Mercury 25 Jet FourStroke Installation Manual

Operation

Maintenance

and

Installation

Manual

© 2018 Mercury Marine

25 Jet FourStroke

8M0145522 418 eng

eng

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.

eng i

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.

California Proposition 65

WARNING: This product can expose you to chemicals including
gasoline engine exhaust, which is known to the State of
California to cause cancer and birth defects or other
reproductive harm. For more information go to

www.P65Warnings.ca.gov.

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.

Mercury Marine products are designed and manufactured to comply with our
own high quality standards, applicable industry standards and regulations, as
well as certain emissions regulations. At Mercury Marine every engine is
operated and tested before it is boxed for shipment to make sure that the
product is ready for use. In addition, certain Mercury Marine products are
tested in a controlled and monitored environment, for up to 10 hours of engine
run time, in order to verify and make a record of compliance with applicable
standards and regulations. All Mercury Marine product, sold as new, receives
the applicable limited warranty coverage, whether the engine participated in
one of the test programs described above or not.

ii eng

Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in
part without permission is prohibited.

Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., 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.

Identification Records

Please record the following applicable information:

Outboard

Engine Model and Horsepower

Engine Serial Number

Gear Ratio

Propeller Number Pitch Diameter

Watercraft Identification Number (WIN) or Hull
Identification Number (HIN)

Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

eng iii

eng iv

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

Remote Steering Notice......................................................................................3

Lanyard Stop Switch........................................................................................... 3

Protecting People in the Water........................................................................... 6

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

Safety Instructions for Hand‑Tilled Outboards.................................................... 7

Exhaust Emissions............................................................................................. 8

Selecting Accessories for Your Outboard......................................................... 10

Safe Boating Recommendations...................................................................... 10

Recording Serial Number................................................................................. 13

Model Year Production Code............................................................................13

Specifications....................................................................................................14

Component Identification.................................................................................. 15

Transporting

Trailering Boat/Outboard.................................................................................. 17

Fuel and Oil

Fuel Requirements........................................................................................... 18

Low Permeation Fuel Hose Requirement ........................................................ 19

EPA Pressurized Portable Fuel Tank Requirements........................................ 19

Fuel Demand Valve (FDV) Requirement.......................................................... 19

Mercury Marine's Pressurized Portable Fuel Tank........................................... 20

Filling Fuel Tank............................................................................................... 21

Engine Oil Recommendations.......................................................................... 21

Checking and Adding Engine Oil...................................................................... 22

Features and Controls

Remote Control Features................................................................................. 24

Tiller Handle Models......................................................................................... 24

Power Trim and Tilt (if Equipped)..................................................................... 30

Warning System............................................................................................... 32

Replaceable Jet Drive Shear Key..................................................................... 35

eng v

Operation

Prestarting Check List.......................................................................................36

Operating in Freezing Temperatures................................................................ 36

Operating in Saltwater or Polluted Water......................................................... 36

Operating in Shallow Water.............................................................................. 37

How the Jet Drive Operates..............................................................................37

Stopping the Boat in an Emergency................................................................. 39

Steering the Boat.............................................................................................. 39

Mooring the Boat.............................................................................................. 40

Water Intake Blockage......................................................................................40

Clearing A Lodged Impeller.............................................................................. 40

Prestarting Instructions..................................................................................... 41

Engine Break‑in Procedure...............................................................................42

Starting the Engine ‑ Remote Control Models.................................................. 42

Starting the Engine ‑ Tiller Handle Models....................................................... 44

Gear Shifting .................................................................................................... 47

Stopping the Engine ........................................................................................ 48

Emergency Starting.......................................................................................... 48

Maintenance

Cleaning Care Recommendations.................................................................... 50

EPA Emission Regulations............................................................................... 52

Inspection and Maintenance Schedule ............................................................ 53

Top Cowl Removal and Installation.................................................................. 54

Worn/Dull Impeller............................................................................................ 54

Impeller Clearance Adjustment.........................................................................55

Impeller Removal and Installation.....................................................................56

Shift Link Rod Adjustment................................................................................ 59

Battery Inspection ............................................................................................ 60

Fuel System...................................................................................................... 60

Steering Link Rod Fasteners............................................................................ 61

Corrosion Control Anode.................................................................................. 62

Spark Plug Inspection and Replacement..........................................................63

Fuse Replacement ‑ Electric Start Models....................................................... 64

Timing Belt Inspection...................................................................................... 65

Lubrication Points............................................................................................. 65

Checking Power Trim Fluid...............................................................................68

Changing Engine Oil ........................................................................................ 69

Submerged Outboard....................................................................................... 71

vi eng

Storage

Storage Preparation..........................................................................................72

Protecting External Outboard Components...................................................... 72

Protecting Internal Engine Components........................................................... 73

Jet Drive............................................................................................................73

Positioning Outboard for Storage..................................................................... 73

Battery Storage................................................................................................. 73

Troubleshooting

Starter Motor will not Crank the Engine (Electric Start Models)........................ 74

Engine Will Not Start.........................................................................................74

Engine Runs Erratically.................................................................................... 74

Engine Overspeed (Excessive RPM)............................................................... 75

Performance Loss.............................................................................................75

Battery Will Not Hold Charge............................................................................ 75

Owner Service Assistance

Service Assistance........................................................................................... 76

Ordering Literature............................................................................................78

Installation

Installation Information......................................................................................80

Top Cowl Removal and Installation.................................................................. 82

Lifting Outboard................................................................................................ 83

Determining the Mounting Height of the Outboard Jet .................................... 83

Fastening the Outboard.................................................................................... 85

Steering Bracket, Steering Cable Installation................................................... 87

Steering Link Rod Fasteners............................................................................ 88

Electrical Harness, Battery Connection, Fuel Tanks........................................ 91

Control Cable Installation..................................................................................94

Water Testing................................................................................................... 98

Maintenance Log

Maintenance Log............................................................................................ 100

eng vii

eng viii

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

eng 1

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

26777

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 remote control connected to your outboard must be equipped with a start
in neutral only protection device. This prevents the engine from starting when
the shift is actuated in any position other than neutral.

!

WARNING

Starting the engine with the drive in gear can cause serious injury or death.
Never operate a boat that does not have a neutral‑safety‑protection device.

N

63103

GENERAL INFORMATION

2 eng

Remote Steering Notice

The steering link rod that connects the steering cable to the engine must be
fastened utilizing self‑locking nuts. These self‑locking nuts must never be
replaced with nonlocking nuts. Nonlocking nuts may loosen and vibrate off,
allowing 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 - Self‑locking nuts

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.

a

a

59490

GENERAL INFORMATION

eng 3

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.

c

a

b

53910

OFF

RUN

ATTACH LANYARD

GENERAL INFORMATION

4 eng

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

eng 5

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.

21604

Always slow down and exercise extreme caution when boating in an area
where there might be people in the water.

Avoid shallow water or where any loose material such as sand, shells,
seaweed, grass, tree branches, etc., can be pulled in and expelled from the
pump as a high speed projectile.

WHILE BOAT IS STATIONARY

!

WARNING

Avoid injury resulting from contacting the rotating impeller or having hair,
clothing, or loose objects drawn into the water intake and wrapping around
the impeller shaft. Stay away from the water intake and never insert an object
into the water intake or water outlet nozzle when the engine is running.

Stop the engine immediately whenever a person is in the water near the boat.
The jet drive is always drawing water through the water intake when the engine
is running. Stay away from the water intake located under the jet drive and
never insert an object into the water intake or outlet nozzle when the engine is
running.

GENERAL INFORMATION

6 eng

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.

26784

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.

Safety Instructions for Hand‑Tilled Outboards

No person or cargo should occupy the area directly in front of the outboard
while the boat is in motion. If an underwater obstacle is struck, the outboard will
tilt up and could seriously injure anyone occupying this area.

MODELS WITH CLAMP SCREWS:

Some outboards come with transom bracket clamp screws. The use of clamp
bracket screws alone, is insufficient to properly and safely secure the outboard
to the transom. Proper installation of the outboard includes bolting the engine to
the boat through the transom. Refer to Installation ‑ Fastening the Outboard
for more complete installation information.

GENERAL INFORMATION

eng 7

!

WARNING

Failure to correctly fasten the outboard could result in the outboard propelling
off the boat transom resulting in property damage, serious injury, or death.
Before operation, the outboard must be correctly installed with the required
mounting hardware.

If an obstacle is struck at planing speed and the outboard is not securely
fastened to the transom, it is possible the outboard could lift off the transom
and land in the boat.

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

41127

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

GENERAL INFORMATION

8 eng

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:

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

21626

a

b

GENERAL INFORMATION

eng 9

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.
Acquire and read the installation, operation and maintenance manuals for all
your selected accessories.

