XR2 XR2 SS
1998, Mercury Marine 90Ć848717980 298
for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Marine, a world leader in marine technology and outboard
manufacturing since 1939. These years of experience
have been committed to the goal of producing the finest
quality products. This led to Mercury Marine’s reputation
for strict quality control, excellence, durability , lasting performance and being the best at providing after-the-sale
support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use and care of your outboard.
All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating.
Again, thank you for your confidence in Mercury Marine.
Mercury Hi-Performance,
N7480 County Road “UU”
Fond du Lac, WI 54935-9585
0
1
TABLE OF CONTENTS
General Information
Boater’s Responsibilities 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating Your Outboard 4. . . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed And High-Performance Boat Operation 5. . . . . . . . .
Outboard Remote Control 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Steering Notice 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lanyard Stop Switch 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 10. . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Emissions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Accessories For Your Outboard 13. . . . . . . . . . . . . . . .
Safe Boating Suggestions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording Serial Number 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Requirements 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
Installing Outboard 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting
Trailering Boat/Outboard 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel & Oil
Gasoline Recommendations 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Recommendation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline/Oil Mixture 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Fuel Tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features & Controls
Remote Control Features 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning System 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim And Tilt 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(continued on next page)
2
TABLE OF CONTENTS
Operation
Pre-Starting Check List 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Operating Instructions 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Break-in Procedure 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting The Engine 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shifting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping The Engine 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Outboard Care 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Replacement Parts For Your Outboard 38. . . . . . . . . .
EPA Emissions Regulations 38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Maintenance Schedule 39. . . . . . . . . . . . . . . . . . .
Flushing The Cooling System 41. . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Cowl Removal And Installation 42. . . . . . . . . . . . . . . . . . . . . .
Fuel System 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod Fasteners 45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion Control Anode 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Replacement 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubrication 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Submerged Outboard 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage
Storage Preparation 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 56. . . . . . . . . . . . . . . . . .
Protecting External Engine Components 56. . . . . . . . . . . . . . . . .
Gear Case 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Storage 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(continued on next page)
3
TABLE OF CONTENTS
Troubleshooting 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Wiring Diagram 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Log 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The description and specifications contained herein were in e ffect at
the time this manual was approved for printing. Mercury Marine,
whose policy is one of continued improvement, reserves the right to
discontinue models at any time, to change specifications, designs,
methods, or procedures without notice or incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A. Litho in U.S.A.
1998 Mercury Marine
Following are registered trademarks of Brunswick Corporation: AutoBlend,
Force, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury,
Mercury Marine, Mercury Hi-Performance, Quicksilver, RideGuide and
Thruster
4
GENERAL INFORMATION
oba1
Boater’s Responsibilities
The operator (driver) is responsible for the correct and safe operation
of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand
this entire manual before operating the outboard.
Be sure at least one additional person on board is instructed in the
basics of starting and operating the outboard and boat handling in
case the driver is unable to operate the boat.
obb1
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
!
DANGER – Immediate hazards which WILL result in severe
personal injury or death.
WARNING
!
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.
5
GENERAL INFORMATION
1
2
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS)
XXX
MAXIMUM WEIGHT
CAPACITY
XXX
obc1
Boat Horsepower Capacity
1
Do not overpower or overload your boat. Most boats will carry a
required capacity plate indicating the maximum acceptable pow-
er 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.
hbd1
High-Speed And High-Performance Boat
Operation
2
If your outboard is to be used on a high-speed or high-performance boat with which you are unfamiliar, we recommend that
you never 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, read the
“Guide to Hi-Performance Boat Operation” booklet included in
your literature package.
6
GENERAL INFORMATION
21
a
a
obe1
Outboard Remote Control
1 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.
obf1
Remote Steering Notice
2 The steering link rod that connects the steering cable to the en-
gine must be fastened utilizing self-locking nuts (a). These selflocking nuts must never be replaced with common nuts (non
locking) as they will work loose and vibrate of f, freeing the link rod
to disengage.
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.
7
GENERAL INFORMATION
2
1
hbg1
Lanyard Stop Switch
1
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.
2 The lanyard is a cord usually between 4 and 5 feet (1220 and
1524 mm) in length when stretched out with an element on one
end made to be inserted into the switch and a snap on the other
end for attaching to the operator. The lanyard is coiled to make
its at-rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects. It is made
as long as it is in its stretched condition 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.
Read the following Safety Information before proceeding.
(continued on next page)
8
GENERAL INFORMATION
Lanyard Stop Switch (Continued)
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. Accidental
ejections and falls overboard are more likely to occur in certain types
of boats such as low sided inflatables or bass boats, high-performance boats and light, sensitive-handling fishing boats operated by
hand-tiller. Accidental ejections and falls overboard 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.
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 , t he
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 (e.g. if the operator is accidentally
ejected).
!
WARNING
Should the operator fall out of the boat, the possibility of
serious injury or death from being run over by the boat
can be greatly reduced by stopping the engine immediately. Always properly connect both ends of the stop switch
lanyard – to the stop switch and the operator.
(continued on next page)
9
GENERAL INFORMATION
Lanyard Stop Switch (Continued)
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:
1. 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 gear case or propeller.
2. Loss of power and directional control in heavy seas, strong current or high winds.
3. Loss of control when docking.
!
WARNING
Avoid serious injury or death from deceleration forces resulting from in 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.
10
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 BOAT IS STATIONARY
Shift outboard into neutral and shut off the engine before allowing
people to swim or be in the water near your boat.
WARNING
!
Stop your engine immediately whenever anyone in the water
is near your boat. Serious injury to the person in the water is
likely if contacted by a rotating propeller, a moving boat, a
moving gear case, or any solid device rigidly attached to a
moving boat or gear case.
11
ob
GENERAL INFORMATION
Courtesy of ABYC
1
ob
Exhaust Emissions
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, stern drives and inboard
engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning which should not be
confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea.
WARNING
!
Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient
concentration can lead to unconsciousness, brain damage, or
death.
GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches to
remove fumes.
