Mercury 10 EFI FourStroke Installation, Operation & Maintenance Manual Download Page 125

Page: 125 / 139

3. Loosen, but do not remove the screw that secures the cowl latch to the

driveshaft housing covers.

63041

4. Loosen the seven screws that secure the starboard driveshaft cover, and

remove the cover.

63039

Installation

Install the starboard cover after the shift and throttle cables are installed.

1. Position the starboard cover on the driveshaft housing and secure it with

seven screws.

2. Tighten the seven starboard‑side screws and the cowl latch screw to the

specified torque.

Description

lb‑in.

lb‑ft

Driveshaft housing cover and cowl

latch screws (11)

–

ENGINE INSTALLATION

eng

115

Summary of Contents for 10 EFI FourStroke

Page 1: ...Outboard Installation Operation Maintenance Manual 2017 Mercury Marine 10 EFI FourStroke 8M0131791 817 eng ...

Page 2: ...eng ...

Page 3: ...anual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Manual included with the product The Warranty Manual contains a description...

Page 5: ...Skyhook SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine ...

Page 6: ...eng iv ...

Page 7: ...10 Selecting Accessories for Your Outboard 12 Safe Boating Recommendations 12 Recording Serial Number 15 Model Year Production Code 16 Specifications 10 HP 16 Conditions Affecting Performance 18 Transporting Carrying Storing and Transporting Your Outboard when Removed from Boat 22 Trailering Boat Outboard 23 Fuel and Oil Fuel Requirements 25 Low Permeation Fuel Hose Requirement 26 EPA Pressurized ...

Page 8: ...6 Starting the Engine Remote Control Models 59 Gear Shifting 62 Stopping the Engine 64 Emergency Starting Procedure 65 Maintenance Cleaning Care Recommendations 69 EPA Emissions Regulations 70 Inspection and Maintenance Schedule 71 Flushing the Cooling System 73 Top Cowl Removal and Installation 74 Battery Inspection 75 Exterior Care 75 Fuel System 76 Propeller Replacement 81 Fuse Replacement Elec...

Page 9: ...04 Owner Service Assistance Service Assistance 105 Ordering Literature 107 Engine Installation Boat Horsepower Capacity 109 Start in Gear Protection 109 Selecting Accessories for Your Outboard 109 Low Permeation Fuel Hose Requirement 110 Lifting the Outboard 110 Installing Outboard 110 Steering Cable Installation 112 Steering Link Rod Fasteners 113 Remote Wiring Harness and Control Cable Installat...

Page 10: ...eng viii ...

Page 11: ...ng with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

Page 12: ... 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 Outboard Remote Control Models The remote control connected to your...

Page 13: ...thrown within or out of the boat Always use required components and follow instructions and torque procedures 63290 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 rem...

Page 14: ... 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...

Page 15: ...nt 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 lan...

Page 16: ... 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 ove...

Page 17: ...n reduction in boat speed could result in the elevated passenger falling over the front of the boat 26783 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 26784 T...

Page 18: ...e This feature helps the outboard withstand damage in the case of impact with an underwater object at low to moderate speeds At higher speeds the force of the impact may exceed the system s ability to absorb the energy of the impact and cause serious product damage No impact protection exists while in reverse Use extreme caution when operating in reverse to avoid striking underwater objects Reduce...

Page 19: ...amage 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 If water leaks are discovered after an impact immediately...

Page 20: ...th the required mounting hardware If the outboard strikes an underwater object the required mounting hardware prevents the outboard from propelling off the transom A decal on the swivel bracket reminds the installer of the potential hazard Avoid serious injury or death Secure engine to transom with bolts WARNING 37 896853 007 52375 Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon mon...

Page 21: ...ediately behind the boat platform dragging teak body surfing This dangerous practice not only places a person in an area of high engine exhaust concentration but also subjects them to the possibility of injury from the boat propeller GOOD VENTILATION Ventilate the passenger area open side curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATIO...

Page 22: ...es are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of nonapproved accessories can damage the product Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maint...

Page 23: ...r Radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device one per person onboard Watch for signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you ...

Page 24: ...that all passengers have a proper seat and are in it before any boat movement Never operate a boat while under the influence of alcohol or drugs It is the law Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly Know your boating area and avoid hazardous locations Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and...

Page 25: ...oats 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 XXXXXXX XXXXX...

