Mercury 4 TwoStroke, 4.9 TwoStroke, 5 TwoStroke Installation Manual

Operation

Maintenance

and

Installation

Manual

© 2017 Mercury Marine

4, 4.9, 5 TwoStroke

8M0133462 617 eng

eng

Welcome

You have selected one of the finest marine power packages available. It
incorporates numerous design features to ensure operating ease and durability.

With proper care and maintenance, you will enjoy using this product for many
boating seasons. To ensure maximum performance and carefree use, we ask
that you thoroughly read this manual.

The Operation and Maintenance Manual contains specific instructions for using
and maintaining your product. We suggest that this manual remain with the
product for ready reference whenever you are on the water.

Thank you for purchasing one of our products. We sincerely hope your boating
will be pleasant!

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

Name / function:

John Pfeifer, President,
Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your
dealer. Your dealer can also provide a demonstration of actual starting and
operating procedures.

Notice

Throughout this publication, and on your power package, warnings, cautions,

and notices, accompanied by the International Hazard Symbol

!

, may be
used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully.

These safety alerts alone cannot eliminate the hazards that they signal. Strict
compliance with these special instructions while performing the service, plus
common sense operation, are major accident prevention measures.

!

WARNING

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

!

CAUTION

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

eng i

NOTICE

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

IMPORTANT: Identifies information essential to the successful completion of
the task.

NOTE: Indicates information that helps in the understanding of a particular step
or action.

IMPORTANT: The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard, and the safety of all occupants
aboard. We strongly recommend that the operator read this Operation and
Maintenance Manual and thoroughly understand the operational instructions for
the power package and all related accessories before the boat is used.

!

WARNING

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

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

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

Warranty Message

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

Mercury Marine products are designed and manufactured to comply with our
own high quality standards, applicable industry standards and regulations, as
well as certain emissions regulations. At Mercury Marine every engine is
operated and tested before it is boxed for shipment to make sure that the
product is ready for use. In addition, certain Mercury Marine products are
tested in a controlled and monitored environment, for up to 10 hours of engine
run time, in order to verify and make a record of compliance with applicable
standards and regulations. All Mercury Marine product, sold as new, receives
the applicable limited warranty coverage, whether the engine participated in
one of the test programs described above or not.

ii eng

Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in
part without permission is prohibited.

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

Identification Records

Please record the following applicable information:

Outboard

Engine Model and Horsepower

Engine Serial Number

Gear Ratio

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

eng iii

eng iv

General Information

Boater's Responsibilities..................................................................................... 1

Before Operating Your Outboard........................................................................ 1

Boat Horsepower Capacity................................................................................. 1

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

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

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

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

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

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

Model Year Production Code............................................................................10

Component Identification—4C/4.9/5BD............................................................ 12

4/4.9/5 Specifications........................................................................................13

Installation

Installing Outboard............................................................................................16

Transporting

Removing the Motor......................................................................................... 18

Carrying the Motor............................................................................................ 18

Storing the Motor.............................................................................................. 18

Trailering the Boat............................................................................................ 19

Fuel and Oil

Fuel Requirements........................................................................................... 21

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

Mixing Fuel and Oil........................................................................................... 22

Engine Break‑In................................................................................................ 23

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

Features and Controls

Remote Control Features................................................................................. 24

Tilting Outboard................................................................................................ 26

Shallow Water Operation.................................................................................. 27

Trim Angle Adjustment..................................................................................... 28

eng v

Operation

Prestarting Check List.......................................................................................30

Operating in Freezing Temperatures................................................................ 30

Operating at High Elevations............................................................................ 30

Operating in Saltwater or Polluted Water......................................................... 30

Engine Break‑in Procedure...............................................................................31

Warming Up the Engine....................................................................................31

Starting the Engine........................................................................................... 32

Gear Shifting..................................................................................................... 36

Stopping the Engine......................................................................................... 36

Maintenance

Outboard Care.................................................................................................. 37

Inspection and Maintenance Schedule ............................................................ 37

Flushing the Cooling System............................................................................ 38

Top Cowl Removal And Installation.................................................................. 39

Corrosion Control Anode.................................................................................. 39

Exterior Care.....................................................................................................40

Fuel System...................................................................................................... 40

Propeller Replacement..................................................................................... 41

Propeller Selection............................................................................................43

Spark Plug Inspection And Replacement......................................................... 43

Lubrication Points............................................................................................. 44

Gearcase Lubrication........................................................................................46

Submerged Outboard....................................................................................... 48

Storage

Storage Preparation..........................................................................................49

Protecting External Outboard Components...................................................... 49

Protecting Internal Engine Components........................................................... 49

Gearcase.......................................................................................................... 50

Positioning Outboard for Storage..................................................................... 50

vi eng

Owner Service Assistance

Local Repair Service.........................................................................................51

Service Away from Home................................................................................. 51

Parts and Accessories Inquiries....................................................................... 51

Service Assistance........................................................................................... 51

Mercury Marine Service Offices........................................................................ 51

Maintenance Log

Maintenance Log.............................................................................................. 53

Accessories

Optional Accessories........................................................................................ 54

Wiring Diagram................................................................................................. 56

Wire Color Code Abbreviations........................................................................ 57

Tool Kit and Spare Parts...................................................................................57

Propeller Recommendation.............................................................................. 58

eng vii

eng viii

Boater's Responsibilities

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

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

Before Operating Your Outboard

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

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

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

!

