Mercury 40 FourStroke Tiller Handle Installation Manual

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8M0104951 315 eng

Outboard

Operation

Maintenance

Warranty

Installation

Manual

40 FourStroke Tiller Handle

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Thank You

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

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

Thank you for your confidence in Mercury Marine.

EPA Emissions Regulations

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

emission control devices and systems may be performed by any marine engine repair establishment or individual.

Engines are labeled with an Emission Control Information decal as permanent evidence of EPA certification.

WARNING

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

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 Information section of this manual. The warranty statement 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.

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

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Mercury Premier Service

Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment to service.

Earning a Mercury Premier Service rating means a dealer:

• Achieves a high 12 month customer satisfaction index (CSI) score for warranty service.

• Possesses all necessary service tools, test equipment, manuals, and parts books.

• Employs at least one Certified or Master technician.

• Provides timely service for all Mercury Marine customers.

• Offers extended service hours and mobile service, when appropriate.

• Uses, displays, and stocks adequate inventory of genuine Mercury Precision Parts.

• Offers a clean, neat shop with well organized tools and service literature.

Copyright and Trademark Information

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

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WARRANTY INFORMATION

Warranty Registration United States and Canada.............................................. 1

Transfer of Warranty United States and Canada................................................1

Transfer of Mercury Product Protection (Extended Service Coverage) Plan

United States and Canada..................................................................................2

3 Year Limited Warranty Against Corrosion....................................................... 2

Warranty Coverage and Exclusions................................................................... 4

U.S. EPA Emissions Limited Warranty............................................................... 6

Emission Control System Components.............................................................. 6

California Emissions Limited Warranty............................................................... 7

California Air Resources Board Explanation of Your California Emission Control

Warranty Statement............................................................................................ 9

Emission Certification Star Label...................................................................... 10

Warranty Policy—Australia and New Zealand.................................................. 11

Global Warranty Charts Outboard and Jets......................................................15

General Information

Boater's Responsibilities................................................................................... 20

Before Operating Your Outboard...................................................................... 20

Boat Horsepower Capacity............................................................................... 20

High‑Speed and High‑Performance Boat Operation........................................ 21

Lanyard Stop Switch......................................................................................... 21

Protecting People in the Water......................................................................... 24

Passenger Safety Message ‑ Pontoon Boats and Deck Boats.........................24

Wave and Wake Jumping................................................................................. 26

Impact with Underwater Hazards......................................................................27

Safety Instructions for Hand‑Tilled Outboards.................................................. 28

Exhaust Emissions........................................................................................... 28

Selecting Accessories for Your Outboard......................................................... 30

Safe Boating Recommendations...................................................................... 30

Recording Serial Number................................................................................. 33

40 FourStroke Specifications............................................................................ 33

Component Identification.................................................................................. 35

Transporting

Trailering Boat/Outboard ................................................................................. 36

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Fuel and Oil

Fuel Recommendations.................................................................................... 37

Low Permeation Fuel Hose Requirement ........................................................ 38

EPA Pressurized Portable Fuel Tank Requirements........................................ 38

Fuel Demand Valve (FDV) Requirement.......................................................... 38

Mercury Marine's Pressurized Portable Fuel Tank........................................... 39

Filling Fuel Tank............................................................................................... 40

Engine Oil Recommendations.......................................................................... 40

Checking and Adding Engine Oil...................................................................... 41

Features and Controls

Warning System ‑ Manual Starting Models...................................................... 43

SmartCraft Product........................................................................................... 44

Manual Tilt System .......................................................................................... 44

Throttle Grip Friction Adjustment ‑ Tiller Handle Models.................................. 48

Steering Friction Adjustment ‑ Tiller Handle Models......................................... 48

Trim Tab Adjustment........................................................................................ 49

Operation

Important Daily Inspection Before Each Use ................................................... 50

Prestarting Check List.......................................................................................50

Operating in Freezing Temperatures................................................................ 51

Operating in Saltwater or Polluted Water......................................................... 51

Prestarting Instructions..................................................................................... 51

Engine Break‑in Procedure...............................................................................52

Starting the Engine ‑ Tiller Handle Models....................................................... 52

Gear Shifting .................................................................................................... 55

Stopping the Engine ........................................................................................ 56

Emergency Starting ......................................................................................... 56

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Maintenance

Outboard Care.................................................................................................. 58

EPA Emissions Regulations............................................................................. 58

Inspection and Maintenance Schedule............................................................. 59

Flushing the Cooling System............................................................................ 60

Top Cowl Removal and Installation.................................................................. 62

Exterior Care.....................................................................................................62

Battery Inspection ............................................................................................ 62

Fuel System...................................................................................................... 63

Engine Fuel Filter ‑ Manual Starting Models..................................................... 63

Corrosion Control Anode.................................................................................. 64

Propeller Replacement..................................................................................... 65

Spark Plug Inspection and Replacement..........................................................68

Timing Belt Inspection...................................................................................... 69

Lubrication Points............................................................................................. 70

Changing Engine Oil ........................................................................................ 72

Gearcase Lubrication........................................................................................73

Gearcase Lubricant Recommendation............................................................. 75

Submerged Outboard....................................................................................... 75

Storage

Storage Preparation..........................................................................................76

Protecting External Outboard Components...................................................... 76

Protecting Internal Engine Components........................................................... 76

Gearcase.......................................................................................................... 77

Positioning Outboard for Storage..................................................................... 77

Battery Storage................................................................................................. 77

Troubleshooting

Engine Will Not Start.........................................................................................78

Engine Runs Erratically.................................................................................... 78

Performance Loss.............................................................................................78

Battery Will Not Hold Charge............................................................................ 79

Owner Service Assistance

Parts and Accessories Inquiries....................................................................... 80

Service Assistance........................................................................................... 80

Ordering Literature............................................................................................82

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Installation

Mercury Marine Validated Engine Mounting Hardware.................................... 84

Installation Information......................................................................................84

Fuel Hose Connection...................................................................................... 90

Flo‑Torq I Propeller Installation.........................................................................90

Flo‑Torq Reflex Drive Hub Propeller Installation.............................................. 92

Trim Tab Adjustment........................................................................................ 98

Maintenance Log

Maintenance Log.............................................................................................. 99

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WARRANTY INFORMATION

Warranty Registration United States and Canada

To be eligible for warranty coverage, the product must be registered with Mercury Marine.

At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, e‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration.

