Mercury 2.5 FourStroke, 3.5 FourStroke, 8 FourStroke, 9.9 FourStroke, 9.9 Command Thrust Installation Manual

Operation

Maintenance

and

Installation

Manual

© 2017 Mercury Marine

2.5/3.5 FourStroke

8M0133467 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, 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

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

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

Exhaust Emissions............................................................................................. 5

Selecting Accessories for Your Outboard........................................................... 7

Safe Boating Recommendations........................................................................ 7

Recording Serial Number................................................................................. 10

Model Year Production Code............................................................................11

Specifications....................................................................................................11

Installation

Installing the Outboard......................................................................................13

Transporting

Carrying, Storing, and Transporting the Outboard When Removed from Boat

.......................................................................................................................... 14

Trailering the Boat............................................................................................ 15

Fuel and Oil

Fuel Requirements........................................................................................... 17

Special Features of the Fuel Tank.................................................................... 18

Filling the Fuel Tank......................................................................................... 19

Engine Oil Recommendations.......................................................................... 19

Checking Engine Oil......................................................................................... 20

Features and Controls

Features and Controls...................................................................................... 22

Tilting Outboard................................................................................................ 24

Setting the Operating Angle of the Outboard ...................................................25

eng v

Operation

Prestarting Check List.......................................................................................26

Operating in Freezing Temperatures................................................................ 26

Operating in Saltwater or Polluted Water......................................................... 26

Engine Break‑in Procedure...............................................................................27

Starting the Engine........................................................................................... 27

Gear Shifting..................................................................................................... 30

Reversing Boat................................................................................................. 31

Stopping the Engine......................................................................................... 31

Maintenance

Outboard Care.................................................................................................. 32

EPA Emission Regulations............................................................................... 32

Inspection and Maintenance Schedule ............................................................ 33

Flushing the Cooling System............................................................................ 34

Top Cowl Removal and Installation.................................................................. 35

Corrosion Control Anode.................................................................................. 36

Exterior Care.....................................................................................................36

Propeller Replacement..................................................................................... 37

Spark Plug Inspection and Replacement..........................................................39

Lubrication Points............................................................................................. 40

Changing Engine Oil ........................................................................................ 41

Gearcase Lubrication........................................................................................42

Submerged Outboard....................................................................................... 43

Storage

Storage Preparation..........................................................................................44

Protecting External Outboard Components...................................................... 44

Protecting Internal Engine Components........................................................... 44

Gearcase.......................................................................................................... 45

Positioning Outboard for Storage..................................................................... 45

Owner Service Assistance

Service Assistance........................................................................................... 46

Ordering Literature............................................................................................48

vi eng

Maintenance Log

Maintenance Log.............................................................................................. 50

eng vii

eng viii

Boater's Responsibilities

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

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

Before Operating Your Outboard

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

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

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

!

WARNING

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

!

CAUTION

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

NOTICE

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

Boat Horsepower Capacity

!

WARNING

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

GENERAL INFORMATION

eng 1

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

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON
CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT
CAPACITY

XXX

26777

Lanyard Stop Switch

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

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

GENERAL INFORMATION

2 eng

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

eng 3

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

4 eng

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.

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.

GENERAL INFORMATION

eng 5

!

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.

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.

GENERAL INFORMATION

6 eng

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)

Selecting Accessories for Your Outboard

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

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

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

Safe Boating Recommendations

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

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

21626

a

b

a

b

21628

GENERAL INFORMATION

eng 7

• 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

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.

GENERAL INFORMATION

8 eng

• 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.

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.