Page 26: ...Alpha Production Code A B C D E F G H K X Corresponding Number 1 2 3 4 5 6 7 8 9 0 Examples XX 2000 HK 2089 AG 2017 Specifications 10 HP Attributes Specification Power rating 7 4 kW 10 hp Weight MH 46 7 kg 103 lbs MLH 48 5 kg 107 lbs E 47 6 kg 105 lbs EL 49 kg 108 lbs Engine idle speed Not in gear 900 1000 RPM In gear 900 1000 RPM Recommended RPM range at WOT 5700 6200 RPM Bore x stroke 61 0 mm x ...

Page 27: ...sure at WOT 59 kPa 8 5 psi Oil type All temperatures general use FC W 10W 30 Alternate viscosity above 4 C 40 F FC W 25W 40 Oil capacity 1 0 L 1 1 U S qt Alternator type Single phase Alternator output at 900 RPM 4 6 A Alternator output at 5000 RPM 11 5 A Fuel system Computer controlled sequential multiport electronic fuel injection Fuel type Automotive unleaded regular Fuel pump type Mechanical lo...

Page 28: ...in some cases Nothing will regain this speed for the boater but cooler dry weather Pointing out the consequences of weather effects an engine running on a hot humid day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes The density of air is depe...

Page 29: ...speed a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore and aft direction Hook Exists when bottom is concave in fore and aft direction when viewed from the side When boat is planing hook causes more lift on bottom near transom and allows bow to drop thus greatly increasing wetted surface and reducing boat speed Hook frequently is c...

Page 30: ...g weather conditions In most cases recommended RPM can be achieved by changing to a lower pitch propeller DETONATION Detonation in a 4 cycle engine resembles the pinging heard in an automobile engine It can be otherwise described as a tin like rattling or plinking sound Detonation is the explosion of the unburned fuel air charge after the spark plug has fired Detonation creates severe shock waves ...

Page 31: ...mended WOT operating RPM range with a normal load If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal wear and damage After initial propeller selection the following common problems may require th...

Page 32: ...ility of oil leaks 1 With the outboard in the water disconnect the remote fuel line and run the engine until it stops 2 Remove the outboard and hold it upright until the water has drained out 3 Carry transport or store the outboard in an upright position horizontal with the front of the engine facing up tiller handle facing up or on the port side 63254 Upright position TRANSPORTING 22 eng ...

Page 33: ...ard 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 32176 IMPORTANT Do not rely on the power tilt system or th...

Page 34: ...Shift the outboard into reverse gear This prevents the propeller from spinning TRANSPORTING 24 eng ...

Page 35: ...ently in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittin...

Page 36: ...r 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 g m 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fuel hose ...

Page 37: ...e 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 seate...

Page 38: ...ow 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 fill 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 press...

Page 39: ... recommended SAE viscosity Checking Engine Oil IMPORTANT Do not overfill For accurate readings check oil only when engine is cold or after engine has not run for at least an hour 1 Tilt the outboard to vertical operating position 2 Remove the top cowl Refer to Maintenance Top Cowl Removal and Installation 3 Pull out the dipstick Wipe the dipstick end with a clean rag or towel and push it back in a...

Page 40: ...isture that accumulate in the crankcase These conditions include operating at idle for long periods repeated short trips slow speed or quick stop and go operation and operating in cooler climates This additional fuel and moisture that collects in the crankcase eventually ends up in the oil sump and will add to the total volume of oil that appears on the dipstick reading This increase in oil volume...

Page 41: ...8 Install top cowl FUEL AND OIL eng 31 ...

Page 42: ...ob counterclockwise to decrease the friction a Quick reference decal b Shift lever c Throttle grip friction knob Shift lever The outboard has three gear shift positions to provide operation forward F neutral N and reverse R F N R 63077 Tiller handle Handle can be tilted for convenient handling during transportation and storage Tiller lock release lever Push the lock release lever down to allow the...

Page 43: ...e adjustment knob a Adjustment knob at the lowest setting 63908 b Adjustment knob at the highest setting 63909 Tiller handle yaw The tiller handle yaw allows the operator to change the angle of the handle up to 18 left or right of center Each increment demarcation is 6 a Remove the rubber boot covering the clamp screw nut a b 63082 FEATURES AND CONTROLS eng 33 ...

