures.

• An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law).

• A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

• Know your boats' maximum load capacity. Look at the boat capacity plate.

• Fuel supply OK.

• Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat.

• Tell someone where you are going and when you expect to return.

• It is illegal to operate a boat while under the influence of alcohol or drugs.

• Know the waters and area you will be boating; tides, currents, sand bars, rocks, and other hazards.

•

Make inspection checks listed in Maintenance ‑ Inspection and

Maintenance Schedule.

OPERATION

52 eng

Page 63

Operating in Freezing Temperatures

When using your outboard or having your outboard moored in freezing or near freezing temperatures, keep the outboard tilted down at all times so the gearcase is submerged. This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other components.

If there is a chance of ice forming on the water, the outboard should be removed and drained completely of water. If ice should form at the water level inside the outboard driveshaft housing, it will block water flow to the engine causing possible damage.

Operating in Saltwater or Polluted Water

We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water. This will prevent a buildup of deposits from clogging the water passages. Refer to Maintenance ‑ Flushing the Cooling System.

If you keep your boat moored in the water, always tilt the outboard so the gearcase is completely out of water (except in freezing temperatures) when not in use.

Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

Operating at High Elevations

Your engine automatically compensates for high elevation changes. A different pitch propeller may help reduce some normal performance loss resulting from reduced oxygen in the air. Consult your dealer.

Effects of Elevation and Weather on Performance

The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems:

• Above sea level elevations

• High temperature

• Low barometric pressure

• High humidity

These conditions above reduce air density to the engine, which in turn lowers the following:

• Boost pressure on supercharged engines

• Horsepower and torque throughout the RPM range

• Peak RPM

• Cranking compression

OPERATION

eng 53

Page 64

EXAMPLE: An engine running at an elevation of 8,000 feet will have over a 30% power loss while a loss of engine power on a hot and humid day could be as much as 14%. These losses apply to normally aspirated and supercharged engines.

Compensating for power robbing conditions:

• Switch to lower pitch propeller.

• Change gear ratio.

Some boat performance can be improved by dropping to a lower pitch propeller, but engine performance will still remain lower. In some cases, a gear ratio reduction may be more beneficial. To optimize engine performance, prop the engine to allow it to operate at or near the top end of the recommended maximum RPM range at wide‑open throttle with a normal boat load.

Other advantages to propeller or gear ratio changes:

• Reduces the possibility of detonation

• Enhances overall reliability and durability of the engine

Setting Trim Angle While Running Engine at Idle Speed

The exhaust relief hole on the outboard can become submerged on some boats if the engine is trimmed full in while running at idle speed. This may result in exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim outboard up until exhaust relief hole is out of the water.

a - Relief hole submerged

(wrong)

b - Relief hole above water

line (correct)

Engine Break‑in Procedure

IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures.

1. For the first two hours of operation, run the engine at varied throttle settings up to 4500 RPM or at three‑quarter throttle, and at full throttle for approximately one minute every ten minutes.

2. For the next eight hours of operation, avoid continuous operation at full throttle for more than five minutes at a time.

2729

OPERATION

54 eng

Page 65

Starting the Engine

Before starting, read the Pre‑Starting Check List, special operating instructions, Engine Break‑in Procedure, and Gear Shifting in the Operation section and the remote control features and operation in the Features and Controls section.

NOTICE

Without 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 during operation.

1. Make sure the cooling water intake is submerged.

14836

2. Check the engine oil level.

27780

3. Open fuel tank vent on manual venting type tanks.

19748

NOTE: The engine will not start unless the lanyard is set to the "RUN" position.

OPERATION

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Page 66

Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch.

19791

5. Shift outboard to neutral (N) position.

3413

3417

NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON" position for approximately one minute. This operates the fuel lift pump. Turn the ignition key switch back to the "OFF" position and then return the ignition key switch to the "ON" position again for an additional minute. Turn the ignition key switch back to the "OFF" position. The filling of the fuel system is complete.

6. Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking. Turn the key to "START" position again until engine starts.

3485

OPERATION

56 eng

Page 67

7. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.

15301

IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat. Have the outboard checked by your dealer. Operating the engine while overheated will cause engine damage.

