Mercury 10 Marathon User Manual Download

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INSTALLATION

DISCONNECTING OUTBOARD BATTERY CABLES

1. First, disconnect the black battery cable from the (-) negative terminal

and then disconnect the red battery cable from the (+) positive terminal.

ob00506

Propeller Selection

The propeller supplied with your outboard provides the best overall

performance under average operating conditions.
Alternative propellers are available for specific boating requirements. See

your outboard dealer.

Summary of Contents for 10 Marathon

Page 1: ...dealer If the outboard motor s serial number plate contains the CE mark in the lower left hand corner the following statement applies This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industrel de Petit Rechain Belgium complies with the requirements of the following directives and standards as amended Recreational Craft Directive 94 25 EC std ISO...

Page 2: ...fore Operating Your Outboard 15 Boat Horsepower Capacity 16 High Speed And High Performance Boat Operation 16 Outboard Remote Control Models 17 Remote Steering Notice 17 Lanyard Stop Switch 18 Protecting People In The Water 20 Passenger Safety Message Pontoon Boats And Deck Boats 20 Wave And Wake Jumping 22 Impact With Underwater Hazards 23 Safety Instructions For Hand Tilled Outboards 24 Exhaust ...

Page 3: ...4 Tilting Outboard 45 Shallow Water Operation 46 Setting The Transom Angle Of Your Outboard 47 Adjusting Transom Angle 49 OPERATION Pre Starting Check List 50 Operating In Freezing Temperatures 50 Operating In Salt Water Or Polluted Water 50 Operating at High Elevations 51 Operating Outboard As An Auxiliary Engine 51 Pre Starting Instructions 51 Engine Break in Procedure 52 Starting The Engine Til...

Page 4: ...on And Replacement 74 Carburetor Adjustments 75 Lubrication Points 77 Gearcase Lubrication 80 Submerged Outboard 81 STORAGE Storage Preparation 82 Protecting External Outboard Components 82 Protecting Internal Engine Components 83 Gearcase 83 Positioning Outboard For Storage 83 Battery Storage 83 TROUBLESHOOTING Starter Motor Will Not Crank The Engine Electric Start Models 84 Engine Will Not Start...

Page 5: ...TABLE OF CONTENTS v Parts And Accessories Inquiries 86 Service Assistance 86 Mercury Marine Service Offices 87 ...

Page 6: ...vi ...

Page 7: ...wner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Mercury Marine Service Office closest to you Warranty Registration United States And Canada 1 You may change your address at any time including at time of warranty claim by calling Mercury Marine or sending a letter or fax with y...

Page 8: ...ame and address product model and serial numbers date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product 3 A copy of the Warranty Registration Card designated as the Purchaser s Copy MUST be given to you immediately after the card has been completely filled out by ...

Page 9: ...rial and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for two 2 years from the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial users of these products receive warranty coverage of two 2 years from the date of first retail s...

Page 10: ...epairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonabl...

Page 11: ... fuel intake air intake or exhaust system Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental o...

Page 12: ... Motors Mercruiser Inboard or Sterndrive engine products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for one 1 year from the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial users of th...

Page 13: ... repairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasona...

Page 14: ...e fuel intake air intake or exhaust system Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental ...

Page 15: ...Year Limited Warranty Against Corrosion WHAT IS COVERED Mercury Marine warrants that each new Mercury Mariner Mercury Racing Sport Jet M2 Jet Drive Tracker by Mercury Marine Outboard MerCruiser Inboard or sterndrive engine Product will not be rendered inoperative as a direct result of corrosion for the period of time described below DURATION OF COVERAGE This limited corrosion warranty provides cov...

Page 16: ...ion repairing a corroded part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reaso...

Page 17: ...by the use of a corrosion protection system such as the Mercury Precision Parts or Quicksilver MerCathode system and or Galvanic Isolator Corrosion damage caused by improper application of copper base anti fouling paints is also not covered by this limited warranty If anti fouling protection is required Tri Butyl Tin Adipate TBTA base anti fouling paints are recommended on Outboard and MerCruiser ...

Page 18: ...at are not covered by warranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure the International Limited Outboard Warranty and the United States and Canada Limited Outboard Warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship ...