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

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

Tools necessary for minor repairs

a

b

21628

GENERAL INFORMATION

10 eng

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.

GENERAL INFORMATION

eng 11

• 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.

GENERAL INFORMATION

12 eng

Recording Serial Number

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

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

Model Year Production Code

The serial number decal lists the year of manufacture as an alpha code. This
code can be deciphered into a corresponding number utilizing the following
table.

XXXXXXXXX

XXXXXXXX

XXXX

AG

62972

Serial number decal alpha code

Model Year Manufactured Code
Alpha Production Code A B C D E F G H K X
Corresponding Number 1 2 3 4 5 6 7 8 9 0

24800

XXXXXXX

XXXXX XX

Mercury

Marine

Serial Number

Brunswick Corp.
Made in Japan

XX

XXXX XXX

HP XXX
LB XXX

KG XXX

KW XXX

Model Number

b

c

a

d

GENERAL INFORMATION

eng 13

Examples:

• XX = 2000

• HK = 2089

• AG = 2017

Specifications

Models 25
Power 18.4 kw (25 hp)
Full throttle RPM range 5000–5500 RPM
Idle speed in forward gear 850 ± 25 RPM
Number of cylinders 3
Piston displacement 526 cc (32.09 cid)
Cylinder bore 61 mm (2.40 in.)
Stroke 60 mm (2.36 in.)
Valve clearance (cold)

Intake valve 0.13–0.17 mm (0.005–0.007 in.)
Exhaust valve 0.18–0.22 mm (0.007–0.008 in.)
Recommended spark plug NGK DCPR6E
Spark plug gap 0.8–0.9 mm (0.031–0.035 in.)
Recommended gasoline

Refer to Fuel and Oil

Recommended oil

Refer to Fuel and Oil

Recommended lubricant for
the jet pump driveshaft
bearing

Refer to Maintenance

Engine oil capacity 1.8 liter (1.9 US qt)

Battery rating

465 marine cranking amps (MCA) or 350 cold

cranking amps (CCA)

Emission control system

Electronic engine control (EC)

Multiport fuel injection (MFI)

GENERAL INFORMATION

14 eng

Component Identification

TILLER HANDLE/GAS ASSIST MODEL

a - Top cowl
b - Manual start handle
c - Engine stop switch
d - Throttle friction adjustment knob
e - Gear shift
f - Tilt support lever
g - Gas tilt assist lever
h - Jet drive housing
i - Water intake housing
j - Reverse gate
k - Water outlet housing
l - Chaps
m - Water pump indicator hole
n - Cowl latch
o - Warning light

a

b

c

e

f

g

i

h

k

m

p

r

o

q

d

l

n

j

24805

GENERAL INFORMATION

eng 15

p - Electric start button (electric start models)
q - Lanyard stop switch
r - Steering friction adjustment lever

POWER TRIM/REMOTE CONTROL MODEL

a - Transom brackets
b - Tilt support lever
c - Top cowl
d - Cowl latch
e - Bottom cowl
f - Auxiliary tilt switch
g - Chaps
h - Water outlet housing
i - Reverse gate
j - Water intake housing
k - Jet drive housing

a

b

c

e

h

i

j

k

g

f

d

24827

GENERAL INFORMATION

16 eng

Trailering Boat/Outboard

The boat should be trailered with the outboard tilted down in a vertical
operating position.

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.

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.

TRANSPORTING

eng 17

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

18 eng

!

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.

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 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 primer bulb. The fuel
demand valve prevents pressurized fuel from entering the engine and causing
a fuel system overflow or possible fuel spillage.

FUEL AND OIL

eng 19

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

primer bulb

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.

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.

a

c

b

46453

a

b

c

46290

FUEL AND OIL

20 eng

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.

4.

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.

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 or Quicksilver NMMA FC‑W certified SAE 10W‑30 4‑Stroke Marine
Engine Oil is recommended for general, all‑temperature use. If NMMA certified
synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W‑40
Synthetic Blend Marine 4‑Stroke Engine Oil. If the recommended Mercury or
Quicksilver NMMA FC‑W certified outboard oils are not available, a major
FC‑W certified 4‑stroke outboard oil may be used.

FUEL AND OIL

eng 21

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 or oils that contain solid additives are not
recommended.

Recommended SAE viscosity for
engine oil

a - Mercury or Quicksilver SAE

25W‑40 Synthetic Blend Marine
4‑Stroke Engine Oil may be used
at temperatures above 4 °C
(40 °F)

b - Mercury or Quicksilver SAE

10W‑30 4‑Stroke Marine Engine
Oil is recommended for use in all
temperatures

Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted)
when checking oil.

1. Turn the engine off. Have the outboard in a level operating position.
Remove the top cowl.

+20

+40

+60

+80

F° C°

0

+100

–7

+4

+16

+27

–18

+38

a

b

26795

FUEL AND OIL

22 eng

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

a - Full mark
b - Add mark
c - Dipstick
d - Oil fill cap

3. Pull the dipstick back out again and observe the oil level. Oil must be
between full mark and add mark. If the oil level is low, remove the oil fill
cap and fill to (but not over) the upper oil level.

NOTE: Under certain conditions, the operating temperature of 4‑stroke
outboard engines may not get hot enough to evaporate the normal fuel and
moisture that accumulate in the crankcase. These conditions include operating
at idle for long periods, repeated short trips, slow speed or quick stop‑and‑go
operation, and operating in cooler climates. This additional fuel and moisture
that collects in the crankcase eventually ends up in the oil sump and will add
to the total volume of oil that appears on the dipstick reading. This increase in
oil volume is known as oil dilution. Outboard engines can typically handle large
amounts of oil dilution without causing durability problems. However, to ensure
extended life of the outboard engine, Mercury recommends that the oil and
filter be changed regularly following the oil change interval and using the
recommended oil quality. It is further recommended that if your outboard is
operated frequently in the conditions described above, that more frequent oil
change intervals be considered.

4. Push the dipstick back in all the way. Install the oil fill cap hand‑tight.

a

b

c

d

9596

FUEL AND OIL

eng 23

Remote Control Features

Your boat may be equipped with one of the Mercury Precision or Quicksilver
remote controls shown. If not, consult your dealer for a description of the
functions and operations of the remote control.

a - Control handle – forward, neutral, reverse
b - Neutral release lever
c -

Trim/tilt switch (if equipped) – Refer to Features and Controls –

Power Trim and Tilt

d -

Lanyard stop switch – Refer to General Information – Lanyard Stop

Switch

e -

Lanyard – Refer to General Information – Lanyard Stop Switch

f - Throttle friction adjustment – Console controls require cover removal for

adjustment

g - Ignition key switch – "OFF," "ON," START"
h -

Fast idle lever – Refer to Operation – Starting the Engine

i -

Throttle only button – Refer to Operation – Starting the Engine

Tiller Handle Models

FEATURES

• Steering friction adjustment ‑ Adjust this lever to achieve the desired
steering friction (drag) on the tiller handle. Move the lever to the left to
tighten friction or move to the right to loosen friction.

f

a

c

d

e

b

h

c

a

g

d

e

b

i

f

g

i

c

a

f

26800

FEATURES AND CONTROLS

24 eng

!

WARNING

Insufficient friction adjustment can cause serious injury or death due to loss
of boat control. When setting the friction adjustment, maintain sufficient
steering friction to prevent the outboard from steering into a full turn if the
tiller handle or steering wheel is released.

a - Tighten friction
b - Loosen friction

• Warning light ‑ The warning light will turn on, or flash, to alert the operator
to the warning system situations. Refer to Warning System.

15732

• Electric start button (electric start models) ‑ Press to start the engine.

15898

a

b

24830

FEATURES AND CONTROLS

eng 25

• Tiller handle ‑ The tiller handle can be tilted 180° for convenient handling
during transportation and storage.

28535

• Tiller lock release lever ‑ Push the lever to move the tiller handle from one
position to another.

a - Tilt lock release lever

a

3274

FEATURES AND CONTROLS

26 eng

• Tiller handle lock cap ‑ Remove the lock cap on top of the tiller handle to
lock in the up position. Push the tiller lock release lever to release the
handle from the locked up position.

a - Lock cap
b - Locking mechanism

• Engine stop switch

28537

• Throttle grip friction knob ‑ Turn the friction knob to set and maintain the
throttle at desired speed. Turn the knob clockwise to tighten the friction or
turn the knob counterclockwise to loosen the friction.

a - Loosen friction (counterclockwise)
b - Tighten friction (clockwise)

3273

a

b

a

b

28542

FEATURES AND CONTROLS

eng 27

•

Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop
Switch.

19791

BASIC TILTING OPERATION

Models equipped with a gas assisted tilt system allows the operator to lock the
outboard at any tilt position from full down to full up.

This tilt system is designed to be adjusted when the outboard is idling in
neutral, or with the engine turned off.