A copy of the warranty registration should be provided to you by your selling dealer.

NOTE: Registration lists must be maintained by Mercury Marine and any dealer of Mercury Marine products sold in the United States, should a safety recall notification under the Federal Safety Act be required.

You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information. Mercury Marine Attn: Warranty Registration Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 907 6663

OUTSIDE UNITED STATES AND CANADA

For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.

Transfer of Warranty United States and Canada

The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.

To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and Canada, mail to:

Mercury Marine Attn: Warranty Registration Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 907 6663

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WARRANTY INFORMATION

Upon processing the transfer of warranty, Mercury Marine will record the new owner's information.

There is no charge for this service.

OUTSIDE THE UNITED STATES AND CANADA

For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.

Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada

The remaining coverage period of the Product Protection Plan is transferable to the subsequent purchaser of the engine within thirty (30) days from the date of sale. Contracts not transferred within thirty (30) days of the subsequent purchase will no longer be valid and the product will no longer be eligible for coverage under the terms of the contract.

To transfer the plan to the subsequent owner, contact Mercury Product Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.

Plan coverage is not transferable from one product to another product or for noneligible applications.

The certified preowned engine plans are not transferable. For help or assistance, contact Mercury Product Protection Department at

1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST, Monday–Friday or e‑mail mpp_support@mercmarine.com.

3 Year Limited Warranty Against Corrosion

WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing Outboards, Sport‑Jet, M2 Jet Drive, Tracker by

Mercury Marine Outboard, Mercury MerCruiser Inboard or Sterndrive Engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to subsequent (noncommercial use) purchaser upon proper reregistration of the product.

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WARRANTY INFORMATION

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that

purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat, and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed (including, without limitation, the replacement of sacrificial anodes, use of specified lubricants, and touch‑up of nicks and scratches) in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance.

WHAT MERCURY WILL DO: Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury Marine product. Mercury Marine reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury Marine with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair. The purchaser, in that case, shall pay for all related transportation charges and travel time. If the service provided is not covered by this warranty, the purchaser shall pay for all related labor and material, and any other expenses associated with that service. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage.

WHAT IS NOT COVERED: This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse, or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by customer); products used in a commercial application. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes.

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WARRANTY INFORMATION

Corrosion damage caused by stray electrical currents (onshore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty. If antifouling protection is required, Tri‑Butyl‑Tin‑Adipate (TBTA) base antifouling paints are recommended on Outboard and MerCruiser boating applications. In areas where TBTA base paints are prohibited by law, copper base paints can be used on the hull and transom. Do not apply paint to the Outboard or MerCruiser product. In addition, care must be taken to avoid an electrical interconnection between the warranted product and the paint. For MerCruiser product, an unpainted gap of at least 38 mm (1.5 in.) should be left around the transom assembly. Refer to the Operation and Maintenance Manual for additional details.

For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty.

DISCLAIMERS AND LIMITATIONS:

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.

Warranty Coverage and Exclusions

The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited Outboard Warranty.

Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered.

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WARRANTY INFORMATION

Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.

Should you have any questions concerning warranty coverage, contact your authorized dealer. They will be pleased to answer any questions that you may have.

GENERAL EXCLUSIONS FROM WARRANTY

1. Minor adjustments and tune‑ups, including checking, cleaning, or adjusting spark plugs, ignition components, carburetor settings, filters, belts, controls, and checking lubrication made in connection with normal services.

2. Installation errors, accidents, normal wear and tear, and faded paint.

3. Factory installed jet drive units ‑ Specific parts excluded from the warranty are: the jet drive impeller and jet drive liner damaged by impact or wear, and water damaged driveshaft bearings as a result of improper maintenance.

4. Damage caused by neglect, lack of maintenance, accident, abnormal operation, or improper installation or service.

5. Haul‑out, launch, towing charges, removal and/or replacement of boat partitions or material because of boat design for necessary access to the product, all related transportation charges and/or travel time, etc. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an authorized dealer.

6. Additional service work requested by customer other than that necessary to satisfy the warranty obligation.

7. Labor performed by other than an authorized dealer may be covered only under the following circumstances: when performed on emergency basis (providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul‑out, etc., and prior factory approval has been given to have the work performed at this facility).

8. All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility.

9. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.

10. Oils, lubricants, or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

11. Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit.

12. Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty.

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WARRANTY INFORMATION

13. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.

14. Water entering engine through the fuel intake, air intake, or exhaust system or submersion.

15. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high, or trimmed too far out.

16. Use of fuels and lubricants which are not suitable for use with or on the product. Refer to the Maintenance section.

17. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product.

U.S. EPA Emissions Limited Warranty

Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use warranty, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship that cause the engine to fail to conform with applicable regulations. This emission‑related warranty covers all the components listed in the Emission Control System Components.

Emission Control System Components

The EPA and California emission‑related warranty covers all the following list of components:

COMPONENTS OF THE EMISSIONS CONTROL SYSTEM:

1. Fuel metering system

a. Carburetor and internal parts (and/or pressure regulator or fuel

injection system) b. Cold start enrichment system c. Intake valves

2. Air induction system a. Intake manifold b. Turbocharger or supercharger systems (where applicable)

3. Ignition system a. Spark plugs b. Magneto or electronic ignition system c. Spark advance/retard system d. Ignition coil and/or control module

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e. Ignition wires

4. Lubrication system (4‑Stroke engines excluded) a. Oil pump and internal parts b. Oil injectors c. Oil meter

5. Exhaust system a. Exhaust manifold b. Exhaust valves

6. Miscellaneous items used in above systems a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and

mounting hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensitive valves and switches d. Electronic controls

The emission‑related warranty does not cover components whose failure would not increase an engine's emissions on any regulated pollutant.

California Emissions Limited Warranty

The California Air Resources Board has promulgated air emission regulations for outboard engines. The regulations apply to all outboard engines sold to retail consumers in California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System Components), and further warrants that the outboard engine was designed, built, and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. For information regarding the limited warranty for the nonemission‑related components of the outboard, please see the limited warranty statement for your outboard.

WHAT IS COVERED: Mercury Marine warrants the components of the emissions control systems (see the components listed in the Emission Control System Components) of its new, 2001 model year and later outboards, sold by a California dealer to retail customers residing in California, to be free from defects in material or workmanship, that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved). Damage to other engine components caused by the failure of a warranted part will also be repaired under warranty.