1 Example of desired air flow through the boat.
12
ob
GENERAL INFORMATION
a
c
b
d
Courtesy of ABYC
2
Exhaust Emissions (Continued)
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 unclosed area of a stationary boat that contains or
is near a running engine may be exposed to a hazardous level of carbon monoxide.
2 Examples of Poor Ventilation:
While boat is stationary
a. Running the engine when the boat is moored in a confined
space.
b. Mooring close to another boat that has its engine running.
While boat is moving
c. Running the boat with the trim angle of the bow too high.
d. Running the boat with no forward hatches open (station wag-
on effect).
13
GENERAL INFORMATION
Selecting Accessories For Your 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.
obk1
Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local
and other governmental boating regulations and restrictions, and
consider the following suggestions.
Use flotation devices. Have an approved personal flotation device
of suitable size for each person aboard (it is the law) and have it
readily accessible.
Do not overload your boat. Most boats are rated and certified for
maximum load (weight) capacities (refer to your boat capacity plate).
If in doubt, contact your dealer or the boats manufacturer.
Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.
(continued on next page)
14
ob
GENERAL INFORMATION
Safe Boating Suggestions (Continued)
Know and obey all nautical rules and laws of the waterways.
Boat operators should complete a boating safety course. Courses
are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2)
The Power Squadron, (3) The Red Cross and (4) your state boating
law enforcement agency . Inquiries may be made to the Boating Hotline, 1-800-368-5647 or the Boat U.S. Foundation information number 1-800-336-BOAT.
Make sure everyone in the boat is properly seated. Don’t allow
anyone to sit or ride on any part of the boat that was not intended for
such use. This includes backs of seats, gunwales, transom, bow,
decks, raised fishing seats, any rotating fishing seat; 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.
Never be under the influence of alcohol or drugs while boating
(it is the law). They impair your judgment and greatly reduce your
ability to react quickly.
Prepare other boat operators. Instruct at least one person on board
in the basics of starting and operating the outboard and boat handling
in case the driver becomes disabled or falls overboard.
Passenger boarding. Stop the engine whenever passengers are
boarding, unloading or are near the back (stern) of the boat. Just
shifting the outboard into neutral is not sufficient.
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 operators view when operating the
boat above idle speed.
Never drive your boat directly behind a water skier in case the
skier falls. As an example, your boat traveling at 25 miles per hour
(40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet
(61m) in front of you.
(continued on next page)
15
ob
GENERAL INFORMATION
Safe Boating Suggestions (Continued)
Watch fallen skiers. When using your boat for water skiing or similar
activities, always keep a fallen or down skier on the operator’s side
of the boat while returning to attend 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.
obl2
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 Year
c - Model Designation
d - Year Manufactured
e - Certified Europe Insignia
19XX
XX
OGXXXXXX
XXXX
a
c
b
d
e
16
GENERAL INFORMATION
Torque Requirements
ITEM TORQUE
Connecting Rods 30 lb. ft. (41 N·m) 271 Loctite
Crankcase Cover to Block 3/8 in. -- 40 lb. ft. (54 N·m)
Light Oil
5/16 in. -- 200 lb. in. (23 N·m)
Light Oil
Exhaust Divider Plate Cover 200 lb. in. (23 N·m)
Lower End Cap 100 lb. in. (11 N·m) 271 Loctite
Upper End Cap 200 lb. in. (23 N·m) 271 Loctite
Reed Block to Adaptor 100 lb. in. (11 N·m) 271 Loctite
Carburetor Adaptor to Reed
Housing
100 lb. in. (11 N·m) 271 Loctite
Stator Screws 40 lb. in. (5 N·m) 271 Loctite
Ignition Coil Screws Tighten Securely
Cylinder Head Bolts 30 lb. ft. (41 N·m) + 90° or 1/4
Turn, Light Oil
Flywheel Nut 150 lb. ft. (203 N·m)
Spark Plugs 20 lb. ft. (27 N·m)
Exhaust Megaphone 25 lb. ft. (34 N·m) 271 Loctite
Powerhead to Driveshaft Hous-
ing
35 lb. ft. (47 N·m) 271 Loctite
Gearcase to Driveshaft Housing
Tighten Securely
17
GENERAL INFORMATION
Specifications
MODEL XR2
Horsepower 180 (134kw)
Propshaft Kilowatts
1
194
Full Throttle RPM Range 6000-7000
Idle RPM in Forward Gear 650-750
Weight 350 lbs. (159 kg)
Piston Displacement 122 cu. in. (2.0L/1998cc)
Bore 3.125 in. (79.5 mm)
Stroke 2.65 in. (67 mm)
Recommended Spark Plug NGK-BUHW (P/N 33-97180)
Firing Order 1-2-3-4-5-6
Maximum Timing 25° BTDC
Idle Speed Pickup Timing 2° ATDC
Fuel Pressure 5 - 6 psi
Gear Ratio 1.87:1
Recommended Gasoline Refer to Fuel Section
Recommended Oil Refer to Fuel Section
Recommended Gear Case
Oil
Quicksilver Hi-Performance Gear
Lube (92-816026A4)
Gear Case Lubricant Capacity
22.5 fl. oz. (666 ml)
Battery Rating Minimum reserve capacity rating of
100 minutes and CCA of 350
Charging System Output 16 amps @ 7000 RPM
Transom Height Short Shaft = 15” (381mm)
Long Shaft = 20” (508mm)
Water Pres. @ WOT 15 PSI (103.4 kPa)
1
Measured at the propshaft in accordance with ICOMIA28
18
ob
GENERAL INFORMATION
1
23
4
5
6
7
8
9
10
12
7
11
13
Component Identification
1. Top Cowl 8. Transom Brackets
2. Cowl Latch
9. Trim Adjustment Bolt
3. Bottom Cowl
10. Gear Case
4. Water Pump Indicator Hose
(
Tell-Tale
)
11. Water Discharge
(Tell Tale)
5. Drive Shaft Housing
12.
Cooling W
ater Intake Holes
5. Drive Shaft Housing
6. Anti-Ventilation Plate
13.Sk
eg
7. Corrosion Anode
19
INSTALLATION
1-2
Installing Outboard
WARNING
!
Before operation, the outboard must be correctly installed
with four mounting bolts shown. Failure to correctly fasten
outboard could result in outboard ejecting off boat transom
causing serious injury, death, or property damage.