Before operating, the outboard must be locked in its tilt position by moving the
lock lever to the lock position.

!

WARNING

Operating the engine without engaging the tilt lock lever can cause serious
injury or death. The outboard can tilt upwards when decelerating or operating
in reverse, causing loss of boat control. Always lock the outboard in its run
position before operating.

Move the lock lever to the free position. Tilt the outboard to the desired position
and lock in place by moving the tilt lock lever back to the lock position.

a - Free position
b - Lock position

LOCK

FREE

a

b

10257

FEATURES AND CONTROLS

28 eng

TILTING OUTBOARD TO FULL UP POSITION

1. Stop the engine. Move the lock lever to the free position. Take hold of the
top cowl grip and raise the outboard to the full tilt up position. Lock the
outboard in place by moving the lock lever to the lock position.

10284

2. Engage the tilt support lever.

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

LOWERING OUTBOARD TO RUN POSITION

1. Move the lock lever to the free position. Tilt up the outboard slightly and
release the tilt support lever. Lower the outboard to the run position.

2. Move the lock lever to the lock position.

9703

OPERATING ANGLE ADJUSTMENT

The transom brackets have four holes for adjusting the vertical operating angle
(forward stop movement) of the outboard. Use the tilt pin for adjustments in the
four holes.

a - Transom bracket holes
b - Tilt pin

LOCK

FREE

a

b

10290

FEATURES AND CONTROLS

eng 29

Adjust the operating angle of the outboard so that the outboard runs
perpendicular to the water when the boat is at full speed.

Arrange passengers and load in the boat so the weight is distributed evenly.

NOTE: The outboard should be locked against the tilt pin during operation by
setting the tilt lock lever to the lock position.

Power Trim and Tilt (if Equipped)

POWER TRIM AND TILT

Your 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 your boat on plane. The term tilt is generally used when referring to
adjusting the outboard further up and out of the water. With the engine turned
off, 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 - Remote control trim switch
b - Panel mount trim switch
c - Tiller handle trim switch
d - Cowl mounted trim switch (option)
e - Trim range of travel
f - Tilt range of travel

DN

UP

UP
DN

UP

DN

DN

UP

DN

UP

a

b

c

d

e

f

24832

FEATURES AND CONTROLS

30 eng

POWER TRIM OPERATION

The power trim and tilt feature of the outboard is convenient for drifting and
when operating at low throttle speed in very shallow water. When under power,
do not trim out the outboard in an effort to gain speed as is done with a
conventional propeller driven boat.

When planing, the outboard should be positioned vertical or tilted in toward the
boat to provide a scooping angle on the water intake grate. Tilting the outboard
out beyond a vertical position reduces the scoop angle and can cause impeller
slippage and cavitation burns on the impeller blades.

TILTING OPERATION

To tilt the outboard, shut off the engine and press the trim/tilt switch or auxiliary
tilt switch to the up position. The outboard will tilt up until the switch is released
or it reaches its maximum tilt position.

1. Engage the tilt support lever by rotating the lever down.

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

3. Disengage the tilt support lever, by slightly tilting up the outboard and
releasing the tilt support bracket. Lower the outboard.

9703

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.

FEATURES AND CONTROLS

eng 31

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.

9976

AUXILIARY TILT SWITCH

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

9974

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.

Warning System

WARNING HORN

Remote control models have a warning horn located inside the remote control
or connected to the ignition key switch. Tiller handle models have a warning
horn located in the engine cowl.

FEATURES AND CONTROLS

32 eng

WARNING LIGHT

The warning light will turn on or flash to alert the operator to the warning
system situations listed in the following chart.

15732

WARNING SYSTEM OPERATION

The warning horn will emit either a continuous beep or intermittent short beeps
and engine speed will be limited. This alerts the operator and helps identify the
following listed situations.

Warning System

Function Sound

Warning

Light

Description

Engine

Speed

Limited to

2800
RPM

Start up One beep

On for 5

seconds

Normal system
test

Engine over
temperature

Continuous On Engine overheat X

Low oil pressure Continuous On Low oil pressure X

Engine
overspeed

Continuous On

Engine speed
exceeds
maximum
allowable RPM

Water temp or
MAP sensor out
of range

Intermittent
short beep

Flashes

Engine speed will
be limited.
Consult your
dealer for
assistance.

X

FEATURES AND CONTROLS

eng 33

ENGINE OVERHEAT

If the engine overheats, immediately reduce throttle speed to idle. Shift the
outboard into neutral and check for a steady stream of water coming out of the
water pump indicator hole.

9647

If no water is coming out of the water pump indicator hole, or flow is
intermittent; stop the engine and check the cooling water intake holes for
obstruction. If no obstruction is found, there may be a blockage in the cooling
system or a water pump problem. Have the outboard checked by your dealer.
Operating the engine while overheated will cause engine damage.

If a steady flow of water is coming out of the water pump indicator hole and the
engine continues to overheat, consult your dealer. Operating an overheated
engine will cause engine damage.

NOTE: Should overheating occur and you are stranded, stop the engine and
allow it to cool down. This will usually allow some additional low speed (idle)
running time before the engine starts to overheat again.

LOW OIL PRESSURE

The warning system is activated if the oil pressure drops too low. First, stop the
engine and check the oil level. Add oil if necessary. If the oil is at the
recommended level and the warning horn continues to sound, consult your
dealer. Engine speed will be limited to 2800 RPM, however, you should not
continue to operate the engine.

ENGINE OVERSPEED LIMITER

The outboard is equipped with an engine overspeed limiter which limits the
engine maximum RPM. This protects the engine from mechanical damage.

Some causes of engine overspeed are as follows:

• Outboard mounted too high on the transom

• Worn jet pump impeller or liner

• Incorrect jet pump impeller clearance adjustment

• Tilting the outboard out beyond a vertical position

• Cavitation of the impeller due to rough water or obstruction in the boat hull

• Blockage of the water intake

FEATURES AND CONTROLS

34 eng

When the engine overspeed limiter is activated, it will reduce ignition voltage to
momentarily decrease the engine speed. Excessive overspeed (above 6300
RPM) results in cutout of the cylinders to prevent operation above this limit.

Replaceable Jet Drive Shear Key

The jet drive is equipped with a shear key to protect it in the event of a lodged
impeller. The shear key can be reached by removing the water intake housing
and impeller. Refer to Maintenance ‑ Impeller Removal and Installation.

29174

FEATURES AND CONTROLS

eng 35

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.

• Ensure the boat drain plug is installed.

• 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.

• Check steering for free operation.

• Check for debris around the rudder and reverse gate which may jam or
hinder operation.

• Before launching, examine the jet drive water intake for obstructions
which may prevent pumping of water.

• Ensure the driveshaft bearing on the jet drive is lubricated.

Operating in Freezing Temperatures

If there is a chance of ice forming on the water, the jet drive 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. Do not start the engine until the ice is clear.

Operating in Saltwater or Polluted Water

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

Wash down the outboard exterior and flush out the exhaust outlet of the jet
drive with fresh water after each use. Each month, spray Mercury Precision or
Quicksilver Corrosion Guard on external metal surfaces.

OPERATION

36 eng

Operating in Shallow Water

The life of the impeller and water intake can be greatly increased by avoiding
the intake of sand and gravel. The intake suction will act like a dredge when the
water intake comes close to the bottom. It is better to stop the engine and drift
up to shore when landing, and to shove off with an oar when leaving. The
engine can idle through areas of water less than 61 cm (2 ft) deep, but there
should be more than 61 cm (2 ft) of water under the boat when increasing
speed to reach full plane.

Once the boat is on plane, the boat speed will prevent the ingestion of gravel
and other debris from the bottom. The suction is still present, but the water
intake passes too quickly over the bottom to allow debris to be drawn into the
water intake.

When boating through shallow water areas, choose a course of travel that
avoids sharp rocks and other underwater obstacles that could damage the
boat. Running the boat through these areas on full plane may be helpful as the
boat will be riding higher in the water. If the boat gets stuck on the bottom,
immediately stop the engine and move the boat to deeper water.

How the Jet Drive Operates

A jet driven boat has substantially different handling characteristics compared
to a propeller driven boat. It is recommended that the operator adjusts to these
characteristics by experimenting in open water at both high and low speeds.

OPERATION

eng 37

The driveshaft driven impeller draws water up through the water intake and
then directs it at a high pressure through the water outlet nozzle to create
forward thrust. To obtain reverse, the reverse gate moves over the outlet
nozzle to direct the water in the opposite direction.

a - Water intake
b - Water outlet nozzle
c - Reverse gate

When the jet drive is in neutral, the impeller continues to rotate. However, the
reverse gate is positioned so that some of the forward thrust is diverted to
create reverse thrust. This approximate balancing of forward and reverse thrust
will minimize any boat movement. Because the impeller is always rotating and
creating thrust when the engine is running, the boat may tend to move slowly
forward or backward. This is normal for a direct‑drive jet driven boat. The
operator should be aware of this and use caution whenever the engine is
running.