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DURATION OF COVERAGE: This limited warranty provides coverage for the components of the emissions control systems of new, 2001 model year and later outboards, sold to retail customers in California for four (4) years from either the date the product is first sold, or first put into service, whichever occurs first, or the accumulation of 250 hours of engine operation (as determined by the engine's hour meter, if any). Emission‑related normal maintenance items such as spark plugs and filters, that are on the warranted parts list, are warranted up to their first required replacement interval only. Refer to Emission Control System Components and Maintenance Schedule. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent purchaser. (See instructions on transfer of warranty.)

HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury.

WHAT MERCURY WILL DO: Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance items, tune‑ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open throttle RPM range (see General Information ‑ Specifications), operation of the product in a manner inconsistent with the recommended operation procedures, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, jet pump impellers and liners, operation with fuels, oils, or lubricants which are not suitable for use with the product (see Fuel and Oil), alteration or removal of parts.

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Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

Nonwarranty maintenance, replacement, or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual. The use of non‑Mercury parts for nonwarranty maintenance or repairs will not be grounds for disallowing other warranty work. The use of add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

DISCLAIMERS AND LIMITATIONS

If you have any questions regarding your warranty rights and responsibilities, you should contact Mercury Marine at 1‑920‑929‑5040.

California Air Resources Board Explanation of Your California Emission Control Warranty Statement

YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board is pleased to explain the emission control system warranty on your 2014–2015 model year outboard engine. In California, new outboard engines must be designed, built, and equipped to meet the State's stringent anti‑smog standards. Mercury Marine must warrant the emission control system on your outboard engine for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your outboard engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors, and other emission‑related assemblies.

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Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.

MANUFACTURER'S WARRANTY COVERAGE: Select emission control parts from model year 2001 and later outboard engines are warranted for four (4) years, or for 250 hours of use, whichever occurs first. However, warranty coverage based on the hourly period is only permitted for outboard engines and personal watercraft equipped with hour meters as defined in s 2441(a)(13) or their equivalent. If any emission‑related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Marine.

OWNER'S WARRANTY RESPONSIBILITIES: As the outboard engine owner, you are responsible for the performance of the required maintenance listed in the Maintenance section. Mercury Marine recommends that you retain all receipts covering maintenance on your outboard engine, but Mercury Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact Mercury Marine at 1‑920‑929‑5040.

Emission Certification Star Label

Outboards are labeled on the cowl with one of the following star labels.

The symbol for a cleaner marine engine means: Cleaner air and water ‑ for a healthier lifestyle and environment. Better fuel economy ‑ burns up to 30–40 percent less gas and oil than

conventional carbureted two‑stroke engines, saving money and resources.

Longer emission warranty ‑ protects consumer for worry‑free operation.

One Star ‑ Low Emission

The One Star label identifies engines that meet the Air Resources Board's 2001 exhaust emissions standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

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Two Stars ‑ Very Low Emission

The Two Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards. Engines meeting these standards have 20% lower emissions than One Star ‑ Low Emission engines.

Three Stars ‑ Ultra Low Emission

The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines.

Four Stars ‑ Super Ultra Low Emission

The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star ‑ Low Emission engines.

Warranty Policy—Australia and New Zealand

MERCURY/MARINER OUTBOARD LIMITED WARRANTY–AUSTRALIA AND NEW ZEALAND POLICY

This limited warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia (telephone (61) (3) 9791 5822) e‑mail: merc_info@mercmarine.com.

What is Covered

Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.

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Guarantees Under Australian Consumer Law

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Warranty Period for Recreational Use

This Limited Warranty provides coverage for three (3) years from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. Unexpired warranty coverage can be transferred to a subsequent recreational use customer upon proper registration of the product.

Warranty Period for Commercial Use

Commercial users of these products receive warranty coverage under this Limited Warranty of one (1) year from the date of first retail sale, or one (1) year from the date on which the product was first put into service, whichever occurs first. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer.

Conditions That Must Be Met to Obtain Warranty Coverage

Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use, or subsequent change of use from recreational to commercial (unless properly registered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance.

What Mercury Will Do

Mercury Marine's sole and exclusive obligation under this Limited Warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury Marine product. Mercury Marine reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

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WARRANTY INFORMATION

How to Obtain Warranty Coverage Under This Limited Warranty

The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the purchaser for all related transportation charges and travel time. If the service provided is not covered by this limited warranty, the purchaser shall pay for all related labor and material and any other expenses associated with that service, provided that a consumer will not be obligated to pay where the service has been carried out to remedy a failure of an acceptable quality guarantee which is binding on Mercury Marine under the Australian Consumer Law. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage under this Limited Warranty.

What is Not Covered

This limited warranty does not cover routine maintenance items, tune‑ups, adjustments, normal wear and tear, faded paint, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants that are not suitable for use with the product (see the Operation and Maintenance Manual), alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system, or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the engine out of water, mounting the engine too high on the transom, or running the boat with the engine trimmed out too far. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this Limited Warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

. If the purchaser

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WARRANTY INFORMATION

No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty.

Expense of Claiming This Limited Warranty

This Limited Warranty does not cover any expenses you may incur claiming the warranty.

DISCLAIMERS AND LIMITATIONS:

EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY.

TRANSFER OF WARRANTY—AUSTRALIA AND NEW ZEALAND POLICY

To transfer the warranty to the subsequent owner, send or fax a copy of the Bill of Sale or Purchase Agreement, new owner’s name, address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department. In Australia and New Zealand, mail to:

Mercury Marine

Attn: Warranty Registration Department

Brunswick Asia Pacific Group

Private Bag 1420

Dandenong South, Victoria 3164

Australia

Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service.

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WARRANTY INFORMATION

You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.

Global Warranty Charts Outboard and Jets

UNITED STATES WARRANTY CHARTS–OUTBOARD AND JET

Product

FourStroke (2.5–350 hp including Verado, Pro FourStroke and Jet outboards)

OptiMax (75–250 hp including Pro XS and Jet outboards)

OptiMax Jet drive (200 and 250 hp) 1 year 3 years

Racing Product (Recreation use only)

OptiMax (250 XS) 2 years 3 years

OptiMax (300 XS) 2 years 3 years

Verado (400R) 2 years 3 years

Outside the United States

For product purchased outside the United States, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

CANADA WARRANTY CHARTS–OUTBOARD AND JET

Product

2‑Stroke carbureted (50–90 hp) 1 year 3 years

2‑Stroke EFI (150 hp) 2 years 3 years

2‑Stroke carbureted (V6) 2 years 3 years

FourStroke (2.5–350 hp including Verado, Pro FourStroke and jet outboards)

OptiMax (75–250 hp including Pro XS and jet outboards)

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

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WARRANTY INFORMATION

Product

OptiMax jet drive (200 and 250 hp) 1 year 3 years

Racing Product (Recreation use only)

OptiMax (250 XS) 2 years 3 years

OptiMax (225 Sport XS) 2 years 3 years

OptiMax (300 XS) 2 years 3 years

Verado (400R) 2 years 3 years

Outside of Canada

For product purchased outside of Canada, contact the distributor in your country, or the authorized Marine Power Service Center or dealer closest to you.

