Mercury 300 - PRO MAX 3.0L User Manual

for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Rac­ing, a unit of Mercury Marine, the world leader in marine
technology and outboard manufacturing since 1939.
These years of experience have been committed to the
goal of producing the finest quality products. This has led
to Mercury Racing’s reputation for strict quality control,
excellence, durability, lasting performance and being the
best at providing after-the-sale support.

Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you
in the operation, safe use and care of your outboard.

All of us at Mercury Racing took pride in building your out­board and wish you many years of happy and safe boat­ing.

Again, thank you for your confidence in Mercury Marine.

300 - PRO MAX 3.0L

Mercury Racing
N7480 County Road “UU”
Fond du Lac, WI 54935-9585

1999 Mercury Marine 90Ć849233000 499

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TABLE OF CONTENTS

General Information

Boater ’s Responsibilities 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Operating Your Outboard 4. . . . . . . . . . . . . . . . . . . . . . .

Boat Horsepower Capacity 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed And High-Performance Boat Operation 5. . . . . .

Lanyard Stop Switch 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting People In The Water 8. . . . . . . . . . . . . . . . . . . . . . . .

Carbon Monoxide Risk 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wave And Wake Jumping 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impact With Underwater Hazards 12. . . . . . . . . . . . . . . . . . . . . .

Selecting Accessories For Your Outboard 14. . . . . . . . . . . . . . .

Safe Boating Suggestions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recording Serial Number 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Selection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting

Trailering Boat/Outboard 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel & Oil

Gasoline Recommendations 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Recommendation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Filling Remote Oil Tank 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling Engine Mounted Oil Reservoir Tank 24. . . . . . . . . . . . . . .

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TABLE OF CONTENTS

Features & Controls

Remote Control Features 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Horn System 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim And Tilt 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim Operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilting Operation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Tilting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation

Engine Break-in 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Starting Check List 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating In Freezing Temperatures 40. . . . . . . . . . . . . . . . . . . .

Operating In Salt Water Or Polluted Water 40. . . . . . . . . . . . . . .

Operating At High Elevations 40. . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Trim Angle While Running Engine at Idle Speed 41. . .

Operating in Shallow Water 41. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting The Engine 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Shifting 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping The Engine 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Starting 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance

Outboard Care 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Submerged Outboard 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Replacement Parts For Your Outboard 47. . . . . . . . .

EPA Emissions Regulations 47. . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection And Maintenance Schedule 48. . . . . . . . . . . . . . . . . .

Flushing the Cooling System 50. . . . . . . . . . . . . . . . . . . . . . . . . .

Top Cowl Removal and Installation 52. . . . . . . . . . . . . . . . . . . . .

Flywheel Cover Removal and Installation 53. . . . . . . . . . . . . . . .

Fuel System 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(continued on next page)

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TABLE OF CONTENTS

Maintenance (con’t.)

Steering Link Rod Fasteners 55. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corrosion Control Anodes 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Replacement 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Inspection 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Inspection 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Drive Belt Tension Adjustment 60. . . . . . . . . . . . . . . .

Lubrication Points 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Power Trim Fluid 63. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Case Lubricant 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage

Storage Preparation 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Troubleshooting 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Wiring Diagram

Engine Wiring Diagram 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Lo g

Maintenance Log 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The description and specifications contained herein were in effect
at the time this manual was approved for printing. Mercury Racing,
whose policy is one of continued improvement, reserves the right to
discontinue models at any time, to change specifications, designs,
methods, or procedures without notice and without incurring obliga­tion.

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

 1999, Mercury Marine

The following are registered trademarks of Brunswick Corporation:
AutoBlend, Force, Jet-Prop, Mariner, Merc, Mercathode, MerCruis­er, Mercury, Mercury Marine, Mercury Racing, Quicksilver, Ride­Guide and Thruster

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GENERAL INFORMATION

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Boater’s Responsibilities

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

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

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Before Operating Your Outboard

Read this manual carefully. Safety and operating information that is
practiced along with using good common sense can help prevent
personal injury and product damage. If you have any questions,
contact your dealer.

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

WARNING

W ARNING – Hazards or unsafe practices which COULD result
in severe personal injury or death.

CAUTION

CAUTION – Hazards or unsafe practices which could result in
minor injury or product or property damage.

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GENERAL INFORMATION

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U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON
CAPACITY (POUNDS)

MAXIMUM WEIGHT
CAPACITY XXX

XXX

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Boat Horsepower Capacity
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.

WARNING

Overpowering a Boat Can Cause:

• Serious injury, death, or boat damage.

• Loss of Boat Control.

• Flotation Characteristics of Boat to be Altered from Placing

Too Much Weight on Transom.

• Boat to Break Apart, Particularly Around the Transom

Area.

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High-Speed And High-Performance Boat Operation

2 If you are not familiar with high-performance boat operation we

recommend that you first request an orientation/demonstration
ride with your dealer or an operator experienced with your boat/
outboard combination. Refer to the “Guide to Hi-Performance
Boat Operation” booklet (Part Number 90-849250) included in
your literature packet.

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GENERAL INFORMATION

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Lanyard Stop Switch

WARNING

Should the operator fall out of the boat, the possibility of seri­ous injury or death from being run over by the boat can be
greatly reduced by stopping the engine immediately. Always
properly connect both ends of the stop switch lanyard – to the
stop switch and the operator.

1. 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. A lanyard stop switch can be installed as
an accessory – generally on the dashboard or side adjacent to
the operator’s position.

2. 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.

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GENERAL INFORMATION

Lanyard Stop Switch (Continued)

WARNING

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

Accidental or unintended activation of the Lanyard Stop Switch dur­ing normal operation is a possibility and could cause any, or all, of
the following potentially hazardous situations:

1. 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 gear case or propeller.

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

3. Loss of control when docking.

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GENERAL INFORMATION

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Protecting People In The Water

WHILE YOU ARE CRUISING

It is very difficult for a person in the water to take quick action to avoid
a boat heading in their direction even at slow speed.

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

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

WHILE BOAT IS STATIONARY

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

WARNING

Stop your engine immediately whenever anyone in the water
is near your boat. Serious injury to the person in the water is
likely if contacted by a rotating propeller, a moving boat, a
moving gear case, or any solid device rigidly attached to a
moving boat or gear case.

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GENERAL INFORMATION

a

1

Courtesy of ABYC

Carbon Monoxide Risk

WARNING

Avoid the combination of a running engine and poor ventila­tion. Prolonged exposure to carbon monoxide in sufficient
concentration can lead to unconsciousness, brain damage,
or death.

Carbon monoxide is a deadly gas that is odorless, colorless and
tasteless and is present in the exhaust fumes of all internal combus­tion engines.

Early symptoms of carbon monoxide poisoning which should not be
confused with seasickness or intoxication, include headache, dizzi­ness, drowsiness, and nausea.

SUFFICIENT FRESH AIR FLOW

1 Example of desired air flow through the boat;

a. Ventilate passenger area, open side curtains, or forward

hatches to remove carbon monoxide fumes.

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GENERAL INFORMATION

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a

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b

Courtesy of ABYC

Carbon Monoxide Risk (Continued)

INSUFFICIENT FRESH AIR FLOW

Under certain conditions, 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 rare, on a very calm day, swimmers and passengers in an
open stationary boat with a running engine, or near a running engine
may be exposed to a hazardous level of carbon monoxide.

Insufficient Air Flow Could Occur If:

2 While boat is stationary:

a. Boat moored in a confined space with the engine running.
b. Boat is moored close to another boat with its engine running.

3 While boat is moving:

a. Running the boat with the trim angle of the bow too high.
b. Running the boat with no forward hatches open (station

wagon effect).

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GENERAL INFORMATION

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Wave And Wake Jumping

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

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 violently
veer in a new direction. Such a sharp change in direction or turn can
cause occupants to be thrown out of their seats or out of the boat.

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 nearly to a stop in an instant and can send the oc­cupants flying forward. The boat may also steer sharply to one side.

WARNING

Avoid serious injury or death from being thrown within or out
of a boat when it lands after jumping a wave or wake. Avoid
wave or wake jumping whenever possible. Instruct all occu­pants that if a wake or wave jump occurs, get low and hang
on to any boat hand hold.