!

WARNING

Avoid injury resulting from contacting the rotating impeller or having hair,
clothing, or loose objects drawn into the water intake and wrapping around
the impeller shaft. Stay away from the water intake and never insert an object
into the water intake or water outlet nozzle when the engine is running.

The jet drive is always drawing water into the housing when the engine is
running. Do not operate the jet drive with the grate removed from the water
intake. Keep hands, feet, hair, loose clothing, life jackets, etc., away from the
water intake. Never insert an object into the water intake or water outlet nozzle
when the engine is running.

a

c

b

29022

OPERATION

38 eng

Stopping the Boat in an Emergency

A jet powered boat has emergency stopping capability unique to this form of
propulsion.

!

WARNING

Using the emergency stopping capability of a jet drive unit will slow down the
boat in an emergency. However, sudden stopping may cause the occupants
of the boat to be thrown forward or out of the boat resulting in serious injury
or death. Use caution when performing the emergency stopping procedure,
and be sure to practice in a safe area.

In an emergency, putting the jet outboard into reverse and applying reverse
throttle can rapidly slow down the boat and reduce stopping distance. However,
such a maneuver may cause occupants in the boat to be thrown forward or
possibly out of the boat.

Steering the Boat

The jet drive is dependent on water jet thrust for steering the boat. If the water
jet thrust should ever stop (water blockage, engine stops, etc.), the boat will
slow to a stop. However, while slowing there will be a reduced ability to steer
the boat.

!

WARNING

Steering the vessel in a tight turn can result in loss of boat control. In some
cases, the boat can spin out or roll over, causing serious injury or death.
Avoid steering beyond the capabilities of the vessel, especially at high
speeds.

!

WARNING

A loss or reduction in water jet thrust will directly affect boat directional
control, and may result in property damage, personal injury, or death. Boat
directional control can also be substantially reduced or lost altogether by a
sudden loss of power such as running out of gas, quickly backing off the
throttle, turning off the ignition switch, activating the lanyard stop switch, or
plugging the water intake to the jet pump. Use caution when maneuvering at
high speeds in areas where debris (weeds, logs, gravel, etc.) could be picked
up into the jet drive. The ability to take evasive action is dependent on
sufficient water jet thrust to control the boat.

While steering the boat at engine speeds above idle, the boat will respond
quickly; but, due to the relatively flat‑bottom hulls and lack of a gearcase in the
water, the boat will tend to skid on turns. Turns must be started early and use
sufficient power to maintain steering control.

OPERATION

eng 39

Mooring the Boat

Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach
or tied to a dock in shallow water. Failure to do this may cause the water intake
housing to fill with sand or debris and could prevent the outboard from cranking
over for starting.

Water Intake Blockage

!

WARNING

A rotating impeller could cause injury if contact is made with hands, clothing,
or tools. To avoid injury, keep hands and clothing away from the inlet or
outlet of the jet drive, regardless of whether the boat is in the water. Secure
tools and loose items to avoid being struck by projectiles as a result of
contact with the rotating impeller, and to prevent damage to the impeller.

A large amount of debris being drawn into the water intake may result in a loss
of power. Intake suction holding debris against the grate will result in restricted
water flow. Shutting the engine off may allow the debris to fall off the intake
grate allowing full power to be restored. If debris does not fall off the intake
grate, the engine must be shut off and debris physically removed from the
grate.

Clearing A Lodged Impeller

!

WARNING

Rotating the flywheel to free a lodged impeller can accidentally start the
engine, resulting in serious injury or death. Always turn the ignition key or
lanyard stop switch to the "OFF" position and remove all spark plug leads
from the spark plugs.

It is possible for debris to lodge between the impeller and jet housing wall,
especially after the engine has been stopped. This will lock the driveshaft and
will prevent the engine from being able to crank over for starting. Following are
steps for dislodging the impeller.

1. Position the lanyard stop switch to the "OFF" position.

2. Remove the spark plug leads to prevent the engine from accidentally
starting.

3. Remove the flywheel or rewind cover and rotate the engine flywheel
counterclockwise.

If this does not dislodge the impeller, it will be necessary to remove the six
screws and water intake housing.

OPERATION

40 eng

Prestarting Instructions

1. Connect the remote fuel line to the outboard. Ensure the connector is
snapped into place.

9600

2. Check the engine oil level.

9601

3. Ensure the driveshaft bearing on the jet drive is lubricated. Refer to
Maintenance ‑ Lubrication Points.

29025

OPERATION

eng 41

4. Tiller handle models with manual or electric start, have a quick reference
decal on the tiller handle that shows the sequence for starting the engine.

52396

Tiller handle starting sequence decal

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 hour of operation, run the engine at varied throttle settings up
to 3500 RPM or at approximately half throttle.

2. For the second hour of operation, run the engine at varied throttle settings
up to 4500 RPM or at three‑quarter throttle, and during this period of time,
run it at full throttle for approximately one minute every ten minutes.

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

Starting the Engine ‑ Remote Control Models

Before starting, read the Prestarting Check List, Prestarting Instructions,
and Engine Break‑in Procedure in the Operation 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.

NOTE: If the outboard runs out of fuel, or has been in storage for an extended
period of time, additional attempts to start the engine are required to purge the
fuel system of air.

1. Open the fuel tank vent screw (in filler cap) on manual venting type fuel
tanks.

19748

OPERATION

42 eng

2. Squeeze the fuel line primer bulb several times until it feels firm.

19779

IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb
after engine has warmed up.

3.

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

19791

4. Shift the outboard to the neutral (N) position.

N

26838

5. Move the neutral fast idle speed feature to the fully closed position.

NOTE: To start a flooded engine, advance the neutral fast idle speed feature
to the maximum fast idle speed position and continue to crank the engine for
starting. Immediately reduce engine speed after the engine starts.

6. Turn the ignition key to the START position. If the engine fails to start in
ten seconds, return the key to the ON position, wait 30 seconds and try
again.

19804

OPERATION

eng 43

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

9647

IMPORTANT: If no water is coming out of the water pump indicator hole, stop
the engine and check 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.

Starting the Engine ‑ Tiller Handle Models

Before starting, read the Prestarting Check List, Prestarting Instructions,
and Engine Break‑in Procedure in the Operation 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.

NOTE: If the outboard runs out of fuel, or has been in storage for an extended
period of time, additional attempts to start the engine are required to purge the
fuel system of air.

1. Open the fuel tank vent screw (in filler cap) on manual venting type fuel
tanks.

19748

2. Squeeze the fuel line primer bulb several times until it feels firm.

19779

OPERATION

44 eng

3.

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

19791

4. Set the tiller handle grip to the neutral start position.

START

N

START

N

24834

.

5. Set the gear shift to the neutral N position.

R

N

F

24835

6. Position the tilt lock lever to the lock position.

LOCK

FREE

10251

OPERATION

eng 45

7. Manual starting models ‑ Pull the starter rope slowly until the starter
engages, then pull rapidly to crank the engine. Allow the rope to return
slowly. Repeat until the engine starts.

10173

8. Electric starting models ‑ Push the starter button and crank the engine.
Release the button when the engine starts. Do not operate the starter
motor continuously for longer than ten seconds at a time. If the engine
fails to start in ten seconds, wait 30 seconds and try again.

10187

9. Check for a steady stream of water flowing out of the water pump
indicator hole.

9647

IMPORTANT: If no water is coming out of the water pump indicator hole, stop
engine and check 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 may cause serious engine
damage.

OPERATION

46 eng

Gear Shifting

NOTE: The propeller continues to rotate while the engine is in neutral. Although
the approximate balancing of forward and reverse thrust will minimize boat
movement, the boat may tend to move slowly forward and backward. This is
normal for a direct‑drive jet driven boat. The operator should be aware of this
and use caution whenever the engine is running.

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

•

Tiller handle models ‑ Reduce the engine speed to idle before shifting.

START

N

START

N

24834

R

N

F

24835

•

Remote control models ‑ When shifting, always stop at the neutral
position and allow the engine speed to return to idle.

N

R

27237

• After shifting the outboard into gear, advance the remote control lever or
rotate the throttle grip (tiller handle) to increase speed.

OPERATION

eng 47

Stopping the Engine

Reduce the engine speed and shift the outboard to neutral position. Push in the
stop switch or move the lanyard stop switch to the "OFF" position.

26776

Emergency Starting

If the starter system fails, the engine can be started using the spare starter rope
(provided). Refer to the following procedure for instructions.

1. Remove the flywheel cover or manual starter assembly.

10004

2. Shift the outboard to the neutral ("N") position.

N

26838

R

N

F

24835

OPERATION

48 eng

!