Page 44: ...en the 15 mm nut so it is almost completely off a Clamp screw nut b Rubber boot c Loosen the 6 mm Allen socket head pivot screw 63259 6 mm Allen socket head pivot screw a b 63258 FEATURES AND CONTROLS 34 eng ...

Page 45: ...nut to the specified torque and install the rubber boot Description Nm lb in lb ft Clamp screw nut 50 36 8 f Tighten the 6 mm Allen socket head pivot screw to the specified torque Description Nm lb in lb ft 6 mm Allen socket head pivot screw 24 17 7 Lanyard stop switch Refer to General Information Lanyard Stop Switch a b c 63260 FEATURES AND CONTROLS eng 35 ...

Page 46: ...rd stop switch clip is stored on the tiller handle a Lanyard stop switch b Spare lanyard stop switch clip c Lanyard Engine stop switch Push the button in to stop the engine 63084 a b c 63083 FEATURES AND CONTROLS 36 eng ...

Page 47: ...hrottle grip to increase the engine speed 63086 Power tilt switch if equipped Tiller handle models equipped with power tilt have a switch located on the underside of the tiller handle Press the switch to raise UP or lower DN the engine 63906 Electric start button electric start models Press the button to start the engine if equipped FEATURES AND CONTROLS eng 37 ...

Page 48: ... 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 Tilt switch b Ignition key switch OFF ON START c Throttle only button d Lanyard stop switch Tilt switch Used to trim the drive during operation or raise the drive for trailering launching beaching or shallow water o...

Page 49: ... forward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear Continue pulling back to increase speed IMPORTANT Forcing the shift mechanism while the engine is not operating can result in product damage GEAR SHIFTING IMPORTANT Observe the following Never shift the outboard into or out of gear unless the engine speed is at idle Sh...

Page 50: ...rt to decrease the friction A quick reference decal is located on the transom clamp WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control When setting the friction adjustment maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released Tiller handle model shown a Fric...

Page 51: ...r intake Water pump indicator Water spray from this location indicates the water pump is pumping cooling water up to the engine If there is no water spray inspect the water intake on the gear housing 62870 Water pump indicator Manual Tilt Features and Operation Tilt lever Allows the outboard to be locked into the shallow water drive position or the full up position Refer to Basic Tilt Lever Operat...

Page 52: ...tacle decreasing the potential of severe damage This position also allows the outboard to lock into the shallow water drive position or the full up position When operating the outboard in reverse gear the tilt lever must be in the up position This is the locked position which prevents the outboard from pivoting out of the water a Locked position for reverse operation and tilt release position b Un...

Page 53: ...ward gear IMPORTANT While in the shallow water drive position do not operate the outboard in reverse Operate the outboard at slow speed and keep the cooling water intake submerged The shallow water drive position on the outboard allows you to position the outboard at a higher tilt angle to prevent hitting bottom 1 Reduce the engine speed to idle 2 Shift the engine into forward gear position 3 Posi...

Page 54: ...f the tilt pin There are six adjustment holes provided Proper adjustment allows the boat to run stable achieve optimum performance and minimize steering effort NOTE Refer to the following lists when adjusting the operating angle of your outboard The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed This allows the boa...

Page 55: ...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 Adjusting the outboard away from the boat tran...

Page 56: ...e tilt position of the outboard from full down to full up This tilt system is designed to be adjusted when the engine speed is at idle speed or with the engine turned off At low idle speed the outboard can be tilted up to permit shallow water operation a Cowl mounted tilt switch b Remote control tilt switch c Panel mount tilt switch 63906 Tilt switch on tiller handle models a b c 63100 FEATURES AN...

Page 57: ...APS FEATURE ProKicker centering straps if equipped will center the outboard and prevent the outboard from turning while the outboard is tilted up The ProKicker centering straps will prevent the outboard from turning when tilted up If using a steering tie bar to a second outboard disconnect the steering tie bar to allow steering of the second outboard WARNING Avoid injury or death from loss of stee...

Page 58: ...LEASE If the outboard cannot be tilted using the power 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 Turn out the manual tilt release valve three turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired posit...

Page 59: ...justing the operating angle of your outboard The tilt in stop pins should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed This allows the boat to be driven parallel to the water Arrange passengers and load in the boat so the weight is distributed evenly a Too much angle stern down bow up b Not enough angle stern up bow down c Angle...