Standard Limited Warranty

Standard Limited Corrosion Warranty

AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS–OUTBOARD AND JET

Standard

Products

All outboard 3 years 3 years

Limited Warranty

Standard Limited Corrosion Warranty

Light Commercial

Contact the Marine Power Service Center closest to you

Outside of Australia and New Zealand

For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the Marine Power Service Center closest to you.

SOUTH PACIFIC WARRANTY CHART–OUTBOARD AND JET

Standard

Products

All outboard 2 years 3 years

16 eng

Limited Warranty

Standard Limited Corrosion Warranty

Light Commercial

Contact the Marine Power Service Center closest to you

Page 25

WARRANTY INFORMATION

Outside of South Pacific

For product purchased outside of the South Pacific region, contact the distributor in your country, or the Marine Power Service Center closest to you.

ASIA WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

2‑Stroke 1 year 3 years

FourStroke 1 year 3 years

OptiMax 1 year 3 years

Verado 1 year 3 years

Racing Product (Recreational only)

Verado 400R 1 year 3 years None

Outside of Asia

For product purchased outside of the Asian region, contact the distributor in your country, or the Marine Power Service Center closest to you.

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

Commercial Application

EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES (CIS) WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

2‑Stroke 2 years 3 years

FourStroke 2 years 3 years

OptiMax (including Pro XS)

Verado (including Pro)

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

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WARRANTY INFORMATION

Racing Product (Recreational only)

Verado 400R 2 years 3 years

Outside Europe and CIS

For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you.

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

MIDDLE-EAST AND AFRICA (EXCLUDING SOUTH AFRICA) WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

2‑Stroke 1 year 3 years

FourStroke 2 years 3 years

OptiMax (including Pro XS)

Verado (including Pro)

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

Racing Product (Recreational only)

Verado 400R 2 years 3 years

Outside Middle‑East and Africa

For products purchased outside of the Middle‑East and Africa regions, contact the distributor in your country, or the Marine Power Service Center closest to you.

18 eng

Standard Limited Warranty

Standard Limited Corrosion Warranty

Page 27

WARRANTY INFORMATION

SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

2‑Stroke 2 years 3 years

FourStroke 2 years 3 years

OptiMax (including Pro XS)

Verado (including Pro)

Racing Product (Recreational only)

Verado 400R 2 years 3 years

Outside South Africa

For products purchased outside of the South Africa region, contact the distributor in your country, or the Marine Power Service Center closest to you.

Standard Limited Warranty

3 years 3 years

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

Standard Limited Corrosion Warranty

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GENERAL INFORMATION

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.

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U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT CAPACITY

XXX

26777

GENERAL INFORMATION

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.

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.

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.

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53910

OFF

RUN

ATTACH LANYARD

GENERAL INFORMATION

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

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

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

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

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Page 31

GENERAL INFORMATION

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.

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21604

GENERAL INFORMATION

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.

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.

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26782

26783

GENERAL INFORMATION

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.

WARNING

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

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS

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

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

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26784

GENERAL INFORMATION

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.

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.

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26785

GENERAL INFORMATION

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).

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.

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GENERAL INFORMATION

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.

Safety Instructions for Hand‑Tilled Outboards

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

MODELS WITH CLAMP SCREWS:

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

WARNING

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

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

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

Carbon monoxide is present in the exhaust fumes of all internal combustion engines. This includes the outboards, sterndrives, and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless, and tasteless.

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

WARNING

Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

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21622

21626

GENERAL INFORMATION

GOOD VENTILATION

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

Example of desired air flow through the boat

POOR VENTILATION

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

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

WHILE BOAT IS STATIONARY

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

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21628

GENERAL INFORMATION

WHILE BOAT IS MOVING

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

Selecting Accessories for Your Outboard

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

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

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

Safe Boating Recommendations

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

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

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

Perform safety checks and required maintenance.

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

Check safety equipment onboard.

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

Approved fire extinguishers

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

30 eng

Tools necessary for minor repairs

Page 39

GENERAL INFORMATION

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

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

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

Passenger boarding.

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

Use personal flotation devices.

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

Prepare other boat operators.

• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard.

Do not overload your boat.

• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

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Page 40

GENERAL INFORMATION

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

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

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

Know your boating area and avoid hazardous locations.

Be alert.

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

Never drive your boat directly behind a water skier.

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

Watch fallen skiers.

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

Report accidents.

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

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24125

H P L B

- - - . -

- -

XXXXXXX

XXXXX XX

Mercu ry

Marine

Serial Number

Brunswick Corp. Made in Japan

XXXX XXX

HP XXX LB XXX

KG XXX

KW XXX

Model Number

GENERAL INFORMATION

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)

40 FourStroke Specifications

Models

Horsepower 40

Kilowatts 29.8

Full Throttle RPM Range 5500–6000 RPM

Idle Speed in Forward Gear 800 ± 25 RPM

Number of Cylinders 3

Piston Displacement 747 cc (45.6 cu. in.)

Cylinder Bore 65 mm (2.559 in.)

Stroke 75 mm (2.953 in.)

Valve Clearance (Cold)

Intake Valve 0.15–0.25 mm (0.006–0.010 in.)

Exhaust Valve 0.25–0.35 mm (0.010–0.014 in.)

Recommended Spark Plug

Carburetor Models NGK DPR6EA‑9

Spark Plug Gap 0.9 mm (0.035 in.)