WARNING

The neutral‑speed‑protection device is inoperative when starting the engine
with the emergency starter rope. Set the engine speed at idle and the gear
shift in neutral to prevent the outboard from starting in gear.

3. Electric start models ‑ Turn the ignition key to the "ON" position.

26846

!

WARNING

High voltage is present any time the key is turned on, especially when
starting or operating the engine. Do not touch ignition components or metal
test probes and stay clear of spark plug leads when performing live tests.

!

WARNING

The exposed moving flywheel can cause serious injury. Keep your hands,
hair, clothing, tools, and other objects away from engine when starting or
running the engine. Do not attempt to reinstall the flywheel cover or top
cowl when engine is running.

4. Place the starter rope knot into the flywheel notch and wind the rope
clockwise around the flywheel.

5. Pull the starter rope to start the engine.

10006

OPERATION

eng 49

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

50 eng

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 51

Tube Ref

No.

Description Where Used Part No.

120

Corrosion Guard

External metal surfaces of the powerhead

and powerhead components.

92-802878 55

EPA Emission 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 time of
manufacture.

a - Piston displacement
b - Maximum emission output for the engine family
c - Percent of fuel line permeation
d - Timing specification
e - US EPA engine family name
f - Horsepower rating
g - Engine power ‑ kilowatts
h - Idle speed (in gear)

OWNER RESPONSIBILITY

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

2008

JAN

FEB

MAR

APR

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

THIS ENGINE CONFORMS TO 2010 CALIFORNIA AND U.S. EPA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES. REFER TO OWNER’S
MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
PLEASE PERFORM THE ENGINE MAINTENANCE CORRECTLY.

FAMILY :

MERCURY MARINE

EMISSION CONTROL INFORMATION

a

DISPLACEMENT :
FEL : HC+NOx=

LOW-PERM/HIGH-PERM :

TIMING :

IDLE SPEED (IN GEAR) :

MAXIMUM POWER :

HP :

2008

b

c

d

e

f

g

h

43058

CO=

MAINTENANCE

52 eng

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

• Lubricate the propeller shaft splines

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

• Lubricate the driveshaft 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,
if equipped—dealer item

THREE YEARS OR 300 HOURS

• Replace the spark plugs

• Replace the water pump impeller—dealer item

• Inspect the carbon fiber reeds, if equipped—dealer item

• Inspect the wire harness connectors—dealer item

MAINTENANCE

eng 53

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

• Replace the high‑pressure fuel filter, if equipped—dealer item

• Replace the accessory drive belt, if equipped—dealer item

• Check the power trim fluid level, if equipped—dealer item

• Inspect the engine motor mounts—dealer item

Top Cowl Removal and Installation

REMOVAL

1. Unlock the rear latch by pulling lever up.

10190

2. Lift rear of cowl and disengage front hook.

10191

INSTALLATION

1. Lower the top cowl over the engine. Bring the front of the cowl down first
and engage the front hook, then lower the cowl into its seated position
with the bottom cowl.

2. Apply some downward pressure on the bottom cowl and then lock the
cowl in place by pushing in the cowl latch. Ensure the top cowl is securely
fastened by pulling up on the back of the cowl.

Worn/Dull Impeller

The intake of gravel through the pump can round off and wear the leading
edges of the impeller. Some conditions that could be experienced from a worn/
dull impeller are as follows:

• Noticeable performance loss, especially on acceleration

MAINTENANCE

54 eng

• Difficulty getting the boat on plane

• An increase in engine RPM at wide‑open throttle
IMPORTANT: Do not sharpen or alter the top side lifting angle.
Check the impeller blades occasionally for damage. Use a flat file to sharpen

the leading edges. Sharpen to a 0.8 mm (1/32 in.) radius by removing material
from bottom side only.

a - Leading edge
b - Top side lifting angle

Impeller Clearance Adjustment

The impeller should be adjusted so there is approximately 0.8 mm (0.03 in.)
clearance between the impeller edge and liner. Operating the jet drive in waters
that contain sand and gravel can cause wear to the impeller blades, and the
clearance will start to exceed 0.8 mm (0.03 in.).

As the blades wear, shims located in the stack outside of the impeller can be
transferred behind the impeller. This will move the impeller further down into
the tapered liner to reduce the clearance.

a - Shims
b - Clearance between impeller

edge and liner

Check the impeller clearance by sliding a feeler gauge through the intake grate
and measure the clearance between the impeller edge and liner. If adjustment
is required, refer to Impeller Removal and Installation.

a

b

29079

a

b

29080

MAINTENANCE

eng 55

Impeller Removal and Installation

!

WARNING

Rotating the driveshaft may cause the engine to crank over and start. To
prevent this type of accidental engine starting and possible serious injury
caused from being struck by a rotating impeller, always turn the ignition key
or lanyard stop switch to the "OFF" position and remove the spark plug leads
from the spark plugs while servicing the impeller.

1. Shift the outboard to the neutral position.

R

N

F

24835

2. Position the key switch or lanyard stop switch to the "OFF" position.

3. Remove the spark plug leads to prevent the engine from starting.

26899

4. Remove the six screws securing the water intake housing, and remove
the water intake housing.

29081

MAINTENANCE

56 eng

5. Straighten the bent tabs on the impeller nut retainer and remove the
impeller nut.

a - Tabs
b - Impeller nut

6. Pull the impeller straight off the shaft. If the impeller is tight, use a
hammer and a block of wood to rotate the impeller clockwise on the shaft
until the keyway is directly above the flat on the shaft. This will free the
jammed key and allow removal.

INSTALLATION

1. Lubricate the driveshaft, shear key, and impeller bore.

2. Place the plastic sleeve inside the impeller and install impeller, shear key,
shims, nut retainer, and impeller nut.

a - Plastic sleeve
b - Impeller
c - Shear key
d - Shims
e - Nut retainer
f - Impeller nut

3. Turn the nut tight on the shaft to remove any play between the impeller
and shaft. If the tabs on the retainer do not line up with the flats on the
nut, remove the nut and turn the retainer over and tighten the nut again.

b

a

29082

a

b

c

d

e

f

29083

MAINTENANCE

eng 57

4. Temporarily install the water intake housing in order to check for impeller
clearance. The clearance between the impeller and liner should be

0.8 mm (0.03 in.). Shim washers can be transferred to either side of the
impeller to raise or lower the impeller to the correct clearance setting. The
water intake housing can be shifted sideways a small amount in order to
center the liner.

a - Shims
b - Clearance between

impeller edge and liner

5. After setting the impeller height, tighten the impeller nut snug with a
wrench. Secure impeller nut by bending tabs against the flats on the
impeller nut.

a - Tabs
b - Impeller nut

NOTE: If the outboard is used in saltwater, apply Extreme Grease around the
entire mounting flange on the water intake housing and also to the threads on
the six mounting bolts.

Tube Ref

No.

Description Where Used Part No.

Extreme Grease

Water intake housing mounting flange

and mounting bolts

8M0071842

a

b

29080

b

a

29082

MAINTENANCE

58 eng

6. Install the water intake housing with six bolts. Check clearance around the
impeller to ensure the water intake housing is centered and not rubbing
against the liner. Tighten the mounting bolts to the specified torque.

29081

Description Nm lb‑in. lb‑ft
Water intake housing mounting bolts 13.5 120 –

Shift Link Rod Adjustment

!

WARNING

Pressurized water hitting the reverse gate may cause it to engage, causing
sudden and unexpected slowing of the boat. This can cause serious injury or
death from occupants being thrown within or out of the boat. Adjust the shift
link rod to lock the reverse gate, preventing it from interfering with water flow.

CHECKING SHIFT LINK ROD ADJUSTMENT

Check the shift link rod adjustment in forward shift position. The correct
adjustment will position the shift cam far enough on the roller in order to lock
the reverse gate into forward position. The reverse gate should not be able to
be forced up towards neutral. Pull on the reverse gate by hand to verify.

a - Shift link rod
b - Shift cam
c - Roller
d - Reverse gate

ADJUSTING SHIFT LINK ROD

1. Place the shift handle into full forward shift position.

a

b

c

d

29084

MAINTENANCE

eng 59

2. Adjust the length of the shift link rod so the roller is at the full end of travel
(bottom) in the shift cam when the shift handle is in forward.

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.

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

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.

Before servicing any part of the fuel system, stop the engine and disconnect
the battery. Drain the fuel system completely. Use an approved container to
collect and store fuel. Wipe up any spillage immediately. Material used to
contain spillage must be disposed of in an approved receptacle. Any fuel
system service must be performed in a well ventilated area. Inspect any
completed service work for sign of fuel leakage.