Page 60: ...Adjusting the outboard away from the boat transom can Lift the bow 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 Warning System WARNING HORN LOCA...

Page 61: ...2800 Low oil pressure Low oil pressure Sensor error Six beeps no repeats Six flashes repeats every five minutes Engine sensor fault Overspeed None Engine speed too high Engine misfire may be noticed Restrictor Six beeps no repeats Six flashes repeats every five minutes Restrictor missing 2800 Refer to the Specifications table for RPM limits ENGINE OVERHEAT If the engine overheats immediately reduc...

Page 62: ...es of engine overspeed are as follows Propeller ventilation A propeller that has an incorrect pitch or diameter Propeller hub slippage Outboard mounted too high on the transom Tilting the outboard out beyond a vertical position Cavitation of the propeller due to rough water or obstruction in the boat hull When the engine overspeed limiter is activated the engine timing will be momentarily retarded...

Page 63: ...o 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 possibl...

Page 64: ...en using the main power source IMPORTANT The outboard must be restrained from bouncing while operating the boat using the main power source Bouncing can damage the outboard and boat transom Prestarting Instructions 1 Connect the remote fuel line to the outboard Ensure the connector is snapped into place 63102 Fuel line connector OPERATION 54 eng ...

Page 65: ...nge 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 3 Make sure the cooling water intake is submerged 26837 a b 62881 c OPERATION eng 55 ...

Page 66: ...s follow break in procedures 1 For the first hour of operation run the engine at varied throttle settings up to 2000 RPM or at approximately half throttle 2 For the second hour of operation run the engine at varied throttle settings up to 3000 RPM or at three quarter throttle and at full throttle for approximately one minute every ten minutes 3 For the next eight hours of operation avoid continuou...

Page 67: ...the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm IMPORTANT To prevent engine flooding do not squeeze the primer bulb after the engine has warmed up 27348 3 Insert the lanyard clip into the stop switch This is the RUN position a Lanyard stop switch b Spare lanyard stop switch clip c Lanyard a b c 46290 a b c 63083 OPERATION eng 57 ...

Page 68: ...owly Repeat until the engine starts IMPORTANT Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery Damage to the charging system may result 31954 7 Electric starting models Push the starter button and crank the engine Release button when the engine starts Do not operate the starter motor continuously for longer than ten seconds at a ti...

Page 69: ...icator 62870 IMPORTANT If no water is coming out of the water pump indicator stop the engine and check the cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause serious engine damage WARMING UP...

Page 70: ... lock 2 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 27348 3 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch 19791 a b c 46290 OPERATION 60 eng ...

Page 71: ... to the START position and start the engine If the engine fails to start in ten seconds wait 30 seconds and try again If the engine begins to stall use the throttle only feature and advance the throttle Do not exceed 2000 RPM 19804 6 Verify the warning light turns off NOTE The warning light will remain illuminated for up to five seconds after the outboard starts If the light should stay on refer t...

Page 72: ... operation allow the engine to warm up at idling speed for three minutes Gear Shifting IMPORTANT Observe the following Never shift the outboard into or out of gear unless the engine speed is at idle Shifting at higher than engine idle speed could cause damage to the gearcase Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed Shifting into rev...

Page 73: ...trol models Your outboard has three gear shift positions to provide operation forward F neutral N and reverse R When shifting always stop at the neutral position and allow the engine speed to return to idle N R F 58239 Always shift the outboard into gear with a quick motion After shifting the outboard into gear advance the remote control lever or rotate the throttle grip on the tiller handle to in...

Page 74: ...peed and shift the outboard to the neutral position Turn the ignition key to the OFF position 26843 OFF ON S T A R T 2 Tiller handle models Reduce the engine speed and shift the outboard to the neutral position Push in the engine stop button 26776 OPERATION 64 eng ...

Page 75: ...al speed protection device is inoperative when starting the engine with the emergency starter rope Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear 1 Remove four short screws and washers securing the recoil assembly to the engine 63117 Four short screws securing recoil 2 Pull the neutral interlock cable to disengage the neutral interlock cabl...

Page 76: ... a Neutral interlock cable tension spring b Neutral interlock cable 4 Remove one long and one medium length screw and washers securing the air box to the engine a Long screw b Medium screw c Neutral interlock cable 5 Rotate the air box slightly to allow the recoil to be removed a b 63118 a c 63119 b OPERATION 66 eng ...