WARNING

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

!

CAUTION

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

NOTICE

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

Boat Horsepower Capacity

!

WARNING

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

GENERAL INFORMATION

eng 1

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

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON
CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT
CAPACITY

XXX

26777

Lanyard Stop Switch

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

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

GENERAL INFORMATION

2 eng

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

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

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

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

c

a

b

53910

OFF

RUN

ATTACH LANYARD

GENERAL INFORMATION

eng 3

While activation of the lanyard stop switch will stop the engine immediately, a
boat will continue to coast for some distance depending upon the velocity and
degree of any turn at shut down. However, the boat will not complete a full
circle. While the boat is coasting, it can cause injury to anyone in the boat's
path as seriously as the boat would when under power.

We strongly recommend that other occupants be instructed on proper starting
and operating procedures should they be required to operate the engine in an
emergency (if the operator is accidentally ejected).

!

WARNING

If the operator falls out of the boat, stop the engine immediately to reduce the
possibility of serious injury or death from being struck by the boat. Always
properly connect the operator to the stop switch using a lanyard.

!

WARNING

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

Accidental or unintended activation of the switch during normal operation is
also a possibility. This could cause any, or all, of the following potentially
hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward
motion ‑ a particular concern for passengers in the front of the boat who
could be ejected over the bow and possibly struck by the gearcase or
propeller.

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

• Loss of control when docking.

KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD
OPERATING CONDITION

Before each use, check to ensure the lanyard stop switch works properly. Start
the engine and stop it by pulling the lanyard cord. If the engine does not stop,
have the switch repaired before operating the boat.

Before each use, visually inspect the lanyard cord to ensure it is in good
working condition and that there are no breaks, cuts, or wear to the cord.
Check that the clips on the ends of the cord are in good condition. Replace any
damaged or worn lanyard cords.

GENERAL INFORMATION

4 eng

Protecting People in the Water

WHILE YOU ARE CRUISING

It is very difficult for a person standing or floating in the water to take quick
action to avoid a boat heading in his/her direction, even at slow speed.

21604

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

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

WHILE THE BOAT IS STATIONARY

!

WARNING

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

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

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

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

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

GENERAL INFORMATION

eng 5

!

WARNING

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

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

STAY CLEAR OF EXHAUST AREAS

41127

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

co

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of
concentrated engine exhaust gases. When engines are running, keep
swimmers away from the boat, and do not sit, lie, or stand on swim platforms or
boarding ladders. While underway, do not allow passengers to be positioned
immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust
concentration, but also subjects them to the possibility of injury from the boat
propeller.

GOOD VENTILATION

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

Example of desired air flow through the boat:

21622

POOR VENTILATION

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

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

GENERAL INFORMATION

6 eng

1. Examples of poor ventilation while the boat is stationary:

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

2. Examples of poor ventilation while the boat is moving:

a - Operating the boat with the trim angle of the bow too high
b - Operating the boat with no forward hatches open (station wagon effect)

Selecting Accessories for Your Outboard

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

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

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

Safe Boating Recommendations

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

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

21626

a

b

a

b

21628

GENERAL INFORMATION

eng 7

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

Perform safety checks and required maintenance.

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

Check safety equipment onboard.

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

Approved fire extinguishers

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

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

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

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

Passenger boarding.

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

Use personal flotation devices.

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

Prepare other boat operators.

GENERAL INFORMATION

8 eng

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

Do not overload your boat.

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

Ensure that everyone in the boat is properly seated.

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

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

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

Know your boating area and avoid hazardous locations.

Be alert.

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

Never drive your boat directly behind a water‑skier.

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

Watch fallen skiers.

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

Report accidents.

GENERAL INFORMATION

eng 9

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

Recording Serial Number

It is important to record the serial number and other important information for
future reference.

Please record the serial number of the engine as indicated (on the lower engine
cover and the cylinder block) in the space below. This number will come in
handy in the event of theft and it can help you to quickly identify the product
type.

Serial number:
Model year:
Model designation:
Year manufactured:
Certified Europe Insignia (as applicable):

Model Year Production Code

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

XXXXXXXXX

XXXXXXXX

XXXX

AG

62972

Serial number decal alpha code

GENERAL INFORMATION

10 eng

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

Examples:

• XX = 2000

• HK = 2089

• AG = 2017

GENERAL INFORMATION

eng 11

Component Identification—4C/4.9/5BD

41059

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28 29

30 31 32 33 34

GENERAL INFORMATION

12 eng

1 - Air vent screw
2 - Fuel tank cap
3 - Tilt handle
4 - Upper motor cover
5 - Lower motor cover
6 - Water pump indicator port
7 - Tilt lever
8 - Steering friction adjustment screw
9 - Anode
10 - Anti‑ventilation plate
11 - Water inlet
12 - Propeller
13 - Starter handle
14 - Shift lever
15 - Throttle grip
16 - Choke knob
17 - Stop switch
18 - Fuel connector
19 - Clamp screw
20 - Clamp bracket
21 - Trim position pin
22 - Oil plug (upper)
23 - Oil plug (lower)
24 - Fuel tank
25 - Fuel pickup elbow
26 - Primer bulb
27 - Fuel tank cap
28 - Air vent screw
29 - Fuel connector
30 - Air vent screw
31 - Fuel valve
32 - Choke knob
33 - Stop switch
34 - Fuel connector

4/4.9/5 Specifications

Models

4C 4.9 5B‑D
Overall length 700 mm (27.6 in.)
Overall width 310 mm (12.2 in.)