GENERAL INFORMATION

eng 9

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

- - - . -

- -

XXXXXXX

-

XXXXX XX

XL

Mercury

Marine

Serial Number

Brunswick Corp.
Made in Japan

XX

XXXX XXX

HP XXX
LB XXX

KG XXX

KW XXX

Model Number

b

c

a

d

43128

GENERAL INFORMATION

10 eng

Model Year Production Code

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

XXXXXXXXX

XXXXXXXX

XXXX

AG

62972

Serial number decal alpha code

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

Examples:

• XX = 2000

• HK = 2089

• AG = 2017

Specifications

Models

2.5 3.5
Power 1.8 kw (2.5 hp) 2.6 kw (3.5 hp)
Full throttle RPM range 5000–6000

Idle speed

1200 RPM in forward gear, 1300 RPM in

neutral
Number of cylinders 1
Piston displacement 85.5 cc (5.21 cid)
Cylinder bore 55 mm (2.16 in.)
Piston stroke 36 mm (1.41 in.)
Valve clearance (cold)
Intake valve 0.06–0.14 mm (0.0024–0.0055 in.)
Exhaust valve 0.11–0.19 mm (0.0043–0.0075 in.)

GENERAL INFORMATION

eng 11

Models 2.5 3.5
Engine oil capacity 300 ml (10 fl oz)
Recommended spark plug NGK DCPR6E
Spark plug gap 0.9 mm (0.035 in.)
Gearcase lubricant capacity 180 ml (6.0 fl oz)
Gear ratio 2.15:1
Recommended gasoline

Refer to Fuel and Oil

Recommended oil

Refer to Fuel and Oil
Emission control system Engine modification (EM)
Sound at drivers ear (ICOMIA

39‑94) bBA

79.8

Tiller handle vibration
(ICOMIA 38‑94) m/s²

8.4

GENERAL INFORMATION

12 eng

Installing the Outboard

BOAT TRANSOM HEIGHT REQUIREMENT

Measure the transom height of the boat. The anti‑ventilation plate should be
25–50 mm (1–2 in.) below the bottom of the boat.

a - Anti‑ventilation plate

INSTALLING THE OUTBOARD ON THE TRANSOM

1. Place the outboard on the centerline of the transom.

27005

2. Tighten the transom clamp handles.

19057

a

19053

INSTALLATION

eng 13

Carrying, Storing, and Transporting the Outboard When
Removed from Boat

With the outboard still in the water, close the fuel valve and run the engine until
it stops. This will empty the fuel from the carburetor.

a - Transport mode
b - Vent position
c - Fuel valve position
d - Vent screw
e - Fuel valve

Close the manual vent screw after the engine has stopped.

a - Manual vent screw

Remove the outboard and hold it upright until the water is drained out. Keep the
outboard in an upright position when carrying.

52330

abcde

a

47362

TRANSPORTING

14 eng

Carry, transport, or store the outboard only in the upright position, or with the
tiller handle (port) side facing up. These positions will prevent oil from draining
out of the crankcase. A decal on the port side of the engine indicates which
side should be up.

a - Upright position
b - Tiller handle up position

Never carry, store, or transport the outboard in these positions. Engine damage
could result from oil draining out of the crankcase.

19063

Trailering the Boat

IMPORTANT: The tilt lock mechanism is not intended to support the outboard
in the tilted up position when trailering the boat. Use of the tilt lock mechanism
could allow the outboard to bounce, and drop down causing damage to the
outboard.

The boat should be trailered with the outboard tilted down (normal operating
position).

If additional ground clearance is required, remove the outboard from the boat,
and store securely. Additional clearance may be needed for railroad crossings,
driveways, and trailer bouncing.

a

b

THIS SIDE UP

NOTICE

52333

TRANSPORTING

eng 15

Set the gear shift into forward gear. This prevents the propeller from spinning
freely.

19049

TRANSPORTING

16 eng

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

eng 17

!

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.

Special Features of the Fuel Tank

The Environmental Protection Agency (EPA) will require the fuel tank on
outboards produced after January 1, 2011 to remain fully sealed (pressurized)
up to 24.1 kPa (3.5 psi).

The fuel cap 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 24.1 kPa (3.5 psi). A hissing noise may be heard
as the tank vents to the atmosphere. This is normal.

REMOVING THE FUEL CAP

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. Rotate the fuel cap 1/4 turn to relieve pressure and slowly open the cap.