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GENERAL INFORMATION

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Impact With Underwater Hazards

Reduce speed and proceed with caution whenever you’re driving a
boat in shallow water areas or in areas where the waters are sus­pected of having underwater obstacles that could be struck by the
outboard or the boat bottom. The most important thing you can

do to help reduce injury or impact damage from striking a float­ing or underwater object is control the boat speed. Under these
conditions, boat speed should be kept to a minimum planing
speed (15 to 25 MPH).

WARNING

To avoid serious injury or death from all or part of an outboard
coming into the boat after striking a floating or underwater ob­stacle maintain a top speed no greater than minimum planing
speed.

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

• Part of the outboard or the entire outboard could break loose and

fly into the boat.

• The boat could move suddenly in a new direction. Such a sharp

change in direction or turn can cause occupants to be thrown out
of their seats or out of the boat.

• A rapid reduction in speed. This will cause occupants to be

thrown forward, even out of the boat.

• Impact damage to the outboard and/or boat.

(continued on next page)

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GENERAL INFORMATION

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Impact W ith Underwater Hazards (Continued)

Keep in mind, one of the most important things you can do to help
reduce injury or impact damage in these situations is control the
boat speed. Boat speed should be kept to a minimum planing speed
when driving in waters known to have underwater obstacles.

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

The boat should also be checked for any hull fractures, transom
fractures, water leaks.

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

WARNING

Avoid serious injury or death from from loss of boat control.
Continued boating with major impact damage can result in
sudden outboard component failure with or without subse­quent impacts, Have the outboard thoroughly inspected and
any necessary repairs made.

13

GENERAL INFORMATION

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Selecting Accessories For Your Outboard

Genuine Mercury Marine Accessories have been specifically de­signed and tested for your outboard.

Mercury Marine accessories are available from Mercury Marine
dealers.

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.

WARNING

Check with your dealer before installing accessories. Misuse
of acceptable accessories or the use of unacceptable acces­sories can result in serious injury, death, or product failure.

Safe Boating Suggestions

In order to safely enjoy the waterways, familiarize yourself with local
and other governmental boating regulations and restrictions, and
consider the following suggestions.

Use Life Jackets. Have an approved life jacket of suitable size for
each person aboard and have it readily accessible (it is the law).
However we strongly recommend that everyone aboard wear their
life jacket.

Do not overload your boat. Most boats are rated and certified for
maximum load (weight) capacities (refer to your boat capacity
plate). If in doubt, contact your dealer or the boats manufacturer.

Perform safety checks and required maintenance. Follow a reg­ular schedule and ensure that all repairs are properly made.

Know and obey all nautical rules and laws of the waterways.
Boat operators should complete a boating safety course. Courses
are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2)
The Power Squadron, (3) The Red Cross and (4) your state boating
law enforcement agency. Inquiries may be made to the Boating Hot­line, 1-800-368-5647 or the Boat U.S. Foundation information num­ber 1-800-336-BOAT.

(continued on next page)

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GENERAL INFORMATION

Safe Boating Suggestions (Continued)

Make sure everyone in the boat is properly seated. Don’t allow

anyone to sit or ride on any part of the boat that was not intended
for such use. This includes backs of seats, gunwales, transom, bow,
decks, raised fishing seats, any rotating fishing seat; 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.

Never be under the influence of alcohol or drugs while boating
(it is the law). They impair your judgment and greatly reduce your

ability to react quickly.
Prepare other boat operators. Instruct at least one person on

board in the basics of starting and operating the outboard and boat
handling in case the driver becomes disabled or falls overboard.

Passenger boarding. Stop the engine whenever passengers are
boarding, unloading or are near the back (stern) of the boat. Just
shifting the outboard into neutral is not sufficient.

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 operators view when operating the
boat above idle speed.

Never drive your boat directly behind a water skier in case the
skier falls. As an example, your boat traveling at 25 miles per hour

(40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet
(61m) in front of you.

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 val-

ue exceeds $500.00 or 4. there is complete loss of the boat. Seek
further assistance from local law enforcement.

(continued on next page)

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Recording Serial Number

a

OGXXXXXX

19XX

XXXX

b

c

e

XX

d

Record the following numbers from your engine as shown for future
reference.

a-Serial Number
b-Model Year
c-Model Designation
d-Year Manufactured
e-Certified Europe Insignia

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GENERAL INFORMATION

Specifications

Models 300 - Pro Max 3.0L

Propshaft Horsepower 300
Propshaft Kilowatts 224
ECU Box Rev Limit 6200
Idle RPM (In or Out of Gear) 650 RPM

Weight
Piston Displacement 185 cu. in. (3044cc)

Bore 3.626 in. (92.1mm)
Stroke 3.00 in (76.2 mm)
Recommended Spark Plug Champion QL77CC (.035” Gap)
Firing Order 1-2-3-4-5-6
Idle Speed Pickup Timing Non Adjustable
Fuel Pressure 38-40 psi. (262-276 kPa)
Min. Water Pres.

@ 7500 -5500 RPM

Fleetmaster

Gear Ratio Torquemaster

Sportmaster
Recommended Gasoline Refer to Fuel Section
Recommended Oil Refer to Fuel Section
Recommended Gear Case

Oil
Gear Case Lubricant Cap. 27 fl. oz. (798 ml)

Mercury Precision Hi-Performance

Gear Lube (92-802854A1)

465 lbs.
(211 kg)

12 psi. Minimum

1.75:1

1.75:1

1.62:1 or 1.75:1

Battery Rating
Charging System Output 60 amps Max. (847Watts)

Minimum reserve capacity rating

of 100 minutes and CCA of 350

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GENERAL INFORMATION

Component Identification

1

3

9

10

4

6

8

7

8

15

1. Top Cowl

2. Cowl Latch (Front)

3. Cowl Latch (Rear)

4. Water Pump Indicator Hose

(Tell-Tail)

5. Bottom Cowl

6. Drive Shaft Housing

7. Anti-Ventilation Plate

8. Corrosion Anode(s)

2

5

11

12

13

8

14

14

9. Cowl Mount Trim Switch

10. Wiring Harness, Fuel line and

Control Cables (Install thru bot­tom cowl)

11. Transom Brackets

12. Trim Adjustment Bolt

13. Gear Case

14. Cooling Water Intake Holes

15. Skeg

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GENERAL INFORMATION

Propeller Selection

Select a propeller that allows the engine to operate in the upper half
of the recommended full throttle RPM range with the boat normally
loaded (refer to Specifications).

If changing conditions (such as warmer, more humid weather, oper­ation at higher elevations, increased boat load, or a dirty boat bot­tom/gear case) cause the RPM to drop below the recommended
range a propeller change or boat cleaning may be required.

Check full-throttle RPM using an accurate tachometer with the en­gine trimmed out to a balanced-steering condition (steering effort
equal in both directions) without causing the propeller to “break
loose.”

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TRANSPORTING

1

2

Trailering Boat/Outboard
1 Trailer your boat with the outboard tilted down when ever pos-

sible (vertical operating position).

2 If additional ground clearance is required for, railroad crossings,

driveways or trailer bouncing, support the outboard using a sup­port device. Contact your local dealer for recommendations.

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.

To prevent the propeller from spinning freely shift into forward gear.

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FUEL & OIL

Gasoline Recommendations

USA AND CANADA

Use a major brand of automotive unleaded gasoline with a minimum
posted octane rating (R + M
contain fuel injector cleaner are recommended for added internal
engine cleanliness.

INTERNATIONAL

Use a major brand of automotive unleaded gasoline with a minimum
posted octane rating of 98RON. Automotive gasolines that contain
fuel injector cleaner are preferred for added internal engine cleanli­ness. Leaded gasoline is acceptable in areas where unleaded gaso­line is not available. However, exhaust passageway corrosion may
occur due to the accumulation of exhausted lead particles.

GENERAL RECOMMENDATIONS

During periods of extended non use, a fuel stabilizer is highly recom­mended (See Storage Section).

Leaded Gasoline is acceptable to use in areas where unleaded is
not available. However, exhaust passageway corrosion may occur
due to the accumulation of exhausted lead particles.

