Mercury 100 EFI Owner'S Manual Download Page 68

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OUTBOARD INSTALLATION

Important Information

Rigging boats, which includes proper engine installation has become more complex over the years. As a result,

Mercury Marine recommends that engines be installed only by Mercury authorized dealers. If you intend to

disregard this recommendation, and install the engine yourself, please make sure to read and comply with these

instructions. Failure to comply with these installation instructions could lead to serious injury or death.

NOTE: Do not install an accessory electric fuel pump or a fuel line primer bulb into the fuel system of this engine.

Boat Horsepower Capacity

WARNING

Using an outboard that exceeds the maximum horsepower limit of a boat can: 1) cause loss of boat control

2) place too much weight at the transom altering the designed flotation characteristics of the boat or 3) cause

the boat to break apart particularly around the transom area. Overpowering a boat can result in serious injury,

death or boat damage.

Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum

acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt,

contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON
CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT
CAPACITY

XXX

ob00306

Start in Gear Protection

WARNING

Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design

of this outboard requires that the remote control used with it must have a built in start in neutral only 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 designed and tested for this

outboard.
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this

outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals

for all selected accessories.

Summary of Contents for 100 EFI

Page 1: ... de Petit Rechain Belgium complies with the requirements of the following directives by meeting the associated standards as amended If the CE mark is accompanied by a notified body number the following Recreational Craft Directive applies Recreational Craft Directive 2003 44 EC amending 94 25 EC Owner s manual A 2 5 ISO 10240 Handling characteristics A 4 ISO 8665 Outboard engine starting A 5 1 4 I...

Page 2: ...36 EC Generic emission standard EN 61000 6 3 Generic immunity standard EN 61000 6 1 Vehicles boats and internal combustion engine driven devices radio disturbance characteristics SAE J551 CISPR 12 Electrostatic discharge testing EN 61000 6 2 EN 61000 4 2 EN 61000 4 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe Patrick C Mackey President Mercur...

Page 3: ...Performance Boat Operation 9 Outboard Remote Control Models 9 Remote Steering Notice 9 Outboard Mounting Notice 10 Propeller Selection 10 Lanyard Stop Switch 11 Protecting People In The Water 12 Passenger Safety Message Pontoon Boats And Deck Boats 13 Wave And Wake Jumping 13 Impact With Underwater Hazards 14 Exhaust Emissions 15 Selecting Accessories For Your Outboard 16 Safe Boating Suggestions ...

Page 4: ...e for Top and Bottom Cowls 39 Cleaning Care for the Powerhead Saltwater Use 39 Battery Inspection 40 Air Filter 40 Fuel System 41 Corrosion Control Anode 44 Propeller Replacement 44 Spark Plug Inspection and Replacement 47 Fuse Replacement 48 Alternator Drive Belt Inspection 49 Lubrication Points 50 Checking Power Trim Fluid 52 Changing Engine Oil 52 Gearcase Lubrication 54 Storage Storage Prepara...

Page 5: ...power Capacity 62 Start in Gear Protection 62 Selecting Accessories For Your Outboard 62 Fuel Tanks 63 Filling the Fuel System 63 Installation Specifications 63 Lifting Outboard 63 Steering Cable Starboard Side Routed Cable 64 Steering Link Rod Fasteners 65 Determining Recommended Outboard Mounting Height 67 Drilling Outboard Mounting Holes 68 Fastening the Outboard to the Transom 69 Electrical Fu...

Page 6: ...vi ...

Page 7: ...r the Federal Safety Act be required 2 To be eligible for warranty coverage the product must be registered with Mercury Marine At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration 3 Upon processing the warranty registratio...

Page 8: ...ion date Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re registration of the product Unexpired warrant coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purch...

Page 9: ...ty and if made shall not be enforceable against Mercury Marine For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE A...

Page 10: ...his limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section ...

Page 11: ...y performed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repai...

Page 12: ...YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY Warranty Coverage And Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The following information explains some of the types of services that are not covered by warranty The provisions set forth following have been incorporated b...

Page 13: ...r preparing for racing or other competitive activity or operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty 12 Lower unit and or propeller damage caused by striking a submerged ob...

Page 14: ...structions that should be followed DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or proper...

Page 15: ...r dealer distributor or Mercury Marine ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device This prevents the engine from starting when the shift is actuated in any position other than neutral WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine The desig...

