Mercury 200 Pro XS, 200, 250 XS OptiMax, 300 XS OptiMax Installation Manual

Operation

Maintenance

and

Installation

Manual

© 2017 Mercury Marine

200–250 OptiMax Including Pro XS

8M0133618 617 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.

!

WARNING

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

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

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

Warranty Message

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

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

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

Propeller Selection..............................................................................................3

Remote Steering Notice......................................................................................5

Lanyard Stop Switch........................................................................................... 5

Protecting People in the Water........................................................................... 8

Passenger Safety Message ‑ Pontoon Boats and Deck Boats...........................8

Wave and Wake Jumping................................................................................. 10

Impact with Underwater Hazards......................................................................11

Exhaust Emissions........................................................................................... 12

Selecting Accessories for Your Outboard......................................................... 14

Safe Boating Recommendations...................................................................... 14

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

200/200 Pro XS OptiMax Specifications........................................................... 17

225/250 Pro XS Specifications......................................................................... 17

250 OptiMax Specifications.............................................................................. 18

Component Identification.................................................................................. 20

Transporting

Trailering Boat/Outboard ................................................................................. 21

Fuel and Oil

Fuel Requirements........................................................................................... 22

Oil Recommendation........................................................................................ 23

Fuel Additives................................................................................................... 23

Fuel Requirements........................................................................................... 23

Avoiding Fuel Flow Restriction......................................................................... 24

Low Permeation Fuel Hose Requirement ........................................................ 24

EPA Pressurized Portable Fuel Tank Requirements........................................ 24

Fuel Demand Valve (FDV) Requirement.......................................................... 24

Mercury Marine's Pressurized Portable Fuel Tank........................................... 25

Filling Remote Oil Tank.................................................................................... 26

Filling Engine Mounted Oil Reservoir Tank...................................................... 26

Filling Fuel Tank............................................................................................... 27

eng v

Features and Controls

Remote Control Features................................................................................. 28

Warning System............................................................................................... 28

Power Trim and Tilt...........................................................................................31

Operation

Important Information........................................................................................35

Engine Break‑in................................................................................................ 36

Engine Break‑in Fuel Mixture........................................................................... 36

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

Operating in Freezing Temperatures................................................................ 37

Operating in Saltwater or Polluted Water......................................................... 37

Operating at High Elevations............................................................................ 37

Effects of Elevation and Weather on Performance........................................... 37

Setting Trim Angle While Running Engine at Idle Speed................................. 38

Operating in Shallow Water.............................................................................. 38

Starting the Engine........................................................................................... 39

Gear Shifting..................................................................................................... 42

Stopping the Engine......................................................................................... 42

Maintenance

Cleaning Care Recommendations.................................................................... 43

EPA Emissions Regulations............................................................................. 45

Inspection and Maintenance Schedule ............................................................ 46

Flushing the Cooling System............................................................................ 47

Top Cowl Removal and Installation.................................................................. 47

Alternator Belt Inspection..................................................................................48

Fuel System...................................................................................................... 48

Steering Link Rod Fasteners............................................................................ 50

Fuses ............................................................................................................... 51

Corrosion Control Anode.................................................................................. 52

Battery Inspection ............................................................................................ 53

Battery Information (All Batteries Including DTS)............................................. 53

Propeller Replacement..................................................................................... 54

Spark Plug Inspection and Replacement..........................................................58

Air Compressor Filter........................................................................................ 59

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

Checking Power Trim Fluid...............................................................................64

Gearcase Lubrication........................................................................................65

Submerged Outboard....................................................................................... 66

vi eng

Storage

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

Fuel System...................................................................................................... 67

Protecting Internal Engine Components........................................................... 69

Protecting External Outboard Components...................................................... 69

Gearcase.......................................................................................................... 69

Positioning Outboard for Storage..................................................................... 69

Battery Storage................................................................................................. 70

Troubleshooting

Starter Motor Will Not Crank the Engine........................................................... 71

Engine Will Not Start.........................................................................................71

Engine Runs Erratically.................................................................................... 71

Performance Loss.............................................................................................72

Warning Horn Activates (With Power Loss)...................................................... 72

Warning Horn Activates (No Power Loss)........................................................ 72

Battery Will Not Hold Charge............................................................................ 73

Owner Service Assistance

Service Assistance........................................................................................... 74

Ordering Literature............................................................................................76

eng vii

Outboard Installation

Mercury Marine Validated Engine Mounting Hardware.................................... 78

Accessories Mounted to the Transom Clamp Bracket...................................... 78

Boat Horsepower Capacity............................................................................... 82

Start in Gear Protection.................................................................................... 82

Selecting Accessories for Your Outboard......................................................... 83

Fuel System...................................................................................................... 83

Installation Specifications................................................................................. 85

Lifting the Outboard.......................................................................................... 85

Steering Cable ‑ Starboard Side Routed Cable................................................ 86

Steering Link Rod Fasteners............................................................................ 87

Recommended Mounting Height...................................................................... 89

Drilling Outboard Mounting Holes..................................................................... 92

Fastening the Outboard to the Transom........................................................... 93

Electrical, Hoses, Control Cables, and Front Clamp........................................ 98

Oil Injection Set‑Up......................................................................................... 109

Trim In Pin...................................................................................................... 111

Maintenance Log

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

viii eng

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

Propeller Selection

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

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

SELECTING THE CORRECT PROPELLER

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

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

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

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

a - Diameter
b - Pitch ‑ Travel during one revolution

a

b

22669

GENERAL INFORMATION

eng 3

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

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

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

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

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

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

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

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

PROPELLER MATERIAL

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

3 BLADE VS. 4 BLADE

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

GENERAL INFORMATION

4 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 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 - 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

27740

GENERAL INFORMATION

eng 5

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

6 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 7

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 any time you are boating in an
area where there might be people in the water.

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

WHILE THE BOAT IS STATIONARY

!

WARNING

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

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

Passenger Safety Message ‑ Pontoon Boats and Deck Boats

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

BOATS HAVING AN OPEN FRONT DECK

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

GENERAL INFORMATION

8 eng

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

26782

!

WARNING

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

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS

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

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

26783

GENERAL INFORMATION

eng 9

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.