FUEL LINE INSPECTION

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

FUEL FILTER (LOW PRESSURE)

Check the fuel filter for water accumulation or sediment. If water is in the fuel,
remove the sight bowl and drain the water. If the filter appears to be
contaminated, remove and replace.

REMOVAL

1.

Read the Fuel System servicing information and Warning, preceding.

MAINTENANCE

60 eng

2. Loosen the hex nut and remove the filter assembly from the mount. Hold
on to the cover to prevent it from turning and remove the sight bowl.
Empty the contents into an approved container.

3. Inspect the filter element. If replacement is necessary, replace the filter
assembly.

a - Cover
b - Filter element
c - O‑ring seal
d - Sight bowl

INSTALLATION

1. Push the filter element into the cover.

2. Place the O‑ring seal into its proper position on the sight bowl and screw
the sight bowl hand‑tight into the cover.

3. Install the filter assembly back into the mount.

IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the
primer bulb until firm, forcing fuel into the filter.

Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the
engine must be fastened using the steering link rod fastening hardware
supplied with the engine. Never replace the locknuts (11‑16147‑‑3) with
common nuts (nonlocking) 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

b

c

d

9694

MAINTENANCE

eng 61

Assemble steering link rod to steering cable with flat washer and nylon insert
locknut. Tighten locknut until it seats, then back nut off 1/4 turn.

Assemble steering link rod to engine with bolt, locknut, spacer, and flat
washers. Tighten the locknut to the specified torque.

a - Bolt (10‑898101018)
b - Flat washer (12‑95392‑10)
c - Spacer (23‑853826001)
d - Nylon insert locknut (11‑16147‑‑3)
e - Install steering link rod into side hole
f - Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off

1/4 turn)

Description Nm lb‑in. lb‑ft
Nylon insert locknut "d" 27 – 20

Nylon insert locknut "f"

Tighten until it seats, then back off ¼

turn

Corrosion Control Anode

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

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.

a

b

c

b

d

e

b

f

9691

MAINTENANCE

62 eng

One anode is installed in the engine block. Remove the flange screw at the
location shown. Remove the screw securing the anode. Fasten the anode to
the flange screw. Tighten the screw to the specified torque. Install the flange
screw with a new O‑ring. Tighten the flange screw to the specified torque.

a - Flange screw
b - O‑ring
c - Anode
d - Screw

Description Nm lb‑in. lb‑ft
Flange screw 6 53 –
Screw 6 53 –

The second anode is on the water intake housing and the third anode is
installed on the transom brackets.

a - Water intake housing

anode

b - Transom bracket

anode

Spark Plug Inspection and Replacement

!

WARNING

Damaged spark plug boots may emit sparks that can ignite fuel vapors under
the engine cowl, resulting in serious injury or death from a fire or explosion.
To avoid damaging the spark plug boots, do not use any sharp object or
metal tool to remove the spark plug boots.

a

b

c

d

57328

a

24838

b

10239

MAINTENANCE

eng 63

1. Remove the spark plug leads. Twist the rubber boots slightly and pull off.

26899

2. Remove the spark plugs to inspect. Replace spark plug if electrode is
worn or the insulator is rough, cracked, broken, blistered, or fouled.

26946

3. Set the spark plug gap to specifications.

27848

Spark Plug Gap
Spark plug 0.80–0.90 mm (0.031–0.035 in.)

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

Description

Nm lb‑in. lb‑ft

Spark plug 20 177 –

Fuse Replacement ‑ Electric Start Models

IMPORTANT: Always carry spare SFE 20 amp fuses.
The electric starting circuit is protected from overload by an SFE 20 amp fuse.

If the fuse is blown, the electric starter motor will not operate. Try to locate and
correct the cause of the overload. If the cause is not found, the fuse may blow
again.

MAINTENANCE

64 eng

Open the fuse holder and look at the silver colored band inside the fuse. If band
is broken, replace the fuse. Replace fuse with a new fuse with the same rating.

a - Good fuse
b - Blown fuse

Timing Belt Inspection

Inspect the timing 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 the belt teeth.

• Excessive wear at the roots of the cogs.

• Rubber portion swollen by oil.

• Belt surfaces roughened.

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

9701

Lubrication Points

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

a b

15917

MAINTENANCE

eng 65

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Driveshaft bearing 8M0071842

95

2-4-C with PTFE Driveshaft bearing 92-802859A 1

• Driveshaft bearing

IMPORTANT: It is important not to use a general all‑purpose grease for this
bearing. The lubricant recommended is a water‑resistant grease of the proper
consistency for this application. If a substitute is used, be sure that it is
water‑resistant and of the same consistency.

i. Pull the vent hose off of the grease fitting.
ii. Pump in grease through the grease fitting, using the grease gun

provided, until excess grease starts to exit the vent hose.

iii. Reconnect the vent hose onto the grease fitting after greasing.

a - Grease fitting
b - Vent hose

NOTE: After 30 hours of operation, pump in extra grease to purge out any
moisture. Visually inspecting the purged grease at this time will give an
indication of conditions inside the bearing housing. A gradual increase in
moisture content, indicates seal wear. If the grease begins to turn dark or dirty
gray, the driveshaft bearing and seals should be inspected and replaced if
necessary. Some discoloration of the grease is normal during the break‑in
period on a new set of seals.

2. 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 tube, transom clamp

screws, steering cable grease fitting

8M0071842

95

2-4-C with PTFE

Swivel bracket, tilt tube, transom clamp

screws, steering cable grease fitting

92-802859A 1

a

b

29101

MAINTENANCE

66 eng

• Swivel bracket ‑ Lubricate through fitting.

24839

• Tilt tube ‑ Lubricate through fittings.

15915

• Lubricate the threads on the transom clamp screws (if equipped).

15914

MAINTENANCE

eng 67

• Steering cable grease fitting (if equipped) ‑ Rotate the steering wheel
to fully retract the steering cable end into the outboard tilt tube.
Lubricate through fitting.

a - Fitting
b - Steering cable end

!

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.

3. Lubricate the following with lightweight oil.

• Steering link rod pivot points ‑ Lubricate the pivot points.

59491

Checking Power Trim Fluid

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

9703

a

b

59492

MAINTENANCE

68 eng

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
Lubricants Power Trim and Steering Fluid. If not available, use automotive
(ATF) automatic transmission fluid.

9701

Tube Ref

No.

Description Where Used Part No.

114

Power Trim and
Steering Fluid

Power trim system 92-858074K01

Changing Engine Oil

ENGINE OIL CAPACITY

Capacity

Fluid Type

Engine oil

1.8 liter

(1.9 quarts)

Mercury Precision Parts or Quicksilver

10W‑30 4‑Stroke Marine Engine Oil

Mercury Precision Parts or Quicksilver

Synthetic Blend 4‑Stroke Marine Engine Oil

OIL CHANGING PROCEDURE

1. Tilt the outboard up to the trailer position.

MAINTENANCE

eng 69

2. Turn the steering on the outboard so that the drain hole is facing
downward. Remove the drain plug and drain the engine oil into an
appropriate container. Lubricate the seal on the drain plug with oil and
install.

a - Drain plug

CHANGING OIL FILTER

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

2. Unscrew the old filter by turning the filter to the left.

9735

3. Clean the mounting base. Apply a film of clean oil to the filter gasket. Do
not use grease. Screw the new filter on until the gasket contacts the base,
then tighten 3/4 to 1 turn.

OIL FILLING

1. Remove the oil fill cap and add oil to the proper operating level.

a

24854

MAINTENANCE

70 eng

2. Idle the engine for five minutes and check for leaks. Stop the engine and
check oil level on the dipstick. Add oil if necessary.

a - Oil fill cap

Submerged Outboard

A submerged outboard will require service within a few hours by an authorized
dealer once the outboard is recovered from the water. This immediate attention
by a servicing dealer is necessary once the engine is exposed to the
atmosphere to minimize internal corrosion damage to the engine.

9737

a

MAINTENANCE

eng 71

Storage Preparation

The major consideration in preparing your outboard for storage is to protect it
from rust, corrosion, and damage caused by freezing of trapped water.

The following storage procedures should be followed to prepare your outboard
for out‑of‑season storage or prolonged storage (two months or longer).

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.

FUEL SYSTEM

IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a
formation of acid during storage and can damage the fuel system. If the
gasoline being used contains alcohol, it is advisable to drain as much of the
remaining gasoline as possible from the fuel tank, remote fuel line, and engine
fuel system.

Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help
prevent formation of varnish and gum. Proceed with the following instructions.

• Portable fuel tank—Pour the required amount of gasoline stabilizer (follow
the instructions on container) into the fuel tank. Tip the fuel tank back and
forth to mix the stabilizer with the fuel.

• Permanently installed fuel tank—Pour the required amount of gasoline
stabilizer (follow the instructions on container) into a separate container
and mix with approximately 1 Liter (1 US qt) of gasoline. Pour this mixture
into the fuel tank.