Page 77: ...the distance after rotation 6 Carefully remove the recoil starter assembly 7 Install the medium length screw to retain the air box Tighten the screw securely 63146 8 Shift the outboard into neutral 9 Ensure the lanyard stop switch is in the run position 10 Remote control models Ensure the key switch is in the ON position WARNING High voltage is present when starting or operating the engine Do not ...

Page 78: ...ce the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 63121 Emergency start rope on flywheel 12 Pull the rope quickly NOTE This engine does not require a battery to run the fuel injection system or the ignition system The fuel injection and ignition systems are powered by the alternator under the flywheel Therefore several attempts to start the engine wit...

Page 79: ...ilure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product CLEANING GAUGES IMPORTANT Never use high pressure water to clean gauges Routine cleaning of the gauges is recommended to prevent a buildup of salt and other environmental debris Crystalized s...

Page 80: ...owls with clean water to remove dirt and dust that may scratch the surface 2 Wash the cowls 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 clean soft cloth 5 To remove minor scratches use Me...

Page 81: ...Verify that the lanyard stop switch stops the engine Inspect the outboard for tightness to the boat transom If any looseness of the outboard or mounting fasteners exist tighten the outboard mounting fasteners to the specified torque Refer to Engine Installation Installing Outboard Visually inspect the fuel system for deterioration or leaks Check steering system for binding or loose components Chec...

Page 82: ...d lubricate the propeller shaft Refer to Propeller Replacement Check corrosion control anodes Check more frequently when used in saltwater Refer to Corrosion Control Anodes and Continuity Wire Drain and replace gearcase lubricant Refer to Gearcase Lubricant Inspect battery Refer to Battery Inspection Saltwater usage Remove and inspect spark plugs for corrosion and replace as necessary Apply Anti S...

Page 83: ...lines on the upper driveshaft dealer service Check the wiring and connectors dealer service Replace the water pump impeller dealer service 1 BEFORE PERIODS OF STORAGE Refer to Storage section Flushing the Cooling System 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...

Page 84: ...engine above idle while flushing 4 Check for a steady stream of water flowing out of the water pump indicator hole Continue flushing the outboard for 3 5 minutes carefully monitoring the water supply at all times 5 Stop the engine turn off the water and remove the water hose 6 Install the plug into the flush fitting 7 Install the propeller Top Cowl Removal and Installation REMOVAL 1 Release the re...

Page 85: ...afety 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 Exteri...

Page 86: ...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 pr...

Page 87: ...tents into an approved container To protect the environment immediately clean up spilled fluids and dispose of according to local laws and regulations NOTE A drain hose can be temporarily installed onto the center drain port of the drain fitting to assist emptying the contents into an approved container 63110 Drain fitting 5 If installed remove the drain hose and tighten the threaded drain fitting...

Page 88: ...e engine and swing the assembly over the edge of the engine cowl 63109 Filter assembly mounting bracket 2 Remove the rubber mount from the filter assembly 3 Remove the sight bowl from the filter housing a Filter housing b Rubber mount c Sight bowl 4 Pull the filter element off the filter housing a b c 63111 MAINTENANCE 78 eng ...

Page 89: ...O ring The O ring may remain on the filter housing The O ring should be removed before installing the fuel filter 63112 Fuel filter Filter Installation a Fuel filter O ring seal b Fuel filter c Red ring d Sight bowl O ring seal e Sight bowl 63113 a b c d e MAINTENANCE eng 79 ...

Page 90: ...l 3 Push the fuel filter element onto the filter housing Verify the filter is completely installed by pushing on the filter in the locations shown in the following illustration 63115 4 Install the sight bowl O ring seal onto the sight bowl and place the red ring into the sight bowl 5 Install the sight bowl onto the filter housing hand tight MAINTENANCE 80 eng ...

Page 91: ... fuel leaks Repair as needed Propeller Replacement WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation ...

Page 92: ... Tiller handle models N 63103 Remote control models 3 Straighten the cotter pin and pull it out using a pair of pliers 4 Place a block of wood between the gearcase and the propeller to prevent rotation and remove the propeller nut MAINTENANCE 82 eng ...

Page 93: ...ecially in saltwater always apply the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 6 Apply Extreme Grease or 2 4 C with PTFE to the propeller shaft 31927 Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 7 Install the front th...