Gear Shifting

IMPORTANT: Observe the following:

•

Never shift the outboard into or out of gear unless the engine speed is at idle. Shifting at higher than engine idle speed could cause damage to the gearcase.

•

Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed. Shifting into reverse at higher boat speeds could cause the engine to stall, and in some situations, this could cause water to be drawn into the cylinders, resulting in severe engine damage.

•

Do not shift the outboard into reverse when the engine is not running. Damage to the shift linkage could occur.

• The outboard has three gear shift positions: forward (F), neutral (N), and reverse (R).

• When shifting, always stop at the neutral position and allow the engine idle speed to stabilize before shifting into another gear.

• Always shift the outboard into gear with a quick motion.

• After shifting the outboard into gear, advance the lever further to increase speed.

DTS PANEL MOUNT REMOTE CONTROL

IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running.

OPERATION

eng 57

Page 68

• The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R).

3427

• When shifting, always stop at neutral position and allow the engine speed to return to idle.

• Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position.

3428

• Advance the control lever to further increase speed.

DTS CONSOLE MOUNT REMOTE CONTROL

IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running.

OPERATION

58 eng

Page 69

• The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R).

3417

• When shifting, always stop at neutral position and allow the engine speed to return to idle.

• Advance the control lever to further increase speed.

Stopping the Engine

IMPORTANT: Turning key to the "START" position while the engine is running will result in engine shut down, while leaving the DTS system active. This will allow the use of the power trim/tilt from the remote control handle.

Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position.

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OPERATION

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Cleaning Care Recommendations

OUTBOARD CARE

To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability.

Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.

Selecting Replacement Parts For Your Outboard

We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.

DO NOT USE CAUSTIC CLEANING CHEMICALS

IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package. Some cleaning products contain strong caustic agents such as hull cleaners with hydrochloric acid. These cleaners can degrade some of the components they come in contact with including critical steering fasteners. Damage to steering fasteners may not be obvious during visual inspection and this damage may lead to catastrophic failure. Some caustic cleaning chemicals may cause or accelerate corrosion. Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product.

CLEANING GAUGES

IMPORTANT: Never use high‑pressure water to clean gauges. Routine cleaning of the gauges is recommended to prevent a buildup of salt

and other environmental debris. Crystalized salt can scratch the gauge display lens when using a dry or damp cloth. Ensure that the cloth has a sufficient amount of fresh water to dissolve and remove salt or mineral deposits. Do not apply aggressive pressure on the display lens while cleaning.

When water marks cannot be removed with a damp cloth, mix a 50/50 solution of warm water and isopropyl alcohol to clean the display lens. Do not use acetone, mineral spirits, turpentine type solvents, or ammonia based cleaning products. The use of strong solvents or detergents may damage the coating, the plastics, or the rubber keys on the gauges. If the gauge has a sun cover available, it is recommended that the cover be installed when the unit is not in use to prevent UV damage to the plastic bezels and rubber keys.

CLEANING REMOTE CONTROLS

IMPORTANT: Never use high‑pressure water to clean remote controls.

MAINTENANCE

60 eng

Page 71

Routine cleaning of the remote control external surfaces is recommended to prevent a buildup of salt and other environmental debris. Use a cloth towel which has a sufficient amount of fresh water to dissolve and remove salt or mineral deposits.

When water marks cannot be removed with a damp cloth, mix a 50/50 solution of warm water and isopropyl alcohol to clean the remote control. Do not use acetone, mineral spirits, turpentine type solvents, or ammonia based cleaning products. The use of strong solvents or detergents may damage the coating, the plastics, or the rubber components on the remote control.

CLEANING CARE FOR TOP AND BOTTOM COWLS

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Do not use detergents containing hydrochloric acid. Follow the cleaning and waxing procedure.

Cleaning and Waxing Procedure

1. Before washing, rinse the cowls with clean water to remove dirt and dust that may scratch the surface.

2. Wash the cowls with clean water and a mild nonabrasive soap. 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 applied wax by hand using a clean soft cloth.

5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1).