GENERAL INFORMATION

10 eng

Impact with Underwater Hazards

Reduce speed and proceed with caution whenever you drive a boat in shallow
water areas, or in areas where you suspect underwater obstacles may exist
which 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 to control the boat speed. Under these
conditions, boat speed should be kept to a minimum planing speed of
24 to 40 km/h (15 to 25 mph).

26785

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 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, or even out of the boat.

• Impact damage to the outboard and/or boat.

Keep in mind, the most important thing you can do to help reduce injury or
impact damage during an impact 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 it for any broken or loose parts. If damage is present or suspected, the
outboard should be taken to an authorized dealer for a thorough inspection and
necessary repair.

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

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.

GENERAL INFORMATION

eng 11

!

WARNING

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

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

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

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

!

WARNING

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

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

STAY CLEAR OF EXHAUST AREAS

41127

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

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.

GENERAL INFORMATION

12 eng

GOOD VENTILATION

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

Example of desired air flow through the boat:

21622

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

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)

21626

a

b

a

b

21628

GENERAL INFORMATION

eng 13

Selecting Accessories for Your Outboard

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

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

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

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

Safe Boating Recommendations

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

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

• We recommend that all powerboat operators complete a boating safety
course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron,
the Red Cross, and your state or provincial boating law enforcement
agency provide courses. For more information in the U.S., call the Boat
U.S. Foundation at 1‑800‑336‑BOAT (2628).

Perform safety checks and required maintenance.

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

Check safety equipment onboard.

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

Approved fire extinguishers

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

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

GENERAL INFORMATION

14 eng

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.

• 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.

GENERAL INFORMATION

eng 15

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.

Recording Serial Number

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

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

a

XXXXXXXXX

XXXXXXXX

XXXX

c

b

63753

GENERAL INFORMATION

16 eng

200/200 Pro XS OptiMax Specifications

Models

200/200 Pro XS
Cylinder configuration 60° V6
Kilowatts/Horsepower 147/200
Number of cylinders 6
Idle RPM 575 RPM
Full throttle RPM range 5250–5750 RPM
Overspeed rev limit 5850 RPM
Neutral rev limit 2250 RPM
Engine displacement 3032 cc (185 in³)
Cylinder bore 92.075 mm (3.625 in.)
Stroke 76.2 mm (3.0 in.)

Recommended spark plugs

NGK IZFR6J‑11

NGK IZFR6J
Spark plug gap 1.09 mm (0.043 in.)
Firing order 1‑2‑3‑4‑5‑6
Gear ratio 1.75:1
Required fuel

Refer to Fuel and Oil

Recommended oil

Refer to Fuel and Oil
Gearcase lubricant High Performance Gear Lubricant
Gearcase lubricant capacity 970 ml (32.8 fl oz)

Battery rating*

1000 marine cranking amps (MCA)

or

800 cold cranking amps (CCA)
Charging system output (maximum) 60 A
Emission control system Electronic engine control (EC)

*Battery manufacturers may rate and test their batteries to different standards.
MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by
Mercury Marine. Manufacturers that use standards different than these, such
as equivalent MCA, do not meet Mercury Marine battery requirements.

225/250 Pro XS Specifications

Models

225 250
Cylinder configuration 60° V6 60° V6
Propeller shaft horsepower 225 250
Propeller shaft kilowatts 165 184
Number of cylinders 6

GENERAL INFORMATION

eng 17

Models

225 250
Idle RPM 575 RPM
Full throttle RPM range 5500–6000 RPM
Overspeed Rev Limit 6300 RPM
Neutral Rev Limit 2250 RPM
Engine displacement 3032 cc (185 in³)
Cylinder bore 92.075 mm (3.625 in.)
Stroke 76.2 mm (3.0 in.)

Recommended spark plugs

NGK IZFR6J‑11

NGK IZFR6J
Spark plug gap 1.09 mm (0.043 in.)
Firing order 1‑2‑3‑4‑5‑6
Gear ratio 1.75:1
Required fuel

Refer to Fuel and Oil

Recommended oil

Refer to Fuel and Oil

Gearcase lubricant High Performance Gear Lubricant

Gearcase lubricant
capacity

Standard
gearcase

970 ml (32.8 fl oz)

Gen II Torque
Master

1040 ml (35.1 fl oz)

Battery rating

1000 marine cranking amps (MCA)

or

800 cold cranking amps (CCA)

1.

Charging system output (maximum) 60 A
Emission control system Electronic engine control (EC)

250 OptiMax Specifications

Models

250
Cylinder configuration 60° V6
Kilowatts/horsepower 184/250
Number of cylinders 6
Idle RPM 575 RPM
Full throttle RPM range 5500–6000 RPM
Overspeed rev limit 6300 RPM
Neutral rev limit 2250 RPM
Engine displacement 3032 cc (185 in³)

1. Battery manufacturers may rate and test their batteries to different standards. Consult with the specific battery
manufacturer for comparison ratings.

GENERAL INFORMATION

18 eng

Models

250
Cylinder bore 92.075 mm (3.625 in.)
Stroke 76.2 mm (3.0 in.)

Recommended spark plugs

NGK IZFR6J‑11

NGK IZFR6J
Spark plug gap 1.09 mm (0.043 in.)
Firing order 1‑2‑3‑4‑5‑6
Gear ratio 1.75:1
Required fuel

Refer to Fuel and Oil

Recommended oil

Refer to Fuel and Oil
Gearcase lubricant High Performance Gear Lubricant
Gearcase lubricant capacity 970 ml (32.8 fl oz)

Battery rating*

1000 marine cranking amps (MCA)

or

800 cold cranking amps (CCA)
Charging system output (maximum) 60 A
Emission control system Electronic engine control (EC)

*Battery manufacturers may rate and test their batteries to different standards.
MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by
Mercury Marine. Manufacturers that use standards different than these, such
as equivalent MCA, do not meet Mercury Marine battery requirements.

