Mercury 135 Verado Page 111 Manual Download

Page: 111 / 146

MAINTENANCE

103

AIR FILTER REMOVAL

1. Remove the FSM vent hose and the engine ventilation hose

from the flywheel cover.

2. Remove the bolts securing the flywheel cover to the rear

mounting posts.

15247

a -

Flywheel cover bolts

b -

FSM vent hose

c -

Engine ventilation hose

3. Lift the flywheel cover off the front mounting post and the

intake resonator.

4. Remove three screws holding the upper flywheel cover to the

lower flywheel cover.

14309

5. Separate the two flywheel cover sub‑assemblies to access the

air filter.

Summary of Contents for 135 Verado

Page 1: ...the lower corner left hand corner either the CE mark alone or the CE mark accompanied by a notified body number This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industriel de Petit Rechain Belgium complies with the requirements of the following directives by meeting the associated standards as amended If the CE mark is accompanied by a notified ...

Page 2: ...2 ISO 13591 ISO 8469 General steering system ABYC P 17 The following applies to all product covered by this manual Safety of Machinery Directive 98 37 EC Principles of safety integration 1 1 2 EN 292 1 EN 292 2 EN 1050 Noise 1 5 8 ICOMIA 39 94 Vibration ICOMIA 38 94 Electromagnetic Compatibility Directive 89 336 EC Generic emission standard EN 61000 6 3 Generic immunity standard EN 61000 6 1 Vehic...

Page 3: ...iii Patrick C Mackey President Mercury Marine Fond du Lac WI USA European Regulations Contact Regulations and Product Safety Department Mercury Marine Fond du Lac WI USA ...

Page 4: ...iv ...

Page 5: ...Boater s Responsibilities 13 Before Operating Your Outboard 13 Boat Horsepower Capacity 14 High Speed and High Performance Boat Operation 14 Outboard Remote Control Models 14 Lanyard Stop Switch 15 Protecting People In The Water 17 Passenger Safety Message Pontoon Boats And Deck Boats 18 Wave And Wake Jumping 19 Impact With Underwater Hazards 20 Exhaust Emissions 21 Selecting Accessories For Your ...

Page 6: ...on 45 Dual Handle Console Control Features and Operation 50 Dual Handle Console Control with CAN Trackpad Features and Operation 55 Shadow Mode Control Features and Operation 60 Shadow Mode Control with CAN Trackpad Features and Operation 69 Warning System 80 Power Trim and Tilt 82 Operation Pre Starting Check List 88 Operating In Freezing Temperatures 88 Operating In Salt Water Or Polluted Water ...

Page 7: ...trol Anode 110 Propeller Replacement 110 Spark Plug Inspection and Replacement 112 Fuses 116 Steering Link Rod Fasteners 118 DTS Wiring System 119 Accessory Drive Belt Inspection 119 Lubrication Points 119 Checking Power Trim Fluid 123 Checking Power Steering Fluid 124 Changing Engine Oil 124 Gearcase Lubrication 127 Storage Storage Preparation 130 Protecting External Outboard Components 131 Prote...

Page 8: ...ot Shift Into Gear 133 Engine Runs Erratically 134 Performance Loss 134 Battery Will Not Hold Charge 134 Owner Service Assistance Local Repair Service 136 Service Away From Home 136 Parts And Accessories Inquiries 136 Service Assistance 136 Mercury Marine Service Offices 137 ...

Page 9: ...nd du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 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 United...

Page 10: ...he 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 yo...

Page 11: ...d 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 regi...

Page 12: ...roduct 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 d...

Page 13: ...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 installation ...

Page 14: ...verage 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 ARE...

Page 15: ...pection 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 sac...

Page 16: ...aser 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 a...

Page 17: ...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 18: ... 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 connection ...

Page 19: ...nance 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 condition wh...

Page 20: ...r 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 21: ...board 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 si...

Page 22: ...UM 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 capability without first requesting an initial orientation and familiarization demonstration ride with your...

Page 23: ... cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should t...

