Mercury 75, 90, 80 Jet, 115, 115 Pro XS Installation Manual

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Outboard

8M0100515 1214 eng

Operation

Maintenance

Warranty

Installation

Manual

75/90/115/115 Pro XS/125 OptiMax and 80 Jet

Page 2

eng

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Declaration of Conformity – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC

Name of engine manufacturer: Mercury Marine

Address: W6250 W. Pioneer Road, P.O. Box 1939

Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Address: Parc Industriel de Petit‑Rechain

Town: Verviers Post Code: B‑4800 Country: Belgium

Name of Notified Body for exhaust emission assessment: Det Norske

Veritas AS

Address: Veritasveien 1

Town: Hovik

Name of Notified Body for noise emission assessment: Det Norske

Veritas AS

Address: Veritasveien 1

Town: Hovik

Post Code:

1322

Post Code:

1322

Country:

Norway

Country:

Norway

ID Number: 0575

Conformity assessment module used for exhaust emissions:

Conformity assessment module used for noise emissions:

Other Community Directives applied: Safety of Machinery Directive 2006/42/EC; Electromagnetic Compatibility Directive 2004/108/EC

Description of Engines and Essential Requirements

Engine Type

☒ Outboard engine ☒ Petrol ☒ 2 stroke

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☐ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G ☒ H

☐ A ☐ Aa ☐ G ☒ H

Fuel Type Combustion Cycle

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Identification of Engines Covered by This Declaration of Conformity

Unique engine

Name of engine family

1.5L OptiMax 75, 90, 115, 115 Pro XS, 125 hp, 80 Jet

2.5L OptiMax 135, 150, 150 Pro XS, 175 hp

3.0L OptiMax 200, 200 Pro XS, 225, 250 hp

identification number(s) or engine family code(s): starting serial number

0B228000 RCD‑H‑2 Rev 4

Module H Certificate

Other

Essential requirements

Annex 1.B—Exhaust Emissions

B.1 Engine identification

B.2 Exhaust emission requirements

B.3 Durability ☐ ☐ ☒

B.4 Owner's manual

Annex 1.C—Noise Emissions

C.1 Noise emission levels

C.2 Owner's manual

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine manufacturer that the engines mentioned preceding complies with all applicable essential requirements in the way specified.

Standards

☐ ☐ ☒

☒* ☐ ☐

☒ ☐ ☐ ISO 8665: 2006

☒* ☐ ☐ EN ISO 14509

☐ ☒ ☐ Owner's manual

normative

document/

method

Technical

file

Please specify in more detail (* = mandatory standard)

* EN ISO 8178‑1:1996

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Name / function:

John Pfeifer, President, Mercury Marine

Date and place of issue:

November 28, 2014 Fond du Lac, Wisconsin, USA

Welcome

You have selected one of the finest outboards 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, Maintenance and Warranty 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

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.

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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 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, and to change specifications, designs, methods, or procedures without notice and without incurring obligation.

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

Mercury Premier Service

Mercury Marine 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 service Customer Satisfaction Index (CSI) score for warranty service.

• Possesses all of the 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 an adequate inventory of genuine Mercury Precision Parts.

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

Copyright and Trademark Information

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

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WARRANTY INFORMATION

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

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

Transfer of Mercury Product Protection (Extended Service Coverage) Plan

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

Mercury Jet Products Limited Warranty.............................................................. 2

3 Year Limited Warranty Against Corrosion....................................................... 5

Warranty Coverage and Exclusions................................................................... 7

U.S. EPA Emissions Limited Warranty............................................................... 9

Emission Control System Components.............................................................. 9

California Emissions Limited Warranty............................................................. 10

California Air Resources Board Explanation of Your California Emission Control

Warranty Statement.......................................................................................... 12

Emission Certification Star Label...................................................................... 13

Warranty Policy—Australia and New Zealand.................................................. 14

Global Warranty Charts Outboard and Jets......................................................18

General Information

Boater's Responsibilities................................................................................... 23

Before Operating Your Outboard...................................................................... 23

Boat Horsepower Capacity............................................................................... 23

High‑Speed and High‑Performance Boat Operation........................................ 24

Propeller Selection............................................................................................24

Outboard Remote Control Models ................................................................... 26

Remote Steering Notice....................................................................................27

Lanyard Stop Switch......................................................................................... 27

Protecting People in the Water......................................................................... 30

Passenger Safety Message ‑ Pontoon Boats and Deck Boats.........................30

Wave and Wake Jumping................................................................................. 32

Impact with Underwater Hazards......................................................................33

Exhaust Emissions........................................................................................... 34

Selecting Accessories for Your Outboard......................................................... 36

Safe Boating Recommendations...................................................................... 36

Recording Serial Number................................................................................. 38

Specifications....................................................................................................39

80 Jet OptiMax Specifications.......................................................................... 40

Component Identification.................................................................................. 41

Component Identification.................................................................................. 42

Transporting

Trailering Boat/Outboard ................................................................................. 43

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Fuel and Oil

Fuel Recommendations.................................................................................... 44

Fuel Requirements........................................................................................... 45

Fuel Additives................................................................................................... 45

Avoiding Fuel Flow Restriction......................................................................... 45

Low Permeation Fuel Hose Requirement ........................................................ 45

EPA Pressurized Portable Fuel Tank Requirements........................................ 46

Fuel Demand Valve (FDV) Requirement.......................................................... 46

Mercury Marine's Pressurized Portable Fuel Tank........................................... 46

Oil Recommendation........................................................................................ 47

Filling Oil Injection System................................................................................48

Filling Fuel Tank............................................................................................... 50

Features and Controls

Remote Control Features................................................................................. 51

Warning System............................................................................................... 51

Power Trim and Tilt...........................................................................................53

Trim Tab Adjustment........................................................................................ 57

Operation

Important Information........................................................................................58

Prestarting Check List.......................................................................................59

Operating in Freezing Temperatures................................................................ 59

Operating in Saltwater or Polluted Water......................................................... 59

Operating at High Elevations............................................................................ 60

Setting Trim Angle While Running Engine at Idle Speed................................. 60