GENERAL INFORMATION

eng 19

Component Identification

1 - Top cowl
2 - Front cowl latch
3 - Auxiliary tilt switch
4 - Clamp/swivel bracket
5 - Gearcase
6 - Cooling water intake
7 - Skeg
8 - Anti‑ventilation plate
9 - Anodes (one per

side)

10 - Driveshaft housing
11 - Bottom cowl
12 - Water pump indicator

(tell‑tale)

13 - Side cowl latches

(both sides)

1

2

4

5

6

7

8

9

10

11

12

13

3

51577

GENERAL INFORMATION

20 eng

Trailering Boat/Outboard

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

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

28284

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

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

TRANSPORTING

eng 21

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

22 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.

Oil Recommendation

Recommended Oil

OptiMax Oil or Premium Plus 2‑Cycle TCW 3
Outboard Oil

Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended
for your engine. If Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil
is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium
Plus 2‑Cycle Oil. Severe engine damage may result from use of an inferior oil.

Mercury Racing 2‑Stroke Oil is recommended for OptiMax engines that are
used in applications of extreme loads associated with commercial, work, or
extended periods of high RPM. The added lubrication and protection properties
with Mercury Racing 2‑Stroke oil, maximizes engine horsepower while
protecting against heat, reduces wear and carbon deposit build‑up.

Fuel Additives

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

Fuel Requirements

Do not use premixed gas and oil in this engine. The engine automatically
receives extra oil during engine break‑in. Use a fresh supply of the
recommended gasoline during engine break‑in and after engine break‑in.

FUEL AND OIL

eng 23

Avoiding Fuel Flow Restriction

IMPORTANT: Adding components to the fuel supply system (filters, valves,
fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low
speed, and/or a lean fuel condition at high RPM that could cause engine
damage.

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.

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

a

c

b

46273

FUEL AND OIL

24 eng

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.

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.

a

b

c

46290

FUEL AND OIL

eng 25

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 Remote Oil Tank

Remove the filler cap and fill with the specified oil. Oil tank capacity is

11.5 liters (3 gallons). Replace the 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.

2723

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.

1. Remove the top cowl.

2. Loosen the fill cap on the engine oil reservoir tank. Run the engine until all
the air has been vented out of the oil reservoir tank and tank is filled with
oil to the point of overflow.

3. Tighten the fill cap. Stop the engine and replace the top cowl.

29424

FUEL AND OIL

26 eng

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 refill 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.

FUEL AND OIL

eng 27

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

Warning System

WARNING HORN SIGNALS

When the key switch is turned to the ON position, the horn will turn on for a
moment as a test to indicate the horn is working.

There are two types of warning horns to alert the operator of an active problem
within the engine’s operating system.

f

a

c

d

e

b

h

c

a

g

d

e

b

i

f

g

i

c

a

f

26800

FEATURES AND CONTROLS

28 eng

1.

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

2.

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

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

A few of the noncritical conditions indicated by the intermittent short beeps for
six seconds can be corrected by the operator. These operator correctable
conditions are as follows:

•

Water in the engine mounted fuel filter. Refer to Maintenance – Water
Separating Fuel Filter.

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

•

Low engine oil level. Refer to Fuel and Oil – Filling Engine Mounted Oil
Reservoir Tank.

ENGINE GUARDIAN SYSTEM

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

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

FEATURES AND CONTROLS

eng 29

OVERSPEED REV LIMIT

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

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

To reset the Engine Guardian protection:

1. Completely reduce the throttle for three seconds.

2. Engage the throttle. If the engine does not respond, repeat step one.

SMARTCRAFT PRODUCT

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

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

FEATURES AND CONTROLS

30 eng

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 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 - Trim switch
b - Tilt range of travel
c - Trim range of travel

POWER TRIM OPERATION

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

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

a

b

c

28295

FEATURES AND CONTROLS

eng 31

!

WARNING

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

Consider the following lists carefully.

1. Trimming in or down can:

• Lower the bow.

• Result in quicker planing off, especially with a heavy load or a stern
heavy boat.

• Generally improve the ride in choppy water.

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

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

!

WARNING

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

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

2. Trimming out or up can:

• Lift the bow higher out of the water.

• Generally increase top speed.

• Increase clearance over submerged objects or a shallow bottom.

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

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

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

FEATURES AND CONTROLS

32 eng

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 knob to bring the support
lever upward.

2. Lower the 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.

a - Tilt support lever
b - Knob

MANUAL TILTING

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

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

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

22362

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.

b

a

27778

FEATURES AND CONTROLS

eng 33

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

AUXILIARY TILT SWITCH

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

a - Auxiliary tilt switch

a

2745

FEATURES AND CONTROLS

34 eng

Important Information

IMPORTANT DAILY INSPECTION BEFORE EACH USE

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

51985

Decal on the transom bracket

BEFORE STARTING THE ENGINE

NOTICE

Lack of oil pressure in the system can cause severe internal engine damage
during start‑up. Prime the oil injection pump on new or rebuilt engines or after
performing maintenance on the oiling system.

Refer to Outboard Installation ‑ Priming the Oil Injection Pump for
instructions.

FUEL REQUIREMENTS

Do not use premixed gas and oil in this engine. The engine automatically
receives extra oil during engine break‑in. Use a fresh supply of the
recommended gasoline during engine break‑in and after engine break‑in.

OIL RECOMMENDATION

Recommended Oil

OptiMax Oil or Premium Plus 2‑Cycle TC‑W3
Outboard Oil

OptiMax Oil or Premium Plus TC‑W3 is a higher grade oil that provides
increased lubrication and extra resistance to carbon buildup when used with
good or varying grades of gasoline.

OPERATION

eng 35

IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil.
Periodically consult with your dealer to get the latest gasoline and oil

recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is
not available, substitute 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. Damage from use of inferior oil may not be covered under the limited
warranty.

Engine Break‑in

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.

Break‑in Procedure

Vary throttle settings during break‑in. Use the following suggestions.

First Hour

• Allow the engine to warm‑up for 30–60 seconds.

• Do not idle for more than five minutes.

• Run the engine the majority of the time between 4000–5400 RPM
(approximately three‑quarter throttle).

• Short bursts of wide‑open throttle for 10 seconds or less are acceptable.

• Change the engine speed approximately every two minutes.

• Avoid trimming the outboard out (up) beyond a vertical trim position
during operation.

• Avoid using a hydraulic jack plate to raise the engine during the break‑in
cycle.

Next Three Hours: Change the engine speed every 10 minutes.