CLEANING CARE FOR THE POWERHEAD (SALTWATER USE)

If the outboard is operated in saltwater, remove the top cowl and flywheel cover. Inspect the powerhead and powerhead components for salt buildup. Wash off any salt buildup from the powerhead and powerhead components with fresh water. Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

IMPORTANT: Do not allow lubricant or Corrosion Guard spray to come in contact with the alternator drive belt or the belt pulleys. The alternator drive belt could slip and be damaged if it becomes coated with any lubricant or Corrosion Guard spray.

MAINTENANCE

eng 61

Page 72

Tube Ref

No.

Description Where Used Part No.

120

Corrosion Guard

External metal surfaces of the powerhead

and powerhead components.

92-802878 55

EPA Emissions Regulations

All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine spark ignition (SI) engine repair establishment or individual.

EMISSION CERTIFICATION LABEL

An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture.

a - Idle speed b - Engine horsepower c - Piston displacement d - Engine power ‑ kilowatts e - Date of manufacture f - Family number g - Regulated emission limit for the engine family h - Regulated emission limit for the engine family i - Recommended spark plug and gap j - Percent of fuel line permeation

OWNER RESPONSIBILITY

The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards.

SPARK PLUG:

GAP:

EMISSION CONTROL INFORMATION

THIS ENGINE CONFORMS TO EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES

CALIFORNIA AND U.S. EPA

REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS

IDLE SPEED (in gear):

FAMILY:

HC+NOx:FEL:

LOW PERM/HIGH PERM:

g/kWh

HC+NOx:FEL:

g/kWh

CO FEL:

g/kWh

43210

MAINTENANCE

62 eng

Page 73

The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.

Inspection and Maintenance Schedule

DAILY CHECKS

• Check the engine oil level

• Check the lanyard stop switch

• Inspect the fuel system for leaks

• Inspect the engine tightness on the transom

• Check the steering system for binding

• Check the propeller for damage

• Inspect the hydraulic steering fittings and hoses for leaks or signs of damage, if equipped

• Check the hydraulic steering fluid level, if equipped

AFTER EACH USE

• Wash the power package exterior with fresh water

• Flush the outboard cooling system, saltwater or brackish water only

ANNUALLY OR 100 HOURS

• Grease the engine, if applicable

• Change the engine oil and filter, if equipped

• Inspect the thermostat, saltwater or brackish water only

• Add Quickleen to the fuel tank, once per year, per engine

• Apply antiseize to the spark plug threads

• Replace the gear lubricant

• Inspect the corrosion control anodes

• Inspect the condition of the accessory drive belt

• Replace all filters on the suction side of the fuel system—dealer item

• Lubricate the driveshaft splines—dealer item

• Lubricate the propeller shaft splines—dealer item

• Check the tightness on all the fasteners—dealer item

• Check the torque of the outboard mounting hardware—dealer item

• Check the battery condition and tightness of the battery cable connection —dealer item

THREE YEARS OR 300 HOURS

• Replace the spark plugs

• Replace the water pump impeller—dealer item

• Inspect the wire harness connectors—dealer item

MAINTENANCE

eng 63

Page 74

• Check the remote control cable adjustment, if applicable—dealer item

• Replace the high‑pressure fuel filter—dealer item

• Replace the accessory drive belt—dealer item

• Check the power trim fluid level—dealer item

• Inspect the engine motor mounts—dealer item

Flushing the Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.

NOTE: The outboard can be tilted or in the vertical operating position during flushing.

1. With the engine turned off, place the outboard in either the operating position (vertical) or in a tilted position.

2. Remove the flush connector from the bottom cowl.

3. Remove the cover from the flush connector and thread a water hose into the flush connector.

14810

4. Turn on the water tap (1/2 maximum) and let the water flush through the cooling system for about 15 minutes.

5. When flushing is complete, turn off water and disconnect the water hose.

6. Install the cover on the flush connector. Place the flush connector back into the bottom cowl.

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Top Cowl Removal and Installation

REMOVAL

Unlock the top cowl by pulling out on the rear cowl latch. Lift the top cowl off the engine.

29767

INSTALLATION

Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply downward pressure to the back of the cowl to lock it in place. Ensure the cowl is securely fastened by trying to pull up on the back of the cowl.

29768

Battery Inspection

The battery should be inspected at periodic intervals to ensure proper engine starting capability.

IMPORTANT: Read the safety and maintenance instructions which 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 correctly installed. Positive to positive and negative to negative.