1 We strongly recommend that your dealer install your outboard
and related accessories to ensure proper installation and good
performance. If you install the outboard yourself, follow instructions in the Outboard Installation Manual which is provided with
the outboard.
2 The outboard must be secured to the transom with the four 1/2
inch diameter mounting bolts and locknuts provided with the outboard. Install two bolts thru the upper set of holes and two bolts
thru the lower set of holes.
20
oc
INSTALLATION
ghc3
3
4
a
OUTBOARD MOUNTING HEIGHT
3 Use the following chart to determine the proper mounting height
(a) for your outboard.
Gear Case
Application
Minimum Height
(a)
Maximum Height
(a)
Sport Master 27” (68cm) 30” (76cm)
ocb1
Propeller Selection
4 For best all around performance from your outboard/boat combi-
nation, select a propeller that allows the engine to operate in the
upper half of the recommended full throttle RPM range with the
boat normally loaded (refer to Specifications). This RPM range
allows for better acceleration while maintaining maximum boat
speed.
If changing conditions cause the RPM to drop below the recommended range (such as warmer, more humid weather, operation at
higher elevations, increased boat load, or a dirty boat bottom/gear
case) a propeller change or cleaning may be required to maintain
performance and ensure the outboards durability.
Check full-throttle RPM using an accurate tachometer with the engine trimmed out to a balanced-steering condition (steering effort
equal in both directions) without causing the propeller to “break
loose.”
21
TRANSPORTING
odc1
Trailering Boat/Outboard
Trailer your boat with the outboard tilted down (vertical operating position).
If additional ground clearance is required, the outboard should be
tilted up using an outboard support bar. 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.
22
FUEL & OIL
Gasoline Recommendations
UNITED STATES AND CANADA
Use a major brand of automotive unleaded gasoline with a minimum
posted octane rating of 87. Mid-grade automotive gasolines that contain fuel injector cleaner are preferred for added internal engine
cleanliness. Leaded gasoline is not recommended.
INTERNATIONAL
Use a major brand of automotive unleaded gasoline with a minimum
posted octane rating of 90RON. Automotive gasolines that contain
fuel injector cleaner are preferred for added internal engine cleanliness. Leaded gasoline is acceptable in areas where unleaded gasoline is not available.
ALCOHOL IN GASOLINE
We do not recommend the use of gasoline which contains alcohol
because of the possible adverse effect the alcohol may have on the
fuel system. In general, if only gasoline containing alcohol is available, it must not contain more than 10% ethanol or 5% methanol, a nd
the addition of a Quicksilver Water Separating Fuel Filter is recommended.
If gasoline containing alcohol is used or if you suspect the presence
of alcohol in your gasoline, increase your inspection of the fuel system, visually checking for fuel leaks or abnormalities.
Gasoline containing alcohol may cause the following problems to
your outboard and fuel system:
• Corrosion of metal parts.
• Deterioration of elastomers and plastic parts.
• Wear and damage of internal engine parts.
• Starting and operating difficulties.
• Vapor lock or fuel starvation.
Some of these adverse effects are due to the tendency of gasoline
containing alcohol to absorb moisture from the air, resulting in a
phase of water and alcohol which separates from the gasoline in the
fuel tank.
The adverse effects of alcohol are more severe with methanol and
are worse with increasing content of alcohol.
23
FUEL & OIL
Oil Recommendation
Use Mercury Hi-Performance Synthetic Blend 2-Cycle Oil.
Emergency Use Only: If the Hi-Performance 2-Cycle Oil is not avail-
able, Quicksilver NMMA Certified Premium TC-W3 or Premium Plus
TC-W3 2-Cycle Oil may be substituted. These oils should not be
used on a regular basis.
Periodically consult with your dealer to get the latest gasoline and oil
recommendations. If Quicksilver 2-Cycle Outboard Oil is not available, substitute a 2-Cycle outboard manufacturers oil that is NMMA
Certified TC-W3, or 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.
Gasoline/Oil Mixture
During and after break-in, use a 32:1 (3.1%) gasoline/oil mixture in
your fuel tank.
GASOLINE/OIL MIXING RATIO CHART
Gas/Oil
Ratio
1 Gallon Gas
(3.8 Liters)
3 Gallons Gas
(11.5 Liters)
6 Gallons Gas
(23 Liters)
32:1
(3.1%)
4 fl. oz.
(118 ml) Oil
12 fl. oz.
(355 ml) Oil
24 fl. oz.
(710 ml) Oil
oee5
Filling Fuel Tank
WARNING
!
Avoid serious injury or death from a gasoline fire or explosion.
Always stop the engine and DO NOT smoke or allow open
flames or sparks in the area while filling fuel tanks.
Fill fuel tanks outdoors away from heat, sparks, and open flames.
Remove portable fuel tanks from boat to refill them.
Always stop engine before refilling tanks.
Do not overfill the fuel tanks. Fuel will expand in volume as its temper-
ature rises and can leak under pressure.
24
og
FEATURES & CONTROLS
gog142
1
2
3
4
5
6
7
8
9
1
1
2
3
3
4
5
7
9
6
6
Panel
Side Mount Console
oge5
Remote Control Features
Your boat may be equipped with one of the Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control.
1 Control Handle – Forward, Neutral, Reverse
2 Neutral Release Lever
3 Trim/Tilt Switch (if Equipped) – Refer to Power Trim Operation.
4 Lanyard Stop Switch – Read the Lanyard Stop Switch safety ex-
planation and Warning in the General Information Section.
5 Lanyard – Read the lanyard stop switch safety explanation and
warning in the General Information Section.
6 Throttle Friction Adjustment – Console Controls require cover re-
moval for adjustment.
7 Ignition Key Switch – Off, On, Start, Choke
8 Fast Idle Lever – Raising lever will increase engine idle speed in
neutral. Refer to Starting the Engine in the Operation Section.
9 Throttle Only Button – Pushing in the button will enable you to ad-
vance the control handle for increasing engine idle speed without
shifting outboard into gear. Refer to Starting the Engine in the Operation Section.
