Mercury 10 Marathon Operation, Maintenance & Installation Manual Download

Page: 67 / 87

6. Flo‑Torq I Drive Hub Propellers ‑ Install forward thrust hub, propeller, rear

thrust hub and propeller nut onto the shaft.

a -

Propeller nut

b -

Rear thrust hub

c -

Propeller

d -

Forward thrust hub

7. Place a block of wood between gearcase and propeller and tighten

propeller nut.

27341

8. Reinstall spark plug leads.

Spark Plug Inspection And Replacement

WARNING

Damaged spark plug boots may emit sparks that can ignite fuel vapors under

the engine cowl, resulting in serious injury or death from a fire or explosion.

To avoid damaging the spark plug boots, do not use any sharp object or

metal tool to remove the spark plug boots.

1. Remove the spark plug leads. Twist the rubber boots slightly and pull off.

26899

27307

MAINTENANCE

eng

Summary of Contents for 10 Marathon

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 9 9 10 15 TwoStroke 8M0133627 617 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: ...ok 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 Seria...

Page 6: ...eng iv ...

Page 7: ...ats 6 Wave and Wake Jumping 8 Impact with Underwater Hazards 9 Safety Instructions for Hand Tilled Outboards 10 Exhaust Emissions 10 Selecting Accessories for Your Outboard 12 Safe Boating Suggestions 12 Recording Serial Number 14 Model Year Production Code 14 Specifications 15 Transporting Carrying Outboard 16 Trailering Boat 16 Transporting Outboard When Removed From Boat 17 Transporting Portabl...

Page 8: ... Prestarting Check List 32 Operating in Freezing Temperatures 32 Operating in Saltwater or Polluted Water 32 Operating at High Elevations 33 Operating Outboard as an Auxiliary Engine 33 Prestarting Instructions 33 Engine Break in Procedure 34 Starting the Engine Tiller Handle Models and Manual Start Remote Control Models 34 Starting the Engine Electric Start Remote Control Models 37 Gear Shifting ...

Page 9: ...5 Spark Plug Inspection And Replacement 57 Carburetor Adjustments 58 Lubrication Points 59 Gearcase Lubrication 63 Submerged Outboard 64 Storage Storage Preparation 65 Protecting External Outboard Components 65 Protecting Internal Engine Components 66 Gearcase 66 Positioning Outboard for Storage 66 Battery Storage 66 Troubleshooting Starter Motor Will Not Crank the Engine Electric Start Models 67 ...

Page 10: ...n Mercury Marine Validated Engine Mounting Hardware 73 Installing Outboard 73 Battery Installation Electric Start Models 75 Battery Connections 75 Propeller Selection 76 Maintenance Log Maintenance Log 77 viii eng ...

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: ...common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage a 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 remote control unit...

Page 14: ...rd 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 Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boat...

Page 15: ... the operator s station without first disconnecting the stop switch lanyard from the operator 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 Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the b...

Page 16: ... Stop the engine immediately whenever anyone in the water is near your boat Shift the 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 passengers to stand or use seats other than those designated f...

Page 17: ...njury or death Stay back from the front end of deck boats or raised platforms 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 speed could...

Page 18: ...change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches down far enough ...

Page 19: ... 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 thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed Boat speed should be kept to a minimum planing speed when...

Page 20: ...tboard for more complete installation information WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware If an obstacle is struck at planing speed and the outboard is not securely fastened to the tr...

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: ...MPORTANT 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 maintenance manuals for all your selected accessori...

Page 23: ...rating 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 ...

Page 24: ...r of manufacture as an alpha code This code can be deciphered into a corresponding number utilizing the following table XXXXXXXXX XXXXXXXX XXXX AG 62972 Serial number decal alpha code Model Year Manufactured Code 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 63742 XXXXXXX XXXXX XX XL Mercury Marine Serial Number Brunswick Corp M...

Page 25: ...0 cu in Cylinder Bore 60 3 mm 2 375 in Piston Stroke 45 7 mm 1 8 in Recommended Spark Plug NGK BP8HS 15 Spark Plug Gap 1 5 mm 0 060 in Gear Ratio 2 0 1 Recommended Gasoline Refer to Fuel and Oil Recommended Oil Refer to Fuel and Oil Gearcase Lubricant Capacity 200 ml 6 8 fl oz Battery Rating 465 marine cranking amps MCA or 350 cold cranking amps CCA Amp Hours Ah 70 100 GENERAL INFORMATION eng 15 ...

Page 26: ...board 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 WARNING Rotating propellers can cause serious injury or death even if the engine is not operat...

Page 27: ...utboard 29011 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion Follow the transporting instructions supplied with the portable fuel tank Transport the fuel tank in a well ventilated area away from open flame or sparks MANUAL VENTING TYPE FUEL TANK Close the fuel tank air vent when transporting tank This will prevent escape of fuel or vapors f...