MAINTENANCE

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4. Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.

Verado Engine Battery Specifications

IMPORTANT: Verado engines require a 12‑volt absorbed glass mat (AGM) marine starting battery that meets the minimum ratings.

For best performance, Mercury Marine does not recommend using the more common flooded (wet cell) or gel cell type lead acid batteries for starting Verado engines.

Each Verado engine must be equipped with its own starting battery. If the boat application requires additional battery loads for boat accessories or

marine electronics, install an auxiliary battery, or batteries. Choose a 12‑volt absorbed glass mat (AGM) battery that meets the following

ratings.

USA (SAE) Verado Starting Battery Rating

Required Verado starting battery

12‑volt absorbed glass mat (AGM) battery

Required marine cranking amps (MCA) and reserve capacity

800 minimum marine cranking amps with a

minimum reserve capacity of 135 minutes

RC25 rating

International (EN) Verado Starting Battery Rating

Required Verado starting battery

12‑volt absorbed glass mat (AGM)

battery

Required cold cranking amps (CCA) and amp hours (Ah)

975 minimum cold cranking amps with a

minimum of 65 amp hours

NOTE: Do not use an engine starting battery that does not meet the specified ratings. If a battery that does not meet the ratings is used, the electrical system may perform poorly.

IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards, and Coast Guard regulations must be adhered to when installing the battery. Ensure that the battery cable installation meets the pull test requirements and that the positive battery terminal is properly insulated in accordance with regulations. It is recommended (required in some states) that the battery be installed in an enclosed case. Refer to regulations for your area.

When connecting the engine battery, hex nuts must be used to secure the battery leads to the battery posts. Tighten the hex nuts to the specified torque.

MAINTENANCE

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WARNING

Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.

Description Nm lb‑in. lb‑ft Hex nuts 13.5 120 –

IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine installation manual for size requirements.

A decal advising against using deep cycle batteries and wing nuts should be placed on or near the battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut is supplied per battery for wing nut replacement. Metric hex nuts are not supplied.

54395

Place decal on or near battery box for future service reference. Included with the engine rigging components are 5/16" and 3/8” hex nuts to be used for battery terminal wing nut replacement. Metric hex nuts must be obtained locally.

8M0085862

Refer to the outboard owner’s manual for battery requirements. Battery cable size and length is critical. Refer to engine installation manual for size requirements.

NOTICE

IMPORTANT:

DO NOT USE DEEP CYCLE BATTERIES!

13.5Nm (120 lb-in.)

DO NOT

USE

WINGNUTS

Air Filter

The air filter is located within the flywheel cover assembly. The air filter removes airborne particles which may damage engine components. The air filter design allows for maximum unrestricted air flow during engine operation.

AIR FILTER REMOVAL

1. Remove the FSM vent hose and the engine ventilation hose from the flywheel cover.

MAINTENANCE

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2. Remove the bolts securing the flywheel cover to the rear mounting posts.

a - Flywheel cover bolt and washer (2) b - FSM vent hose c - Crankcase ventilation hose

3. Lift the flywheel cover off the front mounting post and the intake resonator.

4. Remove three screws holding the upper flywheel cover to the lower flywheel cover.

14309

5. Separate the two flywheel cover subassemblies to access the air filter.

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MAINTENANCE

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6. Remove the air filter from the lower flywheel cover assembly.

a - Flywheel cover

subassembly

b - Air filter

AIR FILTER INSTALLATION

1. Install the air filter onto the flywheel cover subassembly.

a - Flywheel cover

subassembly

b - Air filter

a b

14145

a b

14145

MAINTENANCE

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Page 80

2. Install the upper half of the flywheel cover subassembly to the lower flywheel cover subassembly. Ensure the upper flywheel cover latch opening is properly secured to the lower flywheel cover.

a - Upper flywheel cover latch

opening

b - Lower flywheel cover latch

3. Push the two subassemblies together and install three screws. Tighten the three screws to the specified torque.

14309

Description

Nm lb‑in. lb‑ft

Screw 6 53 –

4. Install the flywheel cover onto the resonator and the front mounting post.

5. Align the flywheel cover rear bolt holes with the rear mounting posts.

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MAINTENANCE

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Page 81

6. Secure the flywheel cover to the rear mounting posts with two bolts with washers. Tighten bolts to the specified torque.

a - Flywheel cover bolt and washer (2) b - FSM vent hose c - Crankcase ventilation hose

Description Nm lb‑in. lb‑ft Flywheel cover bolt 10 88.5 –

Fuel System

WARNING

Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any spilled fuel immediately.

IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately. Material used to contain spilled fuel must be disposed of in an approved receptacle.

Before servicing any part of the fuel system:

1. Stop engine and disconnect the battery.

2. Perform fuel system service in a well‑ventilated area.

3. Inspect any completed service work for sign of fuel leakage.

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MAINTENANCE

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FUEL LINE INSPECTION

Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line must be replaced.

WATER SEPARATING FUEL FILTER

NOTE: The warning system will turn on when water in the fuel filter reaches the full level.

This filter removes moisture and debris from the fuel. If the filter holder becomes filled with water, the water can be removed. If the filter becomes plugged with debris, replace the filter.

Refer to the Inspection and Maintenance Schedule for the proper maintenance interval.

Filter Removal

1. Turn ignition key switch to "OFF" position.

2. Remove fuel vapor purge relief valve cap located at the rear of the engine.

14765

CAUTION

Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and skin from pressurized fuel and vapors.

MAINTENANCE

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3. Place a rag or towel around the valve, release pressure by pushing core of valve end in.

13282

4. Unscrew the filter in a counterclockwise direction to remove.

14762

Filter Draining

1. Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter holder.

MAINTENANCE

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Page 84

2. Tip the filter holder to drain any fluid into an approved container.

13468

Filter Installation

1. Position filter holder onto bracket and secure filter holder in place.

2. Lubricate the sealing ring on the filter with oil.

3. Install the filter and tighten securely by hand.

IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition key to the "RUN" position, forcing fuel into the filter.

14764

Corrosion Control Anode

The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.

MAINTENANCE

74 eng

Page 85

Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode.

Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket assembly.

14812

Propeller Replacement

1. Shift outboard to neutral position.

2. Straighten the bent tabs on the propeller nut retainer.

26900

3. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut.

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MAINTENANCE

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4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.

5. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products:

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Propeller shaft splines 8M0071842

2-4-C with PTFE Propeller shaft splines 92-802859A 1

Flo‑Torq II drive hub propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft.

a - Propeller nut b - Propeller nut retainer c - Thrust hub d - Propeller e - Replaceable drive

sleeve

f - Forward thrust hub

Flo‑Torq IV drive hub propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft.

a - Propeller nut b - Propeller nut retainer c - Thrust hub d - Propeller e - Replaceable drive sleeve f - Forward thrust hub

8. Place a block of wood between gearcase and propeller and torque to specifications.

Description

Nm lb‑in. lb‑ft

Propeller nut 75 – 55

26941

14797

MAINTENANCE

76 eng

Page 87

9. Secure propeller nut by bending three of the tabs into the thrust hub grooves.

26945

Spark Plug Inspection and Replacement

NOTE: To gain access to the bottom spark plug, remove the rear cover and rear cowl lock.

COWL LOCK AND REAR COVER REMOVAL

1. Remove the pivot screw and flat washer from the rear cowl latch.

2. Pull out on the rear corner of the latch to clear the rear cover. Remove the rear cowl latch.

a - Rear cowl latch

3. Remove the two screws securing the rear cover. Locate the two arrows (pry points) on the rear cover. Use a thin blade screwdriver at these pry points and pry out the cover. Remove the rear cover.

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MAINTENANCE

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4. Remove the six screws securing the cowl lock and remove the lock. Retain the two hex nuts that are used to fasten the top two screws.

a - Rear cover b - Pry point (arrow) c - Cowl lock

SPARK PLUG REMOVAL AND INSPECTION

1. Disconnect the wiring harness connectors from the pencil coils.

2. Remove the mounting bolts that are securing the pencil coils. Pull the pencil coils from the spark plugs using a twisting motion.

a - Wiring harness connector b - Pencil coil c - Bolt

29739

3658

MAINTENANCE

78 eng

Page 89

3. Remove the spark plugs to inspect.

20753

4. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode.