Engine Break‑in................................................................................................ 60

Starting the Engine........................................................................................... 61

Gear Shifting..................................................................................................... 63

Stopping the Engine......................................................................................... 64

Jet Drive Operation........................................................................................... 64

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Maintenance

Outboard Care.................................................................................................. 73

EPA Emissions Regulations............................................................................. 73

Inspection and Maintenance Schedule............................................................. 74

Flushing the Cooling System ........................................................................... 77

Top Cowl Removal and Installation.................................................................. 77

Cleaning Care for Top Cowl............................................................................. 78

Flywheel Cover Removal and Installation......................................................... 78

Side Panel Removal and Installation................................................................ 79

OIl Injection System.......................................................................................... 80

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

Steering Link Rod Fasteners............................................................................ 85

Fuse Replacement............................................................................................86

Corrosion Control Anode.................................................................................. 87

Battery Inspection ............................................................................................ 88

Battery Information (All Batteries Including DTS)............................................. 88

Propellers..........................................................................................................89

Spark Plug Inspection and Replacement..........................................................92

Compressor Air Intake Filter............................................................................. 94

Alternator Belt Inspection..................................................................................95

Lubrication Points............................................................................................. 95

Lubrication Points............................................................................................. 97

Checking Power Trim Fluid...............................................................................99

Gearcase Lubrication......................................................................................100

Storage

Storage Preparation........................................................................................102

Fuel System.................................................................................................... 102

Protecting Internal Engine Components......................................................... 104

Protecting External Outboard Components.................................................... 104

Gearcase........................................................................................................ 104

Jet Drive..........................................................................................................104

Positioning Outboard for Storage................................................................... 104

Battery Storage............................................................................................... 105

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Owner Service Assistance

Local Repair Service.......................................................................................106

Service Away from Home............................................................................... 106

Parts and Accessories Inquiries..................................................................... 106

Service Assistance......................................................................................... 106

Ordering Literature..........................................................................................109

Troubleshooting

Starter Motor Will Not Crank the Engine......................................................... 111

Engine Will Not Start.......................................................................................111

Engine Runs Erratically.................................................................................. 111

Performance Loss...........................................................................................112

Battery Will Not Hold Charge.......................................................................... 112

Jet Application Troubleshooting......................................................................112

Outboard Installation

Mercury Marine Validated Engine Mounting Hardware.................................. 114

Accessories Mounted to the Transom Clamp Bracket.................................... 114

Important Information......................................................................................118

Boat Horsepower Capacity............................................................................. 118

Start in Gear Protection.................................................................................. 119

Fuel System.................................................................................................... 119

Installation Specifications............................................................................... 121

Lifting the Outboard........................................................................................ 121

Steering Cable ‑ Starboard Side Routed Cable.............................................. 122

Determining Recommended Outboard Mounting Height................................ 124

Determining the Mounting Height of the Outboard Jet .................................. 125

Drilling Outboard Mounting Holes................................................................... 127

Fastening the Outboard to the Transom......................................................... 128

Electrical, Fuel Hose, Flush Hose, and Control Cables.................................. 133

Oil Injection Set‑Up......................................................................................... 146

Trim In Pin...................................................................................................... 147

Maintenance Log

Maintenance Log............................................................................................ 149

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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.

Mercury Jet Products Limited Warranty

UNITED STATES AND CANADA

Outside the United States and Canada ‑ Check with your local distributor.

WHAT IS COVERED

Mercury Marine warrants its new Jet products to be free of defects in material and workmanship during the period described below.

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WARRANTY INFORMATION

DURATION OF COVERAGE

This Limited Warranty provides coverage for one (1) year 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 from one recreational use customer to a subsequent recreational use customer upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer. 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. Warranty coverage may be terminated for used repossessed product; or product purchased at auction, from a salvage yard, or from an insurance company.

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. 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's sole and exclusive obligation under this 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 product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

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WARRANTY INFORMATION

HOW TO OBTAIN WARRANTY COVERAGE

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, written notice must be given to Mercury. We 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. The warranty registration card is the only valid registration identification and 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 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 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 wear rings or liners, operation with fuels, oils, or lubricants which 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, or running the engine out of water. Use of the product for racing or other competitive activity, or operating with racing modifications, 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 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.

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.

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WARRANTY INFORMATION

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.

3 Year Limited Warranty Against Corrosion

WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, 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.

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.

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WARRANTY INFORMATION

WHAT MERCURY WILL DO: Mercury'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 product. Mercury 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 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, written notice must be given to Mercury. We 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. 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.

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.

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WARRANTY INFORMATION

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.

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. 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.

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WARRANTY INFORMATION

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

4. 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.

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

6. 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).

7. 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.

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

9. 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.

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

11. 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.

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

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

14. 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.

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

16. 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.

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WARRANTY INFORMATION

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 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

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WARRANTY INFORMATION

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.

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.)

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WARRANTY INFORMATION

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.

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.

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WARRANTY INFORMATION

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.

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 first occurs. 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.

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42537

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WARRANTY INFORMATION

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.

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.

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WARRANTY INFORMATION

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.

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.

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WARRANTY INFORMATION

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.

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. If the purchaser 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.

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WARRANTY INFORMATION

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.

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.

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WARRANTY INFORMATION

DISCLAIMERS AND LIMITATIONS:

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

TRANSFER OF WARRANTY—AUSTRALIA AND NEW ZEALAND POLICY

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

Mercury Marine

Attn: Warranty Registration Department

Brunswick Asia Pacific Group

Private Bag 1420

Dandenong South, Victoria 3164

Australia

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

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.

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WARRANTY INFORMATION

Global Warranty Charts Outboard and Jets

UNITED STATES WARRANTY CHARTS–OUTBOARD AND JET

Product

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

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

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

Racing Product (Recreation use only)

OptiMax (250 XS) 2 years 3 years

OptiMax (300 XS) 2 years 3 years

Verado (400R) 2 years 3 years

Outside the United States

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

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

CANADA WARRANTY CHARTS–OUTBOARD AND JET

Product

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

2‑Stroke EFI (150 hp) 2 years 3 years

2‑Stroke carbureted (V6) 2 years 3 years

FourStroke (2.5 ‑ 300 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

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

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WARRANTY INFORMATION

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 (350 SCi) 2 years 3 years

Outside of Canada

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

Standard Limited Warranty

Standard Limited Corrosion Warranty

AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS–OUTBOARD AND JET

Standard

Products

All outboard 3 years 3 years

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.