INSTALLING THE FUEL CAP

1. When installing the fuel 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.

FUEL AND OIL

18 eng

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

a - Fuel cap
b - Manual vent screw

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

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

Engine Oil Recommendations

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

a

b

47368

FUEL AND OIL

eng 19

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

Recommended SAE viscosity for
engine oil

a - Mercury or Quicksilver SAE

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

b - Mercury or Quicksilver SAE

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

Checking Engine Oil

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

1. Position the outboard so it is sitting level.

2. Verify the oil level through the oil level inspection window. If the oil level is
down toward the lower level mark, remove the oil fill cap, and fill up to the
upper level mark.

+20

+40

+60

+80

F° C°

0

+100

–7

+4

+16

+27

–18

+38

a

b

26795

FUEL AND OIL

20 eng

NOTE: If oil level is at the lower mark, add 100 ml (3 oz.) of oil.

a - Oil level inspection window
b - Upper oil level
c - Lower oil level

3. Install the oil fill cap, and tighten securely.

a - Oil fill cap

c

b

a

52334

a

19139

FUEL AND OIL

eng 21

Features and Controls

Fuel shut off valve ‑ Turn the valve to the closed (OFF) position to prevent fuel
flow to the engine. Turn the valve to the open (ON) position when starting the
engine.

52331

Choke knob ‑ Pull completely out when starting a cold engine. Push halfway in
as the engine is warming up. Push in completely after the engine is warmed up.

19088

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

a - Direction to loosen friction
b - Direction to tighten friction

a

b

19096

FEATURES AND CONTROLS

22 eng

!

WARNING

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

Steering friction adjustment ‑ Adjust this knob to achieve the desired steering
friction (drag) on the tiller handle. Turn the knob clockwise to tighten friction and
counterclockwise to loosen friction.

a - Direction to loosen

friction

b - Direction to tighten

friction

Side handle gear shift ‑ Controls gear shift. Place the gear shift into neutral
position when starting the engine. F = forward gear, N = neutral position.

N

F

19103

19100

a

b

FEATURES AND CONTROLS

eng 23

Engine stop switch/lanyard stop switch ‑ Push in or pull lanyard to stop the
engine. The engine will not start unless the lanyard is engaged with the stop
switch.

a - Engine stop switch/lanyard stop

switch

b - Lanyard

Starter rope ‑ Pulling the starter rope cranks the engine over for starting.

19105

Tilting Outboard

TILTING TO FULL UP POSITION

1. Stop the engine.

2. Take hold of the top cowl grip, and raise outboard to the full up position.

a

b

19104

FEATURES AND CONTROLS

24 eng

3. Push in the tilt support pin. Lower the outboard to rest on the tilt support
pin.

a - Tilt support pin

LOWERING TO RUN POSITION

Lift the outboard and pull out the tilt support pin. Lower the outboard.

Setting the Operating Angle of the Outboard

The vertical operating angle of the outboard is adjusted by changing the
position of the tilt pin in the adjustment holes provided. Proper adjustment
allows the boat to achieve optimum performance, stability, and minimize
steering effort.

The tilt pin should be adjusted so the outboard is positioned to run
perpendicular to the water when the boat is running at full speed. This allows
the boat to be driven parallel to the water.

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

a - Tilt pin

a

19051

a

19052

FEATURES AND CONTROLS

eng 25

Prestarting Check List

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

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

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

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

• Fuel supply OK.

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

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

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

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

•

Make inspection checks listed in Maintenance ‑ Inspection and

Maintenance Schedule.

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.

OPERATION

26 eng

Engine Break‑in Procedure

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

1. For the first hour of operation, run the engine at varied throttle settings up
to 2000 RPM or at approximately half throttle.

2. For the second hour of operation, run the engine at varied throttle settings
up to 3000 RPM or at three‑quarter throttle, and at full throttle for
approximately one minute every ten minutes.

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

Starting the Engine

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

NOTICE

Without sufficient cooling water, the engine, the water pump, and other
components will overheat and suffer damage. Provide a sufficient supply of
water to the water inlets during operation.

1. Check the engine oil level. Place the outboard in a level position and
check that the engine oil level is within the operating range.

a - Oil level inspection window
b - Upper oil level
c - Lower oil level

c

b

a

52334

OPERATION

eng 27

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

N

19170

3. Make sure the cooling water intake is submerged.

19056

4. Open the manual vent screw on the fuel tank.

47370

5. Move the fuel shut off valve to the open (ON) position.

52331

OPERATION

28 eng

6.