ALCOHOL IN GASOLINE

÷ 2) of 92. Automotive gasolines that

We do not recommend gasoline containing alcohol due to the possi­ble adverse effect the alcohol may have on the fuel system. If only
gasoline containing alcohol is available, it must not contain more
than 10% ethanol or 5% methanol, and the addition of a Mercury
Marine Water Separating Fuel Filter is recommended.

If gasoline containing alcohol is used or if you suspect the presence
of alcohol in your gasoline, increase your inspection of the fuel sys­tem, visually checking for fuel leaks or abnormalities.

Gasoline containing alcohol may cause the following problems to
your outboard and fuel system:

• Corrosion of metal parts.

• Deterioration of elastomers and plastic parts.

• Fuel penetrating through flexible fuel lines.

• Wear and damage of internal engine parts.

(continued on next page)

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FUEL & OIL

ALCOHOL IN GASOLINE (CONTINUED)

• Starting and operating difficulties.

• Vapor lock or fuel starvation.

The tendency of gasoline containing alcohol to absorb moisture
from the air , results in a phase of water and alcohol which separates
from the gasoline in the fuel tank.

The adverse effects of alcohol are more severe with methanol and
are worse with increasing content of alcohol.

Oil Recommendation

Use Mercury Precision Premium Plus 2-Cycle TC-W3 Outboard Oil.
Emergency Use Only: If Mercury Precision Premium Plus 2-Cycle

TC-W3 Outboard Oil is not available, NMMA Certified 2-Cycle
TC-W3 Oil may be substituted.

Periodically consult with your dealer to get the latest gasoline and
oil recommendations. If Mercury Precision Premium 2-Cycle
TC-W3 Outboard Oil is not available, substitute a 2-Cycle outboard
manufacturers oil that is NMMA Certified TC-W3, or another brand
of 2-Cycle outboard oil that is NMMA Certified TC-W3. The use of
an inferior 2-Cycle outboard oil can reduce engine durability. Dam-

age from use of inferior oil may not be covered under the lim­ited warranty.

22

oe

FUEL & OIL

Filling Fuel Tank

WARNING

Avoid serious injury or death from a gasoline fire or explo­sion. Always stop the engine and DO NOT smoke or allow
open flames or sparks in the area while filling fuel tanks. To
help prevent a static charge during filling, portable fuel tanks
must be removed from the boat and placed directly on the
ground for filling.

1. Fill fuel tanks outdoors away from heat, sparks, and open
flames.

2. Remove portable fuel tanks from boat to refill them.

3. Always stop engine before refilling tanks.

4. 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.

23

oe

FUEL & OIL

goe9

21

oeo1

Filling Remote Oil Tank
1

Remove filler cap and fill with the specified oil. Oil tank capacity
is 3 gallons (11.5 liters). Replace filler cap and tighten securely.

IMPORTANT: Always make sure the oil tank caps are threaded
on tight. An air leak will prevent oil flow to the engine.

NOTE: Prior to running the engine, mark the oil level in the remote
oil supply tank for later reference. At the end of the break-in period,
visually check to see if the oil level in the remote oil supply tank has
dropped. Oil usage indicates the oil injection system is functioning
correctly.

Filling Engine Mounted Oil Reservoir Tank

NOTE: Filling this tank is only necessary if the oil level should ever
drop and the low oil warning system is activated.

2 Remove top cowl. Loosen engine mounted oil reservoir tank fill-

er cap and fill the remote oil tank with the specified oil. Run en­gine until the oil reservoir tank is filled by the remote tank. Tight­en the oil reservoir tank cap securely. Stop the engine and
replace the top cowl.

24

og

FEATURES & CONTROLS

gog142

Side Mount Console

f

a

c

b

h

Panel

a

c

i

b

c

a

g

i

b

d

e

1

oge5

d

f

g

e

Remote Control Features
1

Your boat may be equipped with one of the Mercury Precision
remote controls shown. If not, consult your dealer for operation
of your remote control.

a-Control Shift/Throttle Handle
b-Neutral Release Lever
c-Trim/Tilt Switch
d-Lanyard Stop Switch – Read the Lanyard Stop Switch safety

explanation and Warning in the General Information Section.

e-Lanyard – Read the lanyard stop switch safety explanation

and warning in the General Information Section.

f-Throttle Friction Adjustment
g-Ignition Key Switch, Choke
h-Fast Idle Lever – Raising lever will increase engine idle

speed in neutral.

i-Throttle Only Button – Pushing the button in will enable ad-

vancing the control handle and increase engine idle speed
without shifting outboard into gear.

f

25

FEATURES & CONTROLS

b

1

a

2

Warning Horn System
1

A warning horn may be located inside the remote control (a) or
under the dash (b) connected to the ignition key switch. The
warning horn sounds when one of the following outboard warn­ing systems is activated.

• Low oil level in oil injection system (see explanation following).

• Engine over-speed protection system is activated (see explana-

tion following).

• An electrical sensor not functioning (see explanation following).

• Engine overheat (see explanation following).

• Water in fuel filter reaches full level (see explanation following).

2 When the ignition key is initially turned on, the warning horn will

sound for a moment as a test to tell you the system is working.
Failure of this test indicates a problem. Have the outboard
checked by your dealer.

NOTE: If you are in a stranded situation, stopping the engine and
allowing it to cool down will usually allow some additional low speed
(idle) running time before the engine starts to overheat again.

IMPORTANT: The overheat problem must be corrected before
you can resume normal operation.

(continued on next page)

26

og

FEATURES & CONTROLS

Warning Horn System (Continued)

LOW OIL LEVEL

The low oil level warning is activated when the remaining oil in the
engine mounted oil reservoir tank drops below 50 fl. oz. (1.5 liters)
You still have an oil reserve remaining for 50 minutes of full speed
operation.

IMPORTANT: The engine mounted oil reservoir tank (located
beneath the top cowl) along with the remote oil tank will have
to be refilled (refer to Fuel & Oil Section).

The low oil level warning system works as follows:

3 The warning horn will begin a series of four beeps. If you contin-

ue to operate the outboard, the horn will beep every two min­utes.The engine has to be shut off to reset the warning system.

CAUTION

To avoid engine damage caused by running out of oil, it is best
to refill the oil injection system as soon as the low oil warning
is activated.

27

(continued on next page)

og

FEATURES & CONTROLS

a

b

5

Warning Horn System (Continued)

ENGINE OVERHEAT

The engine overheat warning is activated when the engine tempera­ture is too hot.

The engine overheat warning system works as follows:

4 The warning horn sounds continuously. The warning system will

automatically limit the engine speed to 3000 RPM.

5 If the engine overheats, immediately reduce throttle speed to

idle. Shift outboard into neutral and check for a steady stream
of water coming out of the water pump indicator hole (a).

CAUTION

Operating the engine while overheated will cause engine
damage. The overheat problem must be corrected before you
can resume normal operation.

a. If no water is coming out of the water pump indicator

hole (a) or flow is intermittent:

• Stop engine and check cooling water intake holes for obstruction.

• If no obstruction is found, this may indicate a blockage in the cool-

ing system or a water pump problem.

• Have the outboard checked by your dealer.

b. If a steady stream of water is coming out of the water

pump indicator hole (a) and warning horn continues:

• There may be insufficient cooling water or an engine problem.

• Stop engine and have it checked by your dealer.

(continued on next page)

28

og

FEATURES & CONTROLS

ogb18

Warning System (Continued)

ENGINE OVER-SPEED PROTECTION SYSTEM

The engine over-speed protection system is activated when the en­gine speed exceeds the maximum allowable RPM.

The engine over-speed protection system works as follows:

6 Anytime the engine over-speed system is activated, the warning

horn begins beeping. In addition, the system will automatically
reduce the engine speed to within the allowable limit by retard­ing the ignition timing.

NOTE: Your engine speed should never reach the maximum limit
to activate the system unless the propeller is ventilating, an incorrect
propeller is being used, or the propeller is faulty. If engine over­speed continues, have the outboard checked by your dealer.

ELECTRICAL SENSOR NOT FUNCTIONING

The warning system is activated if an electrical engine sensor is not
functioning, or is out of its operating range.

The warning system works as follows:

7 The warning horn begins beeping. Have the outboard checked

by your dealer.