Engine Break‑in Fuel Mixture

The propulsion control module (PCM) controls oil and fuel mixture during
engine break‑in.

Prestarting Check List

Engine lowered to run position with all water intake holes submerged

Fuel tank vent cap open or fuel drain valve on

Fuel supply OK

Lanyard stop switch in "RUN" position and cord connected

Remote control in neutral

Top cowl latches secure

Make inspection checks listed in the Inspection and Maintenance
Schedule. Refer to Maintenance section.

OPERATION

36 eng

Operating in Freezing Temperatures

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

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

Operating in Saltwater or Polluted Water

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

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

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

Operating at High Elevations

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

Effects of Elevation and Weather on Performance

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

• Above sea level elevations

• High temperature

• Low barometric pressure

• High humidity

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

• Boost pressure on supercharged engines

• Horsepower and torque throughout the RPM range

• Peak RPM

• Cranking compression

OPERATION

eng 37

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

Compensating for power robbing conditions:

• Switch to lower pitch propeller.

• Change gear ratio.

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

Other advantages to propeller or gear ratio changes:

• Reduces the possibility of detonation

• Enhances overall reliability and durability of the engine

Setting Trim Angle While Running Engine at Idle Speed

Submerging the exhaust relief hole 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.

a - Relief hole submerged

(wrong)

b - Relief hole above waterline

(correct)

Operating in Shallow Water

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

NOTICE

Operating the engine with the outboard in the tilt range can damage the
engine or the transom. If operating the engine in the tilt range, such as in
shallow water, do not exceed 2000 RPM.

1. Reduce the engine speed below 2000 RPM.

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

3. Operate the engine at slow speed only.

a

b

2729

OPERATION

38 eng

Models with a three‑ram trim system: If engine speed exceeds 2000 RPM, the
outboard will automatically return down to the maximum trim range.

Models with a single‑ram trim system: The outboard will remain at the selected
tilt position, regardless of engine RPM.

Starting the Engine

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.

INITIAL STARTING PROCEDURE

NOTE: For the initial start up of a new engine, or for an engine that ran out of
fuel or was drained of fuel, the fuel system should be filled according to the
following procedure.

1. Position the fuel line primer bulb so the arrow on the side of the bulb is
pointing up. Squeeze the fuel line primer bulb until it feels firm.

2. Turn the ignition key switch to the "ON" position for three seconds to
operate the electric fuel pump.

3. Turn the ignition key switch back to the "OFF" position, and squeeze the
primer bulb until it feels firm. Turn the ignition key switch to the "ON"
position again for three seconds. Continue this procedure until the fuel
line primer bulb stays firm.

Before starting, read the prestarting check list and special operating
instructions in the Operation section.

STARTING PROCEDURE

1. Lower the outboard to the "RUN" position. Make sure all the cooling water
intake holes are submerged.

26837

OPERATION

eng 39

2. Open the fuel tank filler cap vent screw (manual venting fuel tanks).

19748

3. Position the fuel line primer bulb so the arrow on the side of the bulb is
pointing up. Squeeze the fuel line primer bulb several times until it feels
firm.

27348

4. Set the lanyard stop switch to the "RUN" position. Read the lanyard stop
switch safety explanation and warning in the General Information
section.

19791

5. Shift the outboard to the neutral position.

N

26838

OPERATION

40 eng

6. Do not advance the throttle‑only feature on the remote control for starting
(if equipped).

27242

7. Turn the ignition key to the "START" position. Release the key when the
engine starts. If the engine fails to start in ten seconds, return the key to
the "OFF" position, wait one second, and try again.

19804

8. Check for water coming out of the water pump indicator hole.

2746

NOTE: The electronic starting system will automatically prime (choke) the
engine and increase idle speed for starting.

NOTICE

Operating the engine while overheated can cause engine damage. If no
water exits the water pump indicator hole, stop the engine and check the
cooling water intake holes for obstruction. No obstruction may indicate a
water pump failure or blockage in the cooling system, which can overheat the
engine. Have an authorized Mercury Marine dealer check the system.

OPERATION

eng 41

Gear Shifting

IMPORTANT: Observe the following:

•

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

•

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

•

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

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

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

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

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

Stopping the Engine

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

26843

OFF

ON

START

OPERATION

42 eng

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

eng 43

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

44 eng

Tube Ref

No.

Description Where Used Part No.

120

Corrosion Guard

External metal surfaces of the powerhead

and powerhead components.

92-802878 55

EPA Emissions Regulations

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

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

EMISSION CERTIFICATION LABEL

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

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

OWNER RESPONSIBILITY

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

SPARK PLUG:

GAP:

EMISSION CONTROL
INFORMATION

THIS ENGINE CONFORMS TO
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES

CALIFORNIA AND U.S. EPA

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

IDLE SPEED (in gear):

FAMILY:

HC+NOx:FEL:

LOW PERM/HIGH PERM:

g/kWh

hp

L

e

d

c

b

a

f

g

h

i

HC+NOx:FEL:

g/kWh

hp

L

CO FEL:

g/kWh

kw

g/kWh

j

43210

MAINTENANCE

eng 45

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

46 eng

• 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

Flushing the Cooling System

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

NOTE: Engine can be stopped, or running at idle speed, when flushing the
cooling system. Do not flush engine using a water system that exceeds

310.26 kPa (45 psi).

1. Remove the plug from fitting in the bottom cowl.

29444

2. Attach a water hose to the fitting. Turn on the water and flush for 3–5
minutes.

29445

Top Cowl Removal and Installation

REMOVAL

1. Release the front and side cowl latches.

2. Lift the top cowl from the outboard.

29447

MAINTENANCE

eng 47

INSTALLATION

1. Position the top cowl over the engine.

2. Ensure the bottom rubber seal fits properly and lock the front and side
latches.

Alternator Belt Inspection

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

a. Cracks or deterioration in the rubber portion of the belt.
b. Belt surfaces rough or uneven.
c. Signs of wear on edges or outer surfaces of belt.

29448

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.

MAINTENANCE

48 eng

WATER SEPARATING FUEL FILTER

This filter removes moisture and debris from the fuel. If the filter becomes filled
with water, the water can be removed. If the filter becomes plugged with debris,
replace the filter. The warning system engages when water in the fuel filter
reaches the full level. Refer to Warning System in Features and Controls.