GENERAL INFORMATION

eng 13

Models 4C 4.9 5B‑D

Overall height

S=1007 mm (39.6 in.), L=1134 mm (44.6 in.)

– – UL=1261 mm (49.6 in.)

Transom
height

S=435 mm (17.1 in.), L=562 mm (22.1 in.),

UL=689 mm (27.1 in.)

Weight

S=20.0 kg (44 lb), L=20.5 kg (45 lb)

– – UL=21.0 kg (46 lb)

Output

2.9 kW
(4 HP)

3.6 kW

(4.9 HP)

3.7 kW
(5 HP)

Max operating
range

4500–5500 RPM

Idle speed in
forward gear

850 RPM

Idle speed in
neutral gear

1000 RPM

Engine type Two‑Stroke
Number of

cylinders

1

Bore x stroke 55 x 43 mm (2.17 x 1.69 in.)
Displacement 102 mL (6.22 in.³)
Exhaust

system

Through hub exhaust

Cooling
system

Thermostat controlled

Lubrication
system

Engine oil mixed gasoline

Fuel

Unleaded regular gasoline pump posted 87 Octane

(research octane rating of 92)
Engine oil Mercury/Quicksilver or recommended Two‑Stroke engine oil
Engine oil

mixing ratio

1:50 (Engine oil:fuel)

Starting
system

Manual starter

Ignition
system

Flywheel magneto CDI

Spark plug NGK BPR7HS‑10
Trim position 6

Gear oil

Mercury/Quicksilver gear oil or API GLS, SAE #80 to #90,

approximately 195 mL (6.6 fl oz)

GENERAL INFORMATION

14 eng

Models 4C 4.9 5B‑D

Fuel tank
capacity

2.5 L

(0.66 US gal)

2.5 L

(0.66 US gal)

2.5 L (0.66 US gal),
12 L (3.17 US gal)*

Gear
reduction ratio

2.15 (13:28)

* In case of dual fuel tank system, use together with 12 L separate tank.

GENERAL INFORMATION

eng 15

Installing Outboard

INSTALLING OUTBOARD ON TRANSOM

IMPORTANT: Most boats are rated and certified in terms of their maximum
horsepower, and this is shown on the boat's certification plate. Do not equip
your boat with an outboard that exceeds this limit. If in doubt, contact your
dealer. Do not operate the engine unit until it has been securely mounted on
the boat in accordance with the instructions below.

1. Position the outboard at the center of the transom. Mount it using a
cushioning pad or plate.

a - Boat transom

BOAT TRANSOM HEIGHT REQUIREMENT

1. Measure the transom height of your boat. The anti‑ventilation plate should
be 30–50 mm (1.2–2 in.) below the bottom of the boat.

a - Bottom of hull
b - Anti‑ventilation plate

37508

a

30–50 mm (1.2” 2”)–

37510

a

b

INSTALLATION

16 eng

ATTACH THE ENGINE TO THE BOAT

1. Tighten the clamp screws by turning the handles. Secure with a cable to
prevent accidental loss overboard.

a - Clamp screw

42041

a

INSTALLATION

eng 17

Removing the Motor

IMPORTANT: Ensure the proper procedures are followed for transportation and
storage of the outboard to avoid the possibility of oil leaks.

1. Stop the engine and close the air vent screw.

2. Close the fuel valve knob. Disconnect the fuel connector.

3. Remove the motor from the hull and completely drain the water from the
gearcase.

Carrying the Motor

Be sure to keep the engine vertical posture whenever you carry the motor.

39485

NOTE: If you carry the motor horizontal posture, keep the power head higher
than the propeller.

IMPORTANT: Beware of explosion danger. Spilled and vapored gasoline may
easily catch fire and explode. Be sure to fully discharge gasoline from the
carburetors when transporting the engine. Wipe off spilled gasoline with a rag.

Storing the Motor

1. With the outboard still in the water, close the fuel shut‑off valve or
disconnect the remote fuel line (if equipped) and run engine until it stops.
This will drain fuel from the carburetor. Remove outboard from the boat
and hold upright until all cooling water is drained out.

TRANSPORTING

18 eng

2. Lay the outboard down on its back side so the tiller handle is facing up as
shown. Place a protective pad under the outboard.

40803

3. Close the fuel tank vent.

Trailering the Boat

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

The boat should be trailered with the outboard tilted down (normal operating
position). If trailering with the engine fully down is not possible (the gearcase
skeg is too close to the road in a vertical position), tilt the motor securely using
a device (like a transom saver bar) in the tilted up position.

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

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

39486

TRANSPORTING

eng 19

NOTE: The tilt support device supplied on your outboard is not intended for
towing. It is intended to support the engine while the boat is docked, beached,
etc.

TRANSPORTING

20 eng

Fuel Requirements

IMPORTANT: Use of improper gasoline can damage your engine. Engine
damage resulting from the use of improper gasoline is considered misuse
of the engine and will not be covered under the limited warranty.

FUEL RATINGS

Mercury outboard engines will operate satisfactorily with any major brand of
unleaded gasoline that meets the following specifications:

USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for
most models. Premium gasoline 91 (R+M)/2 octane is also acceptable for most
models. Do not use leaded gasoline.