Limited Warranty

Standard Limited Corrosion Warranty

Light Commercial

Contact the Marine Power Service Center closest to you

SOUTH PACIFIC WARRANTY CHART–OUTBOARD AND JET

Standard

Products

All outboard 2 years 3 years

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.

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Limited Warranty

Standard Limited Corrosion Warranty

Light Commercial

Contact the Marine Power Service Center closest to you

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WARRANTY INFORMATION

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 350 SCi 1 year 3 years None

Outside of Asia

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

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

Commercial Application

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

Product (Recreational only)

2‑Stroke 2 years 3 years

FourStroke 2 years 3 years

OptiMax (including Pro XS)

Verado (including Pro)

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

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WARRANTY INFORMATION

Racing Product (Recreational only)

Verado 350 SCi 2 years 3 years

Outside Europe and CIS

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

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

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

Product (Recreational only)

2‑Stroke 1 year 3 years

FourStroke 2 years 3 years

OptiMax (including Pro XS)

Verado (including Pro)

Standard Limited Warranty

3 years 3 years

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

Racing Product (Recreational only)

Verado 350 SCi 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

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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 350 SCi 2 years 3 years

Outside South Africa

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

Standard Limited Warranty

3 years 3 years

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Contact the Marine Power Service Center closest to you

Standard Limited Corrosion Warranty

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GENERAL INFORMATION

Boater's Responsibilities

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

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

Before Operating Your Outboard

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

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

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

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

Boat Horsepower Capacity

WARNING

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

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U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT CAPACITY

XXX

26777

GENERAL INFORMATION

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

High‑Speed and High‑Performance Boat Operation

If your outboard is to be used on a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you do not operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat/ outboard combination. For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

Propeller Selection

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

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

SELECTING THE CORRECT PROPELLER

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

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

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GENERAL INFORMATION

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

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

a - Diameter b - Pitch ‑ Travel during one revolution

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

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

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

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

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

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

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GENERAL INFORMATION

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

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

PROPELLER MATERIAL

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

3 BLADE VS. 4 BLADE

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

Outboard Remote Control Models

The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral.

WARNING

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

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GENERAL INFORMATION

Remote Steering Notice

The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.

WARNING

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

a - Self‑locking nuts

Lanyard Stop Switch

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

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

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53910

OFF

RUN

ATTACH LANYARD

GENERAL INFORMATION

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

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

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

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

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GENERAL INFORMATION

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

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

WARNING

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

WARNING

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

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

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

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

• Loss of control when docking.

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

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

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

eng 29

Page 40

21604

GENERAL INFORMATION

Protecting People in the Water

WHILE YOU ARE CRUISING

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

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

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

WHILE THE BOAT IS STATIONARY

WARNING

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

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

Passenger Safety Message ‑ Pontoon Boats and Deck Boats

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

BOATS HAVING AN OPEN FRONT DECK

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

30 eng

Page 41

26782

26783

GENERAL INFORMATION

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

WARNING

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

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS

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

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

eng 31

Page 42

26784

GENERAL INFORMATION

Wave and Wake Jumping

Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.

The primary concern is the boat changing direction while in the midst of the jump. In such case, the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

WARNING

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward. The boat may also steer sharply to one side.

32 eng

Page 43

26785

GENERAL INFORMATION

Impact with Underwater Hazards

Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important

thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed. Under these conditions, boat speed should be kept to a minimum planing speed of 24 to 40 km/h (15 to 25 mph).

Striking a floating or underwater object could result in an infinite number of situations. Some of these situations could result in the following:

• Part of the outboard or the entire outboard could break loose and fly into the boat.

• The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat.

• A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat.

• Impact damage to the outboard and/or boat.

Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles.

After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts. If damage is present or suspected, the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair.

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

Operating a damaged outboard could cause additional damage to other parts of the outboard, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

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Page 44

GENERAL INFORMATION

WARNING

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

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

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

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

WARNING

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

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

STAY CLEAR OF EXHAUST AREAS

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.

34 eng

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21622

21626

21628

GENERAL INFORMATION

GOOD VENTILATION

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

Example of desired air flow through the boat:

POOR VENTILATION

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

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

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

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

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

eng 35

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)

Page 46

GENERAL INFORMATION

Selecting Accessories for Your Outboard

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

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

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

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

Safe Boating Recommendations

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

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

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

Perform safety checks and required maintenance.

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

Check safety equipment onboard.

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

Approved fire extinguishers

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

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

36 eng

Page 47

GENERAL INFORMATION

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

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

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

Passenger boarding.

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

Use personal flotation devices.

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

Prepare other boat operators.

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

Do not overload your boat.

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

Ensure that everyone in the boat is properly seated.

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

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

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

Know your boating area and avoid hazardous locations.

eng 37

Page 48

H P L B

23884

- - - . -

- -

XXXXXXX

XXXXX XX

Mercu ry

Marine

Serial Number

Brunswick Corp. Made in Japan

XXXX XXX

HP XXX LB XXX

KG XXX

KW XXX

Model Number

GENERAL INFORMATION

Be alert.

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

Never drive your boat directly behind a water skier.

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

Watch fallen skiers.

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

Report accidents.

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

Recording Serial Number

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

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

38 eng

Page 49

Specifications

GENERAL INFORMATION

Models 75 90

Horsepower 75 90 115 125

Kilowatts 55.2 66.2 84.6 91.3

Full throttle RPM range

Idle speed in forward gear

Number of cylinders

Piston displacement

Cylinder bore 92.11 mm (3.63 in.)

Piston stroke 76.2 mm (3.0 in.)

Recommended spark plug

Spark plug gap 0.80 mm (0.030 in.)