Page 16: ...t your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself refer to the Outboard Installation section The outboard must be secured to the transom with the four 12 7 mm 1 2 in diameter mounting bolts and locknuts provided Install two bolts through the upper set of holes and two bolts through the lower set of ho...

Page 17: ...und in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard 21629 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 en...

Page 18: ...lar concern for passengers in the front 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 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a b...

Page 19: ... overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water ob00312 WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over 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 ...

Page 20: ...a nearly instantaneous stop and can send the occupants flying forward The boat may also steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce...

Page 21: ...oard component failure with or without subsequent impacts Have the outboard thoroughly inspected and any necessary repairs made Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboards sterndrives and inboard engines that propel boats as well as the generators that power various boat acces...

Page 22: ...njury or death Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations a...

Page 23: ...sible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above idle speed Never drive your boat directly behind a water skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier 6...

Page 24: ...ended Spark Plug NGK LFR4A E Spark Plug Gap 0 8 mm 0 032 in Spark Plug Hex Size 16 mm Gear Ratio 80 100 HP 2 33 1 115 HP 2 07 1 Recommended Gasoline Refer to Fuel Oil Recommended Oil Refer to Fuel Oil Gearcase Lubricant Capacity 710 ml 24 fl oz Engine Oil Capacity With Oil Filter Replacement 5 0 liters 5 3 qt Battery Rating 1000 Marine Cranking Amps MCA 800 Cold Cranking AMPS CCA or 180 Ampere Hou...

Page 25: ... Identification a b c d e f g h i j 20784 a Top cowl b Bottom cowl c Water pump indicator hole d Driveshaft housing e Anti ventilation plate f Trim tab g Auxiliary tilt switch h Transom brackets i Cooling water intake holes j Gearcase ...

Page 26: ...e Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 20759 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This pr...

Page 27: ...r alcohol from the gasoline in the fuel tank The fuel system components on your Mercury Marine engine will withstand up to 10 alcohol content in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specific recommendations on the boat s fuel system components fuel tanks fuel lines and fittings Be aware that gasolines containing alcoh...

Page 28: ...lar viscosity may be used IMPORTANT The use of non detergent oils multi viscosity oils other than Mercury or Quicksilver NMMA FC W certified oil or a major brand NMMA FC W certified oil synthetic oils low quality oils or oils that contain solid additives are not recommended C 100 80 60 40 20 0 38 120 49 27 16 4 7 18 F MERCURY 4 STROKE ENGINE OIL OIL CAPACITY 5 0L 5 3 U S qt 20862 Checking and Addi...

Page 29: ... oil Allow a few minutes for the added oil to drain to the oil sump and recheck the dipstick Repeat the process until the oil level is on the operating range cross hatched region Do not try to fill to the upper end of the operation range cross hatched region 20714 IMPORTANT Inspect oil for signs of contamination Oil contaminated with water will have a milky color to it oil contaminated with fuel w...

Page 30: ...oval for adjustment g Ignition key switch OFF ON START h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer to Operation Starting the Engine Warning System WARNING HORN SIGNALS When the key switch is turned to the ON position the horn will turn on for a moment as a test to indicate the horn is working The warning horn will emit either a continuous beep or intermitt...

Page 31: ...for obstruction Oil pressure low Continuous Engine Guardian System is activated Power limit will vary depending on available oil pressure Stop engine and check oil dipstick Add oil if necessary Refer to Fuel and Oil Checking and Adding Engine Oil Engine overspeed Continuous The warning horn is activated any time the engine speed exceeds the maximum allowable RPM The system will limit the engine sp...

Page 32: ... A few of the functions the instrument package will display are engine RPM coolant temperature oil pressure water pressure battery voltage fuel consumption and engine operating hours The SmartCraft Instrument package will also aid in Engine Guardian diagnostics The SmartCraft Instrument package will display critical engine alarm data and potential problems Power Trim and Tilt The outboard has a tr...

Page 33: ...steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely The boat can now spin out or go into a very tight maximum turn which if unexpected can result in occupants being thrown within the boat or out of the boat Consider the following lists carefully 1 Trimming In or Down Can Lower the bow Result in quicker planing off especially...

Page 34: ... TILTING OPERATION To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 3 Disengage the tilt support lever by ra...

Page 35: ... When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range ...

Page 36: ...hance 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 possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or pollu...