Outside USA and Canada ‑ A posted pump octane rating of 91 RON,
minimum, for most models. Premium gasoline (95 RON) is also acceptable for
all models. Do not use leaded gasoline.

USING REFORMULATED (OXYGENATED) GASOLINE (USA ONLY)

Reformulated gasoline is required in certain areas of the USA and is
acceptable for use in your Mercury Marine engine. The only oxygenate
currently in use in the USA is alcohol (ethanol, methanol, or butanol).

GASOLINE CONTAINING ALCOHOL

Bu16 Butanol Fuel Blends

Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury
Marine fuel rating requirements are an acceptable substitute for unleaded
gasoline. Contact your boat manufacturer for specific recommendations on
your boat's fuel system components (fuel tanks, fuel lines, and fittings).

Methanol and Ethanol Fuel Blends

IMPORTANT: The fuel system components on your Mercury Marine engine will
withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your
boat's fuel system may not be capable of withstanding the same percentage of
alcohol. Contact your boat manufacturer for specific recommendations on your
boat's fuel system components (fuel tanks, fuel lines, and fittings).

Be aware that gasoline containing methanol or ethanol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through the rubber fuel lines

• Likelihood of phase separation (water and alcohol separating from the
gasoline in the fuel tank)

FUEL AND OIL

eng 21

!

WARNING

Fuel leakage is a fire or explosion hazard, which can cause serious injury or
death. Periodically inspect all fuel system components for leaks, softening,
hardening, swelling, or corrosion, particularly after storage. Any sign of
leakage or deterioration requires replacement before further engine
operation.

IMPORTANT: If you use gasoline that contains or might contain methanol or
ethanol, you must increase the frequency of inspection for leaks and
abnormalities.

IMPORTANT: When operating a Mercury Marine engine on gasoline containing
methanol or ethanol, do not store the gasoline in the fuel tank for long periods.
Cars normally consume these blended fuels before they can absorb enough
moisture to cause trouble; boats often sit idle long enough for phase separation
to take place. Internal corrosion may occur during storage if alcohol has
washed protective oil films from internal components.

Oil Recommendation

Recommended Oil

Mercury or Quicksilver Premium 2‑Cycle TC‑W3
Outboard Oil

IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil.
Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for this

engine. For added protection and lubrication, Mercury or Quicksilver Premium
Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil
is not available, substitute another brand of 2‑cycle outboard oil that is NMMA
Certified TC‑W3. Severe engine damage may result from use of an inferior oil.

Mixing Fuel and Oil

Use a 1:25 oil/gasoline mixture in the first tank of fuel.
After the break‑in fuel mixture is used up, use a 1:50 oil/gasoline mixture. Refer

to the table (following) for mixing ratios.

GASOLINE/OIL MIXING RATIO CHART

OIL/GASOLINE MIXING RATIO CHART

Oil/Gas Ratio 3.8 liters (1 gal) gas 11.5 liters (3 gal) gas 23 liters (6 gal) gas

1:25

148 ml (5 fl oz) oil 473 ml (16 fl oz) oil 946 ml (32 fl oz) oil

1:50

89 ml (3 fl oz) oil 237 ml (8 fl oz) oil 473 ml (16 fl oz) oil

MIXING PROCEDURE

Pour the full amount of oil along with approximately one gallon of gasoline into
an approved container. Shake the two together until they are thoroughly mixed.
Add the remainder of gasoline and shake container to ensure mixing.

FUEL AND OIL

22 eng

Engine Break‑In

Engine Break‑In Fuel Mixture

Use a 1:25 oil/gasoline mixture in the first tank of fuel.

Engine Break‑In Procedure

Refer to Operation ‑ Engine Break‑In Procedure for correct break‑in
procedure.

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 fuel tanks outdoors away from heat, sparks, and open flames.
Always stop engine before refilling tanks.
Do not overfill the fuel tank. Fuel will expand in volume as its temperature rises

and can leak under pressure if the tank is completely filled.
The oil and fuel mixture should always be thoroughly mixed in an approved

container before pouring into motor fuel tank. Do not pour separately into fuel
tank.

Pour fuel into tank through a fine mesh strainer to remove dirt which may be
present.

PORTABLE FUEL TANK

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

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

FUEL AND OIL

eng 23

Remote Control Features

Your boat may be equipped with the remote control shown. If not, consult your
dealer for a description of the functions and operations of the remote control.

a - Remote control handle
b - Throttle only lever
c - Ignition key switch
d - Lanyard stop switch

Throttle grip friction knob: The throttle friction can be adjusted in accordance
with your preference by turning the adjustment screw.

a - Direction to heavier friction
b - Direction to lighter friction
c - Throttle adjustment screw

37982

a

b

c

d

41034

c

b

a

FEATURES AND CONTROLS

24 eng

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

38349

Steering friction adjustment: The steering friction can be adjusted in
accordance with your preference by turning the adjustment screw.

a - Steering adjustment screw
b - Turn counterclockwise to lighter steering
c - Turn clockwise to heavier steering

!

WARNING

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

Starter rope: Pull the starter handle slowly until you feel engagement. Then
pull it quickly. Repeat if necessary until engine is started.

28851

After the engine has started, push the choke knob back then return the grip to
SLOW position and run the engine to warm up for several minutes.