Page 28: ... tether cap over the fuel line connector stem This will protect the connector stem from being accidentally pushed in allowing fuel or vapor to escape a Connector stem b Tether cap F a b 26794 TRANSPORTING 18 eng ...

Page 29: ...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 30: ...oard Oil IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Mercury or Quicksilver Premium TC W3 2 Cycle oil is recommended for this engine For added protection and lubrication Mercury or Quicksilver Premium Plus TC W3 2 Cycle oil is recommended If Mercury or Quicksilver outboard oil is not available substitute another brand of 2 cycle outboard oil that is NMMA Certified TC W3 Severe engine da...

Page 31: ... expand 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 the portable fuel tanks from the boat to refill them Pour the full amount of oil along with one gallon of gasoline into the fuel tank ...

Page 32: ...ng the starter rope cranks the engine over for starting 29012 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 29013 Lanyard Lanyard stop switch Refer to General Information Lanyard Stop Switch 19791 FEATURES AND CONTROLS 22 eng ...

Page 33: ...osen friction counterclockwise b Tighten friction clockwise Throttle grip gear shift if equipped Controls gear shift and engine speed a Reverse b Forward Side handle gear shift if equipped Controls gear shift R F N 3022 NOTE Side handle gear shift outboards are furnished in some worldwide market areas Side handle gear shift is also available as a Quicksilver or Mercury Precision Accessory a b 1980...

Page 34: ...ficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released Steering friction adjustment Adjust this lever to achieve the desired steering friction drag on the tiller handle Move lever to the left to tighten or move lever to the right to loosen a Tighten friction b Loosen friction Remote Control Models Manual Start Starter rop...

Page 35: ...nob to adjust idle speed after engine warms up 29013 Control handle Controls gear shift and engine speed N R F 27237 Lanyard Lanyard stop switch Refer to General Information Lanyard Stop Switch 19791 Throttle friction adjustment Adjust to maintain desired tension at the control handle 3024 FEATURES AND CONTROLS eng 25 ...

Page 36: ...tral position 3025 Engine on off switch Turns engine on and off 3026 Remote Control Models Electric Start Control handle Controls gear shift and engine speed N R F 27237 Lanyard Lanyard stop switch Refer to General Information Lanyard Stop Switch 19791 FEATURES AND CONTROLS 26 eng ...

Page 37: ... ON S T A R T Neutral release lever Pull this lever up to move the control handle out of neutral position 3025 Fast idle lever Raising lever will increase engine idle speed in neutral Refer to Operation 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 FEATURE...

Page 38: ...ard to the preset trim position a Tilt lock knob in lock position b Tilt 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 shal...

Page 39: ... 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 should be adjusted so the outboard is p...

Page 40: ...e 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 either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered Adjusting the outboard away from the boat tran...

Page 41: ...utboard 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 Transom angle settings b Tilt release position a b 28589 FEATURES AND CONTROLS eng 31 ...

Page 42: ...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 43: ...ed oxygen in the air causing an overly rich fuel mixture Operating Outboard as an Auxiliary Engine If the outboard is used as an auxiliary engine stop the engine and tilt the outboard out of the water when 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 Prestar...

Page 44: ...ROCEDURE 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 Models Before starting read the Prestarting Check List special operating instructions and Engine Break in Procedure in th...

Page 45: ...Side handle gear shift models 5 Remote control models Move on off switch to the on position 3026 6 Side handle gear shift and remote control models Set the gear shift to neutral position N 26838 R F N 3022 IMPORTANT Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery Damage to the charging system may result OPERATION eng 35 ...

Page 46: ...9013 9 Manual Starting Models Pull the starter rope slowly until starter engages then pull rapidly to crank the engine Allow rope to return slowly Repeat until engine starts 28586 10 Electric Starting Models Push starter button and crank the engine Release button when engine starts Do not operate starter motor continuously for longer than ten seconds at a time If engine fails to start wait 30 seco...

Page 47: ...to the thermostat operation It may take several minutes for the engine to warm up enough for water to start spraying out of the indicator hole 19805 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 t...

Page 48: ...48 2 Squeeze the fuel line primer bulb several times until it feels firm 19779 3 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 4 Set the remote control handle to neutral position N 26838 OPERATION 38 eng ...

Page 49: ... started slowly advance the fast idle speed feature to increase idle speed until engine is warmed up Keep engine speed below 2000 RPM 27242 7 Warm Engine Advance the fast idle lever or throttle only feature to an approximate halfway 1 2 setting After engine starts immediately reduce engine speed back to idle a Fast idle speed lever b Throttle only feature 8 Starting Flooded Engine Advance the fast...

Page 50: ...verheat 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 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...

Page 51: ...e engine 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 26843 OFF ON S T A R T 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 26776 Emergency Starting If the starter system fails ...