Page 94: ...d the ends a Cotter pin b Propeller nut c Rear thrust washer d Front thrust hub Larger diameter end towards propeller Description Nm lb in lb ft Propeller nut 12 106 2 Fuse Replacement Electric Start Models IMPORTANT An ATC fuse has the fuse element enclosed or sealed inside the plastic housing This type of fuse must be used for marine applications Marine applications are exposed to environments t...

Page 95: ...tor circuit b Spare 20 amp fuse c 15 amp fuse Electric starting circuit d Spare 15 amp fuse To access the 15 amp fuse remove the fuse block from the pocket on the ECM rubber mount Then remove the cap from the fuse block Remove the fuse and examine the silver colored band inside the fuse If band is broken replace the fuse Replace the fuse with a new fuse of the same rating Identifying an open fuse ...

Page 96: ... plug boots Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace the spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark plug gap 0 9 mm 0 035 in 4 Before installing the spark plugs clean off any dirt on the spark plug seats Install plugs finger ...

Page 97: ...ons are found Cracks in the back of the belt or in the base of the belt teeth Excessive wear at the roots of the cogs Rubber portion swollen by oil Belt surfaces roughened Signs of wear on edges or outer surfaces of belt 62878 Engine Oil CHANGING THE OIL FILTER 62880 Oil filter MAINTENANCE eng 87 ...

Page 98: ...gine to be rotated when the engine is in the full tilt position 2 Remove the top cowl and remove the oil filter drain hose from it s storage location on the front of the engine 64178 Oil filter drain hose 3 Tilt the engine up and lock the outboard in the full tilt position Allow a few minutes for the oil in the filter to drain into the engine MAINTENANCE 88 eng ...

Page 99: ...oved to gain access to the oil filter restore them to their original positions or install them accordingly DRAINING THE ENGINE OIL 1 Lock the outboard in the full tilt up position 2 Position the outboard so the drain hole is facing downward 3 Remove the drain plug and drain the engine oil into an appropriate container IMPORTANT Do not use a crankcase oil pump when changing the oil or engine damage...

Page 100: ...34 4537 Description Nm lb in lb ft Drain plug 23 7 17 5 FILLING THE CRANKCASE WITH OIL IMPORTANT Do not try to fill the oil level to the top of the operating range upper hole The oil level is correct as long as it appears in the operating range between the upper and lower hole 1 Position the outboard in a level operating position MAINTENANCE 90 eng ...

Page 101: ... and Continuity Wire Your outboard has four corrosion control anodes An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals The continuity wire must be intact to ensure there is a good bonding circuit Without this bonding continuity circuit accelerated corrosion will occur The anodes require periodic inspection e...

Page 102: ... One anode is mounted on the starboard side of the midsection just above the antiventilation plate A screw and nut secure the anode to the midsection 62958 MAINTENANCE 92 eng ...

Page 103: ... from swivel bracket to lower mount d Lubrication fitting e Continuity wire from lower mount to driveshaft housing Two anodes are located near the bottom of the transom brackets The anodes are secured to the brackets with screws 62959 When installing an anode be certain to tighten the fasteners to the specified torque 62942 a b c d e MAINTENANCE eng 93 ...

Page 104: ...tion Where Used Part No Extreme Grease Swivel bracket transom clamp screws tilt tube propeller shaft steering cable grease 8M0071842 95 2 4 C with PTFE Swivel bracket transom clamp screws tilt tube throttle shift cables steering cable grease fitting 92 802859A 1 Swivel bracket lubrication fitting 63336 Tilt tube lubrication fittings MAINTENANCE 94 eng ...

Page 105: ...oard tilt tube Lubricate the steering cable through the fitting a Steering cable lubrication fitting b Steering cable end c Tilt tube lubrication fittings WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant 2 Lubricate the following with lightweight oil a...

Page 106: ...oat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft 31927 Gearcase Lubricant DRAINING AND INSPECTING GEAR HOUSING LUBRICANT 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...

Page 107: ...seals seal surfaces O rings and gear housing components Pressure check the gearcase prior to disassembly NOTE When draining the gearcase for the first time lubricant may appear cream colored due to the mixing of assembly lubricant and gear lubricant This is not an indication of water intrusion If during subsequent draining of the gearcase lubricant appears cream colored or milky water may be prese...