41067

a

b

c

FEATURES AND CONTROLS

eng 25

Tilting Outboard

TILTING TO FULL UP POSITION

1. Stop the engine. Shift the outboard into Forward (F) gear.

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

27023

3. Then slightly lower the motor for locking at tilt‑up position.

a - Tilt up position
b - Tilt stopper
c - Tilt lever

4. The spring loaded tilt lock lever will engage automatically and lock the
outboard in full up position.

LOWERING TO RUN POSITION

1. Raise the outboard and pull up on the tilt release lever. Gently lower
outboard down.

a - Tilt lever
b - Tilt stopper

41065

a

b

c

41066

a

b

FEATURES AND CONTROLS

26 eng

Shallow Water Operation

This outboard has a shallow water drive position. This will allow you to tilt the
outboard to a higher position to prevent hitting bottom.

ENGAGING SHALLOW WATER DRIVE

1. Reduce engine speed to idle in forward gear. Take hold of the top cowl
grip and raise outboard to the higher tilt position. The spring loaded tilt
lock lever will engage automatically and lock the outboard in the shallow
water drive position.

27025

2. Ensure the cooling water intake is submerged.

27029

IMPORTANT: Operate outboard at slow speed for shallow water operation
and keep the cooling water intake submerged.

FEATURES AND CONTROLS

eng 27

3. To release outboard back down to run position, tilt outboard up slightly
(approximately 15°), then pull up on the tilt release lever. Gently lower
outboard down to the normal running position.

a - Tilt lever
b - Tilt stopper

Please follow the instructions below.

• Be sure that the water intake is submerged at all times and that water is
continuously flowing from the cooling water pump indicator hole.

• Be sure to run the engine slowly when using the shallow water drive.
Running at higher speeds will result in lack of control and may damage
the mounting bracket.

• Care must be taken while running in this tilt position not come in contact
with the bottom, or submerged objects, especially in reverse. This may
cause damage to the motor and/or boat.

Trim Angle Adjustment

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

The following instructions explain how to set the best angle of the boat.
The tilt pin should be adjusted so the outboard is positioned to run

perpendicular to the water when the boat is running at full speed. This allows
the boat to be driven parallel to the water.

Arrange passengers and load in the boat so the weight is distributed evenly.
The trim angle is adjusted by setting the trim position pin in the correct trim

position.

TRIM POSITION ADJUSTMENTS

•

Correct trim: The trim angle is optimum when the boat is parallel to the
water surface while running.

•

Trim down: If the trim angle is excessive, the bow will rise out of the
water and the speed will decrease. Furthermore, the bow may sway or the
bottom may slam the water while cruising. In this case, decrease the trim
angle by setting the trim position pin in a lower position.

41066

a

b

FEATURES AND CONTROLS

28 eng

•

Trim up: If the trim angle is too small, the bow will enter the water, the
speed will decrease, and water may enter the boat. In this case, the trim
angle should be increased by setting the trim position pin in a higher
position.

a - Correct trim
b - Trim down
c - Trim up
d - Move pin to raise bow up
e - Move pin to lower bow down
f - Trim position pin

41064

f

b

c

a

d

e

FEATURES AND CONTROLS

eng 29

Prestarting Check List

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

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

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

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

• Fuel supply OK.

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

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

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

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

•

Make inspection checks listed in Maintenance ‑ Inspection and

Maintenance Schedule.

Operating in Freezing Temperatures

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

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

Operating at High Elevations

IMPORTANT: To prevent serious damage to the engine caused by a lean fuel
mixture, do not operate the outboard (if the jets were changed for high
elevation) at a lower elevation unless the jets are changed again to correspond
to the new elevation.

Operating the outboard at an elevation higher than 762 m (2500 ft.) above sea
level may require a carburetor jet change. Consult your dealer. This will reduce
the normal performance loss experienced as a result of reduced oxygen in the
air causing an overly rich fuel mixture.

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.

OPERATION

30 eng

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.

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.

ENGINE BREAK-IN FUEL MIXTURE

Use a 1:25 oil/gasoline mixture in the first tank of fuel.

BREAK-IN PROCEDURE

Vary the throttle setting during the first hour of operation. During the first hour of
operation, avoid remaining at a constant speed for more than two minutes and
avoid sustained wide open throttle.

Warming Up the Engine

It's important to warm‑up the engine for three minutes. This allows the
lubrication system to circulate and deliver oil to all the moving parts of an
engine.

Operating the engine without warm‑up will reduce engine performance and
shorten the life of the engine. Be sure to check that cooling water is coming out
of the water pump indicator hole during warm‑up.

a - Water pump indicator hole

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.

41060

a

OPERATION

eng 31

Engine speed: Idling speed after warming up.

In Gear In Neutral

850 RPM 1000 RPM

Starting the Engine

Before starting, read the Prestarting Check List, special operating
instructions, and Engine Break‑In Procedure in this section.

IMPORTANT: Be sure to connect the emergency lanyard to your waist or
clothing. The engine will shut down if the lanyard becomes disconnected from
the engine.

NOTE: The engine will not start unless the lanyard has been properly
connected to the emergency stop switch.

1. Lower the outboard to the run position. Make sure the cooling water
intake is submerged.

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.