Gear ratio 2.33:1 2.07:1

Recommended gasoline

Recommended oil

Oil tank capacity

Gearcase lubricant capacity

Battery rating*

Charging system output

Emission control system

1000 marine cranking amps (MCA) or 800 cold cranking

5000–5750 RPM

1523.5 cc (92.9 in³)

Refer to Fuel and Oil

4.72 liter (5 US qt)

665 ml (22.5 fl oz)

Electronic engine control (EC)

115/115 Pro

625–675 RPM

IZFR5J

amps (CCA)

60 A

125

eng 39

Page 50

GENERAL INFORMATION

Models 75 90

Sound at drivers ear (ICOMIA 39‑94) dBA

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

115/115 Pro

82.0

125

80 Jet OptiMax Specifications

Models

Horsepower 80

Kilowatts 58.8

Full throttle RPM range 5000–5750 RPM

Idle speed in forward gear

Number of cylinders 3

Piston displacement 1523.5 cc (92.9 in³)

Cylinder bore 92.11 mm (3.63 in.)

Piston stroke 76.2 mm (3.0 in.)

Recommended spark plug

Spark plug gap 0.80 mm (0.030 in.)

Recommended gasoline

Recommended oil

Oil tank capacity 4.72 liters (5 US qt)

Battery rating*

Charging system output 60 A

Emission control system Electronic engine control (EC)

1000 marine cranking amps (MCA) or 800 cold

Refer to Fuel and Oil

cranking amps (CCA)

625–675 RPM

IZFR5J

40 eng

Page 51

29461

GENERAL INFORMATION

Component Identification

a - Top cowl b - Auxiliary tilt switch c - Transom brackets d - Gearcase e - Cooling water intake

holes

f - Trim tab g - Anti‑ventilation plate h - Driveshaft housing i - Water pump indicator

hole

j - Bottom cowl

eng 41

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33496

GENERAL INFORMATION

Component Identification

a - Top cowl b - Auxiliary tilt switch c - Transom brackets d - Jet drive housing e - Water intake

housing

f - Reverse gate g - Water outlet nozzle h - Driveshaft housing i - Water pump

indicator hole

j - Bottom cowl

42 eng

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28419

TRANSPORTING

Trailering Boat/Outboard

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

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

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

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

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FUEL AND OIL

Fuel Recommendations

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

FUEL RATINGS

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

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

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

USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)

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

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

GASOLINES CONTAINING ALCOHOL

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

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

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

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

44 eng

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FUEL AND OIL

WARNING

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

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

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

Fuel Requirements

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

Fuel Additives

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

Avoiding Fuel Flow Restriction

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

Low Permeation Fuel Hose Requirement

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

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

• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑ marine fuel hose.

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FUEL AND OIL

EPA Pressurized Portable Fuel Tank Requirements

The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following:

• An air inlet that opens to allow air to enter as the fuel is drawn out of the tank.

• An air outlet that opens (vents) to the atmosphere if pressure exceeds

34.4 kPa (5.0 psi).

Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and primer bulb. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

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

a - Fuel demand valve ‑ installed in the

fuel hose between the fuel tank and

primer bulb

b - Manual release c - Vent/water drain holes

Mercury Marine's Pressurized Portable Fuel Tank

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

SPECIAL FEATURES OF THE PORTABLE FUEL TANK

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

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

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

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

46 eng

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FUEL AND OIL

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

REMOVING THE FUEL CAP

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

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

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

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

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

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

DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK

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

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

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

Follow Filling Fuel Tank instructions for fueling.

Oil Recommendation

Recommended Oil

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

eng 47

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

Page 58

37147

37143

FUEL AND OIL

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

Filling Oil Injection System

1. Place the outboard in a vertical operating position.

2. Remove the cowl cover.

3. Remove the oil filler cap.

a - Cowl cover b - Oil filler cap

4. Oil filler caps with a dipstick ‑ Check the oil level on the dipstick. The first set of holes indicates 0.94 liters (1 US qt) low. The second set of holes indicates 1.89 liters (2 US qt) low. The third set of holes indicates

2.83 liters (3 US qt) low.

a - Add 0.94 liters (1 US qt) b - Add 1.89 liters (2 US qt) c - Add 2.83 liters (3 US qt)

48 eng

Page 59

29465

29466

37146

FUEL AND OIL

5. Oil filler caps with a chain ‑ Check the oil level on the chain. The first ball marker indicates 0.94 liters (1 US qt) low. The second ball marker indicates 1.89 liters (2 US qt) low.

a - Add 0.94 liters (1 US qt) b - Add 1.89 liters (2 US qt)

Slowly fill the oil tank with the specified oil. Do not overfill. Add only enough oil to bring the oil level up to the bottom of the fill neck.

Capacity

Oil tank 4.72 liters (5 US qt) OptiMax/DFI 2‑Cycle Engine Oil

7. Install the oil filler cap and tighten securely. Install the cowl cover.

Fluid Type

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FUEL AND OIL

Filling Fuel Tank

WARNING

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

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

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

50 eng

Page 61

26800

FEATURES AND CONTROLS

Remote Control Features

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

a - Control handle – forward, neutral, reverse b - Neutral release lever c -

Trim/tilt switch (if equipped) – Refer to Features and Controls –

Power Trim and Tilt

d -

Lanyard stop switch – Refer to General Information – Lanyard Stop

Switch

e -

Lanyard – Refer to General Information – Lanyard Stop Switch

f - Throttle friction adjustment – Console controls require cover removal for

adjustment

g - Ignition key switch – "OFF," "ON," START" h -

Fast idle lever – Refer to Operation – Starting the Engine

i -

Throttle only button – Refer to Operation – Starting the Engine

Warning System

WARNING HORN SIGNALS

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

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

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Page 62

FEATURES AND CONTROLS

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

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

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

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

•

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

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

•

Low engine oil level. Refer to Fuel and Oil – Checking and Adding Engine Oil.

