Mercury 125 OptiMax Page 101 Owner'S Manual Download | Manualshive

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TROUBLESHOOTING

eng

91

Starter Motor Will Not Crank the Engine

POSSIBLE CAUSES

• Blown 20 amp fuse in the starting circuit. Refer to

Maintenance

.

• Outboard is not shifted to neutral position.
• Weak battery or battery connections are loose or corroded.
• Ignition key switch failure.
• Wiring or electrical connection faulty.
• Starter motor solenoid or slave solenoid failure.

Engine Will Not Start

POSSIBLE CAUSES

• Lanyard stop switch not in "RUN" position.
• Battery not fully charged.
• Incorrect starting procedure. Refer to

Operation

section.

• Old or contaminated fuel.
• Fuel is not reaching the engine.

• Fuel tank is empty.
• 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 defective. Refer to

Maintenance

section.

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Summary of Contents for 125 OptiMax

Page 1: ...for your confidence in 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 t...

Page 2: ...ation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2010 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort M with Waves logo Mercury with Waves logo and SmartCraft logo are all registere...

Page 3: ...54936 1939 Country USA Name of Authorized Representative Brunswick Marine in EMEA Inc Address Parc Industriel de Petit Rechain Town Verviers Post Code 4800 Country Belgium Name of Notified Body for exhaust 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...

Page 4: ...RCD H 2 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 B 4 owner s manual ISO 8665 1995 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s manual This decl...

Page 5: ...eng v Name function Mark D Schwabero President Mercury Outboard Date and place of issue July 24 2008 Fond du Lac Wisconsin USA ...

Page 6: ...vi eng ...

Page 7: ... Responsibilities 13 Before Operating Your Outboard 13 Boat Horsepower Capacity 14 High Speed and High Performance Boat Operation 14 Propeller Selection 15 Outboard Remote Control Models 18 Remote Steering Notice 18 Lanyard Stop Switch 19 Protecting People in the Water 23 Passenger Safety Message Pontoon Boats and Deck Boats 24 Wave and Wake Jumping 25 Impact with Underwater Hazards 26 Exhaust Emi...

Page 8: ...uel Tank 41 Features and Controls Remote Control Features 43 Warning System 44 Power Trim and Tilt 47 Trim Tab Adjustment 51 Operation Pre Starting Check List 52 Operating in Freezing Temperatures 52 Operating in Saltwater or Polluted Water 53 Operating at High Elevations 53 Setting Trim Angle While Running Engine at Idle Speed 54 Engine Break In Procedure 54 Starting the Engine 55 Gear Shifting 5...

Page 9: ...nk Rod Fasteners 71 Fuse Replacement 72 Corrosion Control Anode 73 Battery Inspection 74 Battery Information 74 Propellers 75 Spark Plug Inspection and Replacement 79 Compressor Air Intake Filter 80 Alternator Belt Inspection 81 Lubrication Points 81 Checking Power Trim Fluid 83 Gearcase Lubrication 84 Storage Storage Preparation 87 Fuel System 87 Protecting Internal Engine Components 89 Protectin...

Page 10: ... 94 Outboard Installation Important Information 96 Boat Horsepower Capacity 96 Start in Gear Protection 97 Selecting Accessories for Your Outboard 97 Fuel Tanks 97 Low Permeation Fuel Hose Requirement 97 Installation Specifications 98 Lifting the Outboard 98 Steering Cable Starboard Side Routed Cable 99 Determining Recommended Outboard Mounting Height 101 Drilling Outboard Mounting Holes 102 Faste...

Page 11: ...ond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Warranty Registration Uni...

Page 12: ...g the warranty registration Mercury Marine will send registration verification by mail to the purchaser of the product If this registration verification is not received within 30 days please contact your selling dealer immediately Warranty coverage is not effective until your product is registered with Mercury Marine Warranty Registration Outside the United States and Canada 1 It is important that...

Page 13: ...eived from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty ...

Page 14: ... product Unexpired warrant coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that 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 pre...

Page 15: ...l wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installatio...

Page 16: ...Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES A...

Page 17: ...spection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sa...

Page 18: ...chaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage...

Page 19: ...ween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 20: ...ion is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connecti...

Page 21: ...intenance 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 internal engine conditio...

Page 22: ...our products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product ...

Page 23: ...utboard properly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed DANGER Indicates a hazardous ...

Page 24: ...l guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 High Speed and High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capabil...