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

Removal

a - O‑ring seals
b - Filter
c - Raised bosses

1. Disconnect the link rod.

2. Use the shaft of a screwdriver between the filter cap bosses and unscrew
the filter.

Installation

1. Lubricate the O‑ring seals with oil.

2. Install the fuel filter and tighten securely.

3. Connect the link rod.

2733

aa

b

c

MAINTENANCE

eng 49

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

DRAINING WATER FROM THE FUEL FILTER CHAMBER

NOTE: If a sufficient amount of water has accumulated in the fuel filter
chamber, the warning system will turn on. Draining the water from the fuel filter
chamber is required.

1. Pull the drain hose off the right side fitting. Hold the open end of the hose
over a container.

2. Use a 1/8 in. hex wrench and loosen the drain screw and drain the fuel
filter chamber.

3. Tighten the drain screw and attach the hose.

a - Drain hose
b - Side fitting
c - Drain screw

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

Steering Link Rod Fasteners

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

c

a

b

24607

MAINTENANCE

50 eng

!

WARNING

Improper fasteners or improper installation procedures can result in
loosening or disengagement of the steering link rod. This can cause a
sudden, unexpected loss of boat control, resulting in serious injury or death
due to occupants being thrown within or out of the boat. Always use required
components and follow instructions and torque procedures.

a - Special washer head bolt (10‑849838)
b - Flat washer (2)
c - Nylon insert locknut (11‑826709113)
d - Nylon insert locknut (11‑826709113)

Description Nm lb‑in. lb‑ft
Special washer head bolt 27 – 20
Nylon insert locknut "d" 27 – 20

Nylon insert locknut "c"

Tighten until it seats, then back off 1/4

turn

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

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

Fuses

IMPORTANT: Always carry spare 2‑, 15‑, and 20‑amp fuses.

a

b

c

d

27843

MAINTENANCE

eng 51

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

1. Open the fuse holder and look at the silver colored band inside the fuse. If
the band is broken, replace the fuse.

2. Replace the fuse with a new fuse with the same rating.

The fuses and circuits are identified as follows:

Fuse location and identification

a - Good fuse
b - Blown fuse
c - Power‑on circuit – 15‑amp fuse
d - Ignition coil circuit – 20‑amp fuse
e - Spare fuse slot
f - Fuel injector/direct injector/PCM and electric fuel pump circuits –

20‑amp fuse

g - Diagnostic circuit – 2‑amp fuse

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.

2

20

20

15

a

b

g

cde

f

51464

MAINTENANCE

52 eng

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.

The gearcase has three anodes. Two anodes are located on each side of the
gearcase, and a third is an anode plate installed underneath the anti‑ventilation
plate. If a trim tab should be installed, this anode plate will be removed. Another
anode is installed on the bottom of the transom bracket assembly.

a - Corrosion control

anodes (gearcase)

b - Corrosion control anode

(transom bracket)

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.

Battery Information (All Batteries Including DTS)

!

WARNING

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

• Do not use deep cycle batteries. The engine must use a marine starting
battery with 1000 MCA, 800 CCA, or 180 Ah rating.

MAINTENANCE

eng 53

• When connecting the engine battery, use hex nuts to secure the battery
leads to the battery posts. Tighten the nuts to the specified torque.

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

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

54395

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

8M0085862

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

NOTICE

IMPORTANT:

DO NOT USE DEEP CYCLE BATTERIES!

13.5Nm (120 lb-in.)

DO NOT

USE

WINGNUTS

Propeller Replacement

!

WARNING

Rotating propellers can cause serious injury or death. Never operate the boat
out of the water with a propeller installed. Before installing or removing a
propeller, place the drive unit in neutral and engage the lanyard stop switch
to prevent the engine from starting. Place a block of wood between the
propeller blade and the anti‑ventilation plate.

MAINTENANCE

54 eng

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

N

26838

IMPORTANT: Refer to Spark Plug Inspection and Replacement for removing
the spark plug leads.

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

26899

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

26900

MAINTENANCE

eng 55

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

26901

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

6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants
Extreme Grease or 2‑4‑C with PTFE.

26902

Tube Ref

No.

Description Where Used Part No.

95

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

Extreme Grease Propeller shaft 8M0071842

IMPORTANT: To prevent the propeller hub from corroding and seizing to the
propeller shaft (especially in saltwater), 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.

MAINTENANCE

56 eng

7. Flo‑Torq I drive hub propellers ‑ Install forward thrust washer, propeller,
continuity washer, rear thrust hub, propeller nut retainer, and propeller nut
onto the shaft.

a - Propeller nut
b - Propeller nut retainer
c - Rear thrust hub
d - Continuity washer
e - Propeller
f - Forward thrust washer

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

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

sleeve

f - Forward thrust washer

9. Place a block of wood between the gearcase and the propeller and torque
the propeller nut to specifications.

Description

Nm lb‑in. lb‑ft

Propeller nut 75 – 55

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

26945

a

b

c

d

e

f

26908

a

b

c

d

e

f

26941

MAINTENANCE

eng 57

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.

1. Remove the spark plug leads by twisting the rubber boots while pulling
them off the spark plugs.

26899

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

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

a - Precious metal

a

9381

MAINTENANCE

58 eng

3.

Set the spark plug gap. Refer to Specifications.

27848

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

necessary before installation.

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

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

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

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

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

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

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

electrode on a hard surface.

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

Description

Nm lb‑in. lb‑ft

Spark plug 27 – 20

Air Compressor Filter

NOTE: The air compressor filter is only used on specific models.

The filter should be inspected and replaced, if required, every 100 hours of
operation, or once a season.

REMOVAL

1. Open the clamp and lift out the filter housing. Rotate the filter housing 1/4
turn clockwise to the unlock position and remove the air filter.

MAINTENANCE

eng 59

2. Remove the hose cable tie and pull the air filter off the hose.

a - Air filter
b - Nylon washer
c - Rubber washer
d - Clamp
e - Filter housing
f - Cable tie

INSTALLATION

1. Place the nylon washer and rubber washer onto the air filter and insert the
filter into the housing. Rotate the filter 1/4 turn to the lock position.