IMPORTANT: The color of the plug may not accurately reflect its condition. To accurately diagnose a faulty plug, inspect the precious metal on the plug's electrode. If no precious metal is visible, replace the plug.

a - Precious metal

Set the spark plug gap. Refer to Specifications.

27848

9381

MAINTENANCE

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a. All of the spark plugs should have the gap checked and corrected as

necessary before installation.

b. Measure the gap with a feeler gauge or pin gauge. Never use a

wedge‑type gap checking tool to inspect or to adjust the gap.

c. If an adjustment is necessary, do not pry or apply any force on the

center electrode. This is critical with any type of spark plug that has a wear surface, such as platinum or iridium added to either the ground electrode or the center electrode.

d. When it is necessary to widen the gap, use a tool that only pulls back

on the ground electrode without touching the center electrode, the porcelain, or the wear portion of the ground electrode.

e. When it is necessary to close the gap, gently tap the plug ground

electrode on a hard surface.

6. Saltwater use ‑ Apply a thin coating of Anti‑Seize Compound only on threads of spark plugs.

SPARK PLUG INSTALLATION

1. Before installing the spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten 1/4 turn or tighten to the specified torque.

Description

Nm lb‑in. lb‑ft

Spark plug 27 – 20

2. Push the pencil coils into place over the spark plugs using a twisting motion.

3. Secure the coils with retained bolts. Tighten to the specified torque.

Description

Nm lb‑in. lb‑ft

Bolts 8 71 –

4. Connect the wiring harness connectors to the pencil coil connections.

a - Wiring harness connector b - Pencil coil c - Bolt

5. Install the cowl lock, rear cowl, and rear cowl latch. Tighten to the specified torque.

Description

Nm lb‑in. lb‑ft

Rear cowl latch ‑ back screws (4) 15 53 –

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MAINTENANCE

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Page 91

Description Nm lb‑in. lb‑ft Rear cowl latch ‑ top screws with

hex nuts (2)

25 89 –

Rear cover ‑ screws (2) 15 53 – Pivot screw 15 53 –

Fuses

The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.

Remove the fuse puller from the engine. Remove the cover from the fuse holder. Remove the suspected blown fuse and

look at the silver band inside the fuse. If the band is broken, replace the fuse. Replace the fuse with a new fuse with the same amp rating.

a - Fuse puller b - Fuse holder c - Good fuse d - Blown fuse e - Electronic Control Module and purge valve "ECM" ‑ 20 amp fuse f - Ignition coils "IGN. COILS" ‑ 20 amp fuse g - Fuel delivery "FUEL" ‑ 20 amp fuse h - Spare fuses (3) i - Diagnostics terminal ‑ 2 amp fuse j - Injector power and boost valve "INJ. PWR." ‑ 20 amp fuse

20 20 20

29731

MAINTENANCE

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Page 92

Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a" ‑ Part Number 10‑849838) and self‑locking nylon insert locknuts ("c" & "d" ‑ Part Number 11‑826709113). These locknuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off freeing the link rod to disengage.

WARNING

Improper fasteners or improper installation procedures can result 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 being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

a - 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‑ft Special washer head bolt 27 – 20 Nylon insert locknut "d" 27 – 20

Nylon insert locknut "c"

Tighten until seats, then back off 1/4

turn

Assemble the steering link rod to steering cable with two flat washers and self‑locking nylon insert locknut. Tighten the locknut until it seats, then back nut off 1/4 turn.

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MAINTENANCE

82 eng

Page 93

Assemble the steering link rod to the engine with special washer head bolt and self‑locking nylon insert locknut. First torque the bolt, then torque the locknut to specifications.

DTS Wiring System

WARNING

Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system.

• Verify the harnesses are not routed near sharp edges, hot surfaces, or moving parts.

• Verify all unused connectors and receptacles are covered with a weather cap.

• Verify the harnesses are fastened along the routing path.

Accessory Drive Belt Inspection

Inspect the accessory drive belt and have it replaced by an authorized dealer if any of the following conditions are found.

• Cracks in the back of the belt or in the base of V grooves.

• Excessive wear at the roots of the grooves.

• Rubber portion swollen by oil.

• Belt surfaces roughened.