WATER SEPARATING FUEL FILTER IS FULL OF WATER ON
ENGINES WITH ELECTRONIC FUEL INJECTION (EFI)

The water level detection warning is activated when water in the
water separating fuel filter reaches the full level. The water can be
removed from the filter. Refer to Maintenance Section for filter
removal.

8 The warning horn will begin a series of four beeps. If you contin-

ue to operate the outboard, the horn will beep every two min­utes.

29

og

FEATURES & CONTROLS

gog70

a

b

Power Trim And Tilt

Outboard position can be adjusted by pressing trim switch (a).
This range is used while operating your boat on plane.

• Pressing (DN): Moves the outboard in closer to the boat tran-

som, called trimming “in” or “down.”

• Pressing (UP): Moves the outboard further away from the boat

transom, called trimming “out” or “up.”

The term “trim”:

• Generally refers to the adjustment of the outboard within the first
° range of travel (b).

20

The term “tilt”:

• Generally refers to adjusting the outboard further up 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.

(continued on next page)

30

FEATURES & CONTROLS

osf1

Power Trim Operation

With most boats, operating around the middle of the “trim” range will
give satisfactory results. Trimming your outboard all the way in or out
may improve performance but cause some potential control haz­ards.

WARNING

Avoid possible serious injury or death. When the outboard is
trimmed in or out beyond a neutral steering condition, a pull
on the steering wheel in either direction may result. Failure to
keep a continuous firm grip on the steering wheel when this
condition exists can result in loss of boat control as the out­board can turn freely. The boat can now “spin out” or go into
a very tight maximum turn which, if unexpected, can result in
occupants being thrown within the boat or out of the boat.

Consider the following lists carefully.
Trimming In or Down Can:

• Lower the bow of the boat.

• Result in quicker planing off.

• Generally improve the ride in choppy water.

• Increase steering torque or pull to the right (with the normal right

hand rotation propeller).

• In excess, lower the bow to a point at which the boat begins to

plow with the bow in the water while on plane. This can result in
an unexpected turn in either direction called “bow steering” or
“over steering” if any turn is attempted, or if a significant wave is
encountered.

(continued on next page)

31

FEATURES & CONTROLS

a

1

Power Trim Operation (continued)

WARNING

Avoid possible serious injury or death. Adjust outboard to an
intermediate trim position as soon as boat is on plane to avoid
possible ejection due to boat spin-out. Do not attempt to turn
boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel.

1 The trim in limit may be set by inserting the tilt pin (a) into the de-

sired transom bracket hole.

Trimming Out or Up can:

• Lift the bow higher out of the water.

• Generally increase top speed.

• Gain clearance over submerged objects or a shallow bottom.

• Increase steering torque or pull to the left at a normal installation

height (with the normal right hand rotation propeller).

• In excess, cause boat “porpoising” (bouncing) or propeller venti-

lation.

• Cause engine overheating if any cooling water intake holes are

above the water line.

32

og

FEATURES & CONTROLS

gog62

c

a

b

1-3 4

Tilting Operation (Fleet Master & Torque Master Gear Cases)

To tilt 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 (a), by pushing in and rotating knob

(b) to bring support lever upward.

2 Lower outboard to rest on the tilt support lever.
3 Disengage the tilt support lever, by raising the outboard off the

support lever and rotating the lever down. Lower the outboard.

osc1

Auxiliary Tilt Switch
4

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

(continued on next page)

33

FEATURES & CONTROLS

1

2–3

c

4

Tilting Operation (Sport Master Gear Case)

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

1 Push in on the tilt support release knob.
2 Move tilt support lever into locking position and lower outboard

to rest on the tilt support lever.

3 Disengage the tilt support lever by raising the outboard off the

support lever and rotating the lever up until it locks. Lower the
outboard.

osc1

Auxiliary Tilt Switch

This switch (c) can be used to tilt the outboard up or down using

4

the power trim system.

34

og

FEATURES & CONTROLS

og71

1

Manual Tilting (Fleet Master & Torque Master Models Only)

If the outboard cannot be tilted using the power trim/tilt switch, the
outboard can be manually tilted.

1 Turn out the manual tilt release valve 3 turns (counterclockwise).

This allows manual tilting of the outboard. Tilt the outboard to the
desired position and tighten the manual tilt release valve.

NOTE: The manual tilt release valve must be tightened before op­erating the outboard to prevent the outboard from tilting up during
reverse operation.

35

og

FEATURES & CONTROLS

1

2

Manual Tilting (Sportmaster Models)

If the outboard cannot be tilted using the power trim/tilt switch, the
outboard can be manually tilted by the following procedures.

CAUTION

The engine must be supported during lowering in the follow­ing steps or the engine may drop rapidly and personal injury
as well as damage to the engine could occur.

NOTE: Place a suitable container below the connection and wrap
the connection with a cloth to collect any fluid which may be dis­pelled during the following operations.

1 TILTING (DOWN / IN):

• Loosen the (starboard-right, facing engine from front) hydraulic

connection at the front of the swivel bracket.

• Slowly lower the engine to the desired position, and reconnect

the hydraulic connection.

2 TILTING (UP /OUT):

• Loosen the (port-left, facing engine from front) hydraulic connec-

tion at the front of the swivel bracket.

• Slowly lift the engine and engage the tilt lock lever . Reconnect the

hydraulic connection.

IMPORTANT: If the hydraulic lines are disconnected and fluid
is lost, the power trim pump must be refilled and the lines
purged of air.

36

of

OPERATION

Engine Break-in

CAUTION

Severe damage to the engine can result by not complying
with the Engine Break-in Procedure.

BREAK-IN PROCEDURE

For the first 30 gals. (114 L) of fuel mixture, mix oil in the fuel
tank at 25:1 (4%). This is in addition to the oil supplied to the
engine by the oil injection system. (See following chart)

Always vary throttle settings during Break-in
1st HOUR

• Allow engine to warm-up for 30 - 60 seconds.

• Do not idle for more than 10 minutes

• Run the engine the majority of time between 3000 - 4500 RPM

(approximately three quarter throttle).

• Short bursts of full throttle for periods up to 10 seconds are

acceptable.

• Vary engine speed. Change engine speed approximately

every two (2) minutes.

• Avoid trimming the outboard out (up) beyond a vertical trim

position during operation.

• Avoid using hydraulic jack plate (if equipped) to raise engine

during break-in cycle.

NEXT 3 HOURS: Change engine speed every 10 minutes.

CAUTION

It is the boat operators responsibility to always drive in a safe
manner. Improper trim angle of the outboard when driving at
speed can be difficult and dangerous. Trim angle is specified
to help guide the operator in determining how to put the
proper load on the engine during the break-in period. These
guidelines do not suggest or require unsafe boat operation.

37

of

OPERATION

Engine Break-in (con’t)

oeh2

GASOLINE/OIL MIXTURE (FIRST 30 GALS [114L] OF FUEL)

Gas/Oil

Ratio

25:1 (4 %) 5 fl. oz

GASOLINE RECOMMENDATION

Use a major brand of automotive unleaded gasoline with a minimum
posted octane rating (R + M

OIL RECOMMENDATION

Use Mercury Precision Premium Plus 2-Cycle TC-W3 Outboard Oil.

1 US Gal.

Gas

(3.8 L)

(148 ml)

Oil

3 Gallons

Gas

(11.5 L)

15 fl. oz.

(444 ml)

Oil

÷ 2) of 92.

6 Gallons

Gas

(23 L)

31 fl. oz.

(917 ml)

Oil

30 US Gal.

Gas

(114 L)

4.75 US qt
(4.5 L)

Oil

38

of

OPERATION

Pre-Starting Check List

j Operator knows safe navigation, boating/operating procedures.
j An approved personal flotation device of suitable size for each

person aboard and readily accessible (it is the law).

j A ring type life buoy or buoyant cushion designed to be thrown

to a person in the water.

j Know your boats maximum load capacity. Look at the boat ca-

pacity plate.

j Arrange passengers and load in the boat so the weight is distrib-

uted evenly and everyone is seated in a proper seat.

j Tell someone where you are going and when you expect to

return.

j It is illegal to operate a boat while under the influence of alcohol

or drugs.

j Know the waters and area you will be boating; tides, currents,

sand bars, rocks, and other hazards.

j Engine lowered to run position with all water intake holes sub-

merged.

j Fuel tank vent cap open or fuel petcock “On”.
j Fuel supply OK.
j Oil supply (oil injection) OK.
j Lanyard stop switch in “Run” position and cord connected.
j Remote control in “Neutral”.
j Top cowl latches secure.
j Make inspection checks listed in the Inspection and Maintenance

Schedule. Refer to Maintenance Section.