25
og
FEATURES & CONTROLS
gog67
2
1
a
b
ogb32
Warning System
1
The outboard warning system incorporates a warning horn inside
the boat. The warning horn may be located inside the remote
control (a) or under the dash (b) connected to the ignition key
switch.
The system is designed for the warning horn to emit either a continuous beep or intermittent short beeps. This will alert the operator and
help identify the following listed problems.
• The warning horn sounds continuously
The problem is engine overheat. See explanation following.
• The warning horn sounds intermittent short beeps.
The problem is low oil level in the oil injection system. See explanation following.
2 When the ignition key is initially turned on, the warning horn will
sound for a moment as a test to tell you the system is working.
Failure of this test indicates a problem. Have the outboard
checked by your dealer.
26
FEATURES & CONTROLS
a
Warning System (Continued)
THE WARNING HORN SOUNDS CONTINUOUSLY
Problem – Engine overheat. The warning system is activated when
the engine temperature is too hot.
3 If the engine overheats, immediately reduce throttle speed to
idle. Shift outboard into neutral and check for a steady stream of
water coming out of the water pump indicator hole (a).
If no water is coming out of the water pump indicator hole (a) or flow
is intermittent, stop engine and check cooling water intake holes for
obstruction. If no obstruction is found, this may indicate a blockage
in the cooling system or a water pump problem. Have the outboard
checked by your dealer. Operating the engine while overheated will
cause engine damage. See the following note.
If a steady stream of water is coming out of the water pump indicator
hole (a) and the warning horn continues to sound, there still may be
insufficient cooling water or an engine problem. Stop engine and
have it checked by your dealer. Operating the engine while overheated will cause engine damage. See the following note.
NOTE: If you are in a stranded situation, stopping the engine and
allowing it to cool back down will usually allow some additional low
speed (idle) running time before the engine starts to overheat again.
The overheat problem must be corrected before you can resume normal operation.
27
FEATURES & CONTROLS
a
b
c
Power Trim And Tilt
WARNING
!
Avoid possible serious injury or death. Do not trim outboard
beyond its normal trim range above 2000 RPM. In order to significantly raise the strength of the Hi-Performance transom
assembly, the electric trim limit and trim indicator sending
unit mounting positions have been eliminated. Having no trim
limit switch permits the operator to trim the outboard to any
position at any throttle setting.
NOTE: There is no tilt feature on engines with a 15 in. (38.1cm) center section. These outboards can only be trimmed.
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 (a). 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 (b). 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 (c). 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.
(continued on next page)
28
FEATURES & CONTROLS
Power Trim And Tilt (Cont.)
POWER TRIM OPERATION
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. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the
water surface.
WARNING
!
Avoid possible serious injury or death. When the outboard is
trimmed in or out beyond a neutral steering condition, a pull
on the steering wheel or tiller handle in either direction may
result. Failure to keep a continuous firm grip on the steering
wheel or tiller handle when this condition exists can result in
loss of boat control as the outboard can turn freely. The boat
can now “spin out” or go into a very tight maximum turn
which, if unexpected, can result in occupants being thrown
within the boat or out of the boat.
Consider the following lists carefully.
Trimming In or Down Can:
1. Lower the bow.
2. Result in quicker planing off, especially with a heavy load or a
stern heavy boat.
3. Generally improve the ride in choppy water.
4. Increase steering torque or pull to the right (with the normal right
hand rotation propeller).
(continued on next page)
29
FEATURES & CONTROLS
Power Trim And Tilt (Cont.)
POWER TRIM OPERATION (CONT.)
5. In excess, lower the bow of some boats to a point at which 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 “over-steering” if any turn is attempted, or if a significant
wave is encountered.
WARNING
!
Avoid possible serious injury or death. Adjust outboard to an
intermediate trim position as soon as boat is on plane to avoid
possible ejection due to boat spin-out. Do not attempt to turn
boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel.
6. In rare circumstances, the owner may decide to limit the trim in.
This can be accomplished by inserting the tilt pin in whatever adjustment hole in the transom brackets is desired.
Trimming Out or Up can:
1. Lift the bow higher out of the water.
2. Generally increase top speed.
3. Increase clearance over submerged objects or a shallow bottom.
4. Increase steering torque or pull to the left at a normal installation
height (with the normal right hand rotation propeller).
5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation.
6. Cause engine overheating if any cooling water intake holes are
above the water line.
(continued on next page)
30
FEATURES & CONTROLS
1-2-3
a
b
Power Trim And Tilt (Cont.)
TILTING OPERATION (IF EQUIPPED)
To tilt outboard, shut off the engine and press the trim/tilt switch to the
up position. The outboard will tilt up until the switch is released or it
reaches its maximum tilt position.
1 Push in on the tilt support release knob (a) and move tilt support
lever into locking position (b).
2 Lower 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 up until it locks. Lower the outboard.
31
OPERATION
Pre-Starting 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.
Fuel mixture OK.
Arrange passengers and load in the boat so the weight is distrib-
uted evenly and everyone is seated in a proper seat.
Tell someone where you are going and when you expect to return.
It is illegal to operate a boat while under the influence of alcohol
or drugs.
Know the waters and area you will be boating; tides, currents,
sand bars, rocks, and other hazards.
Make inspection checks listed in the Inspection and Maintenance
Schedule. Refer to Maintenance Section.
Special Operating Instructions
OPERATING IN FREEZING TEMPERATURES
When using your outboard or having your outboard moored in freezing or near freezing temperature, keep the outboard tilted down at all
times so the gear case is submerged. This prevents trapped water
in gear case 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 drive shaft housing, it will block water
flow to the engine causing possible damage.
(continued on next page)
32
OPERATION
Special Operating Instructions (Cont.)
OPERATING IN SALT WATER 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 “Flushing The Cooling System” procedure in the Maintenance Section.
If you keep your boat moored in the water, always tilt the outboard
so the gear case is completely out of water (except in freezing temperature) when not in use.
Wash down the outboard exterior and flush out the exhaust outlet of
the propeller and gear case with fresh water after each use. Each
month spray Quicksilver Corrosion Guard on the engine exterior,
electrical components and other metal surfaces (do not spray on corrosion control anodes as this will reduce the effectiveness of the
anodes).