ENGINE GUARDIAN SYSTEM

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

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

52 eng

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27761

FEATURES AND CONTROLS

OVERSPEED REV LIMIT

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

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

To reset the Engine Guardian protection:

1. Completely reduce the throttle for three seconds.

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

SMARTCRAFT PRODUCT

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

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

Power Trim and Tilt

Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the outboard within the first 20° range of travel. This is the range used while operating your boat on plane. The term tilt is generally used when referring to adjusting the outboard further up out of the water. With the engine turned off, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up past the trim range to permit, for example, shallow water operation.

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

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FEATURES AND CONTROLS

POWER TRIM OPERATION

NOTE: When traveling at slow speeds, a slight drop in engine RPM may be noticed on occasion when engaging power trim. This condition is normal and has no adverse affect on the outboard.

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

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

WARNING

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

Consider the following lists carefully.

1. Trimming in or down can:

• Lower the bow.

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

• Generally improve the ride in choppy water.

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

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

WARNING

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

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

2. Trimming out or up can:

54 eng

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FEATURES AND CONTROLS

• Lift the bow higher out of the water.

• Generally increase top speed.

• Increase clearance over submerged objects or a shallow bottom.

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

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

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

TILTING OPERATION

To tilt the outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position.

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

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

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

a - Tilt support lever b - Knob

MANUAL TILTING

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

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

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22362

27779

FEATURES AND CONTROLS

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

SHALLOW WATER OPERATION

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

1. Reduce the engine speed below 2000 RPM.

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

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

AUXILIARY TILT SWITCH

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

a - Auxiliary tilt switch

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FEATURES AND CONTROLS

Trim Tab Adjustment

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

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

Operate your boat at normal cruising speed, trimmed to the desired position. Turn your boat left and right and note the direction the boat turns more easily.

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

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OPERATION

Important Information

IMPORTANT DAILY INSPECTION BEFORE EACH USE

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

Decal on the transom bracket

BEFORE STARTING THE ENGINE

NOTICE

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

Refer to Priming the Oil Injection Pump for instructions.

FUEL REQUIREMENTS

OIL RECOMMENDATION

Recommended Oil

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

IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil.

58 eng

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

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OPERATION

Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3. The use of an inferior 2‑Cycle outboard oil can reduce engine durability. Damage from use of inferior oil may not be covered under the limited warranty.

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 the boat's maximum load capacity. Look at the boat capacity plate.

Fuel supply OK.

Oil supply (oil injection) 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 the inspection checks listed in Maintenance ‑ Inspection and

Maintenance Schedule.

Operating in Freezing Temperatures

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

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

Operating in Saltwater or Polluted Water

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

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OPERATION

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

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

Operating at High Elevations

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

Setting Trim Angle While Running Engine at Idle Speed

The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full‑in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim the outboard up until the exhaust relief hole is out of the water. The outboard should be lowered for accelerating from a standing start or from idle speed.

Engine Break‑in

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

Break‑in Procedure

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

First Hour

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

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OPERATION

Break‑in Procedure

• Do not idle for more than five minutes.

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

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

• Change the engine speed approximately every two minutes.

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

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

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

Starting the Engine

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

NOTICE

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

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

2. Open the fuel tank vent screw, located in the filler cap, on manual venting type fuel tanks.

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19791

26838

OPERATION

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

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

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

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

a. Squeeze the fuel line primer bulb until it feels firm. b. Turn the ignition key switch to the "ON" position for three seconds.

This operates the electric fuel pump.

c. Turn the ignition key switch back to the "OFF" position, and squeeze

the primer bulb again until it feels firm. Turn the ignition key switch to

62 eng

the "ON" position again for three seconds. Continue this procedure until the fuel line primer bulb stays firm.

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19804

19805

OPERATION

7. Do not advance the neutral fast idle speed feature on the remote control for starting.

8. Turn the ignition key to "START" position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to "OFF" position, wait one second and try again.

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

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

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

Gear Shifting

IMPORTANT: Observe the following:

•

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

•

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

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

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OPERATION

• When shifting, always stop at neutral position and allow the engine speed to return to idle.

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

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

Stopping the Engine

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

Jet Drive Operation

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.

Oil supply (oil injection) OK.

Ensure the boat drain plug is installed.

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.

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OPERATION

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.

Check steering for free operation.

Check for debris around the rudder and reverse gate which may jam or hinder operation.

Before launching, examine the jet drive water intake for obstructions which may prevent pumping of water.

Ensure the driveshaft bearing on the jet drive is lubricated.

OPERATING IN FREEZING TEMPERATURES

If there is a chance of ice forming on the water, the jet drive 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. Do not start the engine until the ice is clear.

OPERATING IN SALTWATER OR POLLUTED WATER

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

Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces.

NOTE: Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

OPERATING IN SHALLOW WATER

The life of the impeller and water intake can be greatly increased by avoiding the intake of sand and gravel. The intake suction will act like a dredge when the water intake comes close to the bottom. It is better to stop the engine and drift up to shore when landing, and to shove off with an oar when leaving. The engine can idle through areas of water less than 61 cm (2 ft) deep, but there should be more than 61 cm (2 ft) of water under the boat when increasing speed to reach full plane.

Once the boat is on plane, the boat speed will prevent the ingestion of gravel and other debris from the bottom. The suction is still present, but the water intake passes too quickly over the bottom to allow debris to be drawn into the water intake.

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OPERATION

When boating through shallow water areas, choose a course of travel that avoids sharp rocks and other underwater obstacles that could damage the boat. Running the boat through these areas on full plane may be helpful as the boat will be riding higher in the water. If the boat gets stuck on the bottom, immediately stop the engine and move the boat to deeper water.

HOW THE JET DRIVE OPERATES

A jet driven boat has substantially different handling characteristics compared to a propeller driven boat. It is recommended that the operator adjusts to these characteristics by experimenting in open water at both high and low speeds.

The driveshaft driven impeller draws water up through the water intake and then directs it at a high pressure through the water outlet nozzle to create forward thrust. To obtain reverse, the reverse gate moves over the outlet nozzle to direct the water in the opposite direction.

a - Water intake b - Water outlet nozzle c - Reverse gate

When the jet drive is in neutral, the impeller continues to rotate. However, the reverse gate is positioned so that some of the forward thrust is diverted to create reverse thrust. This approximate balancing of forward and reverse thrust will minimize any boat movement. Because the impeller is always rotating and creating thrust when the engine is running, the boat may tend to move slowly forward or backward. This is normal for a direct‑drive jet driven boat. The operator should be aware of this and use caution whenever the engine is running.