39

of

OPERATION

onf2

Operating In Freezing Temperatures

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

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

one1

Operating In Salt Water Or Polluted Water

We recommend flushing the internal water passages of your out­board with fresh water after each use in salt or polluted water to pre­vent a buildup of deposits from clogging the water passages. Refer
to “Flushing The Cooling System” procedure in the Maintenance
Section.

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

Wash down the outboard exterior and flush out the exhaust outlet
of the propeller and gear case with fresh water after each use. Each
month, spray Mercury Precision Corrosion Guard (92-802878-55)
on external metal surfaces (do not spray on corrosion control
anodes as this will reduce the effectiveness of the anodes).

Operating At High Elevations

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

40

of

OPERATION

b

a

1

onn2

2

Setting Trim Angle While Running Engine at Idle Speed

1

Submerging the exhaust relief hole (a) on the outboard can hap­pen on some boats if you trim “full-in” while running at idle speed,
resulting in, exhaust restriction, rough idle, excessive smoke,
and fouled spark plugs. If this condition exists, trim outboard up
until exhaust relief hole is out of the water (b).

onk2

Operating in Shallow Water
2 When operating in shallow water, you can tilt the outboard be-

yond the maximum trim range to prevent hitting bottom.
a. Operate the engine at slow speed only. Do Not exceed 1200

RPM with the outboard trimmed beyond the side supports of
the swivel bracket.

b. Tilt outboard up. Make sure all the cooling water intake holes

stay submerged at all times.

41

of

OPERATION

12

3

N

4

5

Starting The Engine

Before starting, read the Pre-Starting Check List, Special Operating
Instructions, in the Operation Section.

CAUTION

Never start or run your outboard (even momentarily) without
water circulating through all the cooling water intake holes in
the gear case to prevent damage to the water pump (running
dry) or overheating of the engine.

1 Lower the outboard to the run position. Make sure all the cooling

water intake holes are submerged.

2 Open fuel tank filler cap vent screw (manual venting fuel tanks).
3 Squeeze the fuel line primer bulb several times until it feels firm.
4 Set the lanyard stop switch to RUN position. Read the Lanyard

Stop Switch safety explanation and Warning in the General In­formation Section.

5 Shift outboard to neutral (N) position.

(continued on next page)

42

of

gof82

OPERATION

6

ofe16

7

Starting The Engine (Continued)

NOTE: It is not necessary to use the neutral fast idle speed feature
on the remote control to increase engine speed for starting and
warm up. The electronic starting system will automatically increase
idle speed for starting and will reduce it as the engine warms up.The
engine does not require you to actuate the primer (choke) for start­ing. The electronic starting system will automatically prime the en­gine.

6 Turn the ignition key to START position. Release the key when

engine starts. If engine fails to start in 10 seconds, return the key
to ON position, wait 30 seconds and try again.

NOTE: Starting Flooded Engine – Advance the neutral high idle
speed feature on the remote control to the full high speed position.
Crank engine for 10 seconds, wait 30 seconds and repeat until en­gine starts.

7 Check for a steady stream of water flowing out of the water pump

indicator hole (allow approximately 10-15 seconds for the water
flow to start).

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

43

(continued on next page)

of

OPERATION

gof78

F

ofe15

Starting The Engine (Continued)
Gear Shifting

IMPORTANT: Observe the following:

• Never shift outboard into gear unless engine is at idle.

• Never shift outboard into Reverse without the engine run-

ning.

1 Your outboard has three gear shift positions to provide opera-

tion. Forward (F), Neutral (out of gear) and Reverse (R).

N

R

41-3

2 When shifting, always stop at neutral position and allow the en-

gine speed to return to idle.

3 Always shift outboard into gear with a quick motion. Stopping The Engine

4

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

44

of

OPERATION

gof84

a

123

ofp14

Emergency Starting

If the starter system fails, use a spare starter rope (not provided) and
follow procedure.

IMPORTANT: Electronic Fuel Injected (EFI) models – If the bat­tery voltage drops below 8 volts, the electric fuel pump will not
operate. With this low battery voltage condition, the engine
cannot be manually started.

1 Remove flywheel cover (a). Refer to Maintenance Section.
2 Shift outboard to neutral (N) position.

N

WARNING

When using emergency starter rope to start engine, the start­in-gear protection provided by the remote control is inopera­tive. Make sure to set the outboard gear shift into neutral to
prevent outboard from starting in gear. Sudden unexpected
acceleration could result in serious injury or death.

3 Turn the ignition key to ON position.

(continued on next page)

45

of

OPERATION

4 6

Emergency Starting (Continued)

WARNING

To prevent getting an electrical shock, DO NOT touch any ig­nition component, wiring or spark plug wire when starting or
running the engine.

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 rope knot into the flywheel notch and wind the rope

clockwise around the flywheel under the alternator belt.

5 Pull the starter rope to start the engine.
6 After engine has started, do not reinstall the flywheel cover or

top cowl until the engine has been stopped.

46

oh

MAINTENANCE

Outboard Care

To ensure safety and retain dependability keep your outboard in the
best operating condition by performing the periodic inspections and
maintenance listed in the Inspection and Maintenance Schedule.
Record maintenance performed in Maintenance Log at the back of
this book. Save all maintenance work orders and receipts.

ohr1

WARNING

Neglected outboard inspection and maintenance or perform­ing maintenance or repairs you are not familiar with, could re­sult in personal injury, death or product failure.

Submerged Outboard

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

Selecting Replacement Parts For Your Outboard

We recommend using original Mercury Precision replacement parts
and Lubricants.

WARNING

Using a replacement part that is inferior to the original part
could result in personal injury, death, or product failure.

oti1

EP A Emissions Regulations

All new outboards manufactured by Mercury Marine are certified to
the United States Environmental Protection Agency as conforming
to the requirements of the regulations for the control of air pollution
from new outboard motors. This certification is contingent on certain
adjustments being 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 con-

trol devices and systems may be performed by any marine SI
engine repair establishment or individual.

47

oh

MAINTENANCE

Inspection And Maintenance Schedule

BEFORE EACH USE

1. Check that lanyard stop switch stops the engine.

2. Visually inspect the fuel system for deterioration or leaks.

3. Check outboard for tightness on transom.

4. Check steering system for binding or loose components.

5. Visually check steering link rod fasteners for proper tightness.

6. Check propeller blades for damage.

AFTER EACH USE

1. Flush out the outboard cooling system if operating in salt or pol­luted water.

2. If operating in salt water, wash off salt deposits and flush propel­ler and gear case exhaust outlet with fresh water.

EVERY 50 HOURS OF USE

1. Lubricate all lubrication points. (More frequently in salt water).

2. Inspect and clean/replace spark plugs.

3. Check corrosion control anodes. (More frequently in salt water).

4. Check fuel pressure.*

5. Drain and replace gear case lubricant.

6. Inspect battery.

∗ These items should be serviced by an authorized dealer.

(continued on next page)

48

oh

MAINTENANCE

Inspection And Maintenance Schedule
(Continued)

EVERY 50 HOURS OF USE (CONT.)

7. Check engine timing setup.

8. Check control cable adjustments. ∗

9. Check alternator belt tension.

10. Check tightness of bolts, nuts, and other fasteners.

EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER
OCCURS FIRST

1. Check power trim fluid.

2. Replace Water separating fuel filter.

3. Lubricate splines on the drive shaft and prop shaft. (If used in
salt water, more frequent service may be needed.)

4. Torque Master and Sport Master Gearcases – Lubricate entire
length of driveshaft with Mercury Precision anti-corrosion
grease. (92-802867A1) (If used in salt water, more frequent ser­vice may be needed.)*

5. Inspect fiberglass reeds for chipping or cracks.*

6. Use Mercury Precision QuicKleen (92-802877A1) in fuel.

EVERY 300 HOURS OR USE OR THREE YEARS

∗

∗

1. Replace water pump impeller (more often if: overheating occurs,
used in salt water, or reduced water pressure is noted).