OPERATING AT HIGH ELEVATIONS
Operating your outboard at an elevation higher than 2500 ft. (750 m)
above sea level may require a carburetor jet change and/or different
pitch propeller. Consult your dealer. This will reduce the normal performance loss experienced as a result of reduced oxygen in the air
causing an overly rich fuel mixture.
IMPORTANT: To prevent serious damage to the engine caused
by a lean fuel mixture, DO NOT operate your outboard (if the jets
were changed for high elevation) at a lower elevation unless the
jets are changed again to correspond to the new elevation.
33
of
OPERATION
og124
2
1
a
b
Special Operating Instructions (Cont.)
onk2
OPERATING IN SHALLOW WATER
1 When operating your boat in shallow water, you can tilt the out-
board beyond the maximum trim range to prevent hitting bottom.
a. Reduce engine speed below 2000 RPM.
b. Tilt outboard up. Make sure all the cooling water intake holes
stay submerged at all times.
c. Operate the engine at slow speed only. Never exceed 2000
RPM.
onn1
SETTING TRIM ANGLE WHILE RUNNING ENGINE AT IDLE
SPEED
2 Submerging the exhaust relief hole (a) on the outboard can hap-
pen on some boats if you trim the outboard “full-in” while running
the engine at idle speed. This will cause an exhaust restriction,
resulting in rough idle, excessive smoke, and fouled spark plugs.
If this condition exists, trim outboard up until exhaust relief hole
is out of the water (b).
34
OPERATION
Engine Break-in Procedure
CAUTION
!
Severe damage to the engine can result by not complying with
the Engine Break-in Procedure.
Operate your outboard at varied throttle settings – not to exceed 1/2
throttle (3000-3500 RPM) during the first hour or ten gallons of Engine Gasoline/Oil Mixture. Refer to Fuel Section.
During the second hour of operation, or the second 10 gallons of Engine Gasoline/Oil Mixture, operate the outboard at varied throttle settings not to exceed 4500 RPM.
IMPORTANT: DO NOT operate the engine at full throttle until
the second hour of break-in is completed. This includes full
throttle acceleration, pulling water-skiers or wide open throttle
running.
After the first two hours of running, approximately 20 gallons of fuel,
full throttle operation may be obtained, but not sustained, for the remaining break-in period (approximately 10 gallons of gasoline/oil
mixture or 1 hour of operation).
For the next seven hours of operation, full throttle operation may,
again, be attained, but strongly not recommended for sustained use.
(More than 5 minutes of continuous full throttle operation).
BREAK-IN AND RUNNING JETS
The engine has been shipped with (.094 in.) Break-In jets installed.
After the proper break-in period has been completed these jets must
be removed and (.090 in.) Running Jets installed. Consult the Dealer
for this procedure or refer to the appropriate engine service manual
for your model engine.
35
OPERATION
2
4
1
3
Starting The Engine
Before starting, read the Pre-Starting Check List, Special Operating
Instructions, and Engine Break-in Procedure on the first three pages
in the Operation Section.
CAUTION
!
Prevent damage to the water pump (running dry) or overheating of the engine. Never start or run your outboard (even momentarily) without water circulating through all the cooling
water intake holes in the gear case.
1 Lower the outboard to the run position. Make sure all the cooling
water intake holes are submerged.
2 Open fuel tank vent screw (in filler cap) on manual venting type
fuel tanks.
3 Squeeze the fuel line primer bulb several times until it feels firm.
4 Set the lanyard stop switch to RUN position. Read the Lanyard
Stop Switch safety explanation and Warning in the General Information Section.
36
OPERATION
6
7
5
N
Starting The Engine (Continued)
5
Shift outboard to neutral (N) position.
6 The engine can be manually primed by pushing in on the key
choke switch (if so equipped) or a remote choke switch can be
connected to the yel/blk wire at the engine harness connector.
(Refer to wiring diagram).
Note: Starting Flooded Engine – Advance throttle to at least 1/2 open
(gear case in neutral), and crank engine for 10 seconds. Wait 30 seconds and repeat until engine starts.
7 Check for a steady stream of water flowing out of the water pump
indicator (tell-tale) hose.
IMPORTANT: If n o water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for
obstruction. If no intake obstruction is found this may indicate
a water pump failure or internal blockage in the cooling system.
These conditions will cause the engine to overheat. Have the
outboard checked by your dealer. Operating the engine while
overheated will cause engine damage.
37
OPERATION
5
1-4
N
R
F
Gear Shifting
IMPORTANT: Observe the following:
• Never shift outboard into gear unless engine speed is at idle.
• Do not shift outboard into Reverse when the engine is not
running.
1 Your outboard has three gear shift positions to provide operation.
Forward (F), Neutral (out of gear) and Reverse (R).
2 When shifting, always stop at neutral position and allow the en-
gine speed to return to idle.
3 Always shift outboard into gear with a quick motion.
4 After shifting outboard into gear, advance the lever further to in-
crease speed.
Stopping The Engine
5
Reduce engine speed and shift outboard to neutral position. T urn
ignition key to OFF position.
38
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
have it maintained properly to ensure the safety of you and your passengers and retain its dependability.
WARNING
!
Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your
outboard if you are not familiar with the correct service and
safety procedures could cause personal injury, death, or
product failure.
Record maintenance performed in 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 Marine Quicksilver replacement parts and Genuine Quicksilver Lubricants.
WARNING
!
Using a replacement part that is inferior to the original part
could result in personal injury, death, or product failure.
oti1
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 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 SI engine
repair establishment or individual.
39
MAINTENANCE
Inspection And Maintenance Schedule
BEFORE EACH USE
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
(page 45)
6. Check propeller blades for damage.
AFTER EACH USE
1. Flush out the outboard cooling system if operating in salt or polluted water. (page 41)
2. Wash off all salt deposits and flush out the exhaust outlet of the
propeller and gear case with fresh water if operating in salt water.
AFTER 10 HOUR BREAK-IN
1. Remove “Break-In Jets” and install running jets.
2. Inspect and clean spark plugs. (page 49)
3. Check engine timing setup.
4. Drain and replace gear case lubricant. (page 53)
5. Inspect battery. (page 49)
6. Check control cable adjustments.
7. Lubricate all lubrication points. (page 50)
8. Check tightness of bolts, nuts and other fasteners.
40
MAINTENANCE
Inspection And Maintenance Schedule (Cont.)
