Mercury 100 FourStroke Operation Maintenance Installation Warranty Manual Download

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Be alert.

•

The operator of the boat is responsible by law to maintain a proper

lookout by sight and hearing. The operator must have an unobstructed

view particularly to the front. No passengers, load, or fishing seats should

block the operator's view when the boat is above idle or planing transition

speed. Watch out for others, the water, and your wake.

Never drive your boat directly behind a water skier.

•

Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is

61 m (200 ft) in front of you in five seconds.

Watch fallen skiers.

•

When using your boat for waterskiing or similar activities, always keep a

fallen or down skier on the operator's side of the boat while returning to

attend to the skier. The operator should always have the down skier in

sight and never back up to the skier or anyone in the water.

Report accidents.

•

Boat operators are required by law to file a boating accident report with

their state boating law enforcement agency when their boat is involved in

certain boating accidents. A boating accident must be reported if 1) there

is loss of life or probable loss of life, 2) there is personal injury requiring

medical treatment beyond first aid, 3) there is damage to boats or other

property where the damage value exceeds $500.00, or 4) there is

complete loss of the boat. Seek further assistance from local law

enforcement.

Recording Serial Number

It is important to record this number for future reference. The serial number is

located on the outboard, as shown.

a -

Serial number

b -

Model designation

c -

Year manufactured

XXXXXXX

Mercury Marine

Serial Number

Brunswick Corp.

Fond du Lac, WI 54935

Assembled in the USA

from US and foreign

components

XXXXXX

XXX

Model Number

XXXXXXX

54204

GENERAL INFORMATION

eng

Summary of Contents for 100 FourStroke

Page 1: ...Outboard Operation Maintenance Warranty Installation Manual 2016 Mercury Marine 75 80 90 100 115 115 Pro XS FourStroke 8M0108376 915 eng ...

Page 2: ...eng ...

Page 3: ...t emission assessment Det Norske Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Name of notified body for noise emission assessment Det Norske Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Conformity assessment module used for exhaust emissions B C B D B E B F G H Conformity assessment module used for noise emis...

Page 4: ...4 Essential requirements Standards Other normative document method Technical file Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 engine identification B 2 exhaust emission requirements EN ISO 8178 1 1996 B 3 durability EN ISO 8178 1 1996 B 4 owner s manual ISO 8665 2006 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s man...

Page 5: ...ill be pleasant Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the fact...

Page 6: ...a Mercury Premier Service rating means a dealer Achieves a high 12 month service Customer Satisfaction Index CSI score for warranty service Possesses all of the necessary service tools test equipment manuals and parts books Employs at least one certified or master technician Provides timely service for all Mercury Marine customers Offers extended service hours and mobile service when appropriate U...

Page 7: ...tralia and New Zealand 11 Global Warranty Charts Outboard and Jets 16 General Information Boater s Responsibilities 21 Before Operating Your Outboard 21 Boat Horsepower Capacity 21 High Speed and High Performance Boat Operation 22 Outboard Remote Control Models 22 Remote Steering Notice 23 Outboard Mounting Notice 23 Propeller Selection 24 Lanyard Stop Switch 25 Protecting People in the Water 27 P...

Page 8: ...e Oil Recommendations 46 Checking and Adding Engine Oil 46 Features and Controls Remote Control Features 49 Warning System 49 Power Trim and Tilt 51 Operation Important Information 55 Operating in Freezing Temperatures 56 Operating in Saltwater or Polluted Water 56 Operating at High Elevations 56 Effects of Elevation and Weather on Performance 56 Setting Trim Angle while Running Engine at Idle Spe...

Page 9: ...em 71 Corrosion Control Anode 73 Propeller Replacement 74 Spark Plug Inspection and Replacement 77 Fuse Replacement 79 Lubrication Points 80 Checking Power Trim Fluid 83 Changing Engine Oil 83 Gearcase Lubrication 86 Storage Storage Preparation 88 Protecting External Outboard Components 88 Protecting Internal Engine Components 89 Gearcase 89 Positioning Outboard for Storage 89 Battery Storage 89 T...

Page 10: ...on 101 Selecting Accessories for Your Outboard 101 Fuel System 101 Installation Specifications 106 Determining Recommended Outboard Mounting Height 107 Drilling Outboard Mounting Holes 108 Lifting Outboard 109 Shipping Bracket Removal 110 Steering Cable Starboard Side Routed Cable 111 Fastening the Outboard to the Transom 112 Steering Link Rod Fasteners if equipped 117 Electrical Fuel Hose and Con...

Page 11: ...y Marine or sending a letter or fax with your name old address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 OUTSIDE UNITED STATES AND CANADA For products pu...

Page 12: ...nder the terms of the contract To transfer the plan to the subsequent owner contact Mercury Product Protection or an authorized dealer to receive a Request for Transfer form Submit to Mercury Product Protection a receipt bill of sale a completed Request of Transfer form and a check payable to Mercury Marine in the amount of 50 00 per engine to cover the transfer fee Plan coverage is not transferab...

Page 13: ...rves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury Marine s sole and exclusive obligation under this warranty is limited to at our option repairing a corroded part replacing such part or parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury Marine product Mercury Marine reserves ...

Page 14: ...ntifouling paints are recommended on Outboard and MerCruiser boating applications In areas where TBTA base paints are prohibited by law copper base paints can be used on the hull and transom Do not apply paint to the Outboard or MerCruiser product In addition care must be taken to avoid an electrical interconnection between the warranted product and the paint For MerCruiser product an unpainted ga...

Page 15: ...elts controls and checking lubrication made in connection with normal services 2 Factory installed jet drive units Specific parts excluded from the warranty are the jet drive impeller and jet drive liner damaged by impact or wear and water damaged driveshaft bearings as a result of improper maintenance 3 Damage caused by neglect lack of maintenance accident abnormal operation or improper installat...

Page 16: ... Refer to the Maintenance section 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 U S EPA Emissions Limite...

Page 17: ...ngine s emissions on any regulated pollutant California Emissions Limited Warranty The California Air Resources Board has promulgated air emission regulations for outboard engines The regulations apply to all outboard engines sold to retail consumers in California and which were manufactured for the 2001 model year and later Mercury Marine in compliance with those regulations provides this limited...

Page 18: ...Emission Control System Components and Maintenance Schedule The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to a subsequent purchaser See instructions on transfer of warranty HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercu...

Page 19: ...lacement or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual The use of non Mercury parts for nonwarranty maintenance or repairs will not be grounds for disallowing other warranty work The use of add on as defined at section 1900 b 1 and b 10 of Title 13 of the California Code of Regulations or modified parts not exempted by th...

Page 20: ... personal watercraft equipped with hour meters as defined in s 2441 a 13 or their equivalent If any emission related part on your engine is defective under warranty the part will be repaired or replaced by Mercury Marine OWNER S WARRANTY RESPONSIBILITIES As the outboard engine owner you are responsible for the performance of the required maintenance listed in the Maintenance section Mercury Marine...

Page 21: ... The Three Star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003 2008 exhaust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines 42539 Four Stars Super Ultra Low Emission The Four Star label identifie...

Page 22: ...s Limited Warranty of one 1 year from the date of first retail sale or one 1 year from the date on which the product was first put into service whichever occurs first Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes Unexp...

Page 23: ... www mercurymarine com au If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine at the address shown above Mercury Marine will then arrange for the inspection and any covered repair This Limited Warranty will not cover the purchaser for all related transportation charges and travel time If the service provided is not covered by this limited war...

Page 24: ... high on the transom or running the boat with the engine trimmed out too far 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 incom...

Page 25: ...is will not apply to products used for commercial applications To transfer the warranty to the subsequent owner send or fax a copy of the Bill of Sale or Purchase Agreement new owner s name address and hull identification number HIN to Mercury Marine s Warranty Registration Department In Australia and New Zealand mail to Mercury Marine Attn Warranty Registration Department Brunswick Asia Pacific G...

Page 26: ...ptiMax 300 XS 2 years 3 years Verado 400R 2 years 3 years Outside the United States For product purchased outside the United States contact the distributor in your country or the authorized Marine Power Service Center closest to you CANADA WARRANTY CHARTS OUTBOARD AND JET Product Standard Limited Warranty Standard Limited Corrosion Warranty 2 Stroke carbureted 50 90 hp 1 year 3 years 2 Stroke EFI ...

Page 27: ... Warranty Light Commercial All outboard 3 years 3 years Contact the Marine Power Service Center closest to you Outside of Australia and New Zealand For product purchased outside of Australia and New Zealand contact the distributor in your country or the Marine Power Service Center closest to you SOUTH PACIFIC WARRANTY CHART OUTBOARD AND JET Products Standard Limited Warranty Standard Limited Corro...

Page 28: ...plication Verado 400R 1 year 3 years None Outside of Asia For product purchased outside of the Asian region contact the distributor in your country or the Marine Power Service Center closest to you EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES CIS WARRANTY CHARTS OUTBOARD AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2 S...

Page 29: ...AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2 Stroke 1 year 3 years Contact the Marine Power Service Center closest to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Ve...

Page 30: ...to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Verado 400R 2 years 3 years Outside South Africa For products purchased outside of the South Africa region contact the distributor in your country or the Marine Power Service Center closest to ...

Page 31: ...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 32: ...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 33: ...y or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts Outboard Mounting Notice 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 ...

Page 34: ...fer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensu...

Page 35: ... usually 122 152 cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator s PFD or wrist The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of...

Page 36: ...hut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency if the operator is accidentally ejected WARNING If the ...

Page 37: ...ng in the water to take quick action to avoid a boat heading in his her direction even at slow speed 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to ro...

Page 38: ... the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can ...

Page 39: ...se the boat to veer violently 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 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...

Page 40: ... 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 41: ...ation include headache dizziness drowsiness and nausea WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning which can lead to unconsciousness brain damage or death Avoid exposure to carbon monoxide Stay clear from exhaust areas when engine is running Keep the boat well ventilated while at rest or underway STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmf...

Page 42: ...ce is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a Operating the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine operating 2 Examples of poor vent...

Page 43: ...yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and your state or provincial boating law enforcement agency provide c...

Page 44: ...e driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat s capacity plate Know your boat s operating and loading limitations Know if your boat will float if it is full of water When in doubt contact your authorized Mercury Marine dealer or the boat manufacturer Ensure that everyone in the boat is...

Page 45: ...to the skier or anyone in the water Report accidents Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is da...

Page 46: ...umber of cylinders 4 Piston displacement 2 061 cc 125 8 cid Cylinder bore 90 mm 3 54 in Stroke 81 mm 3 19 in Recommended spark plug NGK ZFR5F Spark plug gap 0 8 mm 0 032 in Spark plug hex size 16 mm Valve clearance cold Intake valve 0 050 0 102 mm 0 002 0 004 in Exhaust valve 0 128 0 179 mm 0 005 0 007 in Gear ratio Standard 2 07 1 Command Thrust 2 38 1 Gearcase lubricant capacity Standard 800 ml ...

Page 47: ...ronic engine control EC Sound at drivers ear ICOMIA 39 94 dBA 79 2 Specifications 115 Pro XS Models 115 Pro XS Horsepower 115 Kilowatts 85 7 Full throttle RPM range 5300 6300 Idle speed In neutral gear cold warm up 700 800 RPM In neutral gear at operating temperature 700 RPM Idle charging compensation 700 800 RPM Troll control RPM range accessory 550 1000 Number of cylinders 4 Piston displacement ...

Page 48: ...Fuel and Oil Recommended oil Refer to Fuel and Oil Engine oil capacity with oil filter replacement 5 2 liter 5 5 US qt Battery rating 1000 marine cranking amps MCA 800 cold cranking amps CCA or 65 amp hour Ah Emission control system Electronic engine control EC Sound at drivers ear ICOMIA 39 94 dBA 79 2 The idle charging compensation RPM may automatically increase up to 800 RPM to compensate for a...

Page 49: ... Engine flush c Auxiliary tilt switch d Tilt bracket knob e Anode f Cooling water intake holes g Gearcase h Engine oil drain i Water pump indicator hole j Manual release for trim system a b c d e f g h i 54205 j GENERAL INFORMATION eng 39 ...

Page 50: ...cal dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 47333 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propell...

Page 51: ...ASOLINES USA ONLY Reformulated gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels are alcohol ethanol or ether MTBE or ETBE If ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol...

Page 52: ... corrosion may take place during storage if alcohol has washed protective oil films from internal components Fuel Additives To minimize carbon deposit buildup in the engine it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine s fuel at each tank fill throughout the boating season Use additive as directed on container Avoiding Fuel Flow Restriction IMPORT...

Page 53: ...EPA requires that any outboard manufactured after January 1 2009 must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard Low permeation hose is USCG Type B1 15 or Type A1 15 defined as not exceeding 15 g m 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fuel hose EPA Pressurized Portable Fuel Tank Requirements The Environmental Protection...

Page 54: ...ertain portable outboard models SPECIAL FEATURES OF THE PORTABLE FUEL TANK The fuel tank has a two way valve which allows air to enter the tank as the fuel is drawn to the engine and also opens to vent to the atmosphere if internal pressure in the tank exceeds 34 4 kPa 5 0 psi A hissing noise may be heard as the tank vents to the atmosphere This is normal The fuel tank includes a fuel demand valve...

Page 55: ... for operation and cap removal Close the manual vent screw for transportation 3 For fuel hoses that have quick disconnects disconnect the fuel line from the engine or fuel tank when not in use 4 Follow Filling Fuel Tank instructions for fueling Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion Use caution when filling fuel tanks Always stop the engine and do...

Page 56: ...ed IMPORTANT The use of nondetergent oils multiviscosity oils other than Mercury or Quicksilver NMMA FC W certified oil or a major brand NMMA FC W certified oil low quality oils or oils that contain solid additives are not recommended 58247 Checking and Adding Engine Oil IMPORTANT Do not overfill Tilt outboard out up past vertical for approximately one minute to allow trapped oil to drain back to ...

Page 57: ... oil level Oil should be in the operating range cross hatched region IMPORTANT Do not try to fill the oil level to the top of the operating range cross hatched region Oil level is correct as long as it appears in the operating range cross hatched region a Oil level operating range b Top bar c Bottom bar d Upper 1 3 level 53753 a b c d FUEL AND OIL eng 47 ...

Page 58: ...il level is on the operating range cross hatched region Do not try to fill to the upper end of the operating range cross hatched region 53755 IMPORTANT Inspect oil for signs of contamination Oil contaminated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 7 Push the dipstick back...

Page 59: ... to alert the operator of an active problem within the engine s operating system 1 Continuous six second beep Indicates a critical engine condition Depending on the condition the Engine Guardian system may engage and protect the engine by limiting its power You should return to port immediately and contact your servicing dealer 2 Intermittent short beeps for six seconds Indicates a noncritical eng...

Page 60: ...reducing engine power in order to provide engine protection If Engine Guardian has been activated reduce the engine speed The problem will need to be identified and corrected The system must be reset before the engine will operate at higher speeds Moving the throttle lever back to the idle position will reset the Engine Guardian system If the Engine Guardian system has determined the reset has not...

Page 61: ...g out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating the boat on plane The term tilt is generally used when referring to adjusting the outboard further up out of the water With the engine turned off and ignition switch turned on the outboard can be tilted out of the water At low idle speed the outboa...

Page 62: ...plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or oversteering if any turn is attempted or if a significant wave is encountered 2 Trimming out or up can Lift the bow higher out of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the ...

Page 63: ... switch the outboard can be manually tilted NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation Turn out the manual tilt release valve three turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 54177 a b 541...

Page 64: ...ter you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce the engine speed below 2000 RPM 2 Tilt the 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 a 54178 FEATURES AND CONTROLS 54 eng ...

Page 65: ...itable size for each person aboard and readily accessible it is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know your boats maximum load capacity Look at the boat capacity plate Fuel supply OK Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where you are going and wh...

Page 66: ...s tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use Each month spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces Do not spray on corrosion control anodes as this will reduce the effective...

Page 67: ...ommended maximum RPM range at wide open throttle with a normal boat load Other advantages to propeller or gear ratio changes Reduces the possibility of detonation Enhances overall reliability and durability of the engine Setting Trim Angle while Running Engine at Idle Speed The exhaust relief hole on the outboard can become submerged on some boats if the engine is trimmed full in while running at ...

Page 68: ...NT Failure to follow the engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures 1 For the first two hours of operation run the engine at varied throttle settings up to 4500 RPM or at three quarter throttle and at full throttle for approximately one minute every ten minutes 2 For the next eight hours ...

Page 69: ...3 Open the fuel tank vent screw in filler cap on manual venting type fuel tanks 19748 4 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch 19791 5 Shift outboard to neutral N position N 58237 OPERATION eng 59 ...

Page 70: ...ns running Allow the starter motor to cool for 20 30 seconds between start attempts 19804 7 After the engine starts check for a steady stream of water flowing out of the water pump indicator hole IMPORTANT If no water is coming out of the water pump indicator hole stop the engine and check the cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the ...

Page 71: ...ide operation forward F neutral N and reverse R When shifting always stop at the neutral position and allow the engine speed to return to idle Always shift the outboard into gear with a quick motion After shifting the outboard into gear advance the lever further to increase speed N R F 58239 Stopping the Engine Reduce the engine speed and shift the outboard to neutral position Turn the ignition ke...

Page 72: ...or Quicksilver replacement parts and Genuine Lubricants EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory standards For this r...

Page 73: ...emission levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule BEFORE EACH USE Check engine oil level Refer to Fuel and Oil Checking and Adding Engine Oil Check that lanyard stop switch stops the en...

Page 74: ...ating in salt or polluted water Refer to Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater If operating in saltwater inspect the powerhead and powerhead components for salt buildup Refer to Cleaning Care for the Powerhead Saltwater Use EVERY 100 HOURS OF USE OR ONCE YEARLY WHICHEVER OCCUR...

Page 75: ...ing and connectors Check tightness of bolts nuts and other fasteners Check cowl seals to ensure the seals are intact and not damaged Check internal cowl sound reduction foam if equipped to ensure the foam is intact and not damaged Check that the intake silencer if equipped is in place Check that the idle relief muffler if equipped is in place Check for loose hose clamps and rubber boots if equippe...

Page 76: ...ntenance Schedule Decal 75 115 58248 75 115 59342 115 Pro XS The following table shows the icons and a general description of the maintenance schedule decal that is located on the engine MAINTENANCE 66 eng ...

Page 77: ...nternal water passages of the outboard with fresh water after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages NOTE The outboard can be tilted or in the vertical operating position during flushing 1 With the engine turned off place the outboard in either the operating position vertical or in a tilted position 2 Remove t...

Page 78: ...t 15 minutes 5 When flushing is complete turn off the water and disconnect the water hose 6 Install the cover on the flush connector Place the flush connector back into the bottom cowl Top Cowl Removal and Installation REMOVAL Unlock the top cowl by pulling out on the rear cowl latch Lift the top cowl off the engine 53762 INSTALLATION 1 Lower the top cowl over the engine MAINTENANCE 68 eng ...

Page 79: ...ore cleaning Do not use detergents containing hydrochloric acid Follow the cleaning and waxing procedure CLEANING AND WAXING PROCEDURE 1 Before washing rinse the cowls with clean water to remove dirt and dust that may scratch the surface 2 Wash the cowls with clean water and a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using...

Page 80: ...ldup from the powerhead and powerhead components with fresh water Keep water spray out of the air filter intake and alternator After washing allow the powerhead and components to dry Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components Do not allow the Corrosion Guard spray to come in contact with the alter...

Page 81: ...ed so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately IMPORTANT Use an approved container to collect and store fuel Wipe up spilled fuel immediately Material used...

Page 82: ...tch to OFF position 2 Place a rag or towel under the fuel filter to capture fuel that will leak from the hoses and filter WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposu...

Page 83: ... forcing fuel into the fuel filter Repair any fuel leaks found Corrosion Control Anode The outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals Each anode requires periodic inspection especially in saltwater which will accelerate the erosion To maintain...

Page 84: ...ever 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 Shift outboard to the neutral N position N 58237 2 Straighten the bent tabs on the propeller nut retainer ...

Page 85: ... PTFE 47623 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 recommended maintenance intervals and also each time the ...

Page 86: ...uts a Forward thrust washer b Drive sleeve c Propeller d Drive sleeve adapter e Locknut retainer f Locknut g Raised pins h Tabs bent against the locknut Description Nm lb in lb ft Propeller nut 75 55 3 FLO TORQ IV PROPELLERS 1 Install the propeller onto the shaft with the supplied components as shown 2 Tighten the locknut to the specified torque 45232 c d e f a b g h MAINTENANCE 76 eng ...

Page 87: ...washer b Drive sleeve c Propeller d Drive sleeve adapter e Locknut retainer f Locknut g Tabs bent into grooves Description Nm lb in lb ft Propeller nut 75 55 3 Spark Plug Inspection and Replacement 1 Remove the spark plug leads Pull the rubber boots off the spark plugs 53781 c d e f a b g 45248 MAINTENANCE eng 77 ...

Page 88: ...is not visible on the spark plug electrode IMPORTANT The color of the plug may not accurately reflect its condition To accurately diagnose a faulty plug inspect the precious metal on the plug s electrode If no precious metal is visible replace the plug a Precious metal 4 Set the spark plug gap Refer to General Information Specifications 27848 a 9381 MAINTENANCE 78 eng ...

Page 89: ...portion of the ground electrode e When it is necessary to close the gap gently tap the plug ground electrode on a hard surface 5 Saltwater use Apply a thin coating of Anti Seize Compound only on threads of spark plugs Tube Ref No Description Where Used Part No 81 Anti Seize Compound Spark plug threads 92 898101385 6 Before installing spark plugs clean off any dirt on the spark plug seats Install t...

Page 90: ...pin remote control harness cowl trim switch d Fuse 4 IGN 20 amp ignition system e Fuse 2 FUEL 20 amp fuel delivery f Fuse 1 DIAG 2 amp diagnostics vessel accessory harness g Good fuse h Blown fuse Lubrication Points 1 Lubricate the following with Extreme Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 20 20 2 15 a b c d e f g h 53784 MA...

Page 91: ...b from corroding and seizing to the shaft 47623 2 Lubricate the following with 2 4 C with PTFE or Extreme Grease Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Steering cable 92 802859A 1 Extreme Grease Steering cable 8M0071842 Steering cable grease fitting if equipped Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting...

Page 92: ...ompletely retract the end of the steering cable before applying lubricant Tilt lever grease fitting and the swivel pin grease fitting a Tilt lever grease fitting b Swivel pin grease fitting 3 Lubricate the following with lightweight oil Steering link rod pivot points Lubricate pivot points 47652 a b 54186 MAINTENANCE 82 eng ...

Page 93: ...s Power Trim and Steering Fluid If not available use automotive automatic transmission fluid ATF Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim reservoir 92 858074K01 47647 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 5 2 liter 5 5 US qt OIL CHANGING PROCEDURE 1 Tilt the outboard out up past vertical for approximately one min...

Page 94: ... has drained hand tighten the oil drain valve clockwise and remove the oil drain hose 7 Tighten the oil drain valve to the specified torque Clean up any oil in the valve area Description Nm lb in lb ft Oil drain valve 15 133 IMPORTANT Overtightening the oil drain valve can damage the oil sump a Oil drain valve b Drain hose c Loosen 2 1 2 turns maximum CHANGING OIL FILTER 1 Remove the plug from the...

Page 95: ... This will bring the oil level within the midpoint of the operating range 2 Idle engine for five minutes and check for leaks Stop the engine For an accurate oil level reading allow the engine to cool for at least an hour before checking the oil level Refer to Fuel and Oil Checking and Adding Engine Oil NOTE Checking the oil level within five minutes of engine shutdown can falsely read up to 1 lite...

Page 96: ... 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 the outboard in a vertical operating position 2 Remove the propeller Refer to Propeller Replacement 3 Place the drain pan below the outboard 4 Remove the vent plug and fill drain plug and drain lubricant a Vent plug b Fill drain plu...

Page 97: ...icant until it appears at the vent hole a Vent hole b Fill hole IMPORTANT Replace the sealing washers if damaged 4 Stop adding the lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove the lubricant tube and install cleaned fill drain plug and sealing washer a b 22693 MAINTENANCE eng 87 ...

Page 98: ...e engine s fuel system other than the fuel tank will remain stable during normal storage periods without the addition of fuel 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 Quickstor Fuel Stabilizer follow instructions on ...

Page 99: ...nstall the spark plugs Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the ...

Page 100: ...he engine Fuel tank is empty Fuel tank vent not open or restricted 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 o...

Page 101: ...stment 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 alternator or voltage regulator Open circuit in the alternator outpu...

Page 102: ...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 103: ...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 104: ...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 105: ...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 eng 95 ...

Page 106: ... 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 following decal on the transom clamp 51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories such as emergency boa...

Page 107: ...ESSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 1 The following list provides additional guidelines for mounting accessories to the transom clamp bracket The ...

Page 108: ...amp bracket Refer to Figure 1 Figure 1 a Minimum clearance 3 175 mm 0 125 in b Edge of accessory bracket c Transom clamp bracket wall d Radius e Engine supplied mounting fasteners f Fasteners supplied by the accessory manufacturer installed through unused engine mounting bracket holes b c d a f 54624 e OUTBOARD INSTALLATION 98 eng ...

Page 109: ...ecuring the engine to the boat 1 Do not mount an accessory to the transom clamp bracket in an unsupported condition Refer to Figure 2 54625 Figure 2 2 Do not attach an accessory to the boat by use of the engine mounting hardware Refer to Figure 3 Figure 3 a Engine supplied mounting fasteners b Transom clamp bracket c Accessory 53523 a b c OUTBOARD INSTALLATION eng 99 ...

Page 110: ... 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 onto the fuel system for this engine Boat Horsepower Capacity WARNING Exceeding the boat s maximum horsepower rating can cause serio...

Page 111: ... 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 ...

Page 112: ... outlet that opens vents to the atmosphere if pressure exceeds 34 4 kPa 5 0 psi FUEL DEMAND VALVE FDV REQUIREMENT Whenever a pressurized fuel tank is used a fuel demand valve is required to be installed in the fuel hose between the fuel tank and the engine The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage The fuel ...

Page 113: ...thod but is not always practical The objective is to purge the air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port During the key on opening the dump valve will allow the air to be purged from the FSM and fuel rail This method should be used on vessels where the fuel inlet system to the outboard is restrictive contains an anti siphon valve or h...

Page 114: ... Turn the ignition key off and then on The fuel pumps will run for approximately three to five seconds Continue this ignition key cycle until the purged fuel is relatively clear of air bubbles NOTE If the outboard fuel system does not prime within 15 key on events check for leaks in the fuel supply line to the outboard Repair as needed If no leak is found the fuel supply system to the outboard may...

Page 115: ...e required to start the engine 1 Verify the engine is in a level vertical position 2 Verify the vessel fuel supply line is connected to the outboard fuel system inlet fitting 3 Turn the ignition key on The fuel pumps will run for approximately three to five seconds 4 Turn the ignition key to the start position and release the key The ECM controls the activation of the starter The starter may conti...

Page 116: ...ecifications a Minimum transom opening b Engine centerline for dual engine 66 0 cm 26 in minimum Minimum Transom Opening Single engine 84 2 cm 33 in Dual engine 149 9 cm 59 in 18552 a a b OUTBOARD INSTALLATION 106 eng ...

Page 117: ...ly objective 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 from bottom of boat transom For heights over 56 0 cm 22 in a propeller that is designed for surfacing operation is usually preferred f Maximum boat speed MPH anticipated 20 in 21 in 22 in 23 in 24 in 25 in 19 in 10 ...

Page 118: ... 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 Mounting Holes IMPORTANT Before drilling any mounting holes carefully read Determining Recommended Outboard...

Page 119: ...ur 13 5 mm 17 32 in mounting holes 3973 Lifting Outboard 1 Remove the top cowl 2 Install the lifting base to the flywheel using three bolts Tighten the bolts securely 3 Thread the lifting eye into the lifting base 4 Connect a hoist that has a minimum lift capacity of 450 kg 1000 lb to the lifting eye OUTBOARD INSTALLATION eng 109 ...

Page 120: ...heel Puller Lifting Ring 91 895343T02 14869 Removes flywheel from engine Used for lifting powerhead engine Shipping Bracket Removal 1 Remove the two top screws and loosen the two bottom screws 2 Slide the shipping bracket off the bottom screws a b 53797 OUTBOARD INSTALLATION 110 eng ...

Page 121: ...b in lb ft Bottom screws 7 9 70 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 with PTFE O ring seal and entire cable end 92 802859A 1 2 Insert steering cable into tilt tube c b c a 47720 OUTBOARD INSTALLATION eng 111 ...

Page 122: ...421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in thread 67755 1 20 x 4 50 in long 2 25 in thread 8M0033366 20 x 5 00 in long 3 25 in thread 67755 003 20 x 5 50 in long 3 25 in thread 67755 2 20 x 6 50 in l...

Page 123: ... The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom strength If the bolt 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...

Page 124: ...be flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between transom clamp and boat transom not allowed a b 51817 OUTBOARD INSTALLATION 114 eng ...

Page 125: ...ensure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting hardware Tighten the locknuts to the specified torque IMPORTANT Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be drawn ti...

Page 126: ...875 in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 a c d c a d 40952 b e OUTBOARD INSTALLATION 116 eng ...

Page 127: ...ped IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt a Part Number 10 856680 and self locking nylon insert locknuts c and d Part Number 11 826709113 These locknuts must never be replaced with common nuts nonlocking as they will work loose and vibrate off freeing the link rod to disengage OUTBOARD INSTALLATION eng 117 ...

Page 128: ...0 b Flat washers c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 Description Nm lb in lb ft Special washer head bolt 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 Assem...

Page 129: ...nched 1 Route the hoses wiring and cables through the rigging adapter and correct opening in the rigging grommet as shown a Screws M6 x 30 2 b Screw M6 x 50 c Rigging adapter d Rigging grommet e Battery cable opening f Remote 14 pin boat harness opening g SmartCraft harness or additional harness opening h Accessory harness opening i Shift cable opening j Speedometer tube opening k Fuel hose openin...

Page 130: ...orque 3 Secure the wiring hoses and cables together with a cable tie NOTICE Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring harnesses 53884 Cable tie Description Nm lb in lb ft Screws for attaching the rigging adapter 6 53 OUTBOARD INSTALLATION 120 eng ...

Page 131: ...tor on the engine harness Secure the harness with the retainer a Remote 14 pin boat harness b Retainer c 14 pin connector SMARTCRAFT HARNESS AND VESSEL HARNESS CONNECTION 1 If the boat is equipped with a SmartCraft and or vessel accessory harness remove the ignition coil cover located on the port side of the engine 53826 a b c 53886 OUTBOARD INSTALLATION eng 121 ...

Page 132: ...ery cables longer than the factory supplied cables are required the wire gauge size must increase Refer to the following chart for the correct gauge according to the length IMPORTANT Only copper battery cables should be used Do not use aluminum power cables in any marine installation a Wire gauge size b Cable length IMPORTANT The battery cable length specified in the following chart is the sum of ...

Page 133: ...ge AWG Maximum Length Meter Feet 2 12 2 m 40 ft 1 15 2 m 50 ft 1 0 19 6 m 64 ft 2 0 24 4 m 80 ft Single Outboard a Red sleeve positive b Black sleeve negative c Cranking battery b a c 15496 OUTBOARD INSTALLATION eng 123 ...

Page 134: ...ound cable d Cranking battery FUEL HOSE CONNECTION Install and secure the quick disconnect fuel hose fitting with a hose clamp Position the hose clamp so that it will not chafe or cut into an adjacent wiring harness NOTICE Inspect the position of the hose clamp to ensure that it will not chafe or cut into the adjacent wiring harnesses a a b b c d d 15497 OUTBOARD INSTALLATION 124 eng ...

Page 135: ... SHIFT CABLE INSTALLATION 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 Position the remote control and outboard into neutral position OUTBOARD INSTALLATION eng 125 ...

Page 136: ...ntrol handle from neutral into forward and advance the handle to full speed position Slowly return the handle back to the neutral position Place a mark a on the cable against the cable end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed position Slowly return the handle back to the neutral position Place a mark b on the cable against the cable ...

Page 137: ...rel so it slips freely into the barrel cup 7 Secure the shift cable to the anchor pin with the shift cable retainer 8 Lock the barrel in place with the cable latch a Shift cable retainer b Cable latch 9 Check shift cable adjustments as follows a Shift remote control into forward The propeller shaft should be locked in gear If not adjust the barrel closer to the cable end b Shift remote control int...

Page 138: ...ATION Install cables into the remote control following the instructions provided with the remote control 1 Shift remote control into the neutral N position N 58237 2 Install the throttle cable onto the throttle cam anchor pin and secure with the anchor pin latch 3 Adjust the cable barrel so that the throttle cam timing mark will align with the throttle lever a Anchor pin latch b Throttle lever c T...

Page 139: ...r pin latch b Cable latch 6 Press on the cable latch to ensure the cable latch locks onto the bracket 7 Pull up on the throttle cable near the cable latch to confirm the cable latch has locked onto the bracket 54183 53874 b a OUTBOARD INSTALLATION eng 129 ...

Page 140: ...lls 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 a bow down planing condition called plowing Plowing can cause bow steering or oversteering and inefficiently consumes horsepower a Tilt pin not included with engine Stainless Steel Tilt Pin 17 49930A 1 2749 Limits the dow...

Page 141: ...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 131 ...

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Mercury 100 FourStroke, Operation Maintenance Installation Warranty Manual

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