2. Replace cylinder head O-ring seals.∗

BEFORE PERIODS OF STORAGE

1. Refer to Storage procedure.

∗

∗ These items should be serviced by an authorized dealer.

49

MAINTENANCE

c

b

a

1-6

Flushing the Cooling System - Using Cowl Flushing Attachment

NOTE: Let engine cool to ambient temperature before flushing
system.

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

NOTE: Engine should not be running when flushing the cooling
system. Do not flush engine using a water system that exceeds
45 psi.

1 Remove plug (a) from valve body (b) in the bottom cowl (port

side).

2 Attach coupling assembly (22-852400) (c) to the valve body (b).

located in the bottom cowl (port side).

3 Attach a water hose to the coupling assembly (c).
4 Turn water supply on and flush engine for 3 to 5 minutes. Verify

water dump from tell-tale hose.

5 Turn off the water, and remove the flushing attachment.
6 Insert plug (a) into valve body (b) (tighten securely).

50

MAINTENANCE

1-4 5

Flushing the Cooling System (Continued) - Using
Gear Case Flushing Attachments

WARNING

To avoid possible injury when flushing, remove the propeller.
Refer to Propeller Replacement.

1 Remove propeller (refer to Propeller Replacement). Install the

flushing attachment to fit tightly over the cooling water intake.

2 Attach a water hose to the flushing attachment. Turn on the

water and adjust the flow so water is leaking around the flushing
attachment to ensure the engine receives an adequate supply
of cooling water.

3 Start the engine and run it at idle speed in neutral shift position.
4 Adjust water flow so excess water continues leaking out from

around the flushing attachment to ensure the engine is receiving
an adequate supply of cooling water.

5 Check for a steady stream of water flowing out of the water pump

indicator hoses. Continue flushing the outboard for 3 to 5 min­utes, carefully monitoring water supply at all times.

6 Stop the engine, turn off the water, and remove the flushing at-

tachment. Reinstall the propeller.

51

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MAINTENANCE

c

a

b

1

e

f

2

d

Top Cowl Removal and Installation

WARNING

Avoid Serious Injury or Death. Do Not attempt to remove or
install cowl while engine is running.

1 Removal

a-Rotate rear latching handle clockwise.

b-Pull out on front latching handle and at the same time lift

front of cowl.

c-Lift cowl from engine.

2 Installation

d-Lower top cowl into position over engine.

e-Rotate the rear latch counterclockwise to secure the rear

cowl latch.

f-Pull out on front latching handle and push down on the front

of the cowl to engage the front latch.

52

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MAINTENANCE

12

Flywheel Cover Removal and Installation

REMOVAL

1 Remove flywheel cover by lifting off.

INSTALLATION

2 Install the flywheel cover two front pins into the front mounting

holes and push the bottom mounting holes onto the rear pins.

Fuel System

WARNING

Avoid serious injury or death from gasoline fire or explosion.
Carefully follow all fuel system service instructions. Always
stop the engine and DO NOT smoke or allow open flames or
sparks in the area while servicing any part of the fuel system.

Before servicing any part of the fuel system:

• Stop engine and disconnect the battery.

• Drain the fuel system completely.

• Fuel system service must be performed in a well ventilated area.

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

IMPORTANT: 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.

FUEL LINE INSPECTION

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

(continued on next page)

53

h

MAINTENANCE

goh120

a

1

Fuel System (Continued)

WATER SEPARATING FUEL FILTER

NOTE: The warning system will turn on when water in the fuel filter
reaches the full level. Refer to “Warning System” in Features & Con­trols Section.

1 This filter removes moisture and also debris from the fuel. If the

filter becomes filled with water, the water can be removed. If the
filter becomes plugged with debris, the filter must be replaced
with a new filter.

Remove and replace filter as follows:

• Turn ignition key switch to OFF position.

• Disconnect wire (a) at bottom of filter. Remove filter by turning the

filter in the direction of the arrow (clockwise). Tip the filter to drain
fluid in a suitable container.

• Lubricate the sealing ring on the filter with oil. Thread on the filter

and tighten securely by hand. Reconnect the wire to the filter.

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

54

MAINTENANCE

a

d

b

c

ohi1

Steering Link Rod Fasteners

DUAL CABLE STEERING

Installation instructions for dual cable single engine applications are
included with the dual cable kit.

IMPORTANT: The steering link rod that connects the steering
cables to the engine must be fastened using special washer
head bolt (“a” – Part Number 10-849838) and self locking nylon
insert locknuts (“b” & “c” – Part Number 1 1-34863). These lock­nuts must never be replaced with common nuts (non locking)
as they will work loose/vibrate off freeing link rod to disengage.

WARNING

Disengagement of a steering link rod can result in the boat
taking a full, sudden, sharp turn. This potentially violent ac­tion can cause occupants to be thrown overboard exposing
them to serious injury or death.

Assemble steering link rod to steering cable with two flat washers (d)
and self locking nylon insert locknut (“b” – Part Number 11-34863).
Tighten locknut (b) until it seats, then back nut off 1/4 turn.

Assemble steering link rod to engine with special washer head bolt
(“a” – Part Number 10-849838) and self locking nylon insert locknut
(“c” – Part Number 11-34863). First torque bolt (a) to 20 lb. ft. (27.1
N·m), then torque locknut (c) to 20 lb. ft. (27.1 N·m).

55

goh121

MAINTENANCE

a

b

c

1

omh1

2

Fuse Replacement

IMPORTANT: Always carry spare SFE 20 AMP fuses.

1 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. Replace the
fuse with a fuse of the same rating.

Replace with a new SFE 20 AMP fuse.

ohk12

Corrosion Control Anodes

IMPORTANT: Anodes help protect the metal of the outboard
from galvanic corrosion by sacrificing their metal to be slowly
eroded instead of the outboard metals being eroded. All
anodes require periodic inspection, especially in salt water.
Replace any anodes before they are completely eroded. Never
paint or apply protective coating on the anode as effectiveness
of the anode will be reduced.

2 Your outboard has the following (four) corrosion control

anodes.

a-Two bars, one in each side of the gear case housing above

the anti-ventilation plate.

b-One plate installed under the anti-ventilation plate.

c-One bar across the bottom of the transom bracket assembly.

56

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MAINTENANCE

goh112

N

12

Propeller Replacement

WARNING

4-53

If the propeller is rotated while the engine is in gear, there is
the possibility that the engine will crank over and start. To pre­vent this accidental engine starting and possible serious inju­ry caused from being struck by a rotating propeller, always
shift outboard to neutral position and remove spark plug
leads before you service the propeller.

1 Shift outboard to neutral (N) position.
2 Remove spark plug leads to prevent engine from starting.
3 Straighten the bent tabs on the propeller nut retainer.
4 Place a block of wood between gear case and propeller to hold

propeller and remove propeller nut.

5 If propeller is seized to the shaft and cannot be removed, consult

an authorized dealer.

(continued on next page)

57

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MAINTENANCE

a

67

f

e

b

c

e

d

f

8

d

c

a

b

9-10

Propeller Rep l a c e m e n t ( C o n t i n u e d )

Coat the propeller shaft with Mercury Precision Anti-Corrosion

6

Grease or 2-4-C Marine Lubricant with Teflon.

IMPORTANT: To prevent the propeller hub from corroding and
seizing to the propeller shaft, especially in salt water, always
apply a coat of the recommended lubricant to the entire propel­ler shaft at the recommended maintenance intervals and also
each time the propeller is removed.

7 Rubber Hub Propellers - Install thrust washer (a), propeller (b),

continuity washer (c), splined washer (d), propeller nut retainer
(e), and propeller nut (f) onto the shaft.

8 Replaceable Hub Propellers (Using Flo-Torq II Hub Assembly

Kit P/N 835258A1 or 835258A2) - Install forward thrust hub (a),
replaceable drive sleeve (b), propeller (c), drive sleeve adaptor
(d), propeller nut retainer (e) and propeller nut (f) onto the shaft.