EVERY 25 HOURS OF USE OR ONCE A MONTH
1. Lubricate all lubrication points. (page 50)
2. Check level and condition of gear case lubricant. (page 53)
3. Inspect battery. (page 49)
4. Check corrosion control anodes. (page 46)
5. Check tightness of bolts, nuts and other fasteners.
6. Lubricate propshaft with anti-corrosion grease. (50)
EVERY 50 HOURS OF USE OR ONCE A SEASON
IMPORTANT: Increased lubrication and corrosion mainte-
nance is required if unit is used in salt water.
1. Inspect and clean/replace spark plugs. (page 49)
2. Check engine timing setup.*
3. Check charging system.*
4. Inspect reeds.*
5. Drain and replace gear case lubricant. (page 53)
6. Lubricate splines on the drive shaft.*
7. Lubricate entire length of driveshaft with anti-corrosion grease.*
8. Lubricate propshaft with anti-corrosion grease.
9. Check power trim fluid. (page 52)
10. Check control cable adjustments.*
11. Remove engine deposits with Quicksilver Power Tune Engine
Cleaner.
12. Replace final fuel filter element. (Page 44)
13. Replace water pump impeller (more often if overheating occurs
or reduced water pressure is noted).*
BEFORE PERIODS OF STORAGE
1. Refer to Storage procedure. (page 55)
∗ These items should be serviced by an authorized dealer.
41
MAINTENANCE
1–4
5
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.
A nose cone flushing attachment for the Sport Master Gear Case P/N
848998A1 is available thru Quicksilver Accessories.
WARNING
!
WARNING – To avoid possible injury when flushing, remove
the propeller. Refer to Propeller Replacement.
1 Remove propeller (refer to Propeller Replacement). Install the
flushing attachment so the nose cone cup fits tightly over the
cooling water intake.
2 Attach a water hose to the flushing attachment. Turn on water
and adjust flow so water is leaking around flushing attachment to
ensure the engine receives an adequate supply of cooling water .
3 Start engine and run at idle speed in neutral shift position.
4 Adjust water flow (if necessary) so excess water continues leak-
ing out from around the flushing attachment to ensure the engine
is receiving an adequate supply of cooling water.
5 Check for a steady stream of water flowing out of the water pump
indicator hoses at back of engine. Continue flushing the outboard
for 3 to 5 minutes, carefully monitoring water supply at all times.
(continued on next page)
42
MAINTENANCE
a
1-2
Flushing The Cooling System (Cont.)
IMPORTANT: Stop engine before shutting off water. Never operate engine without cooling water. Even momentary engine operation without water could cause severe engine damage.
6 Stop the engine, turn off the water, and remove the flushing at-
tachment. Reinstall the propeller.
Top Cowl Removal And Installation
WARNING
!
Do Not attempt to remove or install cowl while engine is running.
REMOVAL
1 Rotate latch (a) clockwise. Lift rear of cowl and pull back to disen-
gage front latch hook.
2 Lift top cowl up to remove.
INSTALLATION
3 Lower top cowl into position over engine. T ip the front of the cowl
slightly to engage the front alignment bracket. After the front
bracket is engaged, route cowl down into position making sure
the top cowl rubber alignment pins are in the bottom cowl location
bracket. Rotate latch (a) counterclockwise to secure top cowl.
43
MAINTENANCE
Fuel System
WARNING
!
Avoid serious injury or death from gasoline fire or explosion.
Carefully follow all fuel system service instructions. Always
stop the engine and DO NOT smoke or allow open flames or
sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop 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.
44
MAINTENANCE
1
c
Fuel System (Continued)
WATER SEPARATING FUEL FILTER (NOT INCLUDED WITH
ENGINE)
1 A water separating fuel filter is not included with your engine but
is recommended. This filter removes moisture and also debris
from the fuel and should be mounted before the fuel pump supplied with your engine. If the filter becomes filled with water, the
water can be removed and the filter reused. If the filter becomes
plugged with debris, the filter must be replaced with a new filter .
Remove and replace filter as follows
a. Turn ignition key switch to OFF position.
b. Remove filter by turning the filter in the direction of the arrow
indicated above (counterclockwise). Tip the filter to drain fluid
in a suitable container.
c. Lubricate the sealing ring (c) on the filter with oil. Install the
filter and tighten securely by hand.
IMPORTANT: Visually inspect for fuel leakage from the filter after starting the engine.
45
MAINTENANCE
b
a
c
d
ohi1
Steering Link Rod Fasteners
IMPORTANT: The steering link rod that connects the steering
cable to the engine must be fastened using special washer head
bolt (“a” – Part Number 10-14000) and self locking nylon insert
locknuts (“b” & “c” – Part Number 11-34863). 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.
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.
Assemble steering link rod to steering cable with two flat washers (d)
and self locking nylon insert locknut (“b” – Part Number 11-34863).
Tighten locknut (b) until it seats, then back nut off 1/4 turn.
Assemble steering link rod to engine with special washer head bolt
(“a” – Part Number 10-14000) and self locking nylon insert locknut
(“c” – Part Number 11-34863). First torque bolt (a) to 20 lb. ft. (27.1
N·m), then torque locknut (c) to 20 lb. ft. (27.1 N·m).
46
MAINTENANCE
1
a
c
b
Corrosion Control Anode
Your outboard has three corrosion control anodes. One of the
anodes is the round plate installed on the antiventilation plate (a), a
second one is located just above the antiventilation plate (b), and the
third is installed on the bottom of the transom bracket assembly (c).
An anode helps protect the outboard against galvanic corrosion by
sacrificing its metal to be slowly eroded instead of the outboard metals.
1 Each anode requires periodic inspection, especially in salt water
which accelerates 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.
47
MAINTENANCE
12
4–53
N
ohl8
Propeller Replacement
WARNING
!
If the propeller shaft is rotated while the engine is in gear, there
is the possibility that the engine will crank over and start. To
prevent this type of accidental engine starting and possible
serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove
spark plug leads when you are servicing the propeller.