Page 24: ...ling 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 at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat...

Page 25: ...E YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the outboard gear shift is in neutral position there is suff...

Page 26: ...em over the front of the boat Falling over the front of 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 fee...

Page 27: ... 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 re enters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such case th...

Page 28: ... 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 th...

Page 29: ...should also be checked for any hull fractures transom fractures or water leaks Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat If continued running is necessary do so at greatly reduced speeds WARNING Operating a boat or engine with impact damage can result in product damage serious injury or death If the vessel experien...

Page 30: ...rtain running and or wind conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient 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 enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous...

Page 31: ...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 devices Have an approved p...

Page 32: ...ur ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the outboard into neutral is not sufficien...

Page 33: ...e loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record this number for future reference The serial number is located on the outboard as shown a XX OTXXXXXX XXXX a b c d 29688 a Serial number b Model designation c Year manufactured d Certified Europe Insignia as applicable 135 150 175 200 Specifications International Models 135 150 17...

Page 34: ... Gasoline Refer to Fuel Oil Recommended Oil Refer to Fuel Oil Right Hand Rotation Gearcase Lubricant Capacity 970 ml 32 8 fl oz Left Hand Rotation Gearcase Lubricant Capacity 900 ml 30 4 fl oz Engine Oil Capacity With Oil Filter Replacement 6 0 liters 6 3 qt Battery Rating 1000 Marine Cranking Amps MCA 800 Cold Cranking AMPS CCA or 180 Ampere Hour Ah Sound at Drivers Ear ICOMIA 39 94 83 2 ...

Page 35: ...nent Identification a b c d e f g h i 14811 j a Engine flush b Auxiliary tilt switch c Top cowl d Bottom cowl e Engine oil drain f Anti ventilation plate g Gearcase h Cooling water intake holes i Transom brackets j Tilt lock level ...

Page 36: ...erwater obstacles if the outboard is not attached to the transom correctly We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the transom with the four 12...

Page 37: ...while maintaining maximum boat speed 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboards durability Check full throttle RPM using an accurate tachometer with th...

Page 38: ...e Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 14825 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This pr...

Page 39: ...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 Marine engine GASOLINES C...

Page 40: ...n 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 r...

Page 41: ...me as its temperature rises and can leak under pressure if the tank is completely filled PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions Engine Oil Recommendations Mercury Verado NMMA FC W certified synthetic blend 25W 50 multi viscosity 4 Stroke Outboard Oil is recommended for general all tem...

Page 42: ... to the oil sump Tilt outboard to vertical not tilted position when checking engine oil For accurate readings check oil only when engine is cold or after engine has not run for at least an hour 1 Before starting cold engine tilt outboard out up past vertical to allow trapped oil to drain back to the oil sump Allow outboard to remain tilted for approximately one minute 2 Tilt outboard to vertical o...

Page 43: ...ting range 6 If the oil level is below the operating range cross hatched region remove the oil filler cap and add approximately 500 ml 16 oz of specified outboard motor oil Allow a few minutes for the added oil to drain to the oil sump and recheck the dipstick Repeat the process until oil level is on the operating range cross hatched region Do not try to fill to the upper end of the operation rang...

Page 44: ...minated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 7 Push the dipstick back in all the way 8 Reinstall the oil fill cap hand tight 9 Reinstall top cowl ...

Page 45: ...from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3413 2 Shift lock Pressing the shift lock allows the engine to shift The shift lock must always be pressed when moving the control handle out of the neutral position 3428 ...

Page 46: ...m up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button while moving the control handle ahead to the forward detent The horn indicates throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position Engine RPM is limited to prevent engine damage 3416 ...

Page 47: ...er the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch a 22964 7 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn screw clockwise to increase tension and countercloc...

Page 48: ...b a Detent tension adjustment screw b Control handle tension adjustment screw Single Handle Console Control Features and Operation 1 Operation of shift and throttle is controlled by the movement of the control handle Push the control handle forward from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first det...