Attach the lanyard to the stop switch. Refer to General Information ‑
Lanyard Stop Switch.

NOTE: The engine will not start unless the lanyard is engaged with the stop
switch.

a - Stop switch
b - Lanyard

7. If the engine is cold, set the throttle grip to the "START" position. If the
engine is warm, set the throttle grip to the "RE‑START" position.

0%

0%

START

START

RE-START

RE-START

19171

8. If the engine is cold, completely pull out the choke. Push in the choke
halfway as the engine is warming up. Push in completely after the engine
is warmed up.

19088

NOTE: Starting flooded engine ‑ Push in the choke knob. Wait 30 seconds,
then continue to crank the engine for starting.

a

b

19104

OPERATION

eng 29

9. Pull the starter rope slowly until you feel the starter engage, then pull
rapidly to crank the engine. Allow the rope to return slowly. Repeat until
the engine starts.

19172

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

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

19246

Gear Shifting

The outboard has two gear shift positions to provide operation: Forward (F),
and Neutral (N).

Reduce throttle speed to idle speed.

OPERATION

30 eng

Always shift the outboard into gear with a quick motion.

N

F

19103

Reversing Boat

1. Move the throttle grip to the slow position.

2. To reverse direction, turn the outboard 180°. The tiller handle can be
swung back for ease of operation.

3. Return the throttle grip to the slow position when turning the outboard
back to forward direction.

20272

Stopping the Engine

Reduce engine speed and push in the stop switch or pull the lanyard.

a - Stop switch
b - Lanyard

a

b

19104

OPERATION

eng 31

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.

EPA Emission Regulations

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

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

MAINTENANCE

32 eng

EMISSION CERTIFICATION LABEL

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

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

OWNER RESPONSIBILITY

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

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

2008

JAN

FEB

MAR

APR

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

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

FAMILY :

MERCURY MARINE

EMISSION CONTROL INFORMATION

a

DISPLACEMENT :
FEL : HC+NOx=

LOW-PERM/HIGH-PERM :

TIMING :

IDLE SPEED (IN GEAR) :

MAXIMUM POWER :

HP :

2008

b

c

d

e

f

g

h

43058

CO=

MAINTENANCE

eng 33

• 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

• 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.

Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing
attachment.

NOTE: Do not run the engine while flushing the cooling system.

1. Remove the plug and gasket.

MAINTENANCE

34 eng

2. Attach the hose coupling to the engine.

3. Attach a water hose to the hose coupling. Turn on the water gently and
flush the cooling system for 3 to 5 minutes.

4. Turn the water off. Remove the hose coupling and install the plug and
gasket.

a - Plug and gasket
b - Hose coupling

Top Cowl Removal and Installation

REMOVAL

1. Release the rear cowl latch.

47360

b

a

52350

MAINTENANCE

eng 35

2. Lift up the rear of the cowl and push it towards the front of the engine to
clear the front hook.

19043

INSTALLATION

1. Engage the front hook and position the cowl over the engine.

2. Lock the rear cowl latch.

Corrosion Control Anode

Your outboard has a corrosion control anode installed on the gearcase. An
anode helps protect the outboard against galvanic corrosion by sacrificing its
metal to be slowly corroded instead of the outboard metals.

The 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.

28709

Exterior Care

Your outboard is protected with a durable baked enamel finish. Clean and wax
often using marine cleaners and waxes.

MAINTENANCE

36 eng

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.

1. Remove the spark plug lead to prevent the engine from starting.

26899

2. Move the gear shift lever into neutral.

N

19170

3. Straighten and remove the cotter pin.

a - Cotter pin

a

19018

MAINTENANCE

eng 37

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

a - Drive pin

5. Insert the drive pin into the propeller shaft.

a - Drive pin

6. Slide the propeller onto the shaft, making sure the slot in the propeller
engages with the drive pin.

7. Install the cotter pin through the hole in the propeller and bend the cotter
pin ends.

a - Cotter pin

a

19022

a

19023

a

19018

MAINTENANCE

38 eng

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 boot. Twist the rubber boot slightly and pull off.