Page 25: ...ercury dealer SELECTING THE CORRECT PROPELLER An accurate tachometer for measuring engine speed is important in choosing the correct propeller Choose a propeller for your boating application that will allow the engine to operate within the specified full throttle operating range When operating the boat at full throttle under normal load conditions the engine RPM should be in the upper half of the ...

Page 26: ...nce across the imaginary circle that is made when the propeller rotates The correct diameter for each propeller has been predetermined for the design 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 propel...

Page 27: ... PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel Aluminum is suitable for general purpose use and is standard equipment on many new boats Stainless steel is over five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies Stainless steel propellers also...

Page 28: ... neutral WARNING Starting the engine with the drive in gear can cause serious injury or death Never operate a boat that does not have a neutral safety protection device 26779 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self locking nuts These self locking nuts must never be replaced with common nuts non locking as they will...

Page 29: ...nents 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 are equipped with a lanyard stop switch A la...

Page 30: ... as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard a Lanyard cord...

Page 31: ...ting at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel or tiller handle that is pulling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn ...

Page 32: ...sengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use check to ensure the lanyard stop switch works properly Start the engine and stop it ...

Page 33: ...r 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 rotate This neutral propeller rotation can cause serious injury WHILE BOAT IS STATIONARY WARNING A spinning propeller a moving boat or any solid device attached to the boat can cause serious injury or death to swimmers Stop the engine imme...

Page 34: ...the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN OPEN FRONT DECK No one should ever be on 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 w...

Page 35: ...at 26783 Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done with sufficient speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat reenters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such case t...

Page 36: ...so steer sharply to one side Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control ...

Page 37: ...er striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures or water leaks Operating a damaged outboard could cause additional damage to othe...

Page 38: ...an 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 harmful carbon monoxide Avoid areas of concentrated engine exhaust gases When engines are running k...

Page 39: ...cient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an 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 whe...

Page 40: ... are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions Use flotation devic...

Page 41: ...the boat Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly Prepare other boat operators Instruct at least one other person onboard in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Stop ...

Page 42: ...nvolved 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...

Page 43: ... 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 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 syst...

Page 44: ...ers ear ICOMIA 39 94 dBA 82 0 Component Identification a Top cowl 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 ...

Page 45: ...ice Refer to your local 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 ...

Page 46: ... brand of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 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 These reformulated gasolines are acceptable for use in your Mercury...

Page 47: ...ion particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is...

Page 48: ... 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 Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or offered for sale in the United States The Environmental Protection Agency EPA requires that any outboard manufactured a...

Page 49: ... DFI 2 Cycle Engine Oil is not available we recommend using Mercury or Quicksilver TC W3 Premium Plus 2 Cycle Oil Severe engine damage may result from use of an inferior oil 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 a b 37147 ...

Page 50: ...d 0 94 liters 1 US qt b Add 1 89 liters 2 US qt c Add 2 83 liters 3 US qt 5 Oil filler caps with a chain Check the oil level on the chain The first ball marker indicates 0 94 liters 1 US qt low The second ball marker indicates 1 89 liters 2 US qt low a Add 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 th...

Page 51: ...lling 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 not smoke or allow open flames or sparks in the area while filling fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them Always stop engine before refilling tanks ...

Page 52: ...IL 42 eng 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 ...

Page 53: ...ase lever c Trim tilt switch if equipped Refer to Features and Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard 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...

Page 54: ...mit either a continuous beep or intermittent short beeps This will alert the operator and help identify the following listed situations For visual display of the specific engine functions and for additional engine data refer to SmartCraft Product information following Warning Horn Function Sound Description Start up One beep Normal system test Low oil Four beeps every 2 minutes Oil level is low in...

Page 55: ...m is activated Power limit will allow a fast idle The warning horn is activated if the oil pump should ever stop functioning electrically No lubricating oil is being supplied to the engine Engine overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum allowable RPM The system will limit the engine speed to within the allowable range Engine overspeed indicates a...

Page 56: ...le speed The horn will turn off when throttle speed is within the allowable limit Consult your dealer for assistance SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard A few of the functions the instrument package will display are engine RPM coolant temperature battery voltage fuel consumption and engine operating hours The SmartCraft instrument pa...

Page 57: ...ine turned off the outboard can be tilted out of the water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation a Trim switch b Tilt range of travel c Trim range of travel POWER TRIM OPERATION NOTE When traveling at slow speeds a slight drop in engine RPM may be noticed on occasion when engaging power trim This condition is normal a...