Page 19: ... approval has been given to have the work performed at this facility 7 All incidental and or consequential damages storage charges telephone or rental charges of any type inconvenience or loss of time or income are the owner s responsibility 8 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs 9 Oils lubricants or fluids changed as a matter of normal maintenance ...

Page 20: ... 16 Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product ...

Page 21: ...y 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 indicates an imminently hazard...

Page 22: ...urer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX ob00306 High Speed And High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never opera...

Page 23: ... control used with it must have a built in start in neutral only protection device ob00308 Remote Steering Notice 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 The steering link rod that connects the steering cable to the engine m...

Page 24: ... to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard ob00310 a b a Lanyard cord b Lanyard stop switch Read the following Safety Information before proceeding Important Safety Information The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This wo...

Page 25: ...t 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 WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation The boat operator should never leave the operator s station without first disconnecting the stop switch lanyard from ...

Page 26: ...y if contacted by a rotating propeller a moving boat a moving gearcase or any solid device rigidly attached to a moving boat or gearcase Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats And Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passe...

Page 27: ... or deck boat and being run over by the outboard Stay back from the front end of the deck and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat...

Page 28: ...ause occupants to be thrown out of their seats or out of the boat WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to a boat hand hold There is another less common hazardous result from allowing your boa...

Page 29: ...ld result in an infinite number of situations Some of these situations could result in the following Part of the outboard or the entire outboard could break loose and fly into the boat The boat could move suddenly in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thro...

Page 30: ...h transom bracket clamp screws The use of clamp bracket screws alone is insufficient to properly and safely secure the outboard to the transom Proper installation of the outboard includes bolting the engine to the boat through the transom Refer to Installation Installing Outboard for more complete installation information WARNING Avoid serious injury or death from being struck by a disconnected ou...

Page 31: ...b00316 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an enclosed area of a stationary...

Page 32: ...re 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 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...

Page 33: ...ur ability to react quickly Prepare other boat operators Instruct at least one other 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 sufficien...

Page 34: ...ue 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 XXXX XX XXXXXXXX XXXX ob01144 e d a b c a Serial number b Model year c Model designation d Year manufactured e Certified Europe Insignia as applicable Spe...

Page 35: ...5 in Piston Stroke 45 7 mm 1 8 in Recommended Spark Plug NGK BPZ8H N 10 NGK BPZ8HS 15 Spark Plug Gap 1 0 mm 0 040 in 1 5 mm 0 060 in Gear Ratio 2 0 1 Recommended Gasoline Refer to Fuel Oil Recommended Oil Refer to Fuel Oil Gearcase Lubricant Capacity 200 ml 6 8 fl oz Battery Rating 465 Marine Cranking AMPS MCA or 350 Cold Cranking AMPS CCA Ampere Hours Ah 70 100 ...

Page 36: ...uld be aligned or be within 25 mm 1 in above the anti ventilation plate of the outboard ob00502 a a Anti ventilation plate INSTALLING OUTBOARD ON TRANSOM 1 Place outboard on center line of transom ob00446 2 Tighten transom clamp handles WARNING Avoid serious injury or death from being struck by a disconnected outboard The use of clamp bracket handles alone is insufficient to properly and safely se...

Page 37: ... Models MOUNTING BATTERY Follow the battery manufacturer s instructions carefully Mount battery in the boat so it is secured against movement preferably in a battery box Make sure battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals NOTE Electric starting outboards must have the battery cables connected to a battery whenever the engine is running Even...

Page 38: ...terminal and then disconnect the red battery cable from the positive terminal ob00506 Propeller Selection The propeller supplied with your outboard provides the best overall performance under average operating conditions Alternative propellers are available for specific boating requirements See your outboard dealer ...

Page 39: ...sing damage to the outboard The boat should be trailered with the outboard tilted down normal 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 3021 CAUTION Make sure gear sh...

Page 40: ...rizontally on its tiller handle side Place a protective pad under the outboard ob01382 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion Follow portable fuel tank transporting instructions Transport the fuel tank in a well ventilated area away from open flame or sparks MANUAL VENTING TYPE FUEL TANK 1 Close fuel tank air vent when transporting ...