• Remove the fuel filter sight bowl and empty its contents into a suitable
container. Refer to Section 6 ‑ Fuel System for removal and installation
of the filter. Add 3 cc (1/2 tsp) of Quickstor Fuel Stabilizer into the fuel
filter sight bowl and install.

Tube Ref

No.

Description Where Used Part No.

124

Quickstor Fuel
Stabilizer

Fuel filter sight bowl 92-8M0047932

• Place the outboard in the water or connect a flushing attachment for
circulating cooling water. Run the engine for 15 minutes to fill the engine
fuel system.

Protecting External Outboard Components

•

Lubricate all outboard components listed in Maintenance ‑ Inspection
and Maintenance Schedule.

• Touch up any paint nicks. See your dealer for touch‑up paint.

STORAGE

72 eng

• Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on
external metal surfaces (except corrosion control anodes).

Tube Ref

No.

Description Where Used Part No.

120

Corrosion Guard External metal surfaces 92-802878 55

Protecting Internal Engine Components

• Remove the spark plugs and inject a small amount of engine oil inside of
each cylinder.

• Rotate the flywheel manually several times to distribute the oil in the
cylinders. Install the spark plugs.

• Change the engine oil.

Jet Drive

• Pump extra grease into the jet drive bearing to purge out moisture.

Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of the
outboard.

NOTICE

Storing the outboard in a tilted position can damage the outboard. Water
trapped in the cooling passages or rain water collected in the propeller
exhaust outlet in the gearcase can freeze. Store the outboard in the full down
position.

Battery Storage

• Follow the battery manufacturer's instructions for storage and charging.

• Remove the battery from the boat and check water level. Charge if
necessary.

• Store the battery in a cool, dry place.

• Periodically check the water level and charge the battery during storage.

STORAGE

eng 73

Starter Motor will not Crank the Engine (Electric Start Models)

POSSIBLE CAUSES

•

Blown fuse in the starting circuit. Refer to Maintenance section.

• Outboard is not shifted to neutral position.

• Weak battery or battery connections are loose or corroded.

• Ignition key switch failure.

• Wiring or electrical connection faulty.

• Starter motor or starter solenoid failure.

• Impeller is stuck due to blockage.

Engine Will Not Start

POSSIBLE CAUSES

NOTE: If the outboard has run out of fuel, or has been in storage for an
extended period of time, additional attempts to start the engine will be required
to purge the fuel system of air.

• Lanyard stop switch not in "RUN" position.

•

Incorrect starting procedure. Refer to Operation section.

• Old or contaminated gasoline.

•

Engine flooded. Refer to Operation section.

• Fuel is not reaching the engine.

• Fuel tank is empty.

• Fuel tank vent not open or restricted.

• Fuel line is disconnected or kinked.

• Primer bulb not squeezed.

• Primer bulb check valve is faulty.

•

Fuel filter is obstructed. Refer to Maintenance section.

• Fuel pump failure.

• Fuel tank filter obstructed.

•

Open 20‑amp fuse. Refer to Maintenance section.

• Ignition system component failure.

• Wiring or electrical connection faulty.

•

Spark plugs fouled or defective. Refer to Maintenance section.

Engine Runs Erratically

POSSIBLE CAUSES

• Overheating ‑ Warning horn not working.

• Low oil pressure. Check oil level.

•

Spark plugs fouled or defective. Refer to Maintenance section.

TROUBLESHOOTING

74 eng

• Incorrect setup and adjustments.

• Fuel is being restricted to the engine.

a.

Engine fuel filter is obstructed. Refer to Maintenance section.
b. Fuel tank filter obstructed.
c. Stuck antisiphon valve located on permanently built‑in type fuel tanks.
d. Fuel line is kinked or pinched.

• Fuel pump failure.

• Ignition system component failure.

Engine Overspeed (Excessive RPM)

POSSIBLE CAUSES

• Outboard mounted too high on the transom.

• Worn jet pump impeller or liner.

• Incorrect jet pump impeller clearance adjustment.

• Tilting the outboard out beyond a vertical position.

• Cavitation of the impeller due to rough water or obstruction in the boat
hull.

• Blockage of the water intake.

Performance Loss

POSSIBLE CAUSES

• Throttle not fully open.

• Damaged impeller.

• Incorrect engine timing, adjustments, or setup.

• Boat overloaded or load improperly distributed.

• Excessive water in bilge.

• Boat bottom is dirty or damaged.

Battery Will Not Hold Charge

POSSIBLE CAUSES

• Battery connections are loose or corroded.

• Low electrolyte level in battery.

• Worn out or inefficient battery.

• Excessive use of electrical accessories.

• Defective rectifier, alternator, or voltage regulator.

TROUBLESHOOTING

eng 75

Service Assistance

LOCAL REPAIR SERVICE

If you need service for your Mercury‑outboard‑powered boat, take it to your
authorized dealer. Only authorized dealers specialize in Mercury products and
have factory‑trained mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your engine.

NOTE: Quicksilver parts and accessories are engineered and built by Mercury
Marine specifically for your power package.

SERVICE AWAY FROM HOME

If you are away from your local dealer and the need arises for service, contact
the nearest authorized dealer. If, for any reason, you cannot obtain service,
contact the nearest Regional Service Center. Outside the United States and
Canada, contact the nearest Marine Power International Service Center.

STOLEN POWER PACKAGE

If your power package is stolen, immediately advise the local authorities and
Mercury Marine of the model and serial numbers and to whom the recovery is
to be reported. This information is maintained in a database at Mercury Marine
to aid authorities and dealers in the recovery of stolen power packages.

ATTENTION REQUIRED AFTER SUBMERSION

1. Before recovery, contact an authorized Mercury dealer.

2. After recovery, immediate service by an authorized Mercury dealer is
required to reduce the possibility of serious engine damage.

REPLACEMENT SERVICE PARTS

!

WARNING

Avoid fire or explosion hazard. Electrical, ignition, and fuel system
components on Mercury Marine products comply with federal and
international standards to minimize risk of fire or explosion. Do not use
replacement electrical or fuel system components that do not comply with
these standards. When servicing the electrical and fuel systems, properly
install and tighten all components.

Marine engines are expected to operate at or near full throttle for most of their
lives. They are also expected to operate in both fresh and saltwater
environments. These conditions require numerous special parts.

OWNER SERVICE ASSISTANCE

76 eng

PARTS AND ACCESSORIES INQUIRIES

Direct any inquiries concerning Quicksilver replacement parts and accessories
to your local authorized dealer. The dealer has the necessary information to
order parts and accessories for you if they are not in stock. Only authorized
dealers can purchase genuine Quicksilver parts and accessories from the
factory. Mercury Marine does not sell to unauthorized dealers or retail
customers. When inquiring about parts and accessories, the dealer requires the
engine model and serial numbers to order the correct parts.

RESOLVING A PROBLEM

Satisfaction with your Mercury product is important to your dealer and to us. If
you ever have a problem, question or concern about your power package,
contact your dealer or any authorized Mercury dealership. If you need
additional assistance:

1. Talk with the dealership's sales manager or service manager. Contact the
owner of the dealership if the sales manager and service manager have
been unable to resolve the problem.

2. If your question, concern, or problem cannot be resolved by your
dealership, please contact the Mercury Marine Service Office for
assistance. Mercury Marine will work with you and your dealership to
resolve all problems.

The following information will be needed by the Customer Service:

• Your name and address

• Your daytime telephone number

• The model and serial numbers of your power package

• The name and address of your dealership

• The nature of the problem

CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER
SERVICE

For assistance, call, fax, or write to the geographic office in your area. Please
include your daytime telephone number with mail and fax correspondence.

United States, Canada

Telephone

English [phone]
Français [phone]

Mercury Marine
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939

Fax

English [phone]
Français [phone]

Website www.mercurymarine.com

OWNER SERVICE ASSISTANCE

eng 77

Australia, Pacific
Telephone [phone] Brunswick Asia Pacific Group

41–71 Bessemer Drive
Dandenong South, Victoria 3175
Australia

Fax [phone]

Europe, Middle East, Africa
Telephone [phone] Brunswick Marine Europe

Parc Industriel de Petit-Rechain
B-4800 Verviers,
Belgium

Fax [phone]

Mexico, Central America, South America, Caribbean
Telephone [phone] Mercury Marine

11650 Interchange Circle North
Miramar, FL 33025
U.S.A.

Fax [phone]

Japan
Telephone [phone] Kisaka Co., Ltd.