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OPERATION

WARNING

Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running.

The jet drive is always drawing water into the housing when the engine is running. Do not operate the jet drive with the grate removed from the water intake. Keep hands, feet, hair, loose clothing, life jackets, etc., away from the water intake. Never insert an object into the water intake or water outlet nozzle when the engine is running.

STOPPING THE BOAT IN AN EMERGENCY

A jet powered boat has emergency stopping capability unique to this form of propulsion.

WARNING

Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death. Use caution when performing the emergency stopping procedure, and be sure to practice in a safe area.

In an emergency, putting the jet outboard into reverse and applying reverse throttle can rapidly slow down the boat and reduce stopping distance. However, such a maneuver may cause occupants in the boat to be thrown forward or possibly out of the boat.

STEERING THE BOAT

The jet drive is dependent on water jet thrust for steering the boat. If the water jet thrust should ever stop (water blockage, engine stops, etc.), the boat will slow to a stop. However, while slowing there will be a reduced ability to steer the boat.

WARNING

Steering the vessel in a tight turn can result in loss of boat control. In some cases, the boat can spin out or roll over, causing serious injury or death. Avoid steering beyond the capabilities of the vessel, especially at high speeds.

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OPERATION

WARNING

A loss or reduction in water jet thrust will directly affect boat directional control, and may result in property damage, personal injury, or death. Boat directional control can also be substantially reduced or lost altogether by a sudden loss of power such as running out of gas, quickly backing off the throttle, turning off the ignition switch, activating the lanyard stop switch, or plugging the water intake to the jet pump. Use caution when maneuvering at high speeds in areas where debris (weeds, logs, gravel, etc.) could be picked up into the jet drive. The ability to take evasive action is dependent on sufficient water jet thrust to control the boat.

While steering the boat at engine speeds above idle, the boat will respond quickly; but, due to the relatively flat‑bottom hulls and lack of a gearcase in the water, the boat will tend to skid on turns. Turns must be started early and use sufficient power to maintain steering control.

MOORING THE BOAT

Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water. Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting.

WATER INTAKE BLOCKAGE

WARNING

A rotating impeller could cause injury if contact is made with hands, clothing, or tools. To avoid injury, keep hands and clothing away from the inlet or outlet of the jetdrive, regardless of whether the boat is in the water. Secure tools and loose items to avoid being struck by projectiles as a result of contact with the rotating impeller, and to prevent damage to the impeller.

A large amount of debris being drawn into the water intake may result in a loss of power. Intake suction holding debris against the grate will result in restricted water flow. Shutting the engine off may allow the debris to fall off the intake grate allowing full power to be restored. If debris does not fall off the intake grate, the engine must be shut off and debris physically removed from the grate.

CLEARING A LODGED IMPELLER

WARNING

Rotating the flywheel to free a lodged impeller can accidentally start the engine, resulting in serious injury or death. Always turn the ignition key or lanyard stop switch to the "OFF" position and remove all spark plug leads from the spark plugs.

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OPERATION

It is possible for debris to lodge between the impeller and jet housing wall, especially after the engine has been stopped. This will lock the driveshaft and will prevent the engine from being able to crank over for starting. Following are steps for dislodging the impeller.

1. Position the lanyard stop switch to the "OFF" position.

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

3. Remove the flywheel or rewind cover and rotate the engine flywheel counterclockwise.

If this does not dislodge the impeller, it will be necessary to remove the six screws and water intake housing.

STARTING THE ENGINE

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

NOTE: When the engine is being run within the RPM range of 3500–4200 RPM, there may be a slight RPM instability. This is caused by the light engine load conditions normally seen with jet lower units. This condition will not cause any adverse affects on the engine.

NOTICE

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

1. Ensure that the driveshaft bearing on the jet drive is lubricated. Refer to Maintenance ‑ Lubrication Points.

2. Open the fuel tank vent screw, located in the filler cap, on manual venting type fuel tanks.

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OPERATION

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

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

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

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

a. Squeeze the fuel line primer bulb until it feels firm. b. Turn the ignition key switch to the "ON" position for three seconds.

This operates the electric fuel pump.

c. Turn the ignition key switch back to the "OFF" position, and squeeze

the primer bulb again until it feels firm. Turn the ignition key switch to

70 eng

the "ON" position again for three seconds. Continue this procedure until the fuel line primer bulb stays firm.

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19804

19805

OPERATION

7. Do not advance the neutral fast idle speed feature on the remote control for starting.

8. Turn the ignition key to "START" position. Release the key when the engine starts. If the engine fails to start in 10 seconds, return the key to "OFF" position, wait one second and try again.

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

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

GEAR SHIFTING

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

Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R).

When shifting, always stop at neutral position and allow the engine speed to return to idle.

Always shift the outboard into gear with a quick motion.

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OPERATION

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

72 eng

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MAINTENANCE

Outboard Care

To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability.

Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.

SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD

We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.

EPA Emissions Regulations

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

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

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SPARK PLUG:

GAP:

EMISSION CONTROL INFORMATION

THIS ENGINE CONFORMS TO EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES

CALIFORNIA AND U.S. EPA

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

IDLE SPEED (in gear):

FAMILY:

HC+NOx:FEL:

LOW PERM/HIGH PERM:

g/kWh

HC+NOx:FEL:

g/kWh

CO FEL:

g/kWh

43210

MAINTENANCE

EMISSION CERTIFICATION LABEL

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

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

OWNER RESPONSIBILITY

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

The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.

Inspection and Maintenance Schedule

PRIOR TO EVERY USE

• Check that the lanyard stop switch stops the engine.

• Check the steering system for binding or loose components.

• Verify that the outboard is securely attached to the boat transom. If the outboard or any of its fasteners are loose, tighten them to the specified torque. When checking to verify the outboard is securely fastened, look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard transom brackets. Also look for signs of movement between the outboard transom brackets and the boat transom or lift plate/setback bracket.