Gear Ratio 2.00:1

eng 33

Page 42

GENERAL INFORMATION

Models 40

Recommended Gasoline

Recommended Oil

Gearcase Lubricant Capacity 440 ml (14.9 fl oz)

Engine Oil Capacity 3.0 L (3 qt)

Refer to Fuel and Oil

34 eng

Page 43

58166

GENERAL INFORMATION

Component Identification

a - Tilt support knob b - Transom brackets c - Oil drain plug d - Primary cooling water intake e - Gearcase f - Trim tab g - Antiventilation plate h - Driveshaft housing i - Water pump indicator hole j - Bottom cowl k - Top cowl l - Shift handle m - Engine stop switch n - Throttle friction adjustment knob o - Lanyard stop switch p - Steering friction adjustment lever q - Tilt lock lever

eng 35

Page 44

28517

TRANSPORTING

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.

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.

36 eng

Page 45

FUEL AND OIL

Fuel Recommendations

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 damage caused thereby will not be covered under the limited warranty.

FUEL RATINGS

Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications:

USA and Canada ‑ having a posted pump octane rating of 87 (R+M)/2 minimum. Premium gasoline (92 [R+M]/2 octane) is also acceptable. Do not use leaded gasoline.

Outside USA and Canada ‑ having a posted pump octane rating of 90 RON minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.

USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)

This type of gasoline is required in certain areas of the USA. The two types of oxygenates used in these fuels are alcohol (ethanol) or ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol.

These reformulated gasolines are acceptable for use in your Mercury Marine engine.

GASOLINES CONTAINING ALCOHOL

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.

Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank.

The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

eng 37

Page 46

FUEL AND OIL

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.

Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol‑free gasoline be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required.

IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol‑blend fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components.

Low Permeation Fuel Hose Requirement

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

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

• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 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.

38 eng

Page 47

46273

46290

FUEL AND OIL

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

a - Fuel demand valve ‑ installed in the

fuel hose between the fuel tank and

primer bulb

b - Manual release c - Vent/water drain holes

Mercury Marine's Pressurized Portable Fuel Tank

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

SPECIAL FEATURES OF THE PORTABLE FUEL TANK

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

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

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

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

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

REMOVING THE FUEL CAP

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

IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening.

eng 39

Page 48

FUEL AND OIL

1. Open the manual vent screw on top of the fuel cap.

2. Turn the fuel cap until it contacts the tab lock.

3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure.

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

DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK

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

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

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

Follow Filling Fuel Tank instructions for fueling.

Filling Fuel Tank

WARNING

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

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

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

PORTABLE FUEL TANK PLACEMENT IN THE BOAT

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

Engine Oil Recommendations

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

40 eng

Page 49

+20

+40

+60

+80

F° C°

+100

–7

+16

+27

–18

+38

26795

FUEL AND OIL

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

Recommended SAE viscosity for engine oil

a - Mercury or Quicksilver SAE

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

b - Mercury or Quicksilver SAE

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

Checking and Adding Engine Oil

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

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

2. Flip the handle up and pull out the dipstick. Wipe it with a clean rag or

3. Pull the dipstick back out again and observe the oil level. If the oil level is

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.

eng 41

Remove the top cowl.

towel and push it back in all the way.

low, remove the oil filler cap and fill to (but not over) the upper oil level with the recommended oil.

Page 50

28813

FUEL AND OIL

4. Push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. Reinstall the oil filler cap and hand tighten securely.

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

42 eng

Page 51

28521

28831

FEATURES AND CONTROLS

Warning System ‑ Manual Starting Models

The outboard warning system incorporates a warning horn below the tiller handle.

a - Warning horn below tiller handle

WARNING SYSTEM OPERATION

The warning horn will emit either a continuous beep or intermittent short beeps, and engine speed will be limited to 2000 RPM. This will alert the operator and help identify the following situations.

Warning System

Function Sound Description

Engine Over Temperature Continuous Engine Overheat

Low Oil Pressure Intermittent Short Beeps Low Oil Pressure

ENGINE OVERHEAT

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

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

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

eng 43

Page 52

26802

FEATURES AND CONTROLS

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

LOW OIL PRESSURE

The warning system will be activated if the oil pressure drops too low. First, stop the engine and check the oil level. Add oil if necessary. If the oil is at the recommended level and the warning horn continues to sound, consult your dealer. Engine speed will be limited to 2000 RPM, however you should not continue to run engine.

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.

Manual Tilt System

Models without power trim are equipped with a tilt assist system that allows the operator to easily tilt and lock the outboard at any tilt position from full down to full up.

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

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

WARNING

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

BASIC TILTING OPERATION

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

a - Tilt position b - Lock/run position

44 eng

Page 53

26803

28916

FEATURES AND CONTROLS

SHALLOW WATER OPERATION

When operating your boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle. Operate your outboard at slow speed while tilted up for shallow water operation. Keep the cooling water intake holes submerged in the water and continue to check for water discharge from the water pump indicator hole.

TILTING OUTBOARD TO FULL UP POSITION

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

eng 45

Page 54

28931

FEATURES AND CONTROLS

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

a - Tilt support lever b - Knob

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

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

5. Move the tilt lock lever to the lock/run position.

OPERATING ANGLE ADJUSTMENT

The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the five adjustment holes provided. The outboard should be locked against this tilt pin by setting the tilt lock lever to the lock/run position. Proper adjustment allows the boat to run stably, achieve optimum performance, and minimize steering effort.

NOTE: Refer to the following lists when adjusting the operating angle of your outboard.

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.

46 eng

Page 55

26806

FEATURES AND CONTROLS

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

a - Too much angle (stern down ‑ bow up) b - Not enough angle (stern up ‑ bow down) c - Angle adjusted properly (bow slightly up)

Consider the following lists carefully when adjusting the operating angle of your outboard.

Adjusting the outboard close to the boat transom 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.

Adjusting the outboard away from the boat transom can:

• Lift the bow 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

eng 47

Page 56

19807

26811

FEATURES AND CONTROLS

Throttle Grip Friction Adjustment ‑ Tiller Handle Models

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

a - Loosen friction b - Tighten friction

Steering Friction Adjustment ‑ Tiller Handle Models

NOTE: Steering friction adjustment is only provided on models with tiller handles.

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

NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened.

a - Tighten friction b - Loosen friction c - Locknut

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 is released.

48 eng

Page 57

26816

FEATURES AND CONTROLS

Trim Tab Adjustment

Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal result from your outboard not trimmed with the propeller shaft parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the antiventilation plate approximately 50 mm (2 in.) or more above the boat bottom.

TRIM TAB ADJUSTMENT

Operate your boat at normal cruising speed trimmed to desired position by installing the tilt pin in the desired tilt pin hole. Turn your boat left and right and note the direction the boat turns more easily.