Page 49: ... rough water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to the desired tension 4 Detent tension adjustment screw This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions cover must be removed Turning the screw clockwise will increase tension Adjust to the desired tension a b 28556 a Detent tension...

Page 50: ...tion except when in the slide show function Holding the select button for five seconds or more will bring up the Home page 7 Neutral LED The neutral LED illuminates when engine is in neutral gear position It also flashes when throttle only is activated NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the control handle 8 Active LED Th...

Page 51: ...ottle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer d b a c e 5187 a Neutral LED b Select button c Arrow trackpad d Throttle only station select button e Active LED HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control The boat operator should never leave the...

Page 52: ...throttle and gear position NOTE There is a 10 second time frame to complete a helm transfer If the helm transfer is not completed the action will be cancelled and a double beep will sound Pressing the throttle only station select button again will re initiate a helm transfer 1 Place active remote control lever to idle position 2 Proceed to the inactive helm and position remote control lever to the...

Page 53: ...andle is matched and the throttle only station select button can be pressed again to complete the transfer This completes the transfer process and give control to the new station If the helm transfer is not completed within 10 seconds the helm transfer is cancelled Slim Binnacle Control Features and Operation 1 Operation of shift and throttle is controlled by the movement of the control handle Pus...

Page 54: ...trol handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the remote control handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to the desired tension ...

Page 55: ... screw b Control handle tension adjustment screw 5 Start stop button Allows the boat operator to start or stop the engine without using the ignition key 6 Neutral LED The neutral LED illuminates when engine is in neutral gear position It also flashes when throttle only is activated NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the ...

Page 56: ...rottle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer START STOP 22970 d c a b a Start stop button b Throttle only station select button c Neutral LED d Active LED HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control The boat operator should never leave the a...

Page 57: ...er to idle position 2 Proceed to the inactive helm and position remote control lever to the idle position 3 Press throttle only station select button two times The ACTIVE light will illuminate to indicate the remote control is in control of the engine START STOP 22608 a b a Active light b Throttle only station select button 4 The ACTIVE light will switch off at the original helm Synchronizing Helm...

Page 58: ... neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3417 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up or down 5269 3 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough...

Page 59: ...t The horn will sound once and the neutral light will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Tra...

Page 60: ... active LED illuminates to show the remote control is active and ready for use 10 SYNC LED The SYNC LED illuminates when the RPM of the two engines are being synchronized by the DTS system 5270 ACTIVE SYNC THROTTLE ONLY STATION SELECT a b c d e f a Neutral LEDS b Select button c Arrow trackpad d SYNC LED e Throttle only station select button f Active LED SYNCHRONIZING ENGINES The auto synchronizin...

Page 61: ...ngine is in neutral NOTE Idle position is preferred when doing a helm transfer If conditions do not allow the remote control to be placed at idle position a helm transfer can be done while in gear NOTE The active light on the remote control will be illuminated at the helm that is in control of the engine The helm transfer function allows the boat operator to select which helm is in control of engi...

Page 62: ...ginal helm Synchronizing Helms Prior To Helm Transfer Pressing the throttle only station select button one time allows the boat operator 10 seconds to match up the control handle setting at the new station with the handle setting that is at the old to be inactive station If the handle is not matched the neutral light will flash The light blinks faster as the handle is nearing match position Once t...

Page 63: ...om neutral to the first detent for reverse gear Continue pulling the handle back to increase speed F N R 3417 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up and down NEUTRAL SY NC TH RO TT LE ON LY TR OL L TR AN SF ER DOCK 1 LE VE R 22132 3 Neutral lights The neutral lights illuminate when the engine is in neutral gear position The lights will flash when the engine...

Page 64: ... Docking mode reduces throttle capacity to approximately 50 of normal throttle To turn off docking mode shift the engine into neutral and press the DOCK button 7 Throttle only button Allows the boat operator to increase engine RPM for warm up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button and move the c...

Page 65: ...tral LEDS b Troll button c Transfer button d Dock button e Throttle only f 1 lever button g Sync button 10 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease ...