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MAINTENANCE

Description Nm lb‑in. lb‑ft

Outboard mounting locknuts and bolts – standard boat transom

Outboard mounting locknuts and bolts – metal lift plates and setback brackets

• Check the propeller blades for damage.

• Inspect all hoses, clamps, fittings, tubing, sealing gaskets, and mounting hardware for wear.

AFTER EACH SALTWATER OR POLLUTED WATER USE

• Flush all internal passages with fresh water.

• Wash the power package exterior (cowl, midsection, and gearcase) with fresh water.

• Flush the propeller and gearcase exhaust outlet with fresh water.

• Remove the cowl and wipe off any saltwater spray with a damp cloth.

EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATER OR POLLUTED WATER USE

• Spray the powerhead and all external, unpainted metal surfaces (except anodes) with Corrosion Guard.

75 – 55

122 – 90

Tube Ref

No.

120

Description Where Used Part No.

Corrosion Guard

Powerhead and all external, unpainted

metal surfaces (except anodes)

92-802878 55

EVERY 25 HOURS OR EVERY 30 DAYS, WHICHEVER OCCURS FIRST

• Verify that the front and side cowl latches are tight. Tighten them if necessary.

• Inspect the fuel and oil systems for deterioration or leaks.

• Inspect the hydraulic steering hoses for deterioration or leaks.

• Inspect the steering link rod fasteners for wear. Lubricate all of the specified components. Check all attachment hardware to ensure proper torque.

• Check the level and condition of the gearcase lubricant.

• Check the alternator belt tension.

EVERY 50 HOURS OR ONCE A YEAR, WHICHEVER OCCURS FIRST

• Lubricate all of the lubrication points listed in the manual.

•

Lubricate the splines on the driveshaft.

• Lubricate the length of driveshaft with Extreme Grease.

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

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MAINTENANCE

Tube Ref

No.

Description Where Used Part No.

Extreme Grease Length of driveshaft 8M0071842

• Lubricate the splines on the propeller shaft.

• Drain and replace the gearcase lubricant.

• Inspect all belts, pulleys, and idler pulleys for deterioration.

•

Check the fuel pressure.

• Check the control cable adjustments.

• Inspect the battery.

• Check the corrosion control anodes.

• Check the tightness of all fasteners.

• Check the power trim fluid.

• Use Quicksilver products to remove engine deposits. See your dealer for an explanation of which products to use.

EVERY 100 HOURS OR ONCE A YEAR, WHICHEVER OCCURS FIRST

• Tighten the fasteners that secure the outboard to the boat transom to the specified torque.

Description

Outboard mounting locknuts and bolts – standard boat transom

Nm lb‑in. lb‑ft

75 – 55

Outboard mounting locknuts and bolts – metal lift plates and setback

122 – 90

brackets

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

• Replace the spark plugs after the first 100 hours or first year. After that, inspect the spark plugs every 100 hours or once yearly. Replace the spark plugs as needed.

• Replace the water‑separating fuel filter.

• Replace the in‑line oil filter after the first 100 hours of operation.

• Use Quickleen in the fuel.

• Verify that the cowl seals are intact and not damaged.

• Check that the internal cowl sound reduction foam (if equipped) is intact and not deteriorating.

• Ensure that the intake silencer (if equipped) is in place.

• Ensure that the idle relief muffler (if equipped) is in place.

• Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly.

76 eng

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• Inspect the carbon fiber reeds for chipping or cracks.

EVERY 300 HOURS OF OPERATION

• Replace the in‑line oil filter every 300 hours of operation.

BEFORE PERIODS OF STORAGE

•

Refer to Storage section.

Flushing the Cooling System

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

NOTE: The engine can be stopped, or running at idle speed in neutral, when flushing the cooling system. Do not flush the engine using a water source that exceeds 310 kPa (45 psi).

1. Unscrew the cover from the end of the hose adapter.

2. Attach a water hose to the hose adapter.

3. Turn on the water and flush the cooling system for a minimum of three minutes.

IMPORTANT: Do not run engine above idle speed when flushing.

4. Turn off the water and remove the water hose from the hose adapter. Install the cover into the hose adapter.

a - Hose adapter b - Sealing washer c - Cover

Top Cowl Removal and Installation

REMOVAL

1. Unlock the rear latch by pushing lever up.

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2. Lift rear of cowl and disengage front hook.

INSTALLATION

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

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

Cleaning Care for Top Cowl

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Follow the cleaning and waxing procedure.

CLEANING AND WAXING PROCEDURE

1. Before washing, rinse the top cowl with clean water to remove the dirt and dust that may scratch the surface.

2. Wash the top cowl with clean water and a mild nonabrasive soap. Use a soft, clean cloth when washing.

3. Dry thoroughly with a soft, clean cloth.

4. Wax the surface using a nonabrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a soft, clean cloth.

Flywheel Cover Removal and Installation

REMOVAL

Lift the cover off the three mounting pins.

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INSTALLATION

Position the cover onto the three mounting pins. Insert the tabs into the slots in the side panel and push the cover down onto the mounting pins.

a - Flywheel cover b - Mounting pins c - Tabs

Side Panel Removal and Installation

REMOVAL

Pull the side panel off the three mounting pins.

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INSTALLATION

Position the side panel onto the three mounting pins. Insert the tabs on the flywheel cover into the upper slots and push the side panel onto the mounting pins.

a - Side panel b - Upper slots c - Mounting pins

OIl Injection System

OIL INJECTION FILTER

IMPORTANT: The oil injection in‑line filter must be replaced after the first 100 hours of operation. Afterwards, this filter must be replaced every 300 hours of operation. After replacing the in‑line filter, the oil injection system must be purged to remove air trapped in the system.

1. Cut the cable ties securing the in‑line oil filter.

2. Place an appropriate container or shop towels under the in‑line filter to capture oil that will leak out of the hoses.

IMPORTANT: The arrow on the filter identifies the direction of the oil flow and should point towards the oil pump.