Page 108: ... vent hole 62882 IMPORTANT Replace the sealing washers with new sealing washers 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove the lubricant tube and install the cleaned fill drain plug and new sealing washer Checking Power Tilt Fluid if Equipped 1 Tilt the outboard to the full up position and engage the tilt support lever a Tilt suppor...

Page 109: ...e automotive automatic transmission fluid ATF a Fill cap Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine a 31920 MAINTENANCE eng 99 ...

Page 110: ...wing instructions Portable fuel tank Pour the required amount of gasoline stabilizer follow the instructions on container into the fuel tank Tip the fuel tank back and forth to mix the stabilizer with the fuel Permanently installed fuel tank Pour the required amount of gasoline stabilizer follow the instructions on container into a separate container and mix with approximately 1 Liter 1 US qt of g...

Page 111: ...anually several times to distribute the oil in the cylinders Install spark plugs Change the engine oil Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubricant Positioning Outboard for Storage NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can ...

Page 112: ...rankcase into the cylinders or crankcase ventilation system There are bumpers on the aft side of the top cowl also 63255 Battery Storage Follow the battery manufacturer s instructions for storage and charging Remove the battery from the boat and check water level Charge if necessary Store the battery in a cool dry place Periodically check the water level and charge the battery during storage STORA...

Page 113: ...engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Ignition or electronic fuel injection system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erra...

Page 114: ...orrect throttle linkage setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Blown fuse 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 TROUBLESHOO...

Page 115: ...s in the recovery of stolen power packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer is required to reduce the possibility of serious engine damage REPLACEMENT SERVICE PARTS WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine produc...

Page 116: ...erial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geographic office in your area Please include your daytime telephone number with mail and fax correspondence United States Canada Telephone English 1 920 929 5040 Français 1 905 636 4751 Mercury Marine ...

Page 117: ...e Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O ...

Page 118: ...s Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Quantity Item Stock Number Price Total Total Due OWNER SERVICE ASSISTANCE 108 eng ...

Page 119: ... drive in gear can cause serious injury or death Never operate a boat that does not have a neutral safety protection device The remote control connected to the outboard must be equipped with a start in neutral only protection device This prevents the engine from starting in gear Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically desi...

Page 120: ...e fuel tank to the outboard Low permeation hose is USCG Type B1 15 or Type A1 15 defined as not exceeding 15 g m 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fuel hose Lifting the Outboard Use the lifting eye on the engine 62883 Installing Outboard BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat The boat bottom should be aligned or be within 25 mm 1 in abo...

Page 121: ...red mounting hardware If the outboard strikes an underwater object the required mounting hardware prevents the outboard from propelling off the transom A decal on the swivel bracket reminds the installer of the potential hazard Avoid serious injury or death Secure engine to transom with bolts WARNING 37 896853 007 52375 1 Place the outboard on the centerline of the transom 27005 2 Tighten the tran...

Page 122: ...lt models a Power tilt models have four bolts manual tilt models have two bolts b Power tilt models have four washers manual tilt models have two washers c Power tilt models have four nuts manual tilt models have two nuts Description Nm lb in lb ft Transom bracket mounting bolts all models 13 5 120 Steering Cable Installation 1 Lubricate the entire cable end with Mercury or Quicksilver 2 4 C with ...

Page 123: ...ose and vibrate off allowing the link rod to disengage from the steering cable 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 i...

Page 124: ...et f Nylon insert locknut tighten until it seats then back off 1 4 turn Description Nm lb in lb ft Nylon insert locknut d 27 20 Nylon insert locknut f Tighten until it seats then back off 1 4 turn Remote Wiring Harness and Control Cable Installation DRIVESHAFT HOUSING COVER REMOVAL AND INSTALLATION Removal 1 Remove the top cowl 2 Remove the cowl seal a b b c d e b f 63289 ENGINE INSTALLATION 114 e...

Page 125: ...over 63039 Installation Install the starboard cover after the shift and throttle cables are installed 1 Position the starboard cover on the driveshaft housing and secure it with seven screws 2 Tighten the seven starboard side screws and the cowl latch screw to the specified torque Description Nm lb in lb ft Driveshaft housing cover and cowl latch screws 11 6 53 ENGINE INSTALLATION eng 115 ...