If adjustment is necessary, loosen the trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of the trim tab to the left. If the boat turns more easily to the right, move the trailing edge of the trim tab to the right. Tighten the bolt and test.

eng 49

Page 58

51985

OPERATION

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.

Decal on the transom bracket

Prestarting Check List

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

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

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

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

• Fuel supply OK.

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

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

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

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

•

Make inspection checks listed in Maintenance ‑ Inspection and

Maintenance Schedule.

50 eng

Page 59

58163

OPERATION

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.

Prestarting Instructions

1. Check the engine oil level.

a - Full mark b - Add mark c - Dipstick

2. Verify the cooling water intake is submerged.

eng 51

Page 60

26837

19748

OPERATION

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.

Engine Break‑in Procedure

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

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

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

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

Starting the Engine ‑ Tiller Handle Models

Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑in Procedure in the this 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. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks.

52 eng

Page 61

28526

27348

19791

28522

OPERATION

2. Connect the remote fuel line to the outboard. Verify the connector is snapped into place.

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.

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

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

eng 53

Page 62

26839

28917

ART

0%100

START

0%100

START

19799

OPERATION

6. Models without power trim ‑ Position the tilt lock lever to the lock position.

7. Position the throttle grip as follows:

•

Cold engine ‑ Set the throttle grip to the start position.

•

Warm engine ‑ Set the throttle grip to the half‑way position.

•

Flooded engine ‑ Set the throttle grip to the half‑way position.

NOTE: After starting a cold engine (air temperature below 4 °C [40 °F]), slowly advance the throttle speed until the engine is warmed up.

a - Start position b - Half‑way position

8. Manual start models ‑ 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.

54 eng

Page 63

28521

58150

OPERATION

9. 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 the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat. Have the outboard checked by your dealer. Operating the engine while overheated may cause serious engine damage.

WARMING UP ENGINE

Before beginning operation, allow the engine to warm up at idling speed for three minutes.

Gear Shifting

IMPORTANT: Observe the following:

•

Never shift the outboard into gear unless the engine speed is at idle.

•

Do not shift the outboard into reverse when the engine is not running.

• Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear), and reverse.

eng 55

Page 64

26842

26776

26844

OPERATION

• Reduce the engine speed to idle before shifting.

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

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

Stopping the Engine

Reduce the engine speed and shift the outboard to neutral position and push the engine stop button in.

Emergency Starting

If the starter system fails, use the spare starter rope (provided) and follow procedure.

1. Remove flywheel cover or manual starter assembly.

56 eng

Page 65

58150

26848

OPERATION

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

WARNING

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

WARNING

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

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

4. Pull the starter rope to start the engine.

eng 57

Page 66

MAINTENANCE

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 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.

58 eng

Page 67

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:

FEL:

TIMING (IN DEGREES):

COLD VALVE CLEARANCE (mm)

INTAKE:

EXHAUST:

g/kWh

21096

MAINTENANCE

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 - Idle speed b - Engine horsepower c - Piston displacement d - Date of manufacture e - Valve clearance (if applicable) f - Family number g - Maximum emission output for the engine family h - Timing specification i - Recommended spark plug and gap

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 emissions levels to exceed their predetermined factory specifications.

Inspection and Maintenance Schedule

BEFORE EACH USE

•

Check engine oil level. Refer to Fuel and Oil ‑ Checking and Adding Engine Oil.

• Check that lanyard stop switch stops the engine.

• Visually inspect the fuel system for deterioration or leaks.

• Check steering system for binding or loose components.

• Check propeller blades for damage.

eng 59

• Check outboard for tightness on transom.

Page 68

MAINTENANCE

AFTER EACH USE

• Flush out the outboard cooling system if operating in salt or polluted water. Refer to Flushing the Cooling System.

• Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater.

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

• Lubricate all lubrication points. Lubricate more frequently when used in saltwater. Refer to Lubrication Points.

• Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. Refer to Changing Engine Oil.

• Inspect thermostat visually for corrosion and broken spring. Make sure thermostat closes completely at room temperature.

•

Check engine fuel filter for contaminants. Refer to Fuel System.

•

Check engine timing setup.

• Check corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anode.

•

Drain and replace gearcase lubricant. Refer to Gearcase Lubrication.

•

Lubricate splines on the driveshaft.

•

Inspect battery. Refer to Battery Inspection.

•

Inspect timing belt. Refer to Timing Belt Inspection.

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

EVERY 300 HOURS OF USE OR THREE YEARS

• Replace spark plugs at first 300 hours or third year. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. Refer to Spark Plug Inspection and Replacement.

• Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).

•

Check and adjust valve clearance, if necessary.

BEFORE PERIODS OF STORAGE

•

Refer to storage procedure. Refer to Storage section.

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.

IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.

1. These items should be serviced by an authorized dealer.

60 eng

Page 69

28518

MAINTENANCE

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. Place the outboard in either the operating position (vertical) or in a tilted position.

Remove the propeller. Refer to Propeller Replacement.

3. Thread a water hose into the rear fitting. Partially open the water tap (1/2 maximum). Do not open the water tap all the way as this allows a high pressure flow of water.

IMPORTANT: Do not run engine above idle when flushing.

4. Shift the outboard into neutral. Start the engine and flush the cooling system for at least five minutes. Keep the engine speed at idle.

5. Stop the engine. Turn off the water and remove the hose. Reinstall the propeller.

eng 61

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28445

MAINTENANCE

Top Cowl Removal and Installation

REMOVAL

Pull out the rear lock lever and remove the top cowl.

INSTALLATION

1. Lower the top cowl over the engine.

2. Bring the front of the cowl down first and engage the front hook. Lower the cowl into its seated position and apply downward pressure to the back of the cowl to lock it in place. Gently pull up on the back of cowl to make sure it is securely fastened.

Exterior Care

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

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.

62 eng

Page 71

MAINTENANCE

2. Ensure the battery is secure against movement.

3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.

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

Fuel System

WARNING

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

Before servicing any part of the fuel system, stop 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.

