Mercury Four Stroke Installation Manual

IMPORTANT INFORMATION

Section 1D - Outboard Motor Installation

Table of Contents

OUTBOARD MOTOR INSTALLATION

Electric Fuel Pump 1D-1. . . . . . . . . . . . . . . . . . . . . .

Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . . .

Start in Gear Protection 1D-2. . . . . . . . . . . . . . . . . .

Warning Horn Requirement 1D-2. . . . . . . . . . . . . . .

Selecting Accessories For The Outboard 1D-2. . .

Dual Engine Center Line Dimension 1D-2. . . . . . .

Lifting Outboard 1D-3. . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable Seal 1D-4. . . . . . . . . . . . . . . . . . . . .

Steering Link Rod 1D-5. . . . . . . . . . . . . . . . . . . . . . .

Electric Fuel Pump

If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine.
If necessary, install a pressure regulator to regulate the pressure.

Boat Horsepower Capacity

Installing Outboard 1D-6. . . . . . . . . . . . . . . . . . . . . .

Front Cable Clamp Assembly 1D-7. . . . . . . . . . . . .

Remote Wiring Harness 1D-8. . . . . . . . . . . . . . . . . .

Battery Cable Connections to the Engine 1D-9. . .
Battery Cable Connections to the Battery 1D-10. . .

Fuel Hose Connection 1D-11. . . . . . . . . . . . . . . . . . .

Shift Cable Installation 1D-12. . . . . . . . . . . . . . . . . . .

Throttle Cable Installation 1D-14. . . . . . . . . . . . . . . .

Propeller Installation 1D-15. . . . . . . . . . . . . . . . . . . . .

Trim Tab Adjustment 1D-16. . . . . . . . . . . . . . . . . . . . .

1

D

U.S. COAST GUARD CAPACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON

CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT

CAPACITY XXX

Do not overpower or overload the 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.

WARNING

Using an outboard that exceeds the maximum horsepower limit of a boat can: 1.
cause loss of boat control 2. place too much weight at the transom, altering the de­signed flotation characteristics of the boat or 3. cause the boat to break apart, par­ticularly around the transom area. Overpowering a boat can result in serious injury ,
death, or boat damage.

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MAINTENANCE

Start in Gear Protection

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

WARNING

Avoid serious injury or death from a sudden unexpected acceleration when starting
your engine. The design of this outboard requires that the remote control used with
it must have a built in start-in-gear protection device.

Warning Horn Requirement

IMPORT ANT: Warning Horn Requirement – The remote control or key switch assem­bly must be wired with a warning horn. This warning horn is used with the engine
warning system.

Selecting Accessories For The Outboard

Genuine Quicksilver Parts and Accessories have been specifically designed and tested for
this outboard.

Some accessories not manufactured or sold by Quicksilver are not designed to be safely
used with this outboard or outboard operating system. Acquire and read the Installation, Op­eration, and Maintenance manuals for all selected accessories.

Dual Engine Center Line Dimension

b

d

c

a

a-28.5 in. (724 mm)
b-12.5 in. (317 mm)
c-17.8 in. (453 mm)
d-32 Degree

Page 1D-2 90-888465 JUNE 2002

Lifting Outboard

Use 3 point strap 91-883705T.

a-3 point lift strap 91-883705T

Steering Cable

OUTBOARD MOTOR INSTALLATION

a

STARBOARD SIDE ROUTED CABLE

1. Lubricate entire cable end.

a-2-4-C Marine Lubricant with Teflon

a

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MAINTENANCE

2. Insert steering cable into tilt tube.

3. Torque nut to 47.5 Nm (35 lb. ft).

Steering Cable Seal

Install O-ring seal and cap.

a-O-ring Seal
b-Cap

b

a

Page 1D-4 90-888465 JUNE 2002

Steering Link Rod

1. Install steering link rod to rear hole on steering arm per illustration.

OUTBOARD MOTOR INSTALLATION

b

g

c

f

a

a-Special Bolt (10-856680) Torque to 27.1 Nm (20 lb. ft)
b-Nylon Insert Locknut (11-34932) Torque to 27.1 Nm (20 lb. ft)
c-Flat Washer
d-Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then Back

Nut Off 1/4 Turn

e-Flat Washer (2)

f-Install Steering Link Rod into Rear Hole

g-Steering Link Rod

IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” – Part Number 10-856680) and
self locking nylon insert locknut (“d” - Part Number 11-826709113) and self locking
nylon insert locknut (“b” – Part Number 11-34932). These locknuts must never be re­placed with common nuts (non locking) as they will work loose and vibrate off freeing
the link rod to disengage.

e

d

WARNING

Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown over­board exposing them to serious injury or death.

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