1 Shift outboard to neutral (N) position.
2 Remove spark plug leads to prevent engine from starting.
3 Straighten the bent tabs on the propeller nut retainer.
4 Place a block of wood between gear case and propeller to hold
propeller and remove propeller nut.
5 Pull propeller straight off shaft. If propeller is seized to the shaft
and cannot be removed, have the propeller removed by an authorized dealer.
IMPORTANT: Use care to prevent losing forward thrust washer
(located between propeller and gearcase) when removing propeller.
48
MAINTENANCE
6
7
a
b
c
e
d
f
9-10
8
a
c
b
d
e
f
Propeller Replacement (Cont.)
6
Coat the propeller shaft with Quicksilver Anti-Corrosion Grease.
IMPORTANT: T o prevent the propeller hub from corroding and
seizing to the propeller shaft, especially in salt water, always apply a coat of Quicksilver Anti-Corrosion Grease to the entire
shaft at the recommended maintenance intervals and also each
time the propeller is removed.
7 Rubber Hub Propellers - Install thrust washer (a), propeller (b),
continuity washer (c), splined washer (d), propeller nut retainer
(e), and propeller nut (f) onto the shaft.
8 Replaceable Hub Propellers (Using Hi-Performance Hub Kit P/N
835258A1) - Install forward thrust hub (a), replaceable drive
sleeve (b), propeller (c), drive sleeve adaptor (d), propeller nut retainer (e) and propeller nut (f) onto the shaft.
9 Place a block of wood between gear case and propeller and
torque propeller nut to 55 lb. ft. (75 N·m).
10Secure propeller nut by bending three of the tabs into the thrust
hub grooves.
49
MAINTENANCE
12
Spark Plug Inspection
Inspect spark plugs at the recommended intervals.
1 Remove the spark plug leads by twisting the rubber boots slightly
and pull off. Inspect spark plug boots and replace if cracked.
2 Remove the spark plugs to inspect and clean. Replace spark
plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled.
3 Before reinstalling spark plugs, clean away dirt on the spark plug
seats. Install plugs finger tight, and tighten to a torque of 20 lb.
ft. (27 N·m).
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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. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield
to prevent accidental shorting of battery terminals.
50
MAINTENANCE
1
2
3
Lubrication Points
LUBRICATE POINT 1 WITH QUICKSILVER ANTI-CORROSION
GREASE.
1 Propeller Shaft – Refer to Propeller Replacement for removal
and installation of the propeller. Coat the entire propeller shaft
with lubricant to prevent the propeller hub from corroding and
seizing to the shaft.
LUBRICATE POINTS 2 AND 3 WITH QUICKSILVER 2-4-C MARINE LUBRICANT OR SPECIAL LUBRICANT 101.
2 Tilt Lock Grease Fittings – Lubricate through fitting.
3 Swivel Pin Grease Fitting – Lubricate through fitting.
(continued on next page)
51
MAINTENANCE
5
6
4
5a
b
Lubrication Points (Continued)
WARNING
!
The end of the steering cable must be fully retracted into the
outboard tilt tube before adding lubricant. Adding lubricant to
steering cable when fully extended could cause steering cable
to become hydraulically locked. An hydraulically locked
steering cable will cause loss of steering control, possibly resulting in serious injury or death.
LUBRICATE POINTS 4 AND 5 WITH QUICKSILVER 2-4-C MARINE LUBRICANT OR SPECIAL LUBRICANT 101.
4 Tilt Tube – Lubricate through fitting.
5 Steering Cable – Rotate steering wheel to fully retract the steer-
ing cable end (a) into the outboard tilt tube. Lubricate through fitting (b).
LUBRICATE POINT 6 WITH LIGHT WEIGHT OIL.
6 Steering Link Rod Pivot Points – Lubricate pivot points.
52
MAINTENANCE
12
a
b
c
Checking Power Trim Fluid
1
Place outboard in the full down (in) position.
2 Remove fill/vent screw (a). Wipe with a clean, lint-free cloth and
reinstall - D O NOT THREAD INTO PUMP. Remove fill/vent screw
and note oil level. Oil level must be between the “ADD” (c) and
“FULL” (b) marks on dipstick. If necessary, add Quicksilver Power T rim & Steering Fluid or SAE 10W -30 or 10W -40 motor oil thru
the fill/vent screw hole to bring level up to the “FULL” mark on the
dipstick. DO NOT OVERFILL.
3 To purge system of air, raise the outboard 2 or 3 times. Recheck
oil level and add oil if necessary.
4 Reinstall fill/vent screw by turning it all-the-way in, then back it out
one and a half (1-1/2) turns.
CAUTION
!
Fill/Vent screw MUST BE backed out one and a half (1-1/2)
turns (after bottoming out) to vent pump reservoir.
FAILURE
TO BACK SCREW OUT COULD RESULT IN DAMAGE TO
PUMP.
53
MAINTENANCE
2
1
4
3
Gear Case Lubrication
When adding or changing gear case lubricant, visually check for the
presence of water in the lubricant. If water is present, it may have
settled to the bottom and will drain out prior to the lubricant, or it may
be mixed with the lubricant, giving it a milky colored appearance. If
water is noticed, have the gear case checked by your dealer . Water
in the lubricant may result in premature bearing failure or, in freezing
temperatures, will turn to ice and damage the gear case.
Whenever you remove the fill/drain plug, examine the magnetic end
for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and
should be checked by an authorized dealer.
DRAINING GEAR CASE
1 Place outboard in a vertical operating position.
2 Place drain pan below outboard.
3 Remove vent plug.
4 Remove fill/drain plug and drain lubricant.
ohv8
GEAR CASE LUBRICANT CAPACITY
Gear case lubricant capacity is approximately 22.5 fl. oz. (666 ml).
54
MAINTENANCE
a
c
b
d
5-9
Gear Case Lubrication (cont.)
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING
GEAR CASE
5 Place outboard in a vertical operating position.
6 Remove fill plug/sealing washer (a) and top vent plug/sealing
washer (c).
7 Place lubricant tube (b) into the fill hole and add lubricant until it
appears at the vent hole (d).