Engine Fuel Filter ‑ Manual Starting Models

Read the preceding fuel system servicing information and warning. Inspect the fuel filter. If the filter appears to be contaminated, remove and

replace.

eng 63

Page 72

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32211

MAINTENANCE

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

a - Fuel filter

Corrosion Control Anode

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

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

This model has an anode installed on each side of the gearcase and one on the bottom of the transom bracket assembly.

a - Anode on transom bracket assembly b - Gearcase anodes

64 eng

Page 73

58150

26899

26900

MAINTENANCE

Propeller Replacement

WARNING

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

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

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

eng 65

4. Place a block of wood between the gearcase and propeller. Remove the propeller nut.

Page 74

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MAINTENANCE

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

6. Apply 2‑4‑C with PTFE to the propeller shaft.

Tube Ref

No.

Description Where Used Part No.

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

IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.

66 eng

Page 75

43671

26903

26906

MAINTENANCE

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

a - Propeller nut b - Propeller nut retainer c - Propeller d - Forward thrust hub

8. Place the propeller nut retainer over the pins. Place a block of wood between the gearcase and propeller. Tighten propeller nut to the specified torque.

Description

Propeller nut 75 – 55

9. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer. Secure the propeller nut by bending the tabs up and against the flats on the propeller nut.

a - Pins b - Tabs

10. Reflex hub ‑ Install the thrust washer onto the propeller shaft.

11. Install the propeller.

12. Install the aft washer, the tab washer, and secure with the propeller nut included with the kit. Tighten the nut to the specified torque. Bend the tabs on the tab washer onto the nut.

Nm lb‑in. lb‑ft

eng 67

Page 76

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43652

MAINTENANCE

IMPORTANT: The Flo‑Torq Reflex drive hub requires the use of the propeller nut included with the drive hub kit. The use of a propeller nut that was not included with the Flo‑Torq Reflex drive hub kit will result with the nylon portion of the locknut not fully engaging the propeller shaft threads.

a - Thrust washer b - Propeller c - Aft washer d - Tab washer e - Nut

13. Rotate the propeller to verify interference or binding does not exist between the gear housing and the propeller.

Description

Nut 75 – 55

NOTE: A small amount of rotation play is normal.

14. Install the spark plug leads.

Nm lb‑in. lb‑ft

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 boots. Twist the rubber boots slightly and pull off.

68 eng

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26946

26947

MAINTENANCE

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

3. Set the spark plug gap to specification.

Spark Plug

Spark plug gap 0.9 mm (0.035 in.)

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

Description

Spark plug 27 – 20

Nm lb‑in. lb‑ft

Timing Belt Inspection

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

• Cracks in the back of the belt or in the base of the belt teeth.

• Excessive wear at the roots of the cogs.

• Rubber portion swollen by oil.

• Belt surfaces roughened.

eng 69

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MAINTENANCE

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

Lubrication Points

1. Apply a liberal amount of oil to the clamp bracket screw threads.

2. Lubricate the following with 2‑4‑C with PTFE:

Tube Ref

No.

Description Where Used Part No.

2-4-C with PTFE

Tilt support lever, swivel bracket, copilot

shaft, propeller shaft

92-802859A 1

• Tilt support lever ‑ Lubricate through fitting.

70 eng

Page 79

28823

58155

28466

MAINTENANCE

• Swivel bracket ‑ Lubricate through fitting.

a - Tilt support lever b - Swivel bracket

• Copilot shaft (tiller handle models) ‑ Lubricate through fitting. Move the steering friction lever back and forth while lubricating.

• Propeller shaft ‑ Apply a liberal amount on the splines of the propeller shaft.

eng 71

Page 80

28531

MAINTENANCE

Changing Engine Oil

ENGINE OIL CAPACITY

Capacity Fluid Type

Mercury or Quicksilver SAE 25W‑40 Synthetic

Engine oil

3 Liter

(3 US qt)

OIL CHANGING PROCEDURE

1. Tilt the outboard up to the trailer position.

2. Turn the outboard so the drain hole is facing down. Remove the drain plug and drain the engine oil into an appropriate container. Allow several minutes for the engine oil to drain.

3. Lubricate the seal on the drain plug with oil and install. Tighten the drain plug securely.

Blend Marine 4‑Stroke Engine Oil

Mercury or Quicksilver SAE 10W‑30 4‑Stroke

Marine Engine Oil

a - Drain plug b - Drain hole

CHANGING OIL FILTER

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

72 eng

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28418

MAINTENANCE

2. Remove the filter by turning the filter counterclockwise.

3. Clean the mounting base. Lubricate the new oil filter gasket with engine oil. Do not use grease. Thread the filter on until the gasket contacts the base, then tighten 3/4 to 1 turn.

OIL FILLING

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

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

a - Oil fill cap

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 fine 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.

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MAINTENANCE

DRAINING GEARCASE

1. Place outboard in a vertical operating position.

2. Place a drain pan below outboard.

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

a - Vent plug b - Fill/drain plug

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 440 ml (14.9 fl. oz.).

CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE

1. Place outboard in a vertical operating position.

2. Remove vent plug.

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

IMPORTANT: Replace sealing washers if damaged.

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

74 eng

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MAINTENANCE

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

a - Vent hole b - Vent plug c - Fill/drain plug

Gearcase Lubricant Recommendation

Mercury or Quicksilver Premium or High Performance Gear Lubricant.

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.

eng 75

Page 84

STORAGE

Storage Preparation

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

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

NOTICE

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

FUEL SYSTEM

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

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

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

• Permanently installed fuel tank ‑ Pour the required amount of gasoline stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.

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

Protecting External Outboard Components

•

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

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

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

Tube Ref

No.

120

Description Where Used Part No.

Corrosion Guard External metal surfaces 92-802878 55

Protecting Internal Engine Components

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

76 eng

Page 85

STORAGE

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

• Change the engine oil.

Gearcase

•

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

Positioning Outboard for Storage

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

NOTICE

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

Battery Storage

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

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

• Store the battery in a cool, dry place.

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

eng 77

Page 86

TROUBLESHOOTING

Engine Will Not Start

POSSIBLE CAUSES

• Lanyard stop switch not in RUN position.

•

Incorrect starting procedure. Refer to Operation section.

• Old or contaminated gasoline.

•

Engine flooded. Refer to Operation section.

• Fuel is not reaching the engine. a. Fuel tank is empty. b. Fuel tank vent not open or restricted. c. Fuel line is disconnected or kinked. d. Primer bulb not squeezed. e. Primer bulb check valve is faulty. f.

Fuel filter is obstructed. Refer to Maintenance section. g. Fuel pump failure. h. Fuel tank filter obstructed.

• Ignition system component failure.

• Wiring or electrical connection faulty.