27029

2. Loosen the air vent screw on the tank cap.

a - Air vent screw

41046

a

OPERATION

32 eng

19748

3. Attach the fuel connector to the engine connector.

42043

4. The arrow mark on the primer bulb should be facing the engine (separate
fuel tank).

5. Open the fuel valve (internal fuel tank).

a - Air vent screw
b - Fuel valve

6. Feed fuel to the carburetor by squeezing the primer bulb until it is firm
(separate fuel tank).

a - To fuel tank
b - To engine
c - Fuel flow direction

41834

a

b

37714

a

c

b

OPERATION

eng 33

7. Move gear shift lever to neutral (N) position. Be sure that the shift lever is
in neutral (N) when starting the engine. This model is provided with a
function that prevents starting in gear.

F

N

27020

NOTE: If the motor somehow does start in gear, do not operate it. Contact
your authorized dealer.

8. Move the throttle grip to the start position.

28847

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

38349

OPERATION

34 eng

10. 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.

28840

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

11. 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 a
dealer. Operating the engine while overheated may cause serious engine
damage.

IF THE RECOIL STARTER FAILS TO OPERATE

• Remove the upper motor cover and the recoil starter. Wrap a rope around
the starter pulley then pull quickly to start.

• Use a 10 mm socket wrench as a rope handle.

28851

!

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 rewind starter assembly or
top cowl when engine is running.

OPERATION

eng 35

Gear Shifting

Your outboard has three gear shift positions to provide operation: Forward (F),
Neutral (N), and Reverse (R).

Reduce throttle speed to idle speed.

NOTE: Personal injury and/or equipment damage may occur if shifting at high
speed. Engine must be in the slow running position before shifting is attempted.

NOTE: Do not increase engine speed more than necessary in reverse.

a - Reverse
b - Neutral
c - Forward
d - Shift lever

Always shift outboard into gear with a quick motion.

•

Forward: Turn the throttle grip to reduce engine speed. When the engine
reaches trolling (or idling) speed, quickly pull the shift lever to the Forward
(F) position.

•

Reverse: Reduce engine speed, when the engine reaches trolling (or
idling) speed, quickly push the shift lever to the Reverse (R) position.

Stopping the Engine

1. Turn the throttle grip to the slow position.

2. Put the shift lever in Neutral (N) position. Run the engine for 2–3 minutes
at idling speed if it has been running at full speed.

3. Push the stop switch to stop the engine.

a - Lanyard hook
b - Stop switch lock
c - Stop switch

41061

a

b

c

d

41063

a

b

c

OPERATION

36 eng

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.

Inspection and Maintenance Schedule

DAILY CHECKS

• Check the engine oil level

• Check the lanyard stop switch

• Inspect the fuel system for leaks

• Inspect the engine tightness on the transom

• Check the steering system for binding

• Check the propeller for damage

• Inspect the hydraulic steering fittings and hoses for leaks or signs of
damage, if equipped

• Check the hydraulic steering fluid level, if equipped

AFTER EACH USE

• Wash the power package exterior with fresh water

• Flush the outboard cooling system, saltwater or brackish water only

ANNUALLY OR 100 HOURS

• Grease the engine, if applicable

• Change the engine oil and filter, if equipped

• Inspect the thermostat, saltwater or brackish water only

• Add Quickleen to the fuel tank, once per year, per engine

• Apply antiseize to the spark plug threads

• Replace the gear lubricant

• Inspect the corrosion control anodes

• Lubricate the propeller shaft splines

• Replace all filters on the suction side of the fuel system—dealer item

• Lubricate the driveshaft splines—dealer item

• Check the tightness on all the fasteners—dealer item

MAINTENANCE

eng 37

• Check the torque of the outboard mounting hardware—dealer item

• Check the battery condition and tightness of the battery cable connection,
if equipped—dealer item

THREE YEARS OR 300 HOURS

• Replace the spark plugs

• Replace the water pump impeller—dealer item

• Inspect the carbon fiber reeds, if equipped—dealer item

• Inspect the wire harness connectors—dealer item

• Check the remote control cable adjustment, if equipped—dealer item

• Replace the high‑pressure fuel filter, if equipped—dealer item

• Replace the accessory drive belt, if equipped—dealer item

• Check the power trim fluid level, if equipped—dealer item

• Inspect the engine motor mounts—dealer item

Flushing the Cooling System

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

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

1. Remove the water plug from the motor, and install in the flushing
attachment (hose adapter).

2. Attach a hose to the flushing attachment.

3. Turn on the water and adjust the flow so water is exiting the water pump
indicator hose.

a - Flushing attachment
b - Water pump indicator hose

4. Continue flushing the outboard for five minutes.

5. Turn off the water and remove the flushing attachment. Install the water
plug.

61081

a

b

MAINTENANCE

38 eng

Top Cowl Removal And Installation

REMOVAL

1. Unlock the rear latch by pushing lever down.

27084

2. Lift rear of cowl and disengage front hook.

27091

INSTALLATION

1. Engage the front hook and push cowl back over the cowl seal.

2. Push cowl down and move the rear latch lever up to lock.

Corrosion Control Anode

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

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

27092

MAINTENANCE

eng 39

Exterior Care

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

Fuel System

!

WARNING

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

Before servicing any part of the fuel system, stop the engine and disconnect
the battery. Drain the fuel system completely. Use an approved container to
collect and store fuel. Wipe up any spillage immediately. Material used to
contain spillage must be disposed of in an approved receptacle. Any fuel
system service must be performed in a well‑ventilated area. Inspect any
completed service work for sign of fuel leakage.

FUEL LINE INSPECTION

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

CLEANING THE FUEL FILTERS AND THE FUEL TANK

The fuel filter is located between the fuel valve and the fuel pump.