2. Position the filter housing so the inlet hose is facing towards the back of
the engine. Install the hose and secure with a cable tie.

a

b

c

28732

d

e

f

MAINTENANCE

60 eng

3. Secure the filter housing with the clamp.

a - Air filter
b - Filter housing
c - Clamp
d - Inlet hose

Lubrication Points

1. Lubricate the following with Extreme Grease.

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Trim rod ball ends 8M0071842

• Trim rod ball ends ‑ Turn the ball ends to work the lubricant into the
ball sockets.

28458

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

a

b

c

28738

d

MAINTENANCE

eng 61

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Propeller shaft 8M0071842

95

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

•

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

26902

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

Tube Ref

No.

Description Where Used Part No.

Extreme Grease

Alternator belt tensioner pivot shaft,

swivel bracket, tilt support lever, tilt

tube, steering cable

8M0071842

95

2-4-C with PTFE

Alternator belt tensioner pivot shaft,

swivel bracket, tilt support lever, tilt

tube, steering cable

92-802859A 1

• Alternator belt tensioner pivot shaft ‑ Lubricate through fitting.

2884

• Swivel bracket ‑ Lubricate through fitting.

MAINTENANCE

62 eng

• Tilt support lever ‑ Lubricate through fitting.

a - Swivel bracket
b - Tilt support lever

• Tilt tube ‑ Lubricate through fitting.

27874

!

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.

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

a - Fitting
b - Cable end

4. Lubricate the following with lightweight oil.

a

b

27873

a

b

27875

MAINTENANCE

eng 63

• Steering link rod pivot points ‑ Lubricate pivot points.

27876

Checking Power Trim Fluid

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

27877

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

28460

Tube Ref

No.

Description Where Used Part No.

114

Power Trim and
Steering Fluid

Power trim system 92-858074K01

MAINTENANCE

64 eng

Gearcase Lubrication

When adding or changing gearcase lubricant, visually check for the presence of
water in the lubricant. If water is present, it may have settled to the bottom and
will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it
a milky colored appearance. If water is noticed, have the gearcase checked by
your dealer. Water in the lubricant may result in premature bearing failure or, in
freezing temperatures, will turn to ice and damage the gearcase.

Examine the drained gearcase lubricant for metal particles. A small amount of
metal particles indicates normal gear wear. An excessive amount of metal
filings or larger particles (chips) may indicate abnormal gear wear and should
be checked by an authorized dealer.

DRAINING GEARCASE

1. Place the outboard in a vertical operating position.

2.

Remove the propeller. Refer to Propeller Replacement.

3. Place the drain pan below the outboard.

4. Remove the vent plug and fill/drain plug and drain lubricant.

a - Vent plug
b - Fill/drain plug

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 970 ml (32.8 fl oz).

GEARCASE LUBRICANT RECOMMENDATION

Mercury or Quicksilver High Performance Gear Lubricant.

CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE

1. Place the outboard in a vertical operating position.

2. Remove the vent plug/sealing washer.

a

b

22692

MAINTENANCE

eng 65

3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and
add the lubricant until it appears at the vent hole.

a - Vent hole
b - Fill hole

IMPORTANT: Replace the sealing washers if damaged.

4. Stop adding the lubricant. Install the vent plug and sealing washer before
removing the lubricant tube.

5. Remove the lubricant tube and install cleaned fill/drain plug and sealing
washer.

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.

a

b

22693

MAINTENANCE

66 eng

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.

The most effective method of storage preparation is to add the recommended
amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen
products as described on the containers to the fuel tank before the last
operation of the boat. Adding fuel stabilizer will help prevent the formation of
varnish and gum in the gasoline. The Mercury Precision Quickleen product will
help clean and lubricate the fuel injectors.

1. Portable fuel tank ‑ Pour the required amount of gasoline stabilizer and
Quickleen (follow instructions on containers) into fuel tank. Tip fuel tank
back and forth to mix stabilizer and Quickleen with the fuel.

2. Permanently installed fuel tank ‑ Pour the required amount of gasoline
stabilizer and Quickleen (follow instructions on containers) into a separate
container and mix with approximately 1 liter (1 US qt) of gasoline. Pour
this mixture into fuel tank.

3. Pull the drain hose off the right side fitting. Hold the open end of the hose
over a container.

STORAGE

eng 67

4. Loosen drain screw and drain the fuel filter chamber.

a - Drain screw
b - Drain hose
c - Right side fitting

5. Tighten the drain screw and attach the hose.

6. Pull the drain hose off the left side fitting. Hold the open end of the hose
over a container.

7. Loosen the drain screw and drain the float chamber.

a - Left side fitting
b - Drain screw
c - Drain hose

8. Tighten the drain screw and attach the hose.

9. Premix the following in a container:

a. 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision Quickleen

lubricant.

b. 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision Fuel Stabilizer.

10.

Remove the fuel filter. See Maintenance ‑ Fuel System for procedure.

11. Pour this mixture into the fuel filter opening. Install the fuel filter.

12.

Prime the fuel system. See Operation ‑ Starting The Engine.

13. Place the outboard in water or use the flush hose or flushing device or for
circulating cooling water. Start the engine and run at idle speed for five
minutes to allow the treated fuel to fill the fuel system.

a

b

c

23751

a

b

c

23752

STORAGE

68 eng

Flushing Device 91‑44357Q 2

9192

Attaches to the water intakes; provides
a fresh water connection when flushing
the cooling system or operating the
engine.

Protecting Internal Engine Components

NOTE: Make sure the fuel system has been prepared for storage. Refer to

Fuel

System

, preceding.

IMPORTANT: Refer to Spark Plug Inspection and Replacement for correct
procedure for removing spark plug leads.

1. Remove the spark plugs. Add approximately 30 ml (1 oz) of engine oil or
inject a five second spray of storage seal into each spark plug hole.

2. Rotate the flywheel manually several times to distribute the oil or storage
seal in the cylinders.

3. Install the spark plugs.

Protecting External Outboard Components

•

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

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

• 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

Gearcase

•

Drain and refill the gearcase lubricant (refer to Gearcase Lubricant).

Positioning Outboard for Storage

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

STORAGE

eng 69

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

70 eng

Starter Motor Will Not Crank the Engine

POSSIBLE CAUSES

•

Blown 20‑amp fuse in the starting circuit. Refer to Maintenance.