•

Spark plugs fouled or defective. Refer to Maintenance section.

Engine Runs Erratically

POSSIBLE CAUSES

•

Guardian System activated. Refer to Features and Controls—Warning System ‑ Manually Starting Models.

•

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 anti‑siphon valve located on permanently built‑in type fuel tanks. d. Fuel line is kinked or pinched.

• Fuel pump failure.

• Ignition system component failure.

Performance Loss

POSSIBLE CAUSES

•

Engine Guardian System activated. Refer to Features and Controls— Warning System ‑ Manually Starting Models.

• Throttle not fully open.

78 eng

Page 87

TROUBLESHOOTING

• Damaged or improper size propeller.

• Incorrect engine timing, adjustments, or setup.

• Boat overloaded or load improperly distributed.

• Excessive water in bilge.

• Boat bottom is dirty or damaged.

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.

eng 79

Page 88

OWNER SERVICE ASSISTANCE

Parts and Accessories Inquiries

All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer. The dealer has the necessary information to order parts and accessories for you. When inquiring about parts and accessories, the dealer requires the model and serial number to order the correct parts.

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.

80 eng

Page 89

OWNER SERVICE ASSISTANCE

PARTS AND ACCESSORIES INQUIRIES

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

RESOLVING A PROBLEM

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

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

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

The following information will be needed by the Customer Service:

• Your name and address

• Your daytime telephone number

• The model and serial numbers of your power package

• The name and address of your dealership

• The nature of the problem

CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE

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

United States, Canada

Telephone

Fax

Website www.mercurymarine.com

eng 81

English +1 920 929 5040 Français +1 905 636 4751

English +1 920 929 5893 Français +1 905 636 1704

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

Page 90

OWNER SERVICE ASSISTANCE

Australia, Pacific

Telephone +61 3 9791 5822 Brunswick Asia Pacific Group

41–71 Bessemer Drive

Fax +61 3 9706 7228

Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe

Fax +32 87 31 19 65

Mexico, Central America, South America, Caribbean

Telephone +1 954 744 3500 Mercury Marine

Fax +1 954 744 3535

Japan

Telephone +072 233 8888 Kisaka Co., Ltd.

Fax +072 233 8833

Dandenong South, Victoria 3175 Australia

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

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

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

Asia, Singapore

Telephone +65 65466160 Brunswick Asia Pacific Group

T/A Mercury Marine Singapore Pte Ltd

Fax +65 65467789

29 Loyang Drive Singapore, 508944

Ordering Literature

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

Model

Horsepower Year

UNITED STATES AND CANADA

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

82 eng

Serial Number

Page 91

OWNER SERVICE ASSISTANCE

Mercury Marine

Telephone Fax Mail

Mercury Marine

(920) 929‑5110

(USA only)

OUTSIDE THE UNITED STATES AND CANADA

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

Submit the following order form with payment to:

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

Name

Address

City, State, Province

ZIP or postal code

Country

(920) 929‑4894

(USA only)

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

Attn: Publications Department

Fond du Lac, WI 54936-1939

P.O. Box 1939

Quantity Item Stock Number Price Total

. .

Total Due .

eng 83

Page 92

51965

INSTALLATION

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 a 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.

Installation Information

BOAT HORSEPOWER CAPACITY

WARNING

84 eng

Page 93

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT CAPACITY

XXX

26777

INSTALLATION

START IN GEAR PROTECTION

WARNING

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

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

SELECTING ACCESSORIES FOR YOUR OUTBOARD

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

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

ELECTRIC FUEL PUMP

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

eng 85

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58167

58176

INSTALLATION

INSTALLATION SPECIFICATIONS

Minimum Transom Opening

Single engine (tiller) 76.2 cm (30 in.)

LIFTING OUTBOARD

Use the lifting eye on the engine.

86 eng

Page 95

5489

2757

INSTALLATION

INSTALLING OUTBOARD

Drilling Outboard Mounting Holes

1. Mark four mounting holes on the transom using the transom drill fixture.

a - Drill guide holes b - Transom drilling fixture c - Transom centerline

Transom Drilling Fixture 91‑98234A2

Aids in engine installation by acting as a template for engine mounting holes.

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

3973

eng 87

Page 96

18961

20860

INSTALLATION

Checking Boat Transom Construction

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

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

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

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

a - Large transom washer b - Transom reinforcement plate

Description Part Number

Large transom washer 67‑896392

Transom reinforcement plate 67‑896305

88 eng

Page 97

8045

58157

INSTALLATION

Fastening the Outboard to the Transom

1. Install the outboard so that the antiventilation plate is in‑line or within 25 mm (1 in.) below the bottom of the boat.

a - Antiventilation plate b - 25 mm (1 in.)

2. Apply marine sealer to the shanks of the bolts, not the threads.

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

NOTE: For a more accurate torque, tighten the locknuts rather than turning the mounting bolts.

a - Clamp bracket screw b - 1/2 in. diameter bolt (4) c - Flat washer (4) d - Locknut (4)

Description Nm lb‑in. lb‑ft

Outboard mounting hardware 75 – 55

4. Tighten the clamp bracket screws securely.

eng 89

Page 98

28526

26902

INSTALLATION

Fuel Hose Connection

FUEL HOSE CONNECTION

The minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.). The fuel hose connection on this engine model is a snap lock design. Fasten the remote fuel hose to the fitting with a metal hose clamp or the plastic type hose clamp that is provided with the outboard.

Flo‑Torq I Propeller Installation

WARNING

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components.

WARNING

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

1. Lubricate the propeller shaft with 2‑4‑C with PTFE.

90 eng

Page 99

26903

26904

INSTALLATION

Tube Ref

No.

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.

2. Flo‑Torq I drive hub propellers ‑ Install forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft.

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

Description Where Used Part No.

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

a - Propeller nut b - Propeller nut retainer c - Propeller d - Forward thrust hub

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

4. Place the propeller nut retainer over the pins. Place a block of wood between the gearcase and propeller. Tighten the propeller nut to the specified torque.

Description

Propeller nut 75 55

Nm lb‑in. lb‑ft

eng 91

Page 100

12733

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INSTALLATION

5. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer. Secure the propeller nut by bending the tabs up and against the flats on the propeller nut.

a - Pins b - Tabs

6. Install the spark plug leads.

Flo‑Torq Reflex Drive Hub Propeller Installation

WARNING

Lubricate the propeller shaft splines with 2‑4‑C with PTFE.

92 eng