Page 66: ...nizing feature when engaged will automatically adjust all engine speeds to match the speed of the starboard engine Press the SYNC button on the CAN trackpad to turn auto synchronization on or off When the sync LED is yellow the SYNC button has been pressed but the conditions are not right for auto synchronization to engage When the sync LED turns red engine synchronization has been engaged The eng...

Page 67: ...rol to be placed in the neutral position a helm transfer can be done while in gear The helm transfer function allows the boat operator to select which helm is in control of engine operation Pressing the TRANSFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to matc...

Page 68: ...he handles are not matched the neutral lights will flash The light blinks faster as the handles are nearing match position Once the light stays on continuously the handles are matched and the button can be pressed again to complete the transfer This completes the transfer process and gives control to the new station If the helm transfer is not completed within 10 seconds the action will be cancell...

Page 69: ...nes Center engine shift neutral unless both engines are in the same gear Running Running Off Port and center engine throttle and shift controlled by port control handle Off Running Running Starboard and center engine throttle and shift controlled by starboard control handle Running Off Running Port engine throttle and shift controlled by port control handle Starboard engine throttle and shift cont...

Page 70: ...ngaging The center engine speed and gear shift will then be controlled by the functioning outer engine Turning off the center engine while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes one of the outer engines into forced neutral idle condition the center engine will also be forced to neutral idle Operation to the center en...

Page 71: ... starboard control handle Running Running Off Off Port inner and outer engine throttle and shift controlled by port control handle Off Off Running Running Starboard inner and outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Running Port inner engine throttle and shift controlled by port control handle Running Running Running O...

Page 72: ...y switch turned off Starboard inner engine throttle and shift controlled by port control handle Running Off Off Running Port outer engine throttle and shift controlled by port control handle Starboard outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Off ignition key switch turned on Port inner engine throttle and shift control...

Page 73: ...nd moving the port control handle back into neutral position and then re engaging The inner engine speed and gear shift will then be controlled by the port control handle Turning off one of the inner engines while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes the starboard outer engines into forced neutral idle condition th...

Page 74: ...ght will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer 3 Arrow trackpad Navigates through Syst...

Page 75: ...e LED illuminates to show the remote control is active and ready for use 7 Sync LED The SYNC LED illuminates when the RPM of the engines are being synchronized by the DTS system ACTIVE SYNC THROTTLE ONLY STATION SELECT a b c d e f NEUTRAL SELECT 13854 a Neutral LEDS b Select button c Arrow trackpad d Sync LED e Throttle only station select button f Active LED SYNCHRONIZING ENGINES The auto synchro...

Page 76: ...ngine is in neutral NOTE Idle position is preferred when doing a helm transfer If conditions do not allow the remote control to be placed at idle position a helm transfer can be done while in gear NOTE The active light on the remote control will be illuminated at the helm that is in control of the engine The helm transfer function allows the boat operator to select which helm is in control of engi...

Page 77: ...etting at the new station with the handle setting that is at the old to be inactive station If the handle is not matched the neutral light will flash The light blinks faster as the handle is nearing match position Once the light stays on continuously the handle is matched and the throttle only station select button can be pressed again to complete the transfer This completes the transfer process a...

Page 78: ...nes Center engine shift neutral unless both engines are in the same gear Running Running Off Port and center engine throttle and shift controlled by port control handle Off Running Running Starboard and center engine throttle and shift controlled by starboard control handle Running Off Running Port engine throttle and shift controlled by port control handle Starboard engine throttle and shift cont...

Page 79: ...ngaging The center engine speed and gear shift will then be controlled by the functioning outer engine Turning off the center engine while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes one of the outer engines into forced neutral idle condition the center engine will also be forced to neutral idle Operation to the center en...

Page 80: ... starboard control handle Running Running Off Off Port inner and outer engine throttle and shift controlled by port control handle Off Off Running Running Starboard inner and outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Running Port inner engine throttle and shift controlled by port control handle Running Running Running O...

