Mercury Two-stroke Installation Manual

IMPORTANT
INFORMATION

1

D

OUTBOARD INSTALLATION

Table of Contents

Page

Determining Recommended Outboard

Mounting Height 1D-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Notice to Installer and Owner 1D-2. . . . . . . . . . . . . . . . . .

Boat Horsepower Capacity 1D-2. . . . . . . . . . . . . . . . .

Outboard Remote Control 1D-2. . . . . . . . . . . . . . . . . .

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

Selecting Steering Cables and Remote Control

Cables 1D-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locate Center line Of The Outboard 1D-3. . . . . . . . .

Drilling Outboard Mounting Holes 1D-3. . . . . . . . . . . .

Lifting Outboard 1D-4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fastening Outboard To The Transom 1D-4. . . . . . . .

Single Steering Cable and Steering Link

Rod Installation 1D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Ride Guide Steering Cable to the

Outboard 1D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Co-Pilot Installation (Tiller Handle models) 1D-6. . . . . . .

Remote Control Installation 1D-7. . . . . . . . . . . . . . . . . . . .

Required Side Mount Remote Control or Ignition

Key Switch Assembly 1D-7. . . . . . . . . . . . . . . . . . . . . . . . .

Boats Equipped with Side Mount

Remote Control 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Boats Equipped with Panel Or Console Mount

Remote Control 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Remote Wiring Harness to the Engine 1D-7
Shift and Throttle Cable Installation to the Outboard1D-8

Shift Cable Installation 1D-8. . . . . . . . . . . . . . . . . . . . .

Throttle Cable Installation 1D-9. . . . . . . . . . . . . . . . . .

Battery Connections 1D-10. . . . . . . . . . . . . . . . . . . . . . . . .

Set Up Instructions For Oil Injection System 1D-10. . . .

Filling The Oil Injection System 1D-10. . . . . . . . . . . . .

Bleeding Air From The Oil Injection System 1D-11. .

Adjusting The Oil Injection Pump 1D-11. . . . . . . . . . .

Trim Tab Adjustment 1D-12. . . . . . . . . . . . . . . . . . . . . . . . .

90-830234R3 DECEMBER 19971D-0 - IMPORTANT INFORMATION

Notice to Installer and Owner

Outboard Remote Control

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.

W ARNING

WARNING – Hazards or unsafe practices which
COULD result in severe personal injury or death.

CAUTION

CAUTION – Hazards or unsafe practices which could
result in minor injury or product or property damage.

Boat Horsepower Capacity

U.S. COAST GUARD CAPACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON

CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT

CAPACITY XXX

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.

W ARNING

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.

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

Selecting Accessories For
The Outboard

Genuine Mercury Marine Quicksilver Accessories
have been specifically designed and tested for your
outboard.

Mercury Marine Quicksilver accessories are avail­able from Mercury Marine dealers.

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

WARNING

Check with your dealer before installation of ac­cessories. The misuse of acceptable accesso­ries or the use of unacceptable accessories can
result in serious injury , death, or product failure.

Selecting Steering Cables
and Remote Control Cables

Refer to “Quicksilver Accessories Guide” to deter­mine correct length of steering cables and remote
control cables.

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-1

IMPORT ANT : Steering cables and remote control
cables must be the correct length. Sharp bends
on too-short cables result in “kinks”; too-long
cables require unnecessary bends and/or loops.
Both conditions place extra stress on the cables.

Determining Recommended

WARNING

Outboard Mounting Height

26 in.

(660m
m)

25 in.

(635m
m)

24 in.

(609m
m)

23 in.

(584m
m)

e

e

22 in.

(560m
m)

21 in.

(533m
m)

20 in.

(508m
m)

19 in.

(482m
m)

Boat instability can occur at high speeds by
installing engine at the wrong transom height.
Contact the boat manufacturer for their recom­mendations for a specific engine installation.

b

c

a

d

10

NOTE: Add 5 in. (127mm) for XL models and 10 in.

(254mm) for XXL models to listed outboard mounting
height.

a. This solid line is recommended to determine

the outboard mounting height.

IMPORTANT: Increasing the height of outboard
generally will provide the following: 1) Less
steering torque, 2) more top speed, 3) greater
boat stability , but, 4) will cause more prop “break
loose” which may be particularly noticeable
when planing off or with heavy load.

b. These broken lines represent the extremes of

known successful outboard mounting height
dimensions.

c. This line may be preferred to determine out-

board mounting height dimension, if maxi­mum speed is the only objective.

20 30 40 50 60 70 80

f

d. This line may be preferred to determine out-

board mounting height dimension for dual
outboard installation.

e. Outboard mounting height (height of out-

board transom brackets from bottom of boat
transom). For heights over 22 in. (560mm), a
propeller, that is specifically designed for sur­facing operation, such as the “Laser” and “Mi­rage” series, usually are preferred.

f. Maximum boat speed anticipated.

90-830234R3 DECEMBER 19971D-2 - IMPORTANT INFORMATION

Locating Center Line Of The
Outboard

Locate (and mark with pencil) the vertical centerline
(a) of boat transom.

BA

a

DC

a - Centerline of Transom

NOTE: When drilling into a fiberglass boat, place
masking tape directly onto boat where mounting
holes will be drilled to help prevent fiberglass from
chipping.

Use a 17/32 inch (13.5mm) diameter drill bit and drill
4 mounting holes perpendicular to and thru transom.

IMPORTANT: If using “Transom Drilling Fixture”
(part number 91–98234A2), use drill guide holes
marked “A” when drilling outboard mounting
holes.

NOTE: Dimensions “A” & “B” and “C” & “D” are equal

length.

IMPORT ANT : During installation of dual outboards,

the following is recommended. A minimum of 221/2
inches (570mm) centerline to centerline width is rec­ommended. This is required to alleviate cowling in­terference during lock to lock turns if one outboard
would be in the full tilt position, while the other out­board(s) are in the vertical running position.

Drilling Outboard Mounting Holes

IMPORT ANT : Before drilling any mounting holes,
carefully read “Determining Recommended Out­board Mounting Height,” preceding. There is a
3/4 inch (19mm) difference between outboard
mounting holes in transom brackets.

WARNING

DO NOT, under any circumstances, allow upper
outboard mounting bolts to be closer than 1 inch
(25.4mm) from top of boat transom. Upper
mounting bolts must never be installed thru
shims.

b

a

a – Centerline of Transom
b – Transom Drilling Fixture (91–98234A2)

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-3