• Outboard is not shifted to neutral position.

• Weak battery or battery connections are loose or corroded.

• Ignition key switch failure.

• Wiring or electrical connection faulty.

• Starter motor solenoid or slave solenoid failure.

Engine Will Not Start

POSSIBLE CAUSES

• Lanyard stop switch not in "RUN" position.

• Battery not fully charged.

•

Incorrect starting procedure. Refer to Operation section.

• Old or contaminated fuel.

• Fuel is not reaching the engine.

• Fuel tank is empty.

• Fuel tank vent not open or restricted.

• Fuel line is disconnected or kinked.

• Primer bulb not squeezed.

• Primer bulb check valve is faulty.

•

Fuel filter is obstructed. Refer to Maintenance section.

• Fuel pump failure.

• Fuel tank filter obstructed.

•

Open 20‑amp fuse. Check fuses, refer to Maintenance section.

• Threaded connection of an air hose is loose.

• Ignition system component failure.

•

Spark plugs fouled or defective. Refer to Maintenance section.

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.

Engine fuel filter is obstructed. Refer to Maintenance section.
b. Fuel tank filter obstructed.
c. Stuck antisiphon valve on built‑in fuel tank.

TROUBLESHOOTING

eng 71

d. Fuel line is kinked or pinched.
e. Injector plugged.

• Threaded connection of an air hose is loose.

• Fuel pump failure.

• Ignition system component failure.

Performance Loss

POSSIBLE CAUSES

• Throttle not fully open.

• Damaged propeller or improper propeller size.

• Boat overloaded or load improperly distributed.

• Excessive water in bilge.

• Boat bottom is dirty or damaged.

Warning Horn Activates (With Power Loss)

POSSIBLE CAUSES

• Intermittent horn sound:

• The oil level in the engine‑mounted oil reservoir tank is low. Refill the
reservoir tank and the remote oil tank. Refer to Fuel and Oil for
details.

• Battery voltage is out of limits.

• Throttle position sensor failure.

• Continuous horn sound:

• The oil level in the engine‑mounted oil reservoir tank is critically low.
Refill the reservoir tank and the remote oil tank. Refer to Fuel and Oil
for details.

• The oil pump has failed, halting the oil supply to the engine.

• Engine speed exceeds the maximum‑allowable RPM. The system
limits the engine to within the allowable range. If the overspeed
condition continues, Engine Guardian places the engine into power
reduction. Overspeed may be caused by incorrect propeller pitch,
engine height, trim angle, etc.

• High engine temperature or low block water pressure.

• Cooling system clogged.

• Incorrect transom height (water pickups not getting adequate water
supply).

Warning Horn Activates (No Power Loss)

POSSIBLE CAUSES

• Warning horn activates on start up. This is normal operation.

TROUBLESHOOTING

72 eng

•

Water is detected in the water‑separating fuel filter. Refer to Maintenance
for procedures on removing water from the filter.

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.

• Open circuit in the alternator output wire (fused link).

TROUBLESHOOTING

eng 73

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.

PARTS AND ACCESSORIES INQUIRIES

Direct any inquiries concerning genuine Mercury Precision Parts® or
Quicksilver Marine Parts and Accessories® to a local authorized dealer.
Dealers have the proper systems to order parts and accessories, if they are not
in stock. Engine model and serial number are required to order correct parts.

OWNER SERVICE ASSISTANCE

74 eng

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.

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

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]

OWNER SERVICE ASSISTANCE

eng 75

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:

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.

OWNER SERVICE ASSISTANCE

76 eng

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 77

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

Accessories Mounted to the Transom Clamp Bracket

Mercury Marine has been made aware that certain aftermarket marine
accessories, such as emergency boarding ladders, shallow water anchors,
transom wedge kits, and tow sport attaching devices, have been mounted to
the boat by use of the same fasteners that secure the outboard to the transom
or jack plate. Using the same fastener to secure both an accessory and the
engine to the boat compromises the ability of the fasteners to maintain the
proper clamp load. A boat with loose engine mounting fasteners creates the
possibility of performance, durability, and safety issues.

OUTBOARD INSTALLATION

78 eng

!

WARNING

Avoid serious injury or death resulting from a loss of boat control. Loose
engine fasteners could cause the transom bracket to fail, resulting in a loss of
the driver's ability to control the boat. Always ensure that the engine
fasteners are tightened to the specified torque.

ACCEPTABLE ACCESSORY MOUNTING TO THE TRANSOM CLAMP
BRACKET

After the engine is mounted to the transom or jack plate in accordance with the
engine installation instructions, it is acceptable to attach an accessory to the
boat by use of the unused bolt holes in the transom clamp bracket as shown in
Figure 1.

The following list provides additional guidelines for mounting accessories to the
transom clamp bracket.

• The accessory fasteners must pass through the boat transom or jack
plate.

OUTBOARD INSTALLATION

eng 79

• The installation must not create interference issues, as would an
accessory mounting plate resting in the radius of the transom clamp
bracket. Refer to Figure 1.

Figure 1

a - Minimum clearance 3.175 mm (0.125 in.)
b - Edge of accessory bracket
c - Transom clamp bracket wall
d - Radius
e - Engine supplied mounting fasteners
f - Fasteners supplied by the accessory manufacturer installed through

unused engine mounting bracket holes

b

c

d

a

f

54624

e

OUTBOARD INSTALLATION

80 eng

UNACCEPTABLE ACCESSORY MOUNTING

IMPORTANT: Do not use the fasteners that secure the engine to the boat
(either the transom or the jack plate) for any purpose other than securing the
engine to the boat.

1. Do not mount an accessory to the transom clamp bracket in an
unsupported condition. Refer to Figure 2.

54625

Figure 2

2. Do not attach an accessory to the boat by use of the engine mounting
hardware. Refer to Figure 3.

Figure 3

a - Engine supplied mounting

fasteners

b - Transom clamp bracket
c - Accessory

53523

a

b

c

OUTBOARD INSTALLATION

eng 81

3. Do not install wedges or plates between the transom clamp brackets and
the transom (or jack plate). Refer to Figure 4.