Page 81: ...y switch turned off Starboard inner engine throttle and shift controlled by port control handle Running Off Off Running Port outer engine throttle and shift controlled by port control handle Starboard outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Off ignition key switch turned on Port inner engine throttle and shift control...

Page 82: ...nd moving the port control handle back into neutral position and then re engaging The inner engine speed and gear shift will then be controlled by the port control handle Turning off one of the inner engines while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes the starboard outer engines into forced neutral idle condition th...

Page 83: ...Troll button Pressing the TROLL button activates troll control The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering To activate move the control handles into forward detent and press the button Use the or buttons to decrease or increase speed up to the maximum calibrated set point If troll control is set at a desired speed and then shut ...

Page 84: ...ttle only button while moving the control handle ahead to the forward detent The horn will sound once and the neutral light will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage 7 1 lever button Pressi...

Page 85: ...utral LEDS b Troll button c Transfer button d Dock button e Throttle only f 1 lever button g Sync button 9 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease ...

Page 86: ...nizing feature when engaged will automatically adjust all engine speeds to match the speed of the starboard engine Press the SYNC button on the CAN trackpad to turn auto synchronization on or off When the sync LED is yellow the SYNC button has been pressed but the conditions are not right for auto synchronization to engage When the sync LED turns red engine synchronization has been engaged The eng...

Page 87: ...rol to be placed in the neutral position a helm transfer can be done while in gear The helm transfer function allows the boat operator to select which helm is in control of engine operation Pressing the TRANSFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to matc...

Page 88: ...h position Once the light stays on continuously the handles are matched and the button can be pressed again to complete the transfer This completes the transfer process and gives control to the new station If the helm transfer is not completed within 10 seconds the action will be cancelled Warning System WARNING HORN SIGNALS When the key switch is turned to the ON position the horn located on the ...

Page 89: ...ected by the operator These operator correctable 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 SY...

Page 90: ...operator to easily adjust the position of the outboard by pressing the trim switch Moving the outboard in closer to the boat transom is called trimming in or down Moving the outboard further away from the boat transom is called trimming out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating the boat on p...

Page 91: ...s not parallel to the water surface WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control Maintain control of the boat if trimming beyond a neutral 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 loa...

Page 92: ...ater Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a normal installation height with the normal right hand rotation propeller In excess can cause boat porpoising bouncing or propeller ventilation Cause engine overheating if any cooling water intake holes are above the water line TRIM WITHOUT KEY Trim witho...

Page 93: ... been turned off 1 If the ignition key switch has been turned off for over 15 minutes turn it to the ON position 2 Press the trim tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position Tilt At Engine The cowl mounted auxiliary tilt switch can be used to tilt the outboard with the key switch in the OFF position Tilt Support Leve...

Page 94: ...anual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 22362 AUXILIARY TILT SWITCH NOTE This model allows the auxiliary tilt switch to be mounted on either the port side shown or on the starboard side This switch can be used to tilt the outboard up or down using the power trim system 14831 a a Auxiliary tilt switch port side SHALLOW WATER ...

Page 95: ...2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range ...

Page 96: ...nspection 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 all times so the gearcase is submerged This prevents trapped water in gearcase from freezing and causing possible damage to the water pump and other components...

Page 97: ...trimmed full in while running at idle speed This may result in exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim outboard up until exhaust relief hole is out of the water or35 1 a b a Relief hole submerged wrong b Relief hole above water line correct Engine Break in Procedure IMPORTANT Failure to follow the engine break in procedures can result in ...

Page 98: ...eatures and Controls Section NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a sufficient supply of water at the water inlets during operation 1 Make sure the cooling water intake is submerged 14836 2 Check the engine oil level 27780 3 Open fuel tank vent on manual venting type tanks 19748 NOTE The engine will not start unless ...

Page 99: ...hat ran out of fuel or was drained of fuel the fuel system should be filled as follows Turn the ignition key switch to the ON position for approximately one minute This operates the fuel lift pump Turn the ignition key switch back to the OFF position and then return the ignition key switch to the ON position again for an additional minute Turn the ignition key switch back to the OFF position The f...