Page 58: ... 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 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 WARNING Operating the boat at high speeds with the outb...

Page 59: ...line TILTING OPERATION To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating the knob to bring the support lever upward 2 Lower the outboard to rest on the tilt support lever 3 Disengage the tilt support...

Page 60: ...e 22362 SHALLOW WATER OPERATION When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exceeds 2000 RPM the outboard will automatically return down to the...

Page 61: ...ab adjustment will have little 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...

Page 62: ...perate 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 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 keep the outboard tilted down at...

Page 63: ...letely 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 effectiveness of the anodes Operating at High Elevat...

Page 64: ...rom idle speed 28423 Engine Break In Procedure IMPORTANT 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 GASOLINE OIL BREAK IN MIXTURE NOTE Do not use premixed gas and oil during break in Use straight gasoline during engine break in and after engine break in The engine br...

Page 65: ...ertical trim position during operation NOTE It is the driver s responsibility to always drive in a safe manner Improper trim angle of the outboard when driving at high speed can be difficult and dangerous The purpose of specifying trim angle is to help guide the operator in determining how to put the proper load on the engine They are intended to be guidelines and do not suggest or require unsafe ...

Page 66: ...el tank vent screw located in the filler cap on manual venting type fuel tanks 19748 3 Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm 27348 4 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 ...

Page 67: ...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 ignition key switch to the ON position again for three seconds Continue this procedure until the fuel line primer bulb stays firm 7 Do not advance the neutral fast idle speed feature on the remote control for starting 27242 8 Turn the ignition key to START p...

Page 68: ...ockage 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 Observe the following Never shift outboard into gear unless engine speed is at idle Do not shift outboard into reverse when the engine is not running Your outboard has three gear shift pos...

Page 69: ...g 59 After shifting outboard into gear advance the lever further to increase speed N R F 27237 Stopping the Engine Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position 26843 ...

Page 70: ...enance Schedule We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability Record maintenance performed in the Maintenance Log at the back of this book Save all maintenance work orders and receipts SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubr...

Page 71: ... OWNER RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications EMISSION CONTROL INFORMATION TIMING IN DEGREES FAMILY FEL cc ...

Page 72: ...d the boat transom lift plate setback bracket 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 Check steering system for binding or loose components Visually check steering link rod fasteners for proper tightness See Steering Link Rod Fasteners Check propeller blades for da...

Page 73: ...lates and setback brackets 122 90 Check corrosion control anodes Check more frequently when used in saltwater See Corrosion Control Anode Drain and replace gearcase lubricant See Gearcase Lubrication Check power trim fluid See Checking Power Trim Fluid Inspect battery See Battery Inspection Check control cable adjustments 1 Lubricate splines on the driveshaft and shift shaft 1 Check tightness of b...

Page 74: ...al 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 engine can be 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 ho...

Page 75: ...ter a Hose adapter b Sealing washer c Cover Top Cowl Removal and Installation REMOVAL 1 Unlock the rear latch by pushing lever up 2 Lift rear of cowl and disengage front hook 29468 INSTALLATION 1 Engage the front hook and push cowl back over the cowl seal 2 Push cowl down and move the rear latch lever down to lock a b c 22703 ...

Page 76: ...inse 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 non abrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a non abrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth Flywheel Cov...

Page 77: ... three mounting pins 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 ...

Page 78: ...ting pins Fuel System 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 exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fu...

Page 79: ... LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced FUEL FILTER REPLACEMENT Removal 1 Use fuel filter tool 91 896661 or use the shaft of a screwdriver between the lugs on the filter cap and unscrew the filter a Filter b O rings ...

Page 80: ...ired 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 hose b Right side fitting c Drain screw 3 Retighten the drain screw and reattach the hose IMPORTANT Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm forcing f...

Page 81: ...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 washer head bolt 1...

Page 82: ... nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt and self locking nylon insert locknut First torque bolt then torque locknut to specifications Fuse Replacement IMPORTANT Always carry spare 5 and 20 amp fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of ...

Page 83: ...amp fuse d Ignition coil circuit 20 amp fuse e SmartCraft data bus circuit 5 amp fuse f Diagnostics terminal 2 amp fuse g Spare fuse 20 amp fuse h Fuel injectors direct injectors oil pump PCM 20 amp fuse 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 corro...