Page 52: ...ARNING The neutral 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 2 Remove the fuel filter 3032 OPERATION 42 eng ...

Page 53: ...4 Remove three bolts and rewind starter assembly 3034 5 Remote Control Models Turn the ignition key or on off switch to ON position 26846 3026 6 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 OPERATION eng 43 ...

Page 54: ...e 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 spare starter rope around screwdriver tool provided and tie a knot in other end 8 Place the starter rope knot into the flywheel notch and wind the rope clockwise around the ...

Page 55: ...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 56: ...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 Mercury Marine Cowl Finishing Compound 92 859026K 1 CLEANING CARE FOR THE POWERHEAD SALTWATER USE If the outboard i...

Page 57: ...rol devices and systems may be performed by any marine spark ignition SI engine repair establishment or individual EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture a Idle speed b Engine horsepower c Timing specification d Recommended spark plug an...

Page 58: ...teering fluid level if equipped AFTER EACH USE Wash the power package exterior with fresh water Flush the outboard cooling system saltwater or brackish water only ANNUALLY OR 100 HOURS Grease the engine if applicable Change the engine oil and filter if equipped Inspect the thermostat saltwater or brackish water only Add Quickleen to the fuel tank once per year per engine Apply anti seize to the sp...

Page 59: ...equivalent flushing attachment 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 plate 1 Remove prope...

Page 60: ...g the outboard for 3 to 5 minutes carefully monitoring water supply at all times 6 Stop the engine turn off the water and remove the flushing attachment Reinstall the propeller Top Cowl Removal and Installation REMOVAL 1 Unlock the rear latch by pushing lever down 29054 2 Lift rear of cowl and disengage front hook 26851 INSTALLATION 1 Engage the front hook and push cowl back over the cowl seal 2 P...

Page 61: ...s check for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the 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 s...

Page 62: ...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 Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes 3933 b c d a a b c d 29055 MAINTENANCE 52 eng ...

Page 63: ...r 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 instructions and torque procedures a Nylon insert locknut 11 826709113 b Flat washers c Nylon insert locknut 11 82670...

Page 64: ...r 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 corrosion by sacrificing its metal to be slowly eroded instead of the outboard...

Page 65: ...lling 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 plate 1 Shift outboard to neutral N position 28577 N 26838 R F N 3022 2 Remove the spark plug leads to prevent engine from starting 26899 MAINTENANCE eng 55 ...

Page 66: ...uicksilver or Mercury Extreme Grease or 2 4 C with PTFE 27305 Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply a coat of the recommended lubricant to the entire propeller shaft at the recomme...

Page 67: ... nut 27341 8 Reinstall spark plug leads Spark Plug Inspection And Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Remove the spark plug leads Twist the rubber bo...

Page 68: ...irt 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 29111 2 With boat tied securely to dock start engine and allow it to warm up...

Page 69: ... 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 Specifications 3049 2 Engines not equipped with an adjustable speed screw a The carburetor has been calibrat...

Page 70: ...pin tracks shift throttle cable steering cable grease fitting 92 802859A 1 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 a Steering friction adjustment shaft b Swivel bracket 3040 a b MAINTENANCE 60 eng ...

Page 71: ...n Lubricate along the entire tilt pin tracks 3043 Lubricate the throttle and shift cable moving components and pivot points 3044 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 a b 3042 MAINTENANCE eng 61 ...

Page 72: ...icate pivot points 3046 3 Lubricate the following with Quicksilver or Mercury Extreme Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the p...

Page 73: ...s 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 a Fill drain plug b Vent plug GEARCASE LUBRICANT CAPACITY Gearcase lub...

Page 74: ...Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer 27355 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 MAINTENA...

Page 75: ...ystem Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with the 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 amount of ga...

Page 76: ...ry Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel Remove the spark plugs and inject 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 Gearcase Lubricant Positioning Outboa...

Page 77: ...ection 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 system component failure Spark plugs fouled or defective Refer to Maintenance secti...

Page 78: ...p 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 alternator or voltage regulator TROUBLESHOOTING 68 eng ...

Page 79: ...rs 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 produ...

Page 80: ...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 81: ...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 82: ...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 72 eng ...

Page 83: ...ith the outboard For example do not mount tow sport bars or boarding ladders onto the boat using the mounting hardware included with the outboard Installing other products onto the boat that utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have the fo...

Page 84: ...plate INSTALLING OUTBOARD ON TRANSOM 1 Place outboard on center line of transom 27005 2 Tighten transom clamp handles WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware a 27151 INSTALLATION 74 e...

Page 85: ...ured 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 if started manually as damage to the charging system could result Battery Connections CONNECTING OUTBOARD BATTERY CABLE...

Page 86: ...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 INSTALLATION 76 eng ...

Page 87: ...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 77 ...

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