Page 41: ...NG 35 2 Install tether cap over the fuel line connector stem This will protect the connector stem from being accidently pushed in thus allowing fuel or vapor to escape F ob00326 a b a Connector stem b Tether cap ...

Page 42: ...l in Gasoline These reformulated fuels are acceptable for use in the Mercury engine 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 and the addition of a water separating ...

Page 43: ...d TC W3 Severe engine damage may result from use of an inferior oil Mixing Fuel and Oil Use a 25 1 4 gasoline oil mixture in the first tank of fuel After the break in fuel mixture is used up use a 50 1 2 gasoline oil mixture Refer to the table following for mixing ratios GASOLINE OIL MIXING RATIO CHART GASOLINE OIL MIXING RATIO CHART Gas Oil Ratio 3 8 liters 1 gal gas 11 5 liters 3 gal gas 23 lite...

Page 44: ...nd in volume as its temperature rises and can leak under pressure if the tank is completely filled FILLING FUEL TANKS PERMANENTLY INSTALLED Slowly pour the correct amount of oil along with gasoline as the tank is being filled FILLING PORTABLE FUEL TANKS Remove portable fuel tanks from boat to refill them Pour the full amount of oil along with approximately one gallon of gasoline into the fuel tank...

Page 45: ... and storage 3173 Starter rope Pulling the starter rope cranks the engine over for starting ob01383 Primer idle speed knob Pulling the knob out supplies a small amount of fuel to the engine for cold starting Rotate knob to adjust idle speed after engine warms up ob01384 Choke Supplies fuel to the engine for cold starting 4063 ...

Page 46: ...tle grip friction knob Turn friction knob to set and maintain the throttle at desired speed Turn knob clockwise to tighten friction or turn knob counterclockwise to loosen friction a b ob00341 a Loosen friction counterclockwise b Tighten friction clockwise Throttle grip gear shift if equipped Controls gear shift and engine speed a b ob01157 a Reverse b Forward ...

Page 47: ...a Quicksilver or Mercury Precision Accessory Throttle grip side handle gear shift models Controls engine speed ob00543 Electric start button electric start models Press button to start engine ob00545 WARNING Avoid possible serious injury or death from loss of boat control Maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering w...

Page 48: ...sen a b 3023 a Tighten friction b Loosen friction Remote Control Models Manual Start Starter rope Pulling the starter rope cranks the engine over for starting ob01383 Primer idle speed knob Pulling the knob out supplies a small amount of fuel to the engine for cold starting Rotate knob to adjust idle speed after engine warms up ob01384 Control handle Controls gear shift and engine speed N R F ob00...

Page 49: ...mation Lanyard Stop Switch ob00350 Throttle friction adjustment Adjust to maintain desired tension at the control handle 3024 Neutral release lever Pull this lever up to move the control handle out of neutral position 3025 Engine on off switch Turns engine on and off 3026 ...

Page 50: ...R F ob00557 Lanyard Lanyard stop switch Refer to General Information Lanyard Stop Switch ob00350 Throttle friction adjustment Adjust to maintain desired tension at the control handle 3024 Ignition key switch Turn the key switch for starting and stopping the enigne Push in on key switch to choke the engine ob00360 ...

Page 51: ...ion Starting The Engine 3027 Tilting Outboard 1 Stop the engine Shift the outboard into the forward gear position 2 Take hold of the top cowl grip and raise the outboard to the full up position 3 Pull out on the tilt lock knob and move it to the lock position The outboard cannot be lowered while the tilt lock knob is in the lock position 4 To lower the engine move the tilt lock knob to the unlock ...

Page 52: ...t lock knob in unlock position c Tilt range indicator Shallow Water Operation There are three 3 shallow water drive positions that enable the outboard to be tilted up to prevent hitting the bottom 1 Reduce engine speed to idle 2 Shift outboard to neutral or forward gear position IMPORTANT Operate outboard at slow speed for shallow water operation and keep the water intake submerged ...

Page 53: ...ing The Transom Angle Of Your Outboard The vertical transom angle of your outboard is adjusted by changing the position of the preset tilt knob in one of the three adjustment holes provided Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort NOTE Refer to the following lists when adjusting the transom angle of your outboard The preset tilt knob s...

