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40 FourStroke Tiller Handle
Installation Manual
107 pgs4.33 Mb0
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Mercury 40 FourStroke Tiller Handle Installation Manual

Outboard
Operation
Maintenance
Warranty
Installation
Manual

40 FourStroke Tiller Handle

© 2015 Mercury Marine
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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

© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
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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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WARRANTY INFORMATION
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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WARRANTY INFORMATION
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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WARRANTY INFORMATION
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
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.
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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WARRANTY INFORMATION
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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WARRANTY INFORMATION
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.
12 eng
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
eng 13
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
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 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.
14 eng
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
Standard Limited Warranty
3 years 3 years
3 years 3 years
Standard Limited Corrosion Warranty
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
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 Warranty
Standard Limited Corrosion 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
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 Warranty
Standard Limited Corrosion 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
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
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.
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Standard Limited Warranty
Standard Limited Corrosion Warranty
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
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.
20 eng
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.
eng 21
c
a
b
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.
22 eng
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