Page 37: ...e every ten minutes 2 For the next eight hours of operation avoid continuous operation at full throttle for more than five minutes at a time Starting The Engine Remote Control Models Before starting read the Pre Starting Check List and Engine Break in Procedure in the Operation section CAUTION Never start or operate your outboard even momentarily without water circulating through all the cooling w...

Page 38: ...d of fuel the fuel system should be filled as follows Turn the ignition key switch to the ON position for approximately one minute This operates the fuel lift pump Turn the ignition key switch back to the OFF position and then return the ignition key switch to the ON position again for an additional minute Turn the ignition key switch back to the OFF position The filling of the fuel system is comp...

Page 39: ... Before beginning operation allow the engine to warm up at idling speed for three minutes Gear Shifting IMPORTANT Observe the following Never shift outboard into gear unless engine speed is at idle Do not shift outboard into reverse when the engine is not running Your outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R When shifting always stop at neutral...

Page 40: ...OPERATION 34 ob00360 ...

Page 41: ...ercury Precision or Quicksilver replacement parts and Genuine Lubricants WARNING Using a replacement part that is inferior to the original part could result in personal injury death or product failure 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 manufactu...

Page 42: ...y at room temperature 1 Check low pressure fuel filter for contaminants Replace filter if required See Fuel System Check corrosion control anodes Check more frequently when used in saltwater See Corrosion Control Anode Drain and replace gearcase lubricant See Gearcase Lubrication Check power trim fluid See Checking Power Trim Fluid Inspect battery See Battery Inspection Saltwater usage Remove and ...

Page 43: ...ate water through the water passages NOTE You can have the outboard tilted or in the vertical operating position during flushing WARNING To avoid possible injury when flushing remove the propeller Refer to Propeller Replacement 1 Place the outboard in either the operating position vertical or in a tilted position 2 Remove propeller Refer to Propeller Replacement 3 Thread a water hose into the rear...

Page 44: ...p cowl into position over the engine 2 Pull up the rear cowl latch to lock down the rear Push in the front cowl latch to lock down the front Flywheel Cover Removal and Installation REMOVAL Lift the cover off the rear mounting pin and slide the cover forward to release the cover from the front mounting pins ...

Page 45: ...r 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 is operated in saltwater remove the top cowl and flywheel cover Inspect the powerhead and powerhead components for salt build up Wash off any salt build up from the powerhead a...

Page 46: ...gative to negative 5 Make sure the battery is equipped with a non conductive shield to prevent accidental shorting of battery terminals Air Filter The air filter is a one piece assembly The air filter removes airborne particles which may damage engine components The air filter design allows for maximum unrestricted air flow during engine operation AIR FILTER ASSEMBLY REMOVAL 1 Remove the breather ...

Page 47: ... Material used to contain spilled fuel must be disposed of in an approved receptacle Before servicing any part of the fuel system 1 Stop engine and disconnect the battery 2 Perform fuel system service in a well ventilated area 3 Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line for cracks swelling leaks hardness or other signs of deteri...

Page 48: ...pressure A special tool and procedure is required to release the fuel pressure before the filter can be removed Have the high pressure fuel filter serviced by an authorized dealer LOW PRESSURE FUEL FILTER Removal 1 Turn ignition key switch to OFF position 2 Remove the cap from the fuel vapor purge relief valve a 20813 a Fuel vapor purge relief valve ...

Page 49: ...ure by pushing the core of the valve end in 13282 4 Push in on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter a a 20815 b a Fuel hose release tab b Low pressure fuel filter Installation 1 Install the new fuel filter so the arrow points towards the engine 2 Connect the fuel hoses to the fuel filter securely with the locking hose connections 3 If removed place the fuel...

Page 50: ...the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode Two anodes are located on each side of the gearcase Another anode is installed on the bottom of the transom bracket assembly 20761 Propeller Replacement WARNING If the propeller shaft is rotat...

Page 51: ...ller to hold propeller and remove propeller nut ob00377 4 Pull propeller straight off shaft 5 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon ob00378 Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft 92 802867Q1 95 2 4 C Marine Lubricant with Teflon Propeller shaft 92 802859Q1 ...

Page 52: ...aft ob00382 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d Continuity washer e Propeller f Forward thrust hub 7 Flo Torq II and Flo Torq III Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft b c a d f e ob00421 3223 a b c d e f Flo Torq II Flo Torq III a Propeller nut b Pro...