9 Place a block of wood between gear case and propeller and

torque propeller nut to 55 lb. ft. (75 N·m).

10Secure propeller nut by bending three of the tabs into the thrust

hub grooves.

58

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goh63

MAINTENANCE

12

ohm4

3

Spark Plug Inspection

Inspect spark plugs at the recommended intervals.

1 Remove the spark plug leads by twisting the rubber boots slight-

ly and pull off. Inspect spark plug boots and replace if cracked.

2 Remove the spark plugs to inspect and clean. Replace spark

plug if electrode is worn or the insulator is rough, cracked, bro­ken, blistered, or fouled.

3 Set the spark plug gap. See Specification Chart in General In-

formation Section.

4 Before reinstalling spark plugs, clean away dirt on the spark plug

seats. Install plugs finger tight, and tighten 1/4 turn or torque to
20 lb. ft. (27 N·m).

Battery Inspection

The battery should be periodically inspected.

IMPORTANT: Read the safety and maintenance instructions
which accompany your battery.

1. Turn off the engine before servicing the battery.

2. Add water as necessary to keep the battery full.

3. Make sure the battery is secure.

4. Battery cable terminals should be clean, tight, and positive to
positive and negative to negative.

5. Make sure the battery is equipped with nonconductive terminal
shields to prevent accidental shorting of battery terminals.

59

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MAINTENANCE

goh123

2

1

omk1

Alternator Drive Belt Tension Adjustment

The drive belt should be periodically inspected for condition and ten­sion.

1 Check belt tension by pressing in on the belt at the point shown.

Proper tension allows the belt to be pressed in 1/2 in. (12.7mm).

2 If adjustment is required, loosen bolts and adjust belt. Re-torque

adjustment bolts to 40 lb. ft. (55 N·m).

60

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goh124

MAINTENANCE

a

b

1

oho41

2

Lubrication Points

a-Mercury Precision Anti-Corrosion Grease (92-802867A1)

b-Mercury Precision 2-4-C w/Teflon (92-802859A1) or Mercury

Precision Special Lubricant 101 (92-802865A1)

1 (Fleet Master and Torque Master Models Only.) Trim Rod

Ball Ends – Turn the ball ends to work the lubricant into the ball
sockets.

2 Propeller Shaft – Refer to Propeller Replacement for removal

and installation of the propeller. Coat the entire propeller shaft
with lubricant to prevent the propeller hub from corroding and
seizing to the shaft.

(continued on next page)

61

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MAINTENANCE

b

a

c

b

b

b

Lubrication Points (continued)

a-Mercury Precision Anti-Corrosion Grease (92-802867A1)

b-Mercury Precision 2-4-C w/Teflon (92-802859A1) or Mercury

Precision Special Lubricant 101 (92-802865A1)

c-Light Weight Oil

NOTE: Propeller Shaft – Refer to Propeller Replacement for re­moval and installation.

WARNING

The end of the steering cable must be fully retracted into the
outboard tilt tube before adding lubricant thru grease fitting.
Adding lubricant to steering cable when fully extended could
cause steering cable to become hydraulically locked. An hy­draulically locked steering cable could cause loss of steering
control, possibly resulting in serious injury or death.

62

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MAINTENANCE

34

Checking Power Trim Fluid

FLEET MASTER AND TORQUE MASTER MODELS

3 Tilt outboard to the full up position and engage the tilt support

lock.

4 Remove fill cap and check fluid level. The fluid level should be

even with the bottom of the fill hole. Add Mercury Precision Pow­er Trim & Steering Fluid. (92-802880A1) If not available, use au­tomotive (ATF) automatic transmission fluid.

63

(continued on next page)

MAINTENANCE

b

c

a

1-3

2-4

Checking Power T rim Fluid (continued)

SPORT MASTER MODELS

1 Place outboard in the full down (in) position.
2 Remove trim pump fill/vent screw (a)

• Wipe fill/vent screw with a clean, lint-free cloth and reinstall - DO

NOT THREAD INTO PUMP.

• Remove fill/vent screw and note oil level. Oil level must be be-

tween the “ADD” (c) and “FULL” (b) marks on dipstick.

• If necessary, add Mercury Precision Power Trim & Steering Fluid

(92-802880A1) or SAE 10W-30 or 10W-40 motor oil thru the fill/
vent screw hole to bring level up to the “FULL” mark on the dip­stick. DO NOT OVERFILL.

3 To purge system of air, raise the outboard 2 or 3 times. Recheck

oil level and add oil if necessary.

4 Reinstall fill/vent screw by turning it all-the-way in, then back it

out one and a half (1-1/2) turns.

CAUTION

Fill/Vent screw MUST BE backed out one and a half (1-1/2)
turns (after bottoming out) to vent pump reservoir.
TO BACK SCREW OUT COULD RESULT IN DAMAGE TO
PUMP.

64

FAILURE

MAINTENANCE

f

a

e

b

g

c

1

d

a

bf

e

g

2

d

c

Gear Case Lubricant

Checking Gear Case Lubricant / Refilling Gear Case

1 Torquemaster and Sportmaster
2 Fleetmaster

a-Place outboard in a vertical operating position.

b-Remove the (upper) vent plug and sealing washer.

c-Remove the (lower) Fill/Drain plug.

NOTE: Examine the magnetic fill/drain plug for metal particles. A
small amount of metal filings or fine metal particles indicates normal
gear wear. An excessive amount of metal filings or larger particles
(chips) should be checked by an authorized dealer.

d-Quickly place lubricant tube into the fill hole.

e-Slowly add lubricant until it flows from the (upper) vent hole.

IMPORTANT: Replace sealing washers if damaged.

f-Stop adding lubricant. Install the (upper) vent plug and seal-

ing washer before removing the lubricant tube.

g-Remove lubricant tube and reinstall cleaned (lower) fill/drain

plug and sealing washer.

(continued on next page)

65

MAINTENANCE

a

c

d

b

1

a

c

d

b

2

Gear Case Lubricant (Continued)

Water in Gear Lubricant May:

• Settle to bottom and drain out with the lubricant.

• Be mixed with lubricant giving a milky color to lubricant.

Water in Gear Lubricant Will:

• Result in premature bearing failure.

• In freezing temperatures, turn to ice and damage gearcase.

Draining Gear Case

1 Torquemaster/Sportmaster
2 Fleetmaster

a-Place outboard in a vertical operating position.

b-Place drain pan below outboard.

c-Remove (upper) vent plug and sealing ring.

d-Remove (lower) fill/drain plug/sealing ring, drain lubricant.

GEAR CASE LUBRICANT CAPACITY

Gear case lubricant capacity is approximately 22.5 fl. oz. (666 ml).

66

oi

STORAGE

oia2

Storage Preparation

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

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

Positioning Outboard for Storage

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

CAUTION

If outboard is stored tilted up in freezing temperature, water
may enter the propeller exhaust outlet in the gear case and
could freeze causing damage to the outboard.

oib11

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.

To prevent varnish or gum buildup during extended storage, we rec­ommend adding Mercury Precision Fuel System Treatment and
Stabilizer (92-802875A1) to the fuel tank and operation of the en­gine to introduce the additives to the system.

67

STORAGE

Fuel System (Continued)

1. Portable Fuel Tank – Pour the required amount of Mercury Preci­sion Fuel System Treatment and Stabilizer (92-802875A1) (fol­low instructions on container) into fuel tank. Tip fuel tank back
and forth to mix stabilizer with the fuel.

2. Permanently Installed Fuel Tank – Pour the required amount of
Mercury Precision Fuel System Treatment and Stabilizer
(92-802875A1) (follow instructions on container) into a separate
container and mix with approximately one quart (one liter) of
gasoline. Pour this mixture into fuel tank.

CAUTION

Prevent damage to the water pump or overheating of the en­gine, never start or run your outboard (even momentarily)
without an adequate water supply to the engine.

3. Place the outboard in water or connect flushing attachment for
circulating cooling water. Run the engine for ten minutes to allow
treated fuel to fill the fuel system.

hid1

Protecting Internal Engine Components

NOTE: Before performing the following steps, make sure the fuel
system has been prepared for storage. Refer to Fuel System.

1. Remove the spark plugs and inject a five second spray of Mer­cury Precision Storage Seal Rust Inhibitor (92-802878-56)
around the inside of each cylinder.