IMPORTANT: Replace sealing washers if damaged.
8 Stop adding lubricant. Install the top vent plug and sealing wash-
er (c) before removing the lubricant tube.
9 Remove lubricant tube and reinstall cleaned fill/drain plug and
sealing washer (a).
ohr1
Submerged Outboard
A submerged outboard will require service within a few hours by an
authorized dealer once the outboard is recovered from the water.
This immediate attention by a servicing dealer is necessary to minimize internal corrosion damage to the engine once the engine is exposed to the atmosphere.
55
STORAGE
Storage Preparation
The major consideration in preparing your outboard for storage is to
protect it from rust, corrosion, and damage caused by freezing of
trapped water.
The following storage procedures should be followed to prepare your
outboard for out of season storage or prolonged storage (two months
or longer).
CAUTION
!
Prevent damage to the water pump (running dry) or overheating of the engine. Never start or run your outboard (even momentarily) without water circulating through all the cooling
water intake holes in the gear case.
oif3
POSITIONING OUTBOARD FOR STORAGE
Store outboard in an upright (vertical) position to allow water to drain
out of outboard.
CAUTION
!
If outboard is stored tilted up in freezing temperature, trapped
cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause
damage to the outboard.
hib1
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage fuel systems. If the gasoline used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible
from the fuel tank, remote fuel line, and engine fuel system.
The addition of Quicksilver Fuel System Treatment and Stabilizer
(p/n 92-78383A12) or Gasoline Stabilizer (p/n 92-817529A12) are
highly recommended during extended periods of non use.
Fill the fuel system (tank, hoses, and fuel pump) with treated (stabilized) fuel to help prevent formation of varnish and gum.
56
STORAGE
Fuel System (Cont.)
1. Portable Fuel Tank – Pour the required amount of Quicksilver
Gasoline Stabilizer (follow instructions on container) into fuel
tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of
Quicksilver Gasoline Stabilizer (follow instructions on container)
into a separate container and mix with approximately one quart
(one liter) of gasoline. Pour this mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment for
circulating cooling water . Run the engine for ten minutes to allow
treated fuel to reach the carburetors.
Protecting Internal Engine Components
Note: Before performing the following steps, make sure the fuel system has been prepared for storage. Refer to Fuel System on previous page.
1. Place the outboard in water or connect flushing attachment for
circulating cooling water . Start the engine and let it run in neutral
to warm up. Stop engine.
2. Disconnect fuel supply from engine and remove the carburetor
air box. Start engine and run at 2000 RPM. Spray Quicksilver
Storage Seal into the carburetor throats until the engine runs out
of fuel.
3. Remove the spark plugs and inject a five second spray of storage
seal around the inside of each cylinder.
4. Rotate the flywheel manually several times to distribute the storage seal in the cylinders. Reinstall spark plugs.
Protecting External Engine Components
1. Lubricate all outboard components listed in the Inspection and
Maintenance Schedule.
2. Touch up any paint nicks. See your dealer for touch-up paint.
3. Spray Quicksilver Corrosion Guard on external metal surfaces
(except corrosion control anodes).
57
STORAGE
Gear Case
1. Drain and refill the gear case lubricant (refer to maintenance procedure).
Battery Storage
1. Follow the battery manufacturers instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
58
TROUBLESHOOTING
1 – STARTER MOTOR WILL NOT CRANK THE ENGINE
POSSIBLE CAUSES
• Outboard gearshift not in neutral position.
• Weak battery or battery connections are loose or corroded.
• Ignition key switch failure.
• Wiring or electrical connection faulty.
• Starter motor or starter solenoid failure.
2 – ENGINE WILL NOT START
POSSIBLE CAUSES
• Lanyard stop switch not in RUN position.
• Incorrect starting procedure. Refer to Operating Section.
• Old or contaminated gasoline.
• Engine flooded. Refer to Operating Section.
• Fuel is not reaching the engine.
a. Fuel tank is empty or tank shut-off valve closed.
b. Fuel tank vent not open or is restricted.
c. Fuel line disconnected or kinked.
d. Fuel filter obstructed. Refer to Maintenance Section.
e. Fuel pump failure.
f. Fuel tank filter obstructed.
• Ignition system component failure.
• Spark plugs fouled or defective. Refer to Maintenance Section.
3 – ENGINE OVERHEATING (CONTINUOUS HORN
SOUND)
POSSIBLE CAUSES
• Water pickup clogged or blocked.
• Cooling system clogged
• Engine overloaded (cannot attain recommended RPM)
• Incorrect ignition timing.
• Not enough oil in fuel mixture
• Lean fuel mixture
59
TROUBLESHOOTING
4 – ENGINE RUNS ERRATICALLY
POSSIBLE CAUSES
• Spark plugs fouled or defective. Refer to Maintenance Section.
• Incorrect setup and adjustments.
• Fuel pump failure.
• Fuel is being restricted to the engine.
d. Engine Fuel filter is obstructed. Refer to Maintenance Sec-
tion.
e. Fuel tank filter obstructed.
f. Stuck anti-siphon valve located on permanently built in type
fuel tanks.
g. Fuel line is kinked or pinched.
h. Reed valve open or broken.
• Ignition system component failure.
5 – PERFORMANCE LOSS
POSSIBLE CAUSES
• Throttle not fully open.
• Damaged or improper size propeller.
• Incorrect engine timing, adjustments, or setup.
• Boat overloaded or load improperly distributed.
• Excessive water in bilge.
• Boat bottom is dirty or damaged.
6 – BATTERY WILL NOT HOLD CHARGE
POSSIBLE CAUSES
• Battery connections are loose or corroded.
• Low electrolyte level in battery.
• Worn out or inefficient battery.
• Excessive use of electrical accessories.
• Defective rectifier, alternator, or voltage regulator.
60
ENGINE WIRING DIAGRAM
61
MAINTENANCE LOG
Record all maintenance performed on your outboard. Be sure to
save all work orders and receipts.
DATE
MAINTENANCE PERFORMED ENGINE
HOURS
62
ok
MAINTENANCE LOG
DATE MAINTENANCE PERFORMED ENGINE
HOURS
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