Page 84: ...odic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Ensure the battery is secure against movement 3 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative 4 Ensure the battery is equipped with a ...

Page 85: ...ic hex nuts are not supplied NOTICE DTS OptiMax Engines DO NOT USE DEEP CYCLE BATTERIES DTS Digital Throttle and Shift applications and OptiMax engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah rating IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements DO NOT USE WING NUTS 37 895387 3486 13 5Nm 120 lbs in Place deca...

Page 86: ...d 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 the outboard to the neutral N position 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 pr...

Page 87: ...ANT 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 propeller is removed 1 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with PTFE 26902 Tube R...

Page 88: ...up to 3 17 mm 1 8 in and rotate up to 10 degrees 2 Flo Torq III drive hub propellers Install the forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 3 Place a block of wood between the gearcase and propeller Torq...

Page 89: ...ors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken bl...

Page 90: ...r tight and then tighten to the specified value 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 Never run the engine without the air filter REMOVAL 1 Remove three screws and filter cover from engine 2 Remove filter from the cover a Cover b Filter INSTALLATION 1 Install filter into cover a ...

Page 91: ...t replaced by an authorized dealer if any of the following conditions are found a Cracks or deterioration in the rubber portion of the belt b Belt surfaces rough or uneven c Signs of wear on edges or outer surfaces of belt 29477 Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with PTFE Tube Ref No Description Where Used P...

Page 92: ...ision Lubricants 2 4 C with PTFE or Special Lubricant 101 Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Swivel bracket tilt support lever tilt tube steering cable grease fitting 92 802865Q02 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 fit...

Page 93: ...can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant a 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 outboard to the full up position and engage the tilt support lever 2...

Page 94: ...s present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for met...

Page 95: ...NT CAPACITY Gearcase lubricant capacity is approximately 666 ml 22 5 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug b a 26977 ...

Page 96: ...it appears at the rear vent hole 5 Stop adding lubricant Install the rear vent plug and sealing washer before removing lubricant tube 6 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer SUBMERGED OUTBOARD A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servi...

Page 97: ...ng gasoline as possible from the fuel tank remote fuel line and engine fuel system The most effective method of storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on the containers to the fuel tank before the last operation of the boat Adding fuel stabilizer will help prevent the formation of varnish and g...

Page 98: ...h the hose 6 Pull the drain hose off the left side fitting Hold the open end of the hose over a container 7 Loosen the drain screw and drain the float chamber a Left side fitting b Drain screw c Drain hose 8 Retighten the drain screw and reattach the hose 9 Premix the following in a container a 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Quickleen lubricant b 8 cc 0 27 oz or 2 teaspoons of Me...

Page 99: ... water connection when flushing the cooling system or operating the engine Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceding IMPORTANT Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark plug leads 1 Remove the spark plugs Add approximately 30 ml 1 oz of engine oil or inject a five s...

Page 100: ...e 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 gearcase can freeze Store the outboard in the full down position Battery Storage Follow the battery manufacturer s instructions for s...

Page 101: ...witch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel tank is empty 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 ...

Page 102: ...ded connection of an air hose is loose Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not fully open Damaged propeller or improper propeller size 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 ...

Page 103: ...local authorized dealer The dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product...

Page 104: ...4936 1939 Fax English 920 929 5893 Français 905 636 1704 Website www mercurymarine com Australia Pacific Telephone 61 3 9791 5822 Brunswick Asia Pacific 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 Cen...

Page 105: ...OWNER SERVICE ASSISTANCE eng 95 Asia Singapore Telephone 65 65466160 Brunswick Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789 ...

Page 106: ...h Boat Horsepower Capacity WARNING Exceeding the boat s maximum horsepower rating can cause serious injury or death Overpowering the boat can affect boat control and flotation characteristics or break the transom Do not install an engine that exceeds the boat s maximum power rating Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum accepta...

Page 107: ...this outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all selected accessories 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 installed in accordance with industry and federal safety standar...

Page 108: ...m 26 in Minimum Transom Opening Single engine 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...

Page 109: ...5 1 2756 Threads into the flywheel to remove the powerhead assembly from the driveshaft 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 O ring seal and entire cable end 3724 95 ...

Page 110: ...ng 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 3725 3 Torque nut to specification 3727 Description Nm lb in lb ft Nut 47 5 35 ...

Page 111: ...ion if maximum speed is the only 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 ...