4‑130 Kannabecho, Sakai‑ku
Sakai‑shi, Osaka 590‑0984, Japan

Fax [phone]

Asia, Singapore
Telephone [phone] Brunswick Asia Pacific Group

T/A Mercury Marine Singapore Pte Ltd
29 Loyang Drive
Singapore, 508944

Fax [phone]

Ordering Literature

Before ordering literature, have the following information about your power
package available:

Model

Serial Number

Horsepower Year

UNITED STATES AND CANADA

For additional literature for your Mercury Marine power package, contact your
nearest Mercury Marine dealer or contact:

OWNER SERVICE ASSISTANCE

78 eng

Mercury Marine

Telephone Fax Mail

(920) 929‑5110

(USA only)

(920) 929‑4894

(USA only)

Mercury Marine

Attn: Publications Department

P.O. Box 1939

Fond du Lac, WI 54936-1939

OUTSIDE THE UNITED STATES AND CANADA

Contact your nearest Mercury Marine authorized service center to order
additional literature that is available for your particular power package.

Submit the following
order form with payment
to:

Mercury Marine
Attn: Publications Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939

Ship To: (Copy this form and print or type–This is your shipping label)

Name

Address

City, State, Province

ZIP or postal code

Country

Quantity Item Stock Number Price Total

. .
. .
. .
. .
. .

Total Due .

OWNER SERVICE ASSISTANCE

eng 79

Installation Information

MERCURY MARINE VALIDATED ENGINE MOUNTING HARDWARE

IMPORTANT: Mercury Marine provides validated fasteners and installation
instructions, including torque specifications, with all of our outboards so they
can be properly secured to boat transoms. Improper installation of the outboard
can cause performance and reliability issues that can lead to safety concerns.
Follow all of the instructions relating to the outboard installation. DO NOT
mount any other accessory onto the boat with the fasteners provided with the
outboard. For example, do not mount tow sport bars or boarding ladders onto
the boat using the mounting hardware included with the outboard. Installing
other products onto the boat that utilize the outboard mounting hardware will
compromise the ability of that hardware to properly and safely secure the
outboard to the transom.

Outboards that require validated mounting hardware will have the following
decal on the transom clamp.

51965

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.

INSTALLATION

80 eng

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

26777

START IN GEAR PROTECTION

!

WARNING

Starting the engine with the drive in gear can cause serious injury or death.
Never operate a boat that does not have a neutral‑safety‑protection device.

The remote control connected to the outboard must be equipped with a start in
neutral only protection device. This prevents the engine from starting in gear.

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.
Acquire and read the installation, operation and maintenance manuals for all
your selected accessories.

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.

INSTALLATION

eng 81

ELECTRIC FUEL PUMP

If an electric fuel pump is used, the fuel pressure must not exceed 27.58 kPa
(4 psi) at the engine. If necessary, install a pressure regulator to regulate the
pressure.

Top Cowl Removal and Installation

TOP COWL REMOVAL

1. Unlock the cowl latch located at the rear of the engine by lifting the latch
up.

2. Lift up on the rear of the cowl and disengage the front hook.

10170

TOP COWL INSTALLATION

1. Engage the front hook and push the top cowl onto the lower cowl.

2. Push the cowl latch down to lock the cowl in place.

INSTALLATION

82 eng

Lifting Outboard

Use the lifting eye located aft of the flywheel to support the engine when
installing the outboard.

10111

Determining the Mounting Height of the Outboard Jet

The following outboard mounting height settings will work good for most
applications, however, because of different boat/hull designs, the setting should
be checked by test running the boat. Refer to Water Testing.

• Installing the outboard too high on the transom will allow the water intake
to suck in air and cause cavitation. (Cavitation will cause the engine to
overspeed in spurts and reduce thrust.) This condition should be avoided
by proper height setting.

• Installing the outboard too low on the transom will allow excessive drag.

INSTALLATION

eng 83

BOATS WITH A "V" BOTTOM HULL

1. Measure the width of the leading edge on the water intake housing. Make
a horizontal line on the transom up from the "V" bottom the same length
as the width of the water intake housing.

a - Horizontal line
b - Width of the leading edge on the water intake housing

2. Place (center) the outboard on the boat transom. Set the height of the
outboard on the boat transom so that the front edge of the water intake
housing is in line with the horizontal line made in step 1. Temporarily
clamp the outboard to the transom at this position.

3.

Fasten the outboard to the transom at this height. Refer to Fastening the
Outboard.

22403

BOATS WITH A FLAT BOTTOM HULL

1. Place (center) the outboard on the boat transom. Set the height of the
outboard on the boat transom so that the front edge of the water intake
housing is in line with the bottom of the boat as shown. Temporarily clamp
the outboard to the transom at this position.

a

b

22401

INSTALLATION

84 eng

2.

Fasten outboard to the transom at this height. Refer to Fastening the
Outboard.

22403

Fastening the Outboard

!

WARNING

Failure to correctly fasten the outboard could result in the outboard propelling
off the boat transom resulting in property damage, serious injury, or death.
Before operation, the outboard must be correctly installed with the required
mounting hardware.

This product must be secured to the transom with the required mounting
hardware. If the outboard strikes an under water object, the required mounting
hardware prevents the outboard from propelling off the transom. A decal on the
swivel bracket reminds the installer of the potential hazard.

Avoid serious injury
or death. Secure
engine to transom
with bolts.

WARNING

37-896853-007

52375

INSTALLATION

eng 85

IMPORTANT: Determine the strength of the boat transom. The outboard
mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque
without the boat transom yielding or cracking. If the boat transom yields or
cracks under this torque, the construction of the transom may not be adequate.
The boat transom must be strengthened or the load carrying area increased.

a - Transom yielding under bolt torque
b - Transom cracking under bolt torque

When first determining transom strength, use a dial torque wrench. If the bolt or
nut continues to turn without the torque reading on the dial increasing, it is an
indication that the transom is yielding. The load area can be increased by using
a larger washer or a transom reinforcement plate.

NOTE: The inside holes on the transom reinforcement plate are for the lower
transom bolts and the outside holes are for the upper transom bolts.

a - Large transom washer
b - Transom reinforcement plate

1. Drill four 13.5 mm (17/32 in.) mounting holes.

2. Install the outboard so that the water intake housing is set at the correct
height. Refer to Determining the Mounting Height of the Outboard Jet.

3. Apply marine sealer to shanks of bolts. Do not apply marine sealer to the
threads of the bolts.

18961

a

b

a

b

20860

INSTALLATION

86 eng

4. Fasten the outboard with provided mounting hardware shown. Tighten the
locknuts to the specified torque.

The outboard must be secured to the transom with the two transom bracket
clamp screws and four 13 mm (1/2 in.) diameter mounting bolts and locknuts
provided. Install two bolts through the upper set of mounting holes and two
bolts through the lower set of mounting slots.

a - Bolt (4)
b - Transom bracket clamp screws
c - Washer (4)
d - Locknut (4)

Description Nm lb‑in. lb‑ft
Outboard mounting locknuts and

bolts

75 – 55

Steering Bracket, Steering Cable Installation

1. Install the steering bracket with two washers and two 30 x 80 mm bolts.
Tighten the steering bracket bolts to the specified torque.

Description

Nm lb‑in. lb‑ft

Steering bracket bolt 30 – 22

2. Lubricate entire steering cable end with 2‑4‑C with PTFE.

10261

Tube Ref

No.

Description Where Used Part No.

95

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

3. Install the steering cable seal onto the end of the tilt tube.

a

b

c

d

10175

INSTALLATION

eng 87

4. Insert the steering cable into the tilt tube and secure with the steering
cable nut. Tighten the steering cable nut to the specified torque.

a - Steering cable nut
b - Steering bracket bolt and washer (2)
c - Steering cable seal

Description Nm lb‑in. lb‑ft
Steering cable nut 47.5 – 35

Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the
engine must be fastened using the steering link rod fastening hardware
supplied with the engine. Never replace the locknuts with nonlocking nuts.
Nonlocking nuts may loosen and vibrate off, allowing 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

c

b

59494

INSTALLATION

88 eng

1. Install the steering link rod onto the steering bracket aft threaded hole.

59496

2. Assemble the steering link rod onto the steering bracket with the bolt, two
washers, spacer, and a locknut. Do not tighten the bolt or locknut at this
time.

a - Bolt
b - Washer
c - Spacer
d - Steering bracket
e - Locknut
f - Washer

a

b

c

d

e

f

59497

INSTALLATION

eng 89

3. Install the loose end of the steering link onto the steering cable and
secure with a washer and locknut. Tighten the locknut securely and then
back the nut off 1/4 turn.

a - Washer
b - Locknut

4. Tighten the link rod bolt to the specified torque.

5. Secure the link rod bolt so it does not loosen and tighten the locknut to the
specified torque.

a - Link rod bolt
b - Locknut

Description Nm lb‑in. lb‑ft
Link rod bolt 27 – 20
Locknut 27 – 20

a

b

59499

a

b

59500

INSTALLATION

90 eng