• Signs of wear on edges or outer surfaces of belt.

Lubrication Points

1. Lubricate the following with Extreme Grease.

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Trim rod ball ends 8M0071842

MAINTENANCE

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Page 94

• Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets.

28458

2. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE.

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Propeller shaft 8M0071842

2-4-C with PTFE Propeller shaft 92-802859A 1

•

Propeller Shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.

26902

3. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease.

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Swivel bracket, tilt support lever, tilt tube 8M0071842

2-4-C with PTFE Swivel bracket, tilt support lever, tilt tube 92-802859A 1

• Swivel Bracket ‑ Lubricate through fitting.

MAINTENANCE

84 eng

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• Tilt Support Lever ‑ Lubricate through fitting.

a - Swivel bracket b - Tilt support lever

• Tilt Tube ‑ Lubricate through fitting.

a - Tilt tube fitting

4. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Extreme Grease.

WARNING

Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant.

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Steering cable 8M0071842

2-4-C with PTFE Steering cable 92-802859A 1

29759

29757

MAINTENANCE

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Page 96

• Steering Cable ‑ Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through the fitting.

a - Fitting b - Cable end

5. Lubricate the following with lightweight oil.

• Steering Link Rod Pivot Points ‑ Lubricate pivot points.

29765

Checking Power Trim Fluid

1. Tilt the outboard to the full up position and engage the tilt support lever.

27877

29763

MAINTENANCE

86 eng

Page 97

2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricant Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

28460

Tube Ref

No.

Description Where Used Part No.

114

Power Trim and Steering Fluid

Power trim system 92-858074K01

Checking Power Steering Fluid

WARNING

Dirt or contaminants in the hydraulic steering system can damage the steering system's internal components. Damaged components can lead to serious injury or death due to loss of boat control. Do not allow dirt or contamination to enter the helm, lines, or cylinder of this steering system and perform all hydraulic inspections, service, or assembly procedures in a clean work area.

MAINTENANCE

eng 87

Page 98

Remove the power steering cover and fill cap to check the fluid level. The fluid level should be slightly below the bottom of the fill hole. Use Synthetic Power Steering Fluid SAE 0W‑30, if needed.

a - Power steering cover b - Fill cap c - Fill/full level

Tube Ref

No.

Description Where Used Part No.

138

Synthetic Power Steering Fluid SAE 0W-30

Power steering system 92-858077K01

Changing Engine Oil

ENGINE OIL CAPACITY

Engine oil capacity is approximately 6.0 liter (6.3 US qt).

PUMP METHOD

IMPORTANT: Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump.

IMPORTANT: To reduce or prevent oil spillage when removing the oil filter, ensure the outboard is upright (not tilted) and the engine is cold or has not run for at least one hour.

1. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump.

2. Place the outboard in a vertical position.

3. Remove dipstick and slide adapter tube of crankcase oil pump through oil dipstick hole, to bottom of engine oil sump.

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MAINTENANCE

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Page 99

Crankcase Oil Pump 91‑90265A 5

11591

Aids in the removal of engine oil without draining the crankcase.

4. Pump out the engine oil into an appropriate container.

DRAIN METHOD

1. Tilt outboard up to the trailer position.

2. Turn the outboard so the drain hole is facing downward.

3. Remove the drain plug/seal and drain the engine oil into an appropriate container.

4. Lubricate seal washer on the drain plug with oil and reinstall.

15613

CHANGING OIL FILTER

IMPORTANT: To reduce or prevent oil spillage when removing the oil filter, ensure the outboard is upright (not tilted) and the engine is cold or has not run for at least one hour.

1. Remove the top cowl.

2. Place a rag or towel below the oil filter to absorb any spilled oil.

MAINTENANCE

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Page 100

3. Unscrew old filter using oil filter wrench and turning the filter counterclockwise.

14772

Oil Filter Wrench 91‑802653Q02

5221

Assists in removal of oil filter.

4. Clean the oil filter mounting base.

5. Apply a film of clean oil to filter gasket. Do not use grease.

6. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.

MAINTENANCE

90 eng

Mercury 135 Verado FourStroke, 175 Verado FourStroke, 150 Verado FourStroke, 400R Verado FourStroke Maintance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual