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Mercury 115 Pro XS FourStroke, Operation Maintenance Warranty Installation Manual, Page: 10 / 159

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Mercury 115 Pro XS FourStroke Operation Maintenance Warranty Installation Manual Download Page 10

Owner Service Assistance

Local Repair Service.......................................................................................106

Service Away from Home............................................................................... 106

Parts and Accessories Inquiries..................................................................... 106

Service Assistance......................................................................................... 106

Ordering Literature..........................................................................................109

Troubleshooting

Starter Motor Will Not Crank the Engine.........................................................111

Engine Will Not Start.......................................................................................111

Engine Runs Erratically.................................................................................. 111

Performance Loss...........................................................................................112

Battery Will Not Hold Charge.......................................................................... 112

Jet Application Troubleshooting......................................................................112

Outboard Installation

Mercury Marine Validated Engine Mounting Hardware.................................. 114

Accessories Mounted to the Transom Clamp Bracket....................................114

Important Information......................................................................................118

Boat Horsepower Capacity............................................................................. 118

Start in Gear Protection.................................................................................. 119

Fuel System.................................................................................................... 119

Installation Specifications............................................................................... 121

Lifting the Outboard........................................................................................ 121

Steering Cable ‑ Starboard Side Routed Cable.............................................. 122

Determining Recommended Outboard Mounting Height................................ 124

Determining the Mounting Height of the Outboard Jet .................................. 125

Drilling Outboard Mounting Holes................................................................... 127

Fastening the Outboard to the Transom......................................................... 128

Electrical, Fuel Hose, Flush Hose, and Control Cables.................................. 133

Oil Injection Set‑Up......................................................................................... 146

Trim In Pin...................................................................................................... 147

Maintenance Log

Maintenance Log............................................................................................ 149

  

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Summary of Contents for 115 Pro XS FourStroke

Page 1: ...Outboard Operation Maintenance Warranty Installation Manual 2014 Mercury Marine 75 90 115 115 Pro XS 125 OptiMax and 80 Jet 8M0100515 1214 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: ... 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 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 manual This declaration of conformity is issue...

Page 5: ... 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 factory pr...

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 ...

Page 7: ...13 Warranty Policy Australia and New Zealand 14 Global Warranty Charts Outboard and Jets 18 General Information Boater s Responsibilities 23 Before Operating Your Outboard 23 Boat Horsepower Capacity 23 High Speed and High Performance Boat Operation 24 Propeller Selection 24 Outboard Remote Control Models 26 Remote Steering Notice 27 Lanyard Stop Switch 27 Protecting People in the Water 30 Passeng...

Page 8: ...7 Filling Oil Injection System 48 Filling Fuel Tank 50 Features and Controls Remote Control Features 51 Warning System 51 Power Trim and Tilt 53 Trim Tab Adjustment 57 Operation Important Information 58 Prestarting Check List 59 Operating in Freezing Temperatures 59 Operating in Saltwater or Polluted Water 59 Operating at High Elevations 60 Setting Trim Angle While Running Engine at Idle Speed 60 ...

Page 9: ... Corrosion Control Anode 87 Corrosion Control Anode 87 Battery Inspection 88 Battery Information All Batteries Including DTS 88 Propellers 89 Spark Plug Inspection and Replacement 92 Compressor Air Intake Filter 94 Alternator Belt Inspection 95 Lubrication Points 95 Lubrication Points 97 Checking Power Trim Fluid 99 Gearcase Lubrication 100 Storage Storage Preparation 102 Fuel System 102 Protectin...

Page 10: ...ngine Mounting Hardware 114 Accessories Mounted to the Transom Clamp Bracket 114 Important Information 118 Boat Horsepower Capacity 118 Start in Gear Protection 119 Fuel System 119 Installation Specifications 121 Lifting the Outboard 121 Steering Cable Starboard Side Routed Cable 122 Determining Recommended Outboard Mounting Height 124 Determining the Mounting Height of the Outboard Jet 125 Drilli...

Page 11: ... 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 purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Cent...

Page 12: ... 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 transferable from one product to another pr...

Page 13: ...or from an insurance company CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified predelivery inspection process is completed and documented Warranty coverage...

Page 14: ...f the Operation and Maintenance Manual neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impellers and wear rings or liners operation with fuels oils or lubricants which are not suitable for use with th...

Page 15: ...rosion warranty provides coverage for three 3 years from either the date the product is first sold or the date on which the product is first put into service whichever occurs first 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 subseq...

Page 16: ... from damage corrosion which causes purely cosmetic damage abuse or improper service corrosion to accessories instruments steering systems corrosion to factory installed jet drive unit damage due to marine growth product sold with less than a one year limited Product warranty replacement parts parts purchased by customer products used in a commercial application Commercial use is defined as any wo...

Page 17: ...arranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure the International Limited Outboard Warranty and the United States and Canada Limited Outboard Warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship Installation errors acc...

Page 18: ...s a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or 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 i...

Page 19: ...anty covers all the following list of components COMPONENTS OF THE EMISSIONS CONTROL SYSTEM 1 Fuel metering system a Carburetor and internal parts and or pressure regulator or fuel injection system b Cold start enrichment system c Intake valves 2 Air induction system a Intake manifold b Turbocharger or supercharger systems where applicable 3 Ignition system a Spark plugs b Magneto or electronic ig...

Page 20: ...in California to be free from defects in material or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board for the period of time and under the conditions identified below The cost to diagnose a warranty failure is covered under the warr...

Page 21: ...s not allow the engine to run in its recommended wide open throttle RPM range see General Information Specifications operation of the product in a manner inconsistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service jet pump im...

Page 22: ... for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your outboard engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine ...

Page 23: ... engines saving money and resources Longer emission warranty protects consumer for worry free operation 22531 One Star Low Emission The One Star label identifies engines that meet the Air Resources Board s 2001 exhaust emissions standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standa...

Page 24: ...the Australian Consumer Law You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure Warranty Period for Recreational Use This Limited Warranty provides coverage for ...

Page 25: ...e without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage Under This Limited Warranty The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the p...

Page 26: ... 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 27: ...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 28: ...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 29: ...n 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 Corr...

Page 30: ...ication Verado 350 SCi 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 ...

Page 31: ...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 32: ...o 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 350 SCi 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 t...

Page 33: ...ersonal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious inj...

Page 34: ...ts in the propulsion system An improper propeller choice can significantly affect the performance of your boat and could result in damage to the outboard engine When choosing a propeller a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine To view the entire product offering and find the correct propeller that is b...

Page 35: ...ign of your outboard However when more than one diameter is available for the same pitch use a larger diameter for heavy boat applications and a smaller diameter for lighter applications Pitch The pitch is the theoretical distance in inches that a propeller travels forward during one revolution Pitch can be thought of similar to gears in a car The lower the gear the faster the car will accelerate ...

Page 36: ... of sizes and styles that allow you to dial in the ultimate performance for your boat 3 BLADE VS 4 BLADE Available in many sizes of both aluminum and stainless 3 and 4 blade propellers have unique performance characteristics In general 3 blade propellers offer good all around performance and higher top speed than 4 blade propellers However 4 blade propellers are usually faster to plane and more ef...

Page 37: ...or out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote control units ...

Page 38: ...d stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boats...

Page 39: ...the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the bo...

Page 40: ... Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats and Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated f...

Page 41: ...njury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed could...

Page 42: ...hange in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches down far enough w...

Page 43: ... 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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...p 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 ...

Page 49: ...3 in Piston stroke 76 2 mm 3 0 in Recommended spark plug IZFR5J Spark plug gap 0 80 mm 0 030 in Gear ratio 2 33 1 2 07 1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Oil tank capacity 4 72 liter 5 US qt Gearcase lubricant capacity 665 ml 22 5 fl oz Battery rating 1000 marine cranking amps MCA or 800 cold cranking amps CCA Charging system output 60 A Emission con...

Page 50: ...isplacement 1523 5 cc 92 9 in Cylinder bore 92 11 mm 3 63 in Piston stroke 76 2 mm 3 0 in Recommended spark plug IZFR5J Spark plug gap 0 80 mm 0 030 in Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Oil tank capacity 4 72 liters 5 US qt Battery rating 1000 marine cranking amps MCA or 800 cold cranking amps CCA Charging system output 60 A Emission control system El...

Page 51: ...l b Auxiliary tilt switch c Transom brackets d Gearcase e Cooling water intake holes f Trim tab g Anti ventilation plate h Driveshaft housing i Water pump indicator hole j Bottom cowl a j i h b g f e d c 29461 GENERAL INFORMATION eng 41 ...

Page 52: ...b Auxiliary tilt switch c Transom brackets d Jet drive housing e Water intake housing f Reverse gate g Water outlet nozzle h Driveshaft housing i Water pump indicator hole j Bottom cowl a j i h b g f e d c 33496 GENERAL INFORMATION 42 eng ...

Page 53: ...cal dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 28419 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 54: ...e in your area refer to Gasolines Containing Alcohol These reformulated gasolines are acceptable for use in your Mercury Marine engine GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of...

Page 55: ...ive oil films from internal components Fuel Requirements Do not use premixed gas and oil in this engine The engine automatically receives extra oil during engine break in Use a fresh supply of the recommended gasoline during engine break in and after engine break in Fuel Additives To minimize carbon deposit buildup in the engine it is recommended to add Mercury or Quicksilver Quickstor fuel stabil...

Page 56: ...fuel hose between the fuel tank and primer bulb b Manual release c Vent water drain holes Mercury Marine s Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements These fuel tanks are available as an accessory or are provided with certain portable outboard models SPECIAL FEATURES OF THE PORTABLE FUEL TANK The fuel tan...

Page 57: ...l tank cap turn the cap to the right until you hear a click This signals that the fuel cap is fully seated A built in device prevents overtightening 2 Open the manual vent screw on top of the cap 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 Fil...

Page 58: ...posit build up Filling Oil Injection System 1 Place the outboard in a vertical operating position 2 Remove the cowl cover 3 Remove the oil filler cap a Cowl cover b Oil filler cap 4 Oil filler caps with a dipstick Check the oil level on the dipstick The first set of holes indicates 0 94 liters 1 US qt low The second set of holes indicates 1 89 liters 2 US qt low The third set of holes indicates 2 ...

Page 59: ... 0 94 liters 1 US qt b Add 1 89 liters 2 US qt 6 Slowly fill the oil tank with the specified oil Do not overfill Add only enough oil to bring the oil level up to the bottom of the fill neck Capacity Fluid Type Oil tank 4 72 liters 5 US qt OptiMax DFI 2 Cycle Engine Oil 29465 7 Install the oil filler cap and tighten securely Install the cowl cover 29466 a b 37146 FUEL AND OIL eng 49 ...

Page 60: ... filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tanks from the boat to refill them Always stop the engine before filling the tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled FUE...

Page 61: ...ard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal 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 f...

Page 62: ...ectable conditions are as follows Water in the engine mounted fuel filter Refer to Maintenance Water Separating Fuel Filter Cooling system water pressure or engine temperature problem Stop the engine and check the water intake holes in the lower unit for obstruction Low engine oil level Refer to Fuel and Oil Checking and Adding Engine Oil ENGINE GUARDIAN SYSTEM The Engine Guardian system monitors ...

Page 63: ...ine RPM coolant temperature 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 Your outboard has a trim tilt control called power trim This enables the operator to easily adjust the position of t...

Page 64: ...utral steering condition Consider the following lists carefully 1 Trimming in or down can Lower the bow Result in quicker planing off especially with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering torque or pull to the right with the normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow wi...

Page 65: ...ch 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 the knob to bring the support lever upward 2 Lower the outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down Lower the outboard a Tilt suppor...

Page 66: ...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 AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboar...

Page 67: ...le effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 50 mm 2 inches or more above the boat bottom Operate your boat at normal cruising speed trimmed to the desired position Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time If th...

Page 68: ...pump on new or rebuilt engines or after performing maintenance on the oiling system Refer to Priming the Oil Injection Pump for instructions FUEL REQUIREMENTS Do not use premixed gas and oil in this engine The engine automatically receives extra oil during engine break in Use a fresh supply of the recommended gasoline during engine break in and after engine break in OIL RECOMMENDATION Recommended ...

Page 69: ... to return It is illegal to operate a boat while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make the inspection checks listed in Maintenance Inspection and Maintenance Schedule Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures...

Page 70: ... oxygen in the air Consult your dealer Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full in while running at idle speed This will cause exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim the outboard up until the exhaust relief hole is out of the water T...

Page 71: ...n cycle Next Three Hours Change the engine speed every 10 minutes Starting the Engine Before starting read the prestarting check list special operating instructions and engine break in procedure in the Operation section NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets duri...

Page 72: ...a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled as follows a Squeeze the fuel line primer bulb until it feels firm b Turn the ignition key switch to the ON position for three seconds This operates the electric fuel pump c Turn the ignition key switch back to the OFF position and squeeze the primer bulb again until it feels firm Turn the ig...

Page 73: ...ORTANT If no water is coming out of the water pump indicator hole stop the engine and check cooling water intake holes for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system This condition will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage 19805 Gear Shifting IMPORTANT...

Page 74: ... Operator knows safe navigation boating and operating procedures An approved personal flotation device of suitable 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 Oil supply oil injection OK Ensure the boat dra...

Page 75: ...d so the water intake is completely out of the water except in freezing temperatures when not in use Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use Each month spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces NOTE Do not spray on corrosion control anodes as this will reduce the effectiveness of the a...

Page 76: ... water up through the water intake and then directs it at a high pressure through the water outlet nozzle to create forward thrust To obtain reverse the reverse gate moves over the outlet nozzle to direct the water in the opposite direction a Water intake b Water outlet nozzle c Reverse gate When the jet drive is in neutral the impeller continues to rotate However the reverse gate is positioned so...

Page 77: ...low down the boat in an emergency However sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death Use caution when performing the emergency stopping procedure and be sure to practice in a safe area In an emergency putting the jet outboard into reverse and applying reverse throttle can rapidly slow down the boat and reduce sto...

Page 78: ...shallow water Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting WATER INTAKE BLOCKAGE WARNING A rotating impeller could cause injury if contact is made with hands clothing or tools To avoid injury keep hands and clothing away from the inlet or outlet of the jetdrive regardless of whether the boat is in t...

Page 79: ...INE Before starting read the prestarting check list special operating instructions and engine break in procedure in the Operation section NOTE When the engine is being run within the RPM range of 3500 4200 RPM there may be a slight RPM instability This is caused by the light engine load conditions normally seen with jet lower units This condition will not cause any adverse affects on the engine NO...

Page 80: ...a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled as follows a Squeeze the fuel line primer bulb until it feels firm b Turn the ignition key switch to the ON position for three seconds This operates the electric fuel pump c Turn the ignition key switch back to the OFF position and squeeze the primer bulb again until it feels firm Turn the ig...

Page 81: ...ming out of the water pump indicator hole stop the engine and check cooling water intake holes for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system This condition will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage 19805 GEAR SHIFTING IMPORTANT Never shift the outboar...

Page 82: ...After shifting the outboard into gear advance the lever further to increase speed N R F 27237 OPERATION 72 eng ...

Page 83: ...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 84: ...on and Maintenance Schedule PRIOR TO EVERY USE Check that the lanyard stop switch stops the engine Check the steering system for binding or loose components Verify that the outboard is securely attached to the boat transom If the outboard or any of its fasteners are loose tighten them to the specified torque When checking to verify the outboard is securely fastened look for loss of outboard transo...

Page 85: ...with Corrosion Guard Tube Ref No Description Where Used Part No 120 Corrosion Guard Powerhead and all external unpainted metal surfaces except anodes 92 802878 55 EVERY 25 HOURS OR EVERY 30 DAYS WHICHEVER OCCURS FIRST Verify that the front and side cowl latches are tight Tighten them if necessary Inspect the fuel and oil systems for deterioration or leaks Inspect the hydraulic steering hoses for d...

Page 86: ...rd mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 Replace the water pump impeller more often if overheating occurs or reduced water pressure is noted 1 Replace the spark plugs after the first 100 hours or first year After that inspect the spark plugs every 100 hours or once yearly Replace the spark plugs as...

Page 87: ...stopped or running at idle speed in neutral when flushing the cooling system Do not flush the engine using a water source that exceeds 310 kPa 45 psi 1 Unscrew the cover from the end of the hose adapter 2 Attach a water hose to the hose adapter 3 Turn on the water and flush the cooling system for a minimum of three minutes IMPORTANT Do not run engine above idle speed when flushing 4 Turn off the w...

Page 88: ...aning and waxing procedure CLEANING AND WAXING PROCEDURE 1 Before washing rinse the top cowl with clean water to remove the dirt and dust that may scratch the surface 2 Wash the top cowl with clean water and a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat fini...

Page 89: ...s Insert the tabs into the slots in the side panel and push the cover down onto the mounting pins a Flywheel cover b Mounting pins c Tabs Side Panel Removal and Installation REMOVAL Pull the side panel off the three mounting pins c a b 23754 MAINTENANCE eng 79 ...

Page 90: ...n Afterwards this filter must be replaced every 300 hours of operation After replacing the in line filter the oil injection system must be purged to remove air trapped in the system 1 Cut the cable ties securing the in line oil filter 2 Place an appropriate container or shop towels under the in line filter to capture oil that will leak out of the hoses IMPORTANT The arrow on the filter identifies ...

Page 91: ...4 Secure the filter with cable ties a Oil filter 5 Purge the trapped air from the oil injection system Refer to Oil Injection Pump Purge a 10368 MAINTENANCE eng 81 ...

Page 92: ...fore purging the oil injection pump 1 Fill the engine fuel system with fuel Connect the fuel hose and squeeze the primer bulb until it feels firm 19779 2 Turn the ignition key switch to the ON position 26846 3 Within the first 10 seconds after the key switch has been turned on move the remote control handle from neutral into forward gear 3 to 5 times This will automatically start the purging proce...

Page 93: ...ely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness ...

Page 94: ...ATER FROM THE FUEL FILTER CHAMBER NOTE If a sufficient amount of water has accumulated in the fuel filter chamber the warning system will turn on Draining the water from the fuel filter chamber is required 1 Pull the drain hose off the right side fitting Hold the open end of the hose over a container 2 Use a 1 8 in hex wrench and loosen the drain screw and drain the fuel filter chamber a Drain hos...

Page 95: ...eing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected loss of boat control resulting in serious injury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures a Special wash...

Page 96: ...ad by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Open the fuse holder and look at the silver colored band inside the fuse If the band is broken replace the fuse Replace fuse with a new fuse with the same rating a Good fuse b Blown fuse c 14 pin remote control harness cowl trim switch main power relay ...

Page 97: ...side of gearcase b Anode on transom bracket assembly Corrosion Control Anode Your outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals Each anode requires periodic inspection especially in saltwater which will accelerate the erosion To maintain this c...

Page 98: ...nt accidental shorting of battery terminals Battery Information All Batteries Including DTS WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift DTS system leading to serious injury or death due to loss of boat control Secure the battery leads to the battery posts with hex nuts to avoid loose connections Do not use deep cycle batterie...

Page 99: ...owner s manual for battery requirements Battery cable size and length is critical Refer to engine installation manual for size requirements NOTICE IMPORTANT DO NOT USE DEEP CYCLE BATTERIES 13 5Nm 120 lb in DO NOT USE WINGNUTS Propellers REMOVAL IMPORTANT Propellers used on this product require the Mercury Marine Flo Torq III type hub or equivalent WARNING Rotating propellers can cause serious inju...

Page 100: ...N 26838 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing spark plug leads 2 Remove the spark plug leads to prevent the engine from starting 26899 3 Straighten the bent tabs on the propeller nut retainer 26900 MAINTENANCE 90 eng ...

Page 101: ...the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 1 Coat the propeller shaft with Extreme Grease or 2 4 C with PTFE 26902 Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 NOTE The Flo Torq lll propeller drive hubs are designed...

Page 102: ...d propeller Torque the propeller nut to specification Description Nm lb in lb ft Propeller nut 75 55 4 Secure the propeller nut by bending three of the tabs into the thrust hub grooves 26945 Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid d...

Page 103: ...or 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 3 Set the spark plug gap Refer to Specifications 27848 a All of the spark plugs should have the gap checked and corrected as necessary before installation b Measure the gap with a feeler gau...

Page 104: ...p gently tap the plug ground electrode on a hard surface 4 Before installing spark plugs clean off any dirt on the spark plug seats Install the plugs finger tight and then tighten an additional 1 4 turn or tighten to the specified torque Description Nm lb in lb ft Spark plug 27 20 Compressor Air Intake Filter The filter should be changed every 100 hours of operation or once a season IMPORTANT Neve...

Page 105: ...laced by an authorized dealer if any of the following conditions are found Cracks or deterioration in the rubber portion of the belt Belt surfaces rough or uneven Signs of wear on edges or outer surfaces of belt 29477 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 95 2 4 C with ...

Page 106: ...ption Where Used Part No 95 2 4 C with PTFE Swivel bracket tilt support lever tilt tube steering cable grease fitting 92 802859A 1 Swivel bracket Lubricate through fitting Tilt support lever Lubricate through fitting a Swivel bracket b Tilt support lever Tilt tube Lubricate through fitting 29478 Steering cable grease fitting if equipped Rotate steering wheel to fully retract the steering cable end...

Page 107: ...g with Quicksilver or Mercury Precision 2 4 C with PTFE Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Driveshaft bearing 92 802859A 1 IMPORTANT It is important not to use a general all purpose grease for this bearing The lubricant recommended is a water resistant grease of the proper consistency for this application If a substitute is used be sure that it is water resistant Drivesh...

Page 108: ...ed if necessary Some discoloration of the grease is normal during the break in period on a new set of seals 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with PTFE or Extreme Grease Tube Ref No Description Where Used Part No Extreme Grease Swivel bracket tilt support lever tilt tube steering cable grease fitting 8M0071842 95 2 4 C with PTFE Swivel bracket tilt su...

Page 109: ...ng lubricant a Fitting b Steering cable end 3 Lubricate the following with lightweight oil Steering link rod pivot points Lubricate pivot points 29480 Checking Power Trim Fluid 1 Tilt the outboard to the full up position and engage the tilt support lever 27877 2 Remove the fill cap and check the fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury ...

Page 110: ...y result in premature bearing failure or in freezing temperatures will turn to ice 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 the ou...

Page 111: ... Front vent hole c Rear vent hole d Rear vent plug e Fill drain plug 4 Continue adding the lubricant until it appears at the rear vent hole 5 Stop adding the lubricant Install the rear vent plug and sealing washer before removing lubricant tube 6 Remove the lubricant tube and install cleaned fill drain plug and sealing washer SUBMERGED OUTBOARD A submerged outboard will require service within a fe...

Page 112: ...n is to add the recommended amount of Mercury Quickstor fuel stabilizer and Mercury Quickleen products as described on the containers to the fuel tank before the last operation of the boat Adding Quickstor will help prevent the formation of varnish and gum in the gasoline Quickleen will help clean and lubricate the fuel injectors Tube Ref No Description Where Used Part No Quickleen Engine Fuel Sys...

Page 113: ...mix the following in a container a 8 cc 0 27 oz or 2 teaspoons of Mercury Quickleen b 8 cc 0 27 oz or 2 teaspoons of Mercury Quickstor 10 Remove the fuel filter Refer to Maintenance Fuel System for procedure 11 Pour this mixture into the fuel filter opening Install the fuel filter 12 Prime the fuel system Refer to Operation Starting The Engine 13 Place the outboard in water or use the flush hose o...

Page 114: ...ribute the oil or storage seal in the cylinders 3 Install the spark plugs Protecting External Outboard Components Lubricate all outboard components listed in Maintenance Inspection and Maintenance Schedule Touch up any paint nicks See your dealer for touch up paint Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces except corrosion control anodes Tube Ref ...

Page 115: ...let in the gearcase can freeze Store the outboard in the full down position Battery Storage Follow the battery manufacturer s instructions for storage and charging Remove the battery from the boat and check water level Charge if necessary Store the battery in a cool dry place Periodically check the water level and charge the battery during storage STORAGE eng 105 ...

Page 116: ...it to your authorized dealer Only authorized dealers specialize in Mercury products and have factory trained mechanics special tools and equipment and genuine Quicksilver parts and accessories to properly service your engine NOTE Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package SERVICE AWAY FROM HOME If you are away from your local de...

Page 117: ...ssories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring about parts and accessories the dealer requires the engine model and serial numbers to order the correct parts RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us If you ever have a problem question or concern about your power package contact...

Page 118: ...ic Group 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 ...

Page 119: ...blications Department P O Box 1939 Fond du Lac WI 54936 1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To...

Page 120: ...Quantity Item Stock Number Price Total Total Due OWNER SERVICE ASSISTANCE 110 eng ...