Page 112: ...tboard must not exceed 63 5 cm 25 in for L models 76 cm 30 in for XL models Mounting the outboard higher may cause damage to the gearcase components Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause propeller to break loose during planing Drilling Outboard Mounting Holes IMPORTANT Before drilling any mounting holes carefully read De...

Page 113: ...Hardware Supplied with Outboard Part Number Part Name Description 10 67755 1 Outboard mounting bolt 20 x 4 50 in long 2 25 in thread 11 826711 17 Nylon insert locknut 20 12 28421 Flat washer 1 1 2 in diameter 12 54012 Flat washer 7 8 in diameter Available Outboard Mounting Bolts Part Number Description 10 67755005 20 x 2 50 in long 1 25 in thread 10 67755006 20 x 3 50 in long 1 25 in thread 10 814...

Page 114: ...2 75 in thread CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT Determine the strength 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 carry...

Page 115: ...transom reinforcement plate a Large transom washer b Transom reinforcement plate 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 a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be drawn tight while...

Page 116: ...oard mounting bolt 4 b 7 8 in flat washer 4 c Nylon insert locknut 4 d 1 1 2 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 ...

Page 117: ...ine 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 2 Insert the lower alignment pin on the grommet into the hole in the lower cover Ensure the lettered side of the grommet is facing out 3 Route the hoses wiring and cables through the correct opening in the grommet as sho...

Page 118: ... hose b Grommet c Remote boat harness d Shift cable 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 Reinstall the access cover with two bolts Reattach the cowl seal F TH SH B W a c d e f g h i j k b 23638 ...

Page 119: ...red the flush hose 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 ...

Page 120: ...eads 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 batteries Engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah When connecting the engine battery hex nuts must be used to sec...

Page 121: ...ngines DO NOT USE DEEP CYCLE BATTERIES DTS Digital Throttle and Shift applications and OptiMax engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah rating IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements DO NOT USE WING NUTS 37 895387 3486 13 5Nm 120 lbs in Place decal on or near battery box for future service refer...

Page 122: ...ual Outboards Connect a common 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 ...

Page 123: ... outboard route the SmartCraft 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 ...

Page 124: ...OARD INSTALLATION 114 eng 1 The water pressure tube is coiled and attached on the side of the engine Cut the cable tie and route the water pressure tube out through the grommet a Water pressure tube a 23702 ...

Page 125: ...on A barb fitting 22 859731 can be installed for larger diameter hose connection a Plug b Coupler c Barb fitting 22 859731 FUEL HOSE CONNECTION Remote Fuel Hose Size Minimum fuel hose inside diameter ID is 8 mm 5 16 in with separate fuel hose fuel tank pickup for each engine c a b 23708 ...

Page 126: ...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 cables into the remote control following the instructions provided with the remote control 1 Position remote control into neutral N 26838 2 Shift outboard into neutral a b 23709 ...

Page 127: ...OUTBOARD INSTALLATION eng 117 3 Measure the distance between pin and center of barrel pocket a Distance between pin and center of lower hole b Pin c Barrel pocket N R F a b c 23720 ...

Page 128: ...Shift cable end b Cable barrel 5 Place the cable barrel into the pocket Fasten the cable with locknut and flat washer a Cable barrel b Locknut c Flat washer 6 Check shift cable adjustments as follows a Shift the remote control into forward The propeller shaft should be locked in gear If not adjust the barrel closer to the cable end a b 23721 a b c 7736 ...

Page 129: ... to neutral The propeller shaft should turn freely without drag If not adjust the barrel closer to the cable end Repeat steps a through d THROTTLE CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control 1 Position remote control into neutral N 26838 2 Install the throttle cable to the throttle arm with a flat washer and locknut Tighten ...

Page 130: ...at washer b Locknut c Barrel retainer d Cable barrel e Cable latch Oil Injection Set Up FILLING OIL INJECTION SYSTEM 1 Fill the oil tank with the specified oil Refer to Filling Oil Injection System Add only enough oil to bring the oil level up to the bottom of the fill neck 29465 a b c d e 15317 ...

Page 131: ...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 Prime the oil injection pump as follows 1 Fill the engine fuel tank with fuel NOTE Use the primer bulb located in the fuel hose to the engine to draw fuel from the tank to fill the engine fuel system 2 Position the fu...

Page 132: ... 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 which will allow the outboard to be trimmed further in or under This greater trim under capability is desirabl...

Page 133: ... Stainless Steel Tilt Pin 17 49930A 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 ship...

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