Page 100: ...out of the water pump indicator hole 15301 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check the cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause e...

Page 101: ...ed to return to idle Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position 3428 Advance the control lever to further increase speed DTS CONSOLE MOUNT REMOTE CONTROL IMPORTANT Never shift outboard into gear unless engine speed is at idle Do not shift outboard into forward or reverse when the engine is not running ...

Page 102: ... the control lever to further increase speed Stopping The Engine IMPORTANT Turning key to the START position while the engine is running will result in engine shut down while leaving the DTS system active This will allow the use of the power trim tilt from the remote control handle Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position S T A R T OFF ACC ON S T...

Page 103: ...ntenance work orders and receipts SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture e d c b a f g h ...

Page 104: ... Visually check hydraulic steering fittings and hoses for leaks or signs of damage Check tie bar fasteners multiple outboard rigs for proper tightness Check propeller blades for damage AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase w...

Page 105: ...rk Plug Inspection and Replacement Tube Ref No Description Where Used Part No 81 Anti Seize Compound Spark plug threads 92 881091K1 Check wiring and connectors Check tightness of bolts nuts and other fasteners Check cowl seals to make sure seals are intact and not damaged Check internal cowl sound reduction foam if equipped to make sure foam is intact and not damaged Check that the intake silencer...

Page 106: ...esh water after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages NOTE The outboard can be tilted or in the vertical operating position during flushing 1 With the engine turned off place the outboard in either the operating position vertical or in a tilted position 2 Remove the flush connector from the bottom cowl 3 Remo...

Page 107: ...t and engage the front hook Lower the cowl into in seated position and apply downward pressure to the back of the cowl to lock it in place Ensure that the cowl is securely fastened by trying to pull up on the back of the cowl 29767 Cleaning Care for Top and Bottom Cowls IMPORTANT Dry wiping wiping the plastic surface when it is dry will result in minor surface scratches Always wet the surface befo...

Page 108: ...ild up from the powerhead and powerhead components with fresh water Keep water spray out of the air filter intake and alternator After washing allow the powerhead and components to dry Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components Do not allow the Corrosion Guard spray to come in contact with the alt...

Page 109: ...nsure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations IMPORTANT It is recommended required in some states that the battery be installed in an enclosed case Refer to regulations for your area Minimum SAE Starting Battery Requirements BCI GRP 24 MCA 1000 CCA 800 Ah 180 International Rating NOTE D...

Page 110: ...eference One 5 16 in and one 3 8 in hex nut are supplied per battery for wing nut replacement Metric hex nuts are not supplied Place decal on or near battery box for future service reference 5 16 and 3 8 hex nuts supplied for wing nut replacement Metric hex nuts not supplied NOTICE DTS Optimax Engines 37 895387 IMPORTANT Battery cable size and length is critical Refer to engine installation manual...

Page 111: ...heel cover to the rear mounting posts a b c 15247 a Flywheel cover bolts b FSM vent hose c Engine ventilation hose 3 Lift the flywheel cover off the front mounting post and the intake resonator 4 Remove three screws holding the upper flywheel cover to the lower flywheel cover 14309 5 Separate the two flywheel cover sub assemblies to access the air filter ...

Page 112: ...ilter from the lower flywheel cover assembly a b 14145 a Flywheel cover sub assembly b Air filter AIR FILTER INSTALLATION 1 Install the air filter onto the flywheel cover sub assembly a b 14145 a Flywheel cover sub assembly b Air filter ...

Page 113: ... flywheel cover a b 14314 a Upper flywheel cover latch opening b Lower flywheel cover latch 3 Push the two sub assemblies together and install three screws Tighten the three screws to the specified torque 14309 Description Nm lb in lb ft Screw 6 53 4 Install the flywheel cover onto the resonator and the front mounting post 5 Align the flywheel cover rear bolt holes with the rear mounting posts ...

Page 114: ...or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately IMPORTANT Use an approved container to collect and store fuel Wipe up spilled fuel immediately Material used to contain spilled fuel must be disposed of in ...