Page 121: ...pty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose Ignition system component failure Spark plugs fouled or defe...

Page 122: ...lyte 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 Jet Application Troubleshooting PERFORMANCE LOSS Possible causes Throttle not fully open Damaged impeller Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty o...

Page 123: ... Cavitation of the impeller due to rough water or obstruction in the boat hull Blockage of the water intake TROUBLESHOOTING eng 113 ...

Page 124: ... 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 125: ...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 126: ...mp 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 116 eng ...

Page 127: ...curing 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 117 ...

Page 128: ...y 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 Boat Horsepower Capacity WARNING Exceeding the boat s maximum horsepower rating can cause serious injury or death Overpowering the boat can affect ...

Page 129: ...tarting in gear Fuel System AVOIDING FUEL FLOW RESTRICTION IMPORTANT Adding components to the fuel supply system filters valves fittings etc may restrict the fuel flow This may cause engine stalling at low speed and or a lean fuel condition at high RPM that could cause engine damage ELECTRIC FUEL PUMP The fuel pressure must not exceed 28 kPa 4 psi If necessary install a pressure regulator LOW PERM...

Page 130: ...d in to open bypass the valve in case of a fuel blockage in the valve a Fuel demand valve installed in the fuel hose between the fuel tank and primer bulb b Manual release c Vent water drain holes FUEL TANKS Portable Fuel Tank Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place Permanent Fuel Tank Permanent fuel tanks should be install...

Page 131: ...gine 84 2 cm 33 in Dual engine 149 9 cm 59 in Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling causing serious injury or death Before lifting the engine verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight To lift the outboard 1 Rem...

Page 132: ...housing or to lift entire engine for removal installation 3 Connect a hoist to the lifting eye 4 Lift the outboard and place it on the boat transom Steering Cable Starboard Side Routed Cable 1 Lubricate the O ring seal and the 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 OUTBOARD INSTALLATION 122 eng ...

Page 133: ...2 Insert the steering cable into the tilt tube 3725 3 Tighten the nut to the specified torque 3727 Description Nm lb in lb ft Nut 47 5 35 OUTBOARD INSTALLATION eng 123 ...

Page 134: ...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 135: ... components Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause propeller to break loose during planing Determining the Mounting Height of the Outboard Jet The following outboard mounting height settings will work good for most applications however because of different boat hull designs the setting should be checked by test running th...

Page 136: ...so that the front edge of the water intake housing is in line with the horizontal line made in step 1 Temporarily clamp the outboard to the transom at this position 3 Fasten the outboard to the transom at this height Refer to Fastening the Outboard 22403 BOATS WITH A FLAT BOTTOM HULL 1 Place center the outboard on the boat transom Set the height of the outboard on the boat transom so that the fron...

Page 137: ...lling any mounting holes carefully read Determining Recommended Outboard Mounting Height and install outboard to the nearest recommended mounting height 1 Mark four mounting holes on the transom using the transom drilling fixture a Drill guide holes b Transom drilling fixture c Transom centerline 2757 a a b c OUTBOARD INSTALLATION eng 127 ...

Page 138: ...on 8M0071543 Outboard mounting bolt 20 x 5 00 in long 3 25 in thread 826711 17 Nylon insert locknut 20 28421 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 8M0...

Page 139: ...th of the boat transom The outboard mounting locknuts and bolts should be able to hold 75 Nm 55 lb ft of torque without the boat transom yielding or cracking If the boat transom yields or cracks under this torque the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under...

Page 140: ...ransom reinforcement plate a Large transom washer b Transom reinforcement plate FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT The transom mounting surface must 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 al...

Page 141: ...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 142: ...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 132 eng ...

Page 143: ...e Flush Hose and Control Cables FRONT COWL GROMMET NOTE Sufficient slack must exist in wiring battery cables and hoses that are routed between the 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 a Access cover b Screws a b 23714 OUTBOARD INSTALLATION eng 133 ...

Page 144: ... knockouts Refer to Flush Hose Routing a Flush hose b Grommet c Remote boat harness d Not used e Throttle cable f Fuel hose g Upper alignment pin h SmartCraft harness or additional harness opening i Water pressure tube j Battery cables k Lower alignment pin 5 Install the access cover with two screws Tighten the screws to the specified torque Description Nm lb in lb ft Access cover screws 7 3 65 F ...