26899

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

26946

3. Set the spark plug gap to specification.

26947

Spark Plug
Spark plug gap 0.9 mm (0.035 in.)

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

Description

Nm lb‑in. lb‑ft

Spark plug 27 – 20

MAINTENANCE

eng 39

Lubrication Points

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

Tube Ref

No.

Description Where Used Part No.

95

2-4-C with PTFE

Steering friction knob threads, swivel

bracket bushing, tilt support pin, transom

clamp screws

92-802859A 1

Extreme Grease

Steering friction knob threads, swivel

bracket bushing, tilt support pin, transom

clamp screws

8M0071842

• Steering friction knob ‑ lubricate threads.

19231

• Tilt support pin ‑ lubricate pin

• Transom clamp screws ‑ lubricate threads

• Tilt pivot point ‑ lubricate with lightweight oil

a - Tilt support pin
b - Tilt pivot point
c - Transom clamp screws

• Tiller handle rubber bushing ‑ lubricate internal diameter with lightweight
oil.

19234

a

b

b

c

c

19233

MAINTENANCE

40 eng

• Swivel bracket ‑ remove four bolts and rear cover and lubricate the inner
nylon bushing.

a - Rear cover

Changing Engine Oil

ENGINE OIL CAPACITY

Engine oil capacity is approximately 300 ml (10 fl oz).

OIL CHANGING PROCEDURE

1. Place the outboard in an upright (not tilted) position.

2. Turn the outboard to gain access to the drain plug. Remove the drain plug
and drain the engine oil into an appropriate container. Lubricate the seal
on the drain plug with oil and reinstall.

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

a - Drain plug

OIL FILLING

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

a

19240

19128

a

MAINTENANCE

eng 41

Remove the oil fill cap and refill with 300 ml (10 fl oz) of oil. Install the oil fill
cap.

Idle engine for five minutes and check for leaks. Stop engine and check oil
level. Add oil if necessary.

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. Place the drain pan below outboard.

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

NOTE: Replace the sealing washers with new washers.

a - Vent plug
b - Fill/drain plug

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 180 ml (6.0 fl oz).

CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE

1. Place the outboard in a vertical operating position.

2. Remove the vent plug.

a

b

19077

MAINTENANCE

42 eng

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

a - Vent plug and new sealing

washer

b - Vent hole
c - Fill/drain plug and new sealing

washer

Tube Ref

No.

Description Where Used Part No.

82

Premium Gear
Lubricant

Gearcase 92-858058K01

4. Stop adding lubricant. Use new sealing washer and install the vent plug
before removing the lubricant tube.

5. Remove lubricant tube and install cleaned fill/drain plug and new 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.

b

a

c

19080

MAINTENANCE

eng 43

Storage Preparation

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

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

NOTICE

Without sufficient cooling water, the engine, the water pump, and other
components will overheat and suffer damage. Provide a sufficient supply of
water to the water inlets during operation.

FUEL SYSTEM

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

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

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

• Place the outboard in water. Run the engine for five minutes to allow
treated fuel to reach the carburetor.

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

Protecting Internal Engine Components

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

• Rotate the flywheel manually several times to distribute the oil in the
cylinder. Install spark plug.

• Change the engine oil.

STORAGE

44 eng

Gearcase

•

Drain and refill the gearcase lubricant. Refer to Gearcase Lubrication.

Positioning Outboard for Storage

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.

1. Carry, transport, or store the outboard only in the following two positions.
These positions will prevent oil from draining out of the crankcase.

a - Upright position
b - Tiller handle up position

2. Never carry, store, or transport the outboard in the positions shown below.
Engine damage could result from oil draining out of the crankcase.

19063

a

b

THIS SIDE UP

NOTICE

52333

STORAGE

eng 45

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

46 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 47

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

48 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 49

Maintenance Log

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

Date Maintenance Performed Engine Hours

MAINTENANCE LOG

50 eng