Page 54: ...Adjusting the outboard close to the boat transom can Lower the bow Result in quicker planing off especially with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering torque or pull to the right 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 e...

Page 55: ...normal installation height In excess can cause boat porpoising bouncing or propeller ventilation Adjusting Transom Angle 1 Stop the engine Shift the outboard into forward Raise the engine to one of the tilt release positions Change the preset knob position and lower the outboard to the preset transom angle position 2 Repeat step number one if the transom angle needs further adjustment a b ob01178 ...

Page 56: ...ating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at all times so the gearcase is submerged This prevents trapped water in 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 remove...

Page 57: ...he new elevation Operating your outboard at an elevation higher than 750 m 2500 ft 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 Operating Outboard As An Auxiliary Engine If the outboard is used as an auxili...

Page 58: ...ne Break in Procedure ENGINE BREAK IN FUEL MIXTURE Use a 25 1 4 gasoline oil mixture in the first tank of fuel BREAK IN PROCEDURE Vary the throttle setting during the first hour of operation During the first hour of operation avoid remaining at a constant speed for more than two minutes and avoid sustained wide open throttle Starting The Engine Tiller Handle Models And Manual Start Remote Control ...

Page 59: ...imes until it feels firm ob00349 3 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch ob00350 4 Set the throttle grip to start position ob01175 ob00543 5 Remote control models Move on off switch to the on position 3026 ...

Page 60: ... disconnected from the battery Damage to the charging system may result 7 Turn primer idle speed knob if equipped a full clockwise to increase engine idle speed ob01396 8 Starting a cold engine a Sea Pro Marathon Models Pull out choke 4063 b Non Sea Pro Marathon Models Pull out and push in the primer idle speed knob one to three times to prime the engine Leave the knob in the pulled out position w...

Page 61: ...otor continuously for longer than ten seconds at a time If engine fails to start wait 30 seconds and try again ob00545 11 Sea Pro Marathon Models Push in choke after the engine starts If engine begins to stall rechoke until engine is running smoothly 4063 12 Push in the primer idle speed knob after engine starts If engine begins to stall reprime until engine is running smoothly ob01384 NOTE Starti...

Page 62: ...0331 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check 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 Starting The Engine E...

Page 63: ...0350 4 Set the remote control handle to neutral position N ob00351 5 Cold Temperature It may be helpful to prime the engine 1 to 3 times using the manual primer knob before starting ob01384 IMPORTANT Electric starting outboard models must not be started manually using the starter rope or run without having the battery leads connected to a battery Damage to the charging system could result ...

Page 64: ...ng After engine starts immediately reduce engine speed back to idle 3030 a b a Fast idle speed lever b Throttle only feature 8 Starting Flooded Engine Advance the fast idle lever or throttle only feature to the maximum position Without activating primer crank engine for 10 seconds Wait 30 seconds and repeat until engine starts Immediately start to reduce engine speed after engine starts 9 Turn ign...

Page 65: ... check 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 Gear Shifting IMPORTANT Observe the following Never shift outboard into gear unless engine speed is at idle Do...

Page 66: ... to increase speed Stopping The Engine 1 Remote Control Models Reduce engine speed and shift outboard to neutral position Turn ignition key or on off switch to OFF position ob00360 3031 2 Tiller Handle Models Reduce engine speed and shift outboard to neutral position Push in the engine stop button or turn ignition key to OFF position ob00361 Emergency Starting If the starter system fails use the s...

Page 67: ... to start engine the start in gear protection device is inoperative Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear Sudden unexpected acceleration could result in serious injury or death 2 Remove the fuel filter 3032 3 Disconnect the linkage from rewind starter assembly 3033 ...

Page 68: ...nt getting an electrical shock do not touch any ignition component wiring or spark plug wire when starting or running the engine WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running 7 Tie one end of the ...

Page 69: ...OPERATION 63 8 Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 9 Pull the starter rope to start the engine 3035 ...

Page 70: ...our 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 Mercur...

Page 71: ...specification d Recommended spark plug and gap e Valve clearance if applicable f Family number g Maximum emission output for the engine family h Piston placement i Date of manufacture OWNER RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to modify the engine in...