Page 115: ... with water the water can be removed If the filter becomes plugged with debris replace the filter Refer to the Inspection and Maintenance Schedule for the proper maintenance interval Filter Removal 1 Turn ignition key switch to OFF position 2 Remove fuel vapor purge relief valve cap located at the rear of the engine 14765 CAUTION Failure to release pressure from the fuel system will result in fuel...

Page 116: ...e release pressure by pushing core of valve end in 13282 4 Unscrew the filter in a counterclockwise direction to remove 14762 Filter Draining 1 Slide filter holder up to release from bracket Hoses and wire harness can remain attached to filter holder ...

Page 117: ...osition filter holder onto bracket and secure filter holder in place 2 Lubricate the sealing ring on the filter with oil 3 Install the filter and tighten securely by hand IMPORTANT Visually inspect for fuel leakage from the filter while turning the ignition key to the RUN position forcing fuel into the filter 14764 ...

Page 118: ...in salt water which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode Two anodes are located on each side of the gearcase Another anode is installed on the bottom of the transom bracket assembly 14812 Propeller Replacement 1 S...

Page 119: ...aft splines with one of the following Mercury Quicksilver products Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft splines 92 802867Q 1 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A1 6 Flo Torq II Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto ...

Page 120: ...le drive sleeve f Forward thrust hub 8 Place a block of wood between gearcase and propeller and torque to specifications Description Nm lb in lb ft Propeller nut 75 55 9 Secure propeller nut by bending three of the tabs into the thrust hub grooves 26945 Spark Plug Inspection and Replacement NOTE To gain access to the bottom spark plug remove the rear cover and rear cowl lock COWL LOCK AND REAR COV...

Page 121: ...s securing the rear cover Locate the two arrows pry points on the rear cover Use a thin blade screw driver at these pry points and pry out the cover Remove the rear cover 4 Remove the six screws securing the cowl lock and remove the lock Retain the two hex nuts that are used to fasten the top two screws a b c 29739 a Rear cover b Pry point arrow c Cowl lock ...

Page 122: ...e pencil coils from the spark plugs using a twisting motion a b c 3658 a Wiring harness connector b Pencil coil c Bolt 3 Remove the spark plugs to inspect Replace spark plug if electrode is worn threads of seal area are corroded or the insulator is rough cracked broken blistered or fouled 14794 4 Set the spark plug gap to specifications 27848 Spark Plug Spark plug gap 0 8 mm 0 0315 in ...

Page 123: ...que to specifications Description Nm lb in lb ft Spark plug 27 20 2 Push the pencil coils into place over the spark plugs using a twisting motion 3 Secure the coils with retained bolts Torque to specifications Description Nm lb in lb ft Bolts 8 71 4 Reconnect the wiring harness connectors to the pencil coil connections a b c 3658 a Wiring harness connector b Pencil coil c Bolt 5 Reinstall the cowl...

Page 124: ... screw 15 53 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 the overload If the cause is not found the fuse may blow again Remove the fuse puller from the engine ...

Page 125: ...fuse with a new fuse with the same amp rating 20 20 20 20 20 20 20 e g h j 2 i f c d a b 29731 a Fuse puller b Fuse holder c Good fuse d Blown fuse e Electronic Control Module and purge valve ECM 20 amp fuse f Ignition coils IGN COILS 20 amp fuse g Fuel delivery FUEL 20 amp fuse h Spare fuses 3 i Diagnostics terminal 2 amp fuse j Injector power and boost valve INJ PWR 20 amp fuse ...

Page 126: ...teners 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 d b c 29746 a Special washer head bolt 10 849838 b Flat washer ...

Page 127: ...lice or probe into any wire insulation of the DTS system Verify the harnesses are not routed near sharp edges hot surfaces or moving parts Verify that all unused connectors and receptacles are covered with a weather cap Verify that the harnesses are fastened along the routing path Accessory Drive Belt Inspection Inspect the accessory drive belt and have it replaced by an authorized dealer if any o...