28857

•

Drain all fuel from the fuel tank. Remove the fuel lines from the fuel filter.

• Inspect the fuel filter.

MAINTENANCE

40 eng

•

If there is water or dirt inside, replace the filter. Install the filter in the same
orientation as it was removed.

a - Fuel filter

• For external tanks, loosen the fuel pickup elbow, remove it and clean the
fuel filter.

a - Fuel tank filter
b - Fuel pickup elbow

•

Fuel tank: Water or dirt in the fuel tank will cause engine performance
problems. Check and clean the tank at specified time or after the motor
has been stored for a long period of time (over three months).

Propeller Replacement

!

WARNING

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

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

26899

41074

a

41045

a

b

MAINTENANCE

eng 41

2. Move the gear shift lever into neutral.

F

N

27020

3. Straighten and remove the cotter pin.

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

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.

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.

6. Apply Quicksilver or Mercury Precision Lubricants Extreme Grease or
2‑4‑C with PTFE to the entire propeller shaft and splines.

27095

Tube Ref

No.

Description Where Used Part No.

95

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

Extreme Grease Propeller shaft 8M0071842

7. Install the front thrust washer, propeller, rear thrust hub, and propeller nut
onto the shaft.

MAINTENANCE

42 eng

8. Place a block of wood between the gearcase and the propeller to prevent
rotation and tighten the propeller nut. Secure the propeller nut to the shaft
with a cotter pin.

a - Cotter pin
b - Propeller nut
c - Rear thrust hub
d - Propeller
e - Front thrust washer

Propeller Selection

The propeller must be selected that will allow the engine to reach
recommended RPM when cruising at wide‑open throttle.

Wide‑open throttle RPM range

4500–5500

Recommended propellers are listed under Propeller Recommendation in the
Accessories section of this manual.

Spark Plug Inspection And Replacement

!

WARNING

Damaged spark plug boots may emit sparks that can ignite fuel vapors under
the engine cowl, resulting in serious injury or death from a fire or explosion.
To avoid damaging the spark plug boots, do not use any sharp object or
metal tool to remove the spark plug boots.

1. Remove the spark plug boot. Twist the rubber boot slightly and pull off.

26899

a

b

c

d

e

27094

MAINTENANCE

eng 43

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

26946

3. Set the spark plug gap to specification.

26947

Spark Plug
Spark plug gap 1.0 mm (0.040 in.)

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

Description

Nm lb‑in. lb‑ft

Spark plug 27 – 20

Lubrication Points

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

Tube Ref

No.

Description Where Used Part No.

95

2-4-C with PTFE

Co-pilot threads, swivel bracket,

transom clamp screws, tiller handle

bushing, shift handle detent

92-802859A 1

• Co‑Pilot ‑ Lubricate threads.

MAINTENANCE

44 eng

• Swivel Bracket ‑ Lubricate through fittings.

a - Co‑pilot
b - Swivel bracket

• Transom Clamp Screws ‑ Lubricate threads.

27097

NOTE: Lubricating the tiller handle bushing and shift handle detent requires
disassembly of the product. These points should be lubricated at least once a
year by an authorized dealer.

• Tiller Handle Rubber Bushing ‑ Lubricate internal diameter.

27098

• Shift Handle Detent ‑ Lubricate detent.

27099

2. Lubricate the following with Light Weight Oil.

a

b

28862

MAINTENANCE

eng 45

• Tilt Pivot.

28863

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

Tube Ref

No.

Description Where Used Part No.

95

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

Extreme Grease Propeller shaft 8M0071842

•

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

27095

Gearcase Lubrication

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

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

MAINTENANCE

46 eng

DRAINING GEARCASE

1. Tilt the outboard so that the oil drain plug is at the lowest point.

2. Place the drain pan below the outboard.

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

a - Vent plug
b - Fill/drain plug

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 195 cc (6.6 fl oz).

GEARCASE LUBRICANT RECOMMENDATION

Mercury or Quicksilver Premium or High Performance Gear Lubricant.

CHANGING GEAR OIL

1. Place outboard in a vertical operating position.

2. Remove the oil drain plugs (upper and lower), and completely drain the
gear oil into a pan.

NOTE: If water in the oil, giving it a milky colored appearance, contact your
dealer.

a - Oil drain plug (upper)
b - Oil drain plug (lower)

a

b

27146

41070

a

b

MAINTENANCE

eng 47

3. Insert the oil tube nozzle into the lower oil plug hole, and fill with gear oil
by squeezing the oil tube until oil flows out of the upper plug hole.

41072

a

b

4. Replace the oil plug gasket with a new one. Install the upper oil plug, and
then remove oil tube nozzle and install the lower oil plug.

NOTE: Use Mercury or Quicksilver gear oil or the recommended gear oil (API
GL‑5:SAE #80 to #90). Required volume: approx. 195 mL

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.

MAINTENANCE

48 eng

Storage Preparation

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

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

NOTICE

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

FUEL SYSTEM

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

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.

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

• Place the outboard in water or connect flushing attachment for circulating
cooling water. Start the outboard and operate at idle RPM in neutral for
five minutes to allow stabilized fuel to reach the carburetor.

Protecting External Outboard Components

•

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

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

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

Tube Ref

No.

Description Where Used Part No.

120

Corrosion Guard External metal surfaces 92-802878 55

Protecting Internal Engine Components

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

Fuel

System

, preceding.