Page 72: ...l anodes Check more frequently when used in salt water See Corrosion Control Anodes Drain and replace gearcase lubricant See Gearcase Lubrication Lubricate splines on the driveshaft and shift shaft 1 Electric start models Inspect battery See Battery Inspection Remote control models Check control cable adjustments 1 Remove engine deposits with Mercury Precision or Quicksilver Power Tune Engine Clea...

Page 73: ...d the rubber cup to ensure the engine receives an adequate supply of cooling water ob00567 3 Start the engine and run it at idle speed in neutral shift position IMPORTANT Do not run engine above idle when flushing 4 Adjust water flow if necessary so excess water continues leaking out from around the rubber cup to ensure the engine is receiving an adequate supply of cooling water ob00568 5 Check fo...

Page 74: ...pected 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 positiv...

Page 75: ...ain 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 mu...

Page 76: ...ment with open end toward cover into the cover 2 Place the O ring seal into the sight bowl and screw the sight bowl hand tight into the cover IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter Carburetor Fuel Bowl Sea Pro Marathon Models 1 Loosen drain screw to clean 4066 2 Dispose of fuel properly ...

Page 77: ...from overload by an SFE 20 AMP fuse If the fuse is blown the electric starter motor will not operate Try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Replace fuse with a fuse of the same rating 3036 Corrosion Control Anode The outboard has a corrosion control anode installed on the gearcase An anode helps protect the outboard against galvanic co...

Page 78: ...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...

Page 79: ...ved by an authorized dealer ob00579 5 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon ob00580 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and...

Page 80: ...eller nut ob00583 8 Reinstall spark plug leads Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to remove spark pl...

Page 81: ...15 1 5 mm 0 060 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or torque to specifications Description Nm lb in lb ft Spark plug 27 20 Carburetor Adjustments SLOW SPEED MIXTURE ADJUSTMENT 1 Before starting engine turn the slow speed mixture screw in until it is lightly seated then back it out 1 1 2 turns ob01424 2 ...

Page 82: ...MENT 1 Engines equipped with an adjustable idle speed screws a With boat tied securely to dock start engine and allow it to warm up b Shift the outboard to forward gear while maintaining idle speed Make sure the primer fast idle knob is pushed all the way in and turned to the slowest idle speed c Adjust the idle speed screw to obtain the recommended engine idle speed Refer to General Information S...

Page 83: ...4 C with Teflon or Special Lubricant 101 Tilt Tube Lubricate through fittings 3038 Transom Clamp Screws Lubricate threads 3039 Swivel Bracket Lubricate through fitting Steering Friction Adjustment Shaft tiller handle models Lubricate through fitting 3040 a b a Steering friction adjustment shaft b Swivel bracket ...

Page 84: ... Lubricate the throttle and shaft cables move components and pivot points 3044 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 A hydraulically locked steering cable will cause loss of steering control possibly resulting i...

Page 85: ...cate the following with Light Weight Oil Steering Link Rod Pivot Points Lubricate pivot points 3046 3 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon 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 corrodin...

Page 86: ...ase lubricant for metal particles A small amount of 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 GEARCASE 1 Place outboard in a vertical operating position 2 Place drain pan below outboard 3 Remove fill drain plug and vent plug and drain lubricant ob00...

Page 87: ...nt tube ob00599 6 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer ob00600 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...

Page 88: ...d engine fuel system Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with following instructions Portable Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently Installed Fuel Tank Pour the required a...

Page 89: ...a five second spray of storage seal around the inside of the cylinder Rotate the flywheel manually several times to distribute the storage seal in the cylinder Reinstall spark plug Gearcase Drain and refill the gearcase lubricant refer to Maintenance Gearcase Lubrication Positioning Outboard For Storage Store outboard in an upright vertical position to allow water to drain out of outboard CAUTION ...

Page 90: ...Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching the engine a Fuel tank is empty b Fuel tank vent not open or restricted c Fuel line is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty f Fuel filter is obstructed Refer to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Ignition s...

Page 91: ...pen 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 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 ...

Page 92: ...arts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or any authorized Mercury Marine dealership If additio...

Page 93: ...567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9793 5880 Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexi...

Page 94: ...pan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Singapore 508762 Fax 5467789 ...

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