Page 128: ...peller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 26902 3 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Sw...

Page 129: ...e through fitting a b 29759 a Swivel bracket b Tilt support lever Tilt Tube Lubricate through fitting a 29757 a Tilt tube fitting Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 ...

Page 130: ...tely retract the end of the steering cable before applying lubricant Steering Cable Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through the fitting b a 29763 a Fitting b Cable end Lubricate the following with Light Weight Oil Steering Link Rod Pivot Points Lubricate pivot points 29765 ...

Page 131: ... and check fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Precision Lubricants Power Trim Steering Fluid If not available use automotive ATF automatic transmission fluid 28460 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim system 92 858074K0 1 ...

Page 132: ...Y Engine oil capacity is approximately 6 0 liters 6 3 quarts PUMP METHOD IMPORTANT Tilt outboard out up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump IMPORTANT To reduce or prevent oil spillage when removing the oil filter make sure that the outboard is upright not tilted and the engine is cold or has not run for at least one hour 1 Tilt outboard out...

Page 133: ...hole is facing downward 3 Remove the drain plug seal and drain the engine oil into an appropriate container 4 Lubricate seal washer on the drain plug with oil and reinstall 15613 CHANGING OIL FILTER IMPORTANT To reduce or prevent oil spillage when removing the oil filter ensure that the outboard is upright not tilted and the engine is cold or has not run for at least one hour 1 Remove the top cowl...

Page 134: ...he filter counterclockwise 14772 Oil Filter Wrench 91 802653Q02 5221 Assists in removal of oil filter 4 Clean the oil filter mounting base 5 Apply film of clean oil to filter gasket Do not use grease 6 Screw new filter on until gasket contacts base then tighten 3 4 to 1 turn ...

Page 135: ...g or changing gearcase lubricant visually check for the presence of water in the lubricant If water is 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...

Page 136: ...RICANT CAPACITY Gearcase lubricant capacity is approximately 970 ml 32 8 fl oz for right hand rotation gearcases and 900 ml 30 4 fl oz for left hand rotation gearcases GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 970 ml 32 8 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1 Pl...

Page 137: ...ant until it appears at the vent hole a b 22693 a Vent hole b Fill hole IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer ...

Page 138: ...soline as possible from the fuel tank remote fuel line and engine fuel system IMPORTANT This outboard is equipped with a closed fuel system when the engine is not running With this closed system fuel within the engine s fuel system other than the fuel tank will remain stable during normal storage periods without the addition of fuel treatment stabilizers Fill the fuel tank and engine fuel system w...

Page 139: ...ark Plug Inspection and Replacement for correct procedure for removing spark plugs Remove pencil coils and spark plugs Spray approximately 30 ml 1 fl oz of Storage Seal Rust Inhibitor into each spark plug hole Tube Ref No Description Where Used Part No 119 Storage Seal Rust Inhibitor Spark plug holes 92 802878 5 6 Actuate key push button start switch to crank the engine through one start cycle whi...

Page 140: ...exhaust outlet in the gearcase can freeze Store the outboard in the full down position Battery Storage Follow the battery manufacturer s instructions for storage and recharging Remove the battery from the boat and check water level Recharge if necessary Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage ...

Page 141: ...onnection faulty Starter motor solenoid or slave solenoid failure Engine Will Not Start POSSIBLE CAUSES Incorrect starting procedure Refer to Operation section Old or contaminated gasoline Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank fil...

Page 142: ...type fuel tanks d Fuel line is kinked or pinched Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Overheating Warning horn not working Low oil pressure Check oil level Throttle not opening fully Damaged propeller or improper propeller size Incorrect engine timing adjustment or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bot...

Page 143: ...TROUBLESHOOTING 135 Defective rectifier alternator or voltage regulator Open circuit in the alternator output wire fused link ...

Page 144: ...he 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 contact your dealer or a...

Page 145: ...ebsite www mercurymarine com Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9793 5880 Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Recha...

Page 146: ...pan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Singapore 508762 Fax 5467789 ...

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