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

STORAGE

eng 49

• Place the outboard in water. Start the engine and let it run in neutral to
warm up.

• With engine running at fast idle, stop the fuel flow by closing the fuel
shut‑off valve. When engine begins to stall, quickly spray Quicksilver or
Mercury Precision Lubricants Storage Seal into carburetor until engine
stops from lack of fuel.

• Remove the spark plug and inject a five second spray of storage seal
around the inside of the cylinder.

• Rotate the flywheel manually several times to distribute the storage seal
in the cylinder. Reinstall spark plug.

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.

STORAGE

50 eng

Local Repair Service

Always return your outboard to your local authorized dealer should the need for
service arise. Only he has the factory trained mechanics, knowledge, special
tools, equipment, and genuine parts and accessories to properly service your
engine should the need occur. He knows your engine best.

Service Away from Home

If you are away from your local dealer and the need arises for service, contact
the nearest authorized dealer. Refer to the Yellow Pages of the telephone
directory. If, for any reason, you cannot obtain service, contact the nearest
Mercury Marine Service Office.

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

Your satisfaction with your outboard product is very important to your dealer
and to us. If you ever have a problem, question or concern about your outboard
product, contact your dealer or any authorized Mercury Marine dealership. If
additional assistance is required, take these steps.

1. Talk with the dealership's sales manager or service manager. If this has
already been done, then contact the owner of the dealership.

2. Should you have a question, concern, or problem that cannot be resolved
by your dealership, please contact 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 service office:

• Your name and address

• Daytime telephone number

• Model and serial number of your outboard

• The name and address of your dealership

• Nature of problem

Mercury Marine Service Offices

For assistance, call, fax, or write. Please include your daytime telephone
number with mail and fax correspondence.

OWNER SERVICE ASSISTANCE

eng 51

United States, Canada

Telephone

English ‑ (920) 929‑5040
Français ‑ (905) 636‑4751

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

Fax

English ‑ (920) 929‑5893
Français ‑ (905) 636‑1704

Website www.mercurymarine.com

Australia, Pacific
Telephone (61) (3) 9791‑5822 Brunswick Asia Pacific Group

41–71 Bessemer Drive
Dandenong South, Victoria 3175
Australia

Fax (61) (3) 9706‑7228

Europe, Middle East, Africa
Telephone (32) (87) 32 • 32 • 11 Brunswick Marine Europe

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

Fax (32) (87) 31 • 19 • 65

Mexico, Central America, South America, Caribbean
Telephone (954) 744‑3500 Mercury Marine

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

Fax (954) 744‑3535

Japan
Telephone 072‑233‑8888 Kisaka Co., Ltd.

4-130 Kannabecho Sakai-shi Sakai-ku
5900984 Osaka,
Japan

Fax 072‑233‑8833

Asia, Singapore
Telephone [phone] Brunswick Asia Pacific Group

T/A Mercury Marine Singapore Pte Ltd
29 Loyang Drive
Singapore, 508944

Fax [phone]

OWNER SERVICE ASSISTANCE

52 eng

Maintenance Log

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

Date Maintenance Performed Engine Hours

MAINTENANCE LOG

eng 53

Optional Accessories

41075

a

b

c

d

e

f

g

h

i

j

ACCESSORIES

54 eng

a - Alternator (12 V, 60 W)
b - Extension cord for light (Lights are available on the market.)
c - Rectifier
d - Gear oil (500 mL)
e - Flushing attachment
f - Grease (250 g)
g - Vertical starter
h - Remote control box
i - Touch up paint (300 mL)
j - Engine oil (0.4 L, 1 L, 4 L, 20 L)

ACCESSORIES

eng 55

Wiring Diagram

41076

a

b

c

d

f

e

g

h

i

j

k

l

ACCESSORIES

56 eng

a - Battery
b - Extension cord (optional)
c - Rectifier (optional)
d - Light extension cord (optional)
e - Lighting unit (optional)
f - Pulser coil
g - CD unit
h - Ignition coil
i - Spark plug
j - Stop switch (optional)
k - Grommet
l - Secondary stop switch

Wire Color Code Abbreviations

Wire Color Abbreviations

BLK Black

BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark

Tool Kit and Spare Parts

A listed tools and spare parts below are provided with the motor.

Items

Quantity Dimensions Remark

Service tools

Tool bag 1
Pliers 1
Socket wrench 1 10 x 13 mm
Socket wrench 1 21 mm
Socket wrench

handle

1

screwdrivers 1

Cross and

straight point

Screwdriver
handle

1

ACCESSORIES

eng 57

Spare parts

Rope 1 1000 mm

Spark plug 1

NGK BPR

7HS10

Cotter pin 1

Parts packaged
with engine

Fuel tank 12 L 1 5B‑D only
Primer bulb 1set 5B‑D only

Propeller Recommendation

Use Mercury/Quicksilver propeller.
A propeller must be selected so that the engine RPM measured at wide‑open

throttle while cruising is within the recommended range: 4500–5500 RPM.

Light boats ‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑ Heavy boats

Size as indicated on propeller 9 8 7

Propeller size (mm)

Diameter x pitch (in.)

200 x 229

7.9 x 9.0

198 x 203

7.8 x 8.0

198 x 178

7.8 x 7.0

Model Optional

4.9/5B‑D
S, L, UL

4C

S, L

Transom height: S (short), L (long), UL (extra long):

ACCESSORIES

58 eng