Page 126: ...to forward and advance the handle to full speed position Slowly return the handle back to neutral Place a mark a on the cable next to the end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed position Slowly return the handle back to neutral Place a mark b on the cable next to the end guide c Make a center mark c midway between marks a and b Alig...

Page 127: ...st the barrel closer to the cable guide b Shift the remote control into reverse while turning the propeller The propeller shaft should be locked in gear If not adjust the barrel away from the cable guide c Shift the remote control back to neutral The propeller shaft should turn freely without drag If not adjust the barrel closer to the cable guide Repeat steps a through c THROTTLE CABLE INSTALLATI...

Page 128: ...hat exists in the throttle cable as follows a Move the remote control handle from neutral into forward and advance the handle to full speed position Slowly return the handle back to neutral Place a mark a on the cable next to the end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed position Slowly return the handle back to neutral Place a mark b...

Page 129: ...c a 3 Attach the throttle cable end guide to the throttle lever with a washer and bow tie retainer 4 Adjust the cable barrel so the installed throttle cable will maintain alignment 5 Position the throttle cable into the barrel receptacle a Bow tie retainer b Flat washer c Throttle cable d Cable barrel a b c d 63129 ENGINE INSTALLATION eng 119 ...

Page 130: ...en the screw to the specified torque a Cable barrel retainer b Screw Description Nm lb in lb ft Screw 6 53 REMOTE WIRE HARNESS AND GROMMET INSTALLATION 1 Connect the 14 pin remote wire harness connector to the engine harness 63133 a b 63131 ENGINE INSTALLATION 120 eng ...

Page 131: ... specified torque 63136 Description Nm lb in lb ft Driveshaft housing cover screws 6 53 Changing the Tiller Handle Throttle Grip Rotation The engine tiller handle throttle grip rotation can be changed to rotate in the opposite direction from the factory installation 1 Remove the starboard driveshaft housing cover Refer to Driveshaft Housing Cover Removal and Installation 2 Install a flag tape onto...

Page 132: ...e cables to the bracket a Nuts securing the throttle cables to the bracket b Flag on top throttle cable 4 Remove the top cable from the bracket and the throttle drum a Throttle drum b Bracket a b 64613 a b 64614 ENGINE INSTALLATION 122 eng ...

Page 133: ...t 64615 Lower cable 6 Install the cable with the flag onto the throttle drum lower guide and bracket 7 Install the cable without the flag onto the throttle drum top guide and bracket a Cable without flag b Cable with flag a b 64616 ENGINE INSTALLATION eng 123 ...

Page 134: ...9 Push on the top cable threaded end while observing the tiller handle idle alignment marks When the marks are aligned thread the nut that is on the right side up to the bracket Thread the nut on the left side up to the bracket finger tight Push on top cable threaded end a Thread nut up to the bracket b Tiller handle idle alignment marks a b 64617 a b 64618 ENGINE INSTALLATION 124 eng ...

Page 135: ...racket finger tight Push on lower cable threaded end a Throttle drum b Thread nut up to the bracket 11 Rotate the throttle grip to wide open throttle WOT and release the grip The marks should be aligned If they are not aligned rotate the grip to align the marks There should be no resistance when turning the grip to align the marks 12 Tighten the top cable nuts Ensure the position of the cable does...

Page 136: ...o idle several times The idle marks must be aligned and the throttle drum idle stop must be contacting the idle stop on the bracket 15 Rotate the throttle grip to the WOT position and observe the throttle drum The throttle drum WOT stop should contact the stop on the bracket If necessary thread the nut on the right side of the lower cable more towards the bracket Tighten the nuts on the lower cabl...

Page 137: ... the driveshaft housing cover and secure the cowl with the screws Tighten the screws to the specified torque Refer to Driveshaft Housing Cover Removal and Installation Description Nm lb in lb ft Driveshaft housing cover screws 6 53 Battery Installation Electric Start Models MOUNTING BATTERY Follow the battery manufacturer s instructions carefully Mount battery in the boat so it is secured against ...

Page 138: ...tive battery terminal and then connect the black battery cable to the negative battery terminal DISCONNECTING OUTBOARD BATTERY CABLES First disconnect the black battery cable from the negative terminal and then disconnect the red battery cable from the positive terminal 27158 ENGINE INSTALLATION 128 eng ...

Page 139: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 129 ...

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Mercury 10 EFI FourStroke, Installation, Operation & Maintenance Manual

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