Figure 4

a - Boat transom or jack plate
b - Transom clamp bracket
c - Wedge/plate

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.

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.

54058

a

b

c

OUTBOARD INSTALLATION

82 eng

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 this outboard.

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

Fuel System

AVOIDING FUEL FLOW RESTRICTION

IMPORTANT: Adding components to the fuel supply system (filters, valves,
fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low
speed, and/or a lean fuel condition at high RPM that could cause engine
damage.

ELECTRIC FUEL PUMP

The fuel pressure must not exceed 28 kPa (4 psi). If necessary, install a
pressure regulator.

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).

OUTBOARD INSTALLATION

eng 83

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.

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

FUEL TANKS

Portable Fuel Tank

Select a suitable location in the boat within the engine fuel line length
limitations and secure the tank in place.

Permanent Fuel Tank

Permanent fuel tanks should be installed in accordance with industry and
federal safety standards, which include recommendations applicable to
grounding, antisiphon protection, ventilation, etc.

FILLING THE FUEL SYSTEM

For the initial start of a new engine, or for an engine that ran out of fuel or was
drained of fuel, the fuel system should be filled as follows:

1. Squeeze the fuel line primer bulb until it feels firm.

2. Turn the ignition key switch to the "ON" position for three seconds. This
operates the electric fuel pump.

3. Turn the ignition key switch back to the "OFF" position, and squeeze the
primer bulb again until it feels firm. Turn the ignition key switch to the
"ON" position again for three seconds. Continue this procedure until the
fuel line primer bulb stays firm.

a

c

b

46273

OUTBOARD INSTALLATION

84 eng

Installation Specifications

a - Minimum transom opening
b - Engine centerline for dual engine ‑ 66.0 cm (26 in.)

Minimum Transom Opening
Single engine 84.8 cm (33‑3/8 in.)
Dual engine 151.8 cm (59‑3/4 in.)

Lifting the Outboard

!

WARNING

Improperly supporting an engine during lifting can result in the engine falling,
causing serious injury or death. Before lifting the engine, verify that the lifting
ring is threaded into the flywheel for a minimum of five turns and that the
hoist has the correct lifting capacity for the engine weight.

To lift the outboard:

1. Remove the cowl from the outboard.

2. Thread the lifting eye into the flywheel hub for a minimum of five turns.

a - Lifting eye

18552

a

a

b

a

28495

OUTBOARD INSTALLATION

eng 85

3. Connect a hoist to the lifting eye.

4. Lift the outboard and place it on the boat transom.

Lifting Eye 91‑90455‑‑1

2756

Threads into the flywheel to remove the
powerhead assembly from the driveshaft
housing, or to lift entire engine for
removal/installation.

Steering Cable ‑ Starboard Side Routed Cable

1. Lubricate the O‑ring seal and the entire cable end.

3724

95

Tube Ref

No.

Description Where Used Part No.

95

2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1

2. Insert the steering cable into the tilt tube.

3725

OUTBOARD INSTALLATION

86 eng

3. Tighten the nut to the specified torque.

3727

Description Nm lb‑in. lb‑ft
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 a special washer head bolt (P/N 10‑849838)
and self‑locking nylon insert locknuts (P/N 11‑826709113). Never replace
locknuts 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.

OUTBOARD INSTALLATION

eng 87

!

WARNING

Worn, loose, or seized steering components can lead to loss of boat control.
Inspect all steering attachment components for wear, lubricate all attachment
hardware, and check all fasteners for proper tightness in accordance with the
inspection and maintenance schedule.

a - Special washer head bolt (P/N 10‑849838)
b - Nylon insert locknut (P/N 11‑826709113) ‑ used on head bolt
c - Flat washer (2)
d - Nylon insert locknut (P/N 11‑826709113) ‑ used on cable coupler

1. Assemble steering link rod to steering cable coupler with two flat washers
"c" and a self‑locking nylon insert locknut "d." Tighten the locknut until it
seats, then loosen ¼ turn.

2. Assemble the steering link rod to the engine with the special washer head
bolt "a" and self‑locking nylon insert locknut "b."

3. Torque the head bolt, then the locknut to specifications.

Description

Nm lb‑in. lb‑ft

Cable coupler nylon insert locknut
"d"

Tighten locknut until it seats, then

loosen ¼ turn.
Head bolt nylon insert locknut "b" 27 – 20
Special washer head bolt 27 – 20

2767

a

b

c

d

OUTBOARD INSTALLATION

88 eng

Recommended Mounting Height

DETERMINING OUTBOARD MOUNTING HEIGHT FOR A STANDARD
GEAR HOUSING

Standard 20-inch (L) mounting bracket graph

a - The solid line is recommended to determine the outboard mounting

height.

b - The broken lines represent the extremes of known successful outboard

mounting height dimensions.

c - This line may be preferred to determine outboard mounting height

dimension, if maximum speed is the only objective.

d - This line may be preferred to determine outboard mounting height

dimension for dual outboard installation.

e - Outboard mounting height (height of outboard mounting brackets from

bottom of boat transom). For heights over 56.0 cm (22 in.), a propeller
that is designed for piercing the water surface is usually preferred.

f - Maximum boat speed anticipated.

(20 in.)

(21 in.)

(22 in.)

(23 in.)

(24 in.)

(25 in.)

(19 in.)

10

20 30 40 50 60 70 80

63.5 cm

60.9 cm

58.4 cm

56.0 cm

53.3 cm

50.8 cm

48.2 cm

feb

c

d

a

e

24305

OUTBOARD INSTALLATION

eng 89

NOTICE

1. The outboard should be mounted high enough on the transom so that the
exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline
when the engine is running at idle speed. Having the exhaust relief hole
above the waterline will prevent exhaust restrictions. Exhaust restrictions
will result in poor performance at idle.

2. Add 12.7 cm (5 in.) for XL models to the listed outboard mounting
heights.

3. The mounting height of the outboard must not exceed 63.5 cm (25 in.)
for L models, 76 cm (30 in.) for XL models. Mounting the outboard higher
may cause damage to the gearcase components.

Increasing the mounting height will usually:

• Reduce steering torque

• Increase top speed

• Increase boat stability

• Cause the propeller to break loose during planing

OUTBOARD INSTALLATION

90 eng