Page 145: ...can be routed outside the cowling as follows 1 Using a needle nose pliers break out the semi circular knockouts in the access cover and lower cover Smooth the edges of the knockout with sandpaper or a small knife 2 Route the flush hose through this opening a Knockout b Flush hose a 23639 a b 23642 OUTBOARD INSTALLATION eng 135 ...

Page 146: ... Throttle and Shift DTS system leading to serious injury or death due to loss of boat control Secure the battery leads to the battery posts with hex nuts to avoid loose connections Do not use deep cycle batteries The engine must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah rating When connecting the engine battery use hex nuts to secure the battery leads to the battery posts Tight...

Page 147: ...ine rigging components are 5 16 and 3 8 hex nuts to be used for battery terminal wing nut replacement Metric hex nuts must be obtained locally 8M0085862 Refer to the outboard owner s manual for battery requirements Battery cable size and length is critical Refer to engine installation manual for size requirements NOTICE IMPORTANT DO NOT USE DEEP CYCLE BATTERIES 13 5Nm 120 lb in DO NOT USE WINGNUTS...

Page 148: ... ground cable wire size same as engine battery cables between negative terminals on starting batteries a Red sleeve positive b Black sleeve negative c Ground cable d Cranking battery a a b b c d d 15497 OUTBOARD INSTALLATION 138 eng ...

Page 149: ... wiring harness through the grommet and connect it to the SmartCraft harness connector on the engine a SmartCraft harness connector WATER PRESSURE TUBE CONNECTION If a water connection to the engine is required for a water pressure gauge make the connection as follows a 23700 OUTBOARD INSTALLATION eng 139 ...

Page 150: ...te the water pressure tube out through the grommet a Water pressure tube 2 Remove the plug from the coupler and make the connection A barb fitting 22 859731 can be installed for larger diameter hose connection a Plug b Coupler c Barb fitting 22 859731 a 23702 c a b 23708 OUTBOARD INSTALLATION 140 eng ...

Page 151: ...mp a Hose clamp b Remote fuel hose SHIFT CABLE INSTALLATION 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 Install the cables into the remote control following the instructions provided with the remote control 1 Position the remote control into neutral N 26838 2 Shift the outboard into neutral a b 2...

Page 152: ...ce between pin and center of lower hole b Pin c Barrel pocket 4 Push in on the shift cable end until resistance is felt Adjust the cable barrel to attain distance measured in Step 3 a Shift cable end b Cable barrel N R F a b c 23720 a b 23721 OUTBOARD INSTALLATION 142 eng ...

Page 153: ...e propeller shaft should turn freely without drag If not adjust the barrel closer to the cable end Repeat steps a through d SHIFT CABLE INSTALLATION OUTBOARD JET WARNING If not properly installed the reverse gate can interfere with water coming off the rudder suddenly and unexpectedly slowing the boat This can cause serious injury or death from occupants being thrown within or out of the boat Adju...

Page 154: ...e adjustment in forward shift position The correct shift adjustment will position the cam far enough on the roller to lock the reverse gate into forward position Push on the reverse gate by hand to verify it is locked into position The reverse gate should not move when pushed toward the neutral position IMPORTANT The forward locking of the reverse gate must be met If not readjust the shift cable T...

Page 155: ...ff the locknut 1 4 turn 3 Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop 4 Place the cable barrel into the barrel retainer 5 Lock the retainer and cables in place with the cable latch a Flat washer b Locknut c Barrel retainer d Cable barrel e Cable latch a b c d e 15317 OUTBOARD INSTALLATION eng 145 ...

Page 156: ...HE OIL INJECTION PUMP Before starting engine for the first time prime the oil injection pump Priming will remove any air that may be in the pump oil supply hose or internal passages a Oil injection pump b Oil supply hose IMPORTANT Fill the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel pump will run without fuel during the priming process and may be damaged P...

Page 157: ...ming process Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer resulting in the operator losing control of the boat Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner Some boats particularly some bass boats are built with a greater than normal transom angle whic...

Page 158: ...9930A 1 2749 Limits the down trim angle of the power trim equipped engines or aids in determining the trim out angle on non power trim engines The owner may decide to limit the trim in 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 nonstainless steel shipping bolt should not be used i...

Page 159: ...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 149 ...

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