3. Quickly remove the old filter and install a new filter.

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4. Secure the filter with cable ties.

a - Oil filter

Purge the trapped air from the oil injection system. Refer to Oil Injection Pump Purge.

eng 81

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19779

26846

7912

MAINTENANCE

OIL INJECTION PUMP PURGE

Before starting the engine after changing the in‑line oil filter, the oil injection pump must be purged. This will remove any air that may be in the pump, oil supply hose, or internal passages.

a - Oil injection pump b - Oil supply hose

IMPORTANT: Fill the engine fuel system with fuel before purging the oil injection pump.

1. Fill the engine fuel system with fuel. Connect the fuel hose and squeeze the primer bulb until it feels firm.

2. Turn the ignition key switch to the ON position.

3. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times. This will automatically start the purging process.

NOTE: It may take a few minutes for the pump to complete the purge process.

82 eng

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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.

FUEL FILTER REPLACEMENT

Removal

Use fuel filter tool 91‑896661, or the shaft of a screwdriver, between the lugs on the filter cap and unscrew the filter.

a - Filter b - O‑rings

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Fuel Filter Removal/Installation Tool 91‑896661

Aids in the removal and installation of the fuel filter cap assembly.

Installation

1. Lubricate the O‑ring seals with oil.

2. Install the fuel filter and tighten securely.

3. Squeeze the primer bulb until firm and inspect for fuel leakage at the filter.

DRAINING WATER FROM THE FUEL FILTER CHAMBER

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

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

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

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

3. Tighten the drain screw and attach the hose.

84 eng

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

Steering Link Rod Fasteners

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

WARNING

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

Description Nm lb‑in. lb‑ft

Special washer head bolt 27 – 20

Nylon insert locknut "d" 27 – 20

Nylon insert locknut "c"

Tighten until it seats, then back off 1/4

turn

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

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

Fuse Replacement

IMPORTANT: Always carry spare 5 and 20‑amp fuses. The electrical wiring circuits on the outboard are protected from overload by

fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.

Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating.

a - Good fuse b - Blown fuse c - 14 pin remote control harness/cowl trim switch/main power relay ‑

15‑amp fuse

d - Ignition coil circuit ‑ 20‑amp fuse e - SmartCraft data bus circuit ‑ 5‑amp fuse f - Diagnostics terminal ‑ 2‑amp fuse g - Spare fuse ‑ 20‑amp fuse h - Fuel injectors/direct injectors/oil pump/PCM ‑ 20‑amp fuse

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Corrosion Control Anode

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

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

The gearcase has two corrosion control anodes, one on each side. A third anode is installed on the bottom of the transom bracket assembly.

a - Anode (2) on each

side of gearcase

b - Anode on transom

bracket assembly

Corrosion Control Anode

The gearcase has two corrosion control anodes, one on each side. A third anode is installed on the bottom of the transom bracket assembly and the other is located on the water intake housing.

a - Anode on the water intake housing b - Anode on the transom bracket assembly

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Battery Inspection

The battery should be inspected at periodic intervals to ensure proper engine starting capability.

IMPORTANT: Read the safety and maintenance instructions which accompany your battery.

1. Turn off the engine before servicing the battery.

2. Ensure the battery is secure against movement.

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

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

Battery Information (All Batteries Including DTS)

WARNING

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

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

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

Description

Hex nuts 13.5 120 –

88 eng

Nm lb‑in. lb‑ft

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

8M0085862

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

NOTICE

IMPORTANT:

DO NOT USE DEEP CYCLE BATTERIES!

13.5Nm (120 lb-in.)

DO NOT

USE

WINGNUTS

MAINTENANCE

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

Propellers

REMOVAL

IMPORTANT: Propellers used on this product require the Mercury Marine Flo‑Torq III type hub or equivalent.

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.

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

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

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

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

90 eng

Mercury 75, 90, 80 Jet, 115, 115 Pro XS Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

75/90/115/115 Pro XS/125 OptiMax and 80 Jet

Declaration of Conformity – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC

Welcome

EPA Emissions Regulations

Warranty Message

Mercury Premier Service

Copyright and Trademark Information

WARRANTY INFORMATION

Warranty Registration United States and Canada

Transfer of Warranty United States and Canada

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

Mercury Jet Products Limited Warranty

3 Year Limited Warranty Against Corrosion

Warranty Coverage and Exclusions

U.S. EPA Emissions Limited Warranty

Emission Control System Components

California Emissions Limited Warranty

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

Emission Certification Star Label

Warranty Policy—Australia and New Zealand

Global Warranty Charts Outboard and Jets

GENERAL INFORMATION

Boater's Responsibilities

Before Operating Your Outboard

Boat Horsepower Capacity

Propeller Selection

Outboard Remote Control Models

Remote Steering Notice

Lanyard Stop Switch

Protecting People in the Water

Wave and Wake Jumping

Impact with Underwater Hazards

Exhaust Emissions

Selecting Accessories for Your Outboard

Safe Boating Recommendations

Recording Serial Number

Specifications

80 Jet OptiMax Specifications

Component Identification

Component Identification

TRANSPORTING

Trailering Boat/Outboard

FUEL AND OIL

Fuel Recommendations

Fuel Requirements

Fuel Additives

Avoiding Fuel Flow Restriction

Low Permeation Fuel Hose Requirement

EPA Pressurized Portable Fuel Tank Requirements

Fuel Demand Valve (FDV) Requirement

Mercury Marine's Pressurized Portable Fuel Tank

Oil Recommendation

Filling Oil Injection System

Filling Fuel Tank

FEATURES AND CONTROLS

Remote Control Features

Warning System

Power Trim and Tilt

Trim Tab Adjustment

OPERATION

Important Information

Prestarting Check List

Operating in Freezing Temperatures

Operating in Saltwater or Polluted Water

Operating at High Elevations

Setting Trim Angle While Running Engine at Idle Speed

Starting the Engine

Gear Shifting

Stopping the Engine

Jet Drive Operation

MAINTENANCE

Outboard Care

EPA Emissions Regulations

Inspection and Maintenance Schedule

Flushing the Cooling System

Top Cowl Removal and Installation