2. Rotate the flywheel manually several times to distribute the stor­age seal in the cylinders. Reinstall spark plugs.

3. Remove the water separating fuel filter and empty contents in a
suitable container. Refer to Maintenance Section for removal
and installation of filter. Replace fuel filter annually , or every 100
hours of operation, or if large amount of fuel contamination is
present.

68

oi

STORAGE

oic7

Protecting External Outboard Components

1. Lubricate all outboard components listed in the Inspection and
Maintenance Schedule.

2. Touch up any paint nicks. See dealer for touch-up paint.

3. Spray Mercury Precision Corrosion Guard (92-802878-55) on
external metal surfaces, (Do not apply on corrosion control
anodes).

oie1

Gear Case

1. Drain and refill the gear case lubricant (refer to maintenance pro­cedure).

BATTERY STORAGE

1. Follow the battery manufacturers instructions for storage and re­charging.

2. Remove the battery from the boat and check water level. Re­charge if necessary.

3. Store the battery in a cool, dry place.

4. Periodically check the water level and recharge the battery dur­ing storage.

69

oj

TROUBLESHOOTING

ojc1

1 – STARTER MOTOR WILL NOT CRANK THE ENGINE

POSSIBLE CAUSES

• Blown 20 Amp 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.

2 – ENGINE WILL NOT START

POSSIBLE CAUSES

• Lanyard stop switch not in RUN position.

• Incorrect starting procedure. Refer to Operating Section.

• Old or contaminated gasoline.

• Engine flooded. Refer to Operating Section.

• Fuel is not reaching the engine.

a. Fuel tank is empty.
b. Fuel tank vent not open or restricted.
c. Fuel line is disconnected or kinked.
d. Fuel filter is obstructed. Refer to Maintenance Section.
e. Fuel pump failure.
f. Fuel tank filter obstructed.

• Ignition system component failure.

• Spark plugs fouled or defective. Refer to Maintenance Section.

70

oj

TROUBLESHOOTING

3 – ENGINE RUNS ERRATICALLY

POSSIBLE CAUSES

• Spark plugs fouled or defective. Refer to Maintenance Section.

• Incorrect setup and adjustments.

• Fuel is being restricted to the engine.

a. Fuel injectors obstructed.
b. Fuel tank filter obstructed.
c. Water separating filter or In-Line filter clogged.
d. Stuck anti-siphon valve on built in fuel tank.
e. Fuel line is kinked or pinched.
f. Reed valve open or broken.

• Fuel pump failure.

• Ignition system component failure.

4 – PERFORMANCE LOSS

POSSIBLE CAUSES

• Throttle not opening fully.

• Damaged or improper size propeller.

• Incorrect engine timing, adjustments, or setup.

• Boat overloaded or load improperly distributed.

• Excessive water in bilge.

• Boat bottom is dirty or damaged.

71

oj

TROUBLESHOOTING

5 – BATTERY WILL NOT HOLD CHARGE

POSSIBLE CAUSES

• Battery connections are loose or corroded.

• Low electrolyte level in battery.

• Inefficient battery.

• Excessive use of electrical accessories.

• Defective alternator, or voltage regulator.

6 – ENGINE OVERHEATING

(CONTINUOUS HORN SOUND)

POSSIBLE CAUSES

• Cooling system clogged

• Engine overloaded (cannot attain recommended RPM)

• Incorrect ignition timing

• Incorrect transom height (water pickups not getting adequate

water supply)

• Not enough oil in fuel mixture

• Lean fuel mixture

72

NOTES

73

ENGINE WIRING DIAGRAM

123456

BLK = Black

BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red

TAN = Tan

WHT = White

YEL = Yellow

LT. = Light

DK. = Dark

BA BA BA

BRN/PNK

PNK/BRN

RED/PNK

PNK/RED

ORG/PNK

PNK/ORG

BA BA

YEL/PNK

PNK/YEL

DK.BLU/PNK

PNK/DK.BLU

BA

PNK/PPL

PPL/PNK

GRN/PPL

PNK/PPL

PNK/YEL

PNK/RED

PPL/PNK

YEL/PNK

RED/PNK
PNK/DK.BLU
DK.BLU/PNK

GRN/YEL

GRN/RED

BLK
BLK/TAN
BLK/TAN

GRN/BLU
GRN/ORG
GRN/BRN

ORG/PNK
PNK/ORG

BRN/PNK

PNK/BRN

RED/BLU

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

RED/BLU

GRN/BRN

789101112

1-Fuel Injector #1
2-Fuel Injector #2
3-Fuel Injector #3
4-Fuel Injector #4
5-Fuel Injector #5
6-Fuel Injector #6
7-Ignition Coil #1
8-Ignition Coil #2
9-Ignition Coil #3
10-Ignition Coil #4

BLK

RED/BLU

GRN/RED

BLK

RED/BLU

GRN/ORG

BLK

11-Ignition Coil #5
12-Ignition Coil #6
13-MAP Sensor
14-Throttle Position Sensor
15-Crank Position Sensor
16-Air Temperature Sensor
17-Shift Switch
18-Bullet Connectors (Not Used)
19-Cyl. Head Temp Switch
20-Digital Diag. Terminal Sensor

RED/BLU

74

GRN/YEL

BLK

RED/BLU

GRN/BLU

BLK

RED/BLU

GRN/PPL

ABCABCABCABCAB CAB C

BLK

21-Starter
22-Fuel Pump
23-12 Volt Battery
24-Starter Solenoid
25-Remote Control
26-Temperature Gauge
27-Main Power Relay
28-Main Power Relay
29-Electronic Control Module
30-60 Ampere Alternator
31-Water Pressure Sensor

ORG/PNK
PNK/ORG
BRN/PNK
PNK/BRN

RED/BLU

BLK

BLK

BLK

BLK

BLK/TAN

BRN/PNK

21345678

109111213141516

1817192021222324

ORG/PNK

13

PPL/YEL

PNK/BRN

BLK/ORG

12345678

1 234567810911

109111213141516

121314151617181920

1817192021222324

222324252627282921303132

29

PNK/ORG

BLK/ORG

262728

C
Temp

BAC

YEL

YEL

H

PPL/YEL

RED/BLU

RED/BLU

123456789101112131415161718192021222324

14

1

PPL

2

BLU/YEL

3

LT.BLU/WHT

4

WHT/GRN

5

TAN/LT.BLU
6
7
8
9

10

TAN

11
12

BLK/GRN

13

BLK/YEL

14

BLK/RED

15

GRY

16

WHT/DR.BLU

17
18

WHT

19
20

TAN/GRN

21
22

BLK/TAN

WHT/BLK

23
24

YEL/PPL

25
26
27
28

DK.BLU

29
30

GRY/RED

31
32

BAC

BLU/YEL

BLK/GRN

LT.BLU/WHT

BLK

PPL

ABC

GRY/RED

BLK/GRN

GRY

BLU/YEL

15

BLK/RED

BLK/GRN
BLK/GRN
TAN/GRN

TAN

BLK/ORN
PUR/YEL

WHT/GRN

BLK

BLK

BLK

BLK/ORG

TAN

BLK

WHT/BLK

WHT/DR.BLU

WHTAB

DK.BLU

A
B
C

BLK

BLK
BLK

TAN/BLK
TAN/BLK
TAN/BLU
BLK

TAN

DDT

31

16

17

18

19

20

30

RED

85

86

PPL

YEL/PPL

87

87a

RED/BLU

A
B
C

30

RED

85

86

PPL

YEL/PPL

RED
PPL

30

87

87a

25

RED/BLU

RED

TAN

RED

1

BLK/YEL

2

PPL

3

TAN/LT.BLU

4

BLK

5

GRY

6

YEL/RED

7
8

RED

RED

RED

24

BLK

75

YEL/RED

RED

BLK W/YEL ENDS

23

BLK

BLK

21

B
ARED/BLU

22

BLK W/YEL ENDS

ok

MAINTENANCE LOG

Record here all maintenance performed on your outboard. Be sure
to save all work orders and receipts.

Date

Maintenance Performed Engine

Hours

76

ok

MAINTENANCE LOG

Date Maintenance Performed Engine

Hours

77