Page 53: ...ness connectors from the pencil coils 3 Remove the mounting bolts that are securing the pencil coils Pull the pencil coils from the spark plugs using a twisting motion a b d c 20752 a Wiring harness connector b Pencil coil c Bolt d Ground strap 4 Remove the spark plugs to inspect Replace spark plug if electrode is worn threads of seal area are corroded or the insulator is rough cracked broken blis...

Page 54: ...s Torque to specifications Description Nm lb in lb ft Bolts 8 71 10 Reconnect the wiring harness connectors to the pencil coil connections a b d c 20752 a Wiring harness connector b Pencil coil c Bolt d Ground strap 11 Reinstall top cowl Fuse Replacement IMPORTANT Always carry spare fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is...

Page 55: ...pump 20 AMP fuse g Ignition coils 20 AMP fuse h Spare fuse 20 AMP fuse i Fuel injectors purge valve idle air control 20 AMP fuse Alternator Drive Belt Inspection Inspect the alternator drive belt and have it replaced by an authorized dealer if any of the following conditions are found a 20775 a Alternator drive belt Cracks in the back of the belt or in the base of the V grooves Excessive wear at t...

Page 56: ...cement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft ob00378 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Swivel bracket tilt support lever tilt tu...

Page 57: ... a Fitting b Steering cable end 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 in serious injury or death 3 Lubricate the follo...

Page 58: ...cants Power Trim Steering Fluid If not available use automotive ATF automatic transmission fluid ob00688 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 5 liters 5 3 quarts OIL CHANGING PROCEDURE 1 Tilt the outboard up to the trailer position 2 Turn the steering on the outboard so that the drain hole is facing downward Remove drain plug and drain engine oil into an app...

Page 59: ...s base then tighten 3 4 to 1 turn a b 20780 a Oil filter b Loosen OIL FILLING 1 Remove the oil fill cap and add the recommended oil to the midpoint of the operating range midpoint of the cross hatched region Adding approximately 5 liters 5 3 quarts will bring the oil level to mid point of the cross hatched region 2 Idle engine for five minutes and check for leaks Stop the engine Allow a few minute...

Page 60: ...e and damage the gearcase Examine the drained gearcase 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 a drain pan below outboard 3 Remove v...

Page 61: ... c Rear vent hole d Rear vent plug e Fill drain plug 4 Continue adding lubricant until it appears at the rear vent hole 5 Stop adding lubricant Install the rear vent plug and sealing washer before removing lubricant tube 6 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer SUBMERGED OUTBOARD A submerged outboard will require service within a few hours by an authorized d...

Page 62: ... treatment stabilizers 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 Fuel System Treatment and Stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently Installed Fuel T...

Page 63: ...g Outboard For Storage Store outboard in an upright vertical position to allow water to drain out of outboard CAUTION If outboard is stored tilted up in freezing temperature trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard Battery Storage Follow the battery manufacturer s instructions for storage an...

Page 64: ...icted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erratically POSSIBLE CAUSES Overheating Warning horn not working Low oil pressure Check oil level Spark plugs fouled or defective Refer to Maintenance...

Page 65: ... 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 Open circuit in the alternator output wire fused link ...

Page 66: ...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 additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question conce...

Page 67: ...striel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 954 744 3535 Japan 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 Ma...

Page 68: ...er or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX ob00306 Start in Gear Protection WARNIN...

Page 69: ...ly one minute This operates the fuel lift pump Turn the ignition key switch back to the OFF position and then return the ignition key switch to the ON position again for an additional minute Turn the ignition key switch back to the OFF position The filling of the fuel system is complete Installation Specifications a b a 18552 a Minimum transom opening b Engine centerline for dual engine 66 0 cm 26...

Page 70: ...es flywheel from engine Used for lifting powerhead engine Steering Cable Starboard Side Routed Cable 1 Lubricate O ring seal and entire cable end 3724 95 Tube Ref No Description Where Used Part No 95 2 4 C Marine Lubricant with Teflon O ring seal and entire cable end 92 802859Q1 2 Insert steering cable into tilt tube ...

Page 71: ... bolt a Part Number 10 856680 and self locking nylon insert locknuts c d Part Number 11 826709113 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occupants to be thr...

Page 72: ...olt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighten until it seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt and locknut First torque special washer head bolt then torque locknut to sp...

Page 73: ...mended to determine the outboard mounting height b The broken lines represent the extremes of known successful outboard mounting height dimensions c This line may be preferred to determine outboard mounting height dimension if d This line may be preferred to determine outboard mounting height dimension for dual outboard installation e Outboard mounting height height of outboard mounting brackets f...

Page 74: ...odels to the listed outboard mounting heights 3 The mounting height of the outboard must not exceed 63 5 cm 25 in for L models 76 cm 30 in for XL models Mounting the outboard higher may cause damage to the gearcase components Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause propeller to break loose during planing Drilling Outboard ...

Page 75: ...ansom bolt 1 2 20 x 4 50 in long 2 25 in thread 11 826711 17 Nylon insert locknut 1 2 20 12 28421 Washer Inner 0 516 in ID x 1 50 in OD 12 54012 Washer Outer 0 53 in ID x 0 87 in OD Available Transom Mounting Bolts Part Number Part Name Description 10 67755005 Transom bolt 1 2 20 x 2 50 in long 1 25 in thread 10 67755006 Transom bolt 1 2 20 x 3 50 in long 1 25 in thread 10 814259 Transom bolt 1 2 ...

Page 76: ...t or nut continues to turn without the torque reading on the dial increasing it is an indication that the transom is yielding The load area can be increased by using a larger washer or a transom reinforcement plate NOTE The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts a b 20860 a Large transom washer b Transom...

Page 77: ...s and bolts 75 55 Electrical Fuel Hose and Control Cables FRONT COWL GROMMET Installation IMPORTANT Sufficient slack must exist in wiring harnesses battery cables and hoses that are routed between the rubber grommet and engine attachment points to relieve stress and prevent hoses from being kinked or pinched 1 Pull up the cowl seal Remove the access cover from the bottom cowl ...

Page 78: ...s opening i Shift cable opening j Cable tie 2 Route the hoses wiring and cables through the correct opening in the front grommet as shown 3 Reinstall the access cover with two bolts Reattach the cowl seal 4 Attach a cable tie around the outside diameter of the front grommet a 20794 a Cable tie REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front grommet Connect the remote h...

Page 79: ... pin boat harness SMARTCRAFT HARNESS CONNECTION If SmartCraft gauges are being used with the outboard route the SmartCraft wiring harness through the front grommet and connect it to the SmartCraft harness connector on the engine a 20895 a SmartCraft harness connector ...

Page 80: ...eve positive b Black sleeve negative c Cranking battery Dual Outboards Connect a common ground cable wire size same as engine battery cables between negative terminals on starting batteries a a b b c d d or87 a Red sleeve positive b Black sleeve negative c Ground cable d Cranking battery ...

Page 81: ...Install cables into the remote control following the instructions provided with the remote control NOTE Install the shift cable to the engine first The shift cable is the first cable to move when the remote control handle is moved out of neutral 1 Remove the access cover from the bottom cowl NOTE The high pressure fuel hose can be moved out of the way for additional access a b 20893 a Access cover...

Page 82: ... the handle to full speed position Slowly return the handle back to the neutral position Place a mark b on the cable against the cable end guide c Make a center mark c midway between marks a and b Align the cable end guide against this center mark when installing the cable to the engine 6098 b c a 4 Fit the shift cable through the front grommet 6099 5 Position remote control into neutral 6 Align t...

Page 83: ...ral The propeller shaft should turn freely without drag If not adjust the barrel away from the cable end Repeat steps a and b c Shift remote control into reverse while turning propeller The propeller shaft should be locked in gear If not adjust the barrel away from the cable end Repeat steps a through c d Shift remote control back to neutral The propeller shaft should turn freely without drag If n...

Page 84: ...NOTE The high pressure fuel hose can be moved out of the way for additional access a b 20893 a Access cover b High pressure fuel hose 2 Position remote control into neutral N ob00351 3 Install the throttle cable to the throttle arm with the retainer clip 4 Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop 5 Fit the throttle cable through ...

Page 85: ...e opening b Flat washer c Retainer clip d Cable barrel 7 Lock the cable in place with the cable latch 20828 a a Cable latch 8 If the shift cable is already installed place the high pressure fuel hose back into the hose retainers Reinstall the access cover ...

Page 86: ...r under This greater trim under capability is desirable to improve acceleration reduce the angle and time spent in a bow high boat during planing off and in some cases may be necessary to plane off a boat with aft live wells given the variety of available propellers and height range of engine installations However once on plane the engine should be trimmed to a more intermediate position to avoid ...

Page 87: ... This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired A non stainless steel shipping bolt should not be used in this application other than on a temporary basis ...

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