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TROUBLESHOOTING

100

Engine Runs Erratically

POSSIBLE CAUSES

• Spark plugs fouled or defective. Refer to

Maintenance

section.

• Incorrect setup and adjustments.
• Fuel is being restricted to the engine.

• Engine fuel filter is obstructed. Refer to

Maintenance

section.

• Fuel tank filter obstructed.
• Stuck anti‑siphon valve on built in fuel tank.
• Fuel line is kinked or pinched.

• Fuel pump failure.
• Ignition system component failure.

Performance Loss

POSSIBLE CAUSES

• Throttle not fully open.
• Damaged or improper size propeller.
• Incorrect engine timing, adjustments, or setup.
• Boat overloaded or load improperly distributed.
• Excessive water in bilge.
• Boat bottom is dirty or damaged.

Battery Will Not Hold Charge

POSSIBLE CAUSES

• Battery connections are loose or corroded.
• Low electrolyte level in battery.
• Worn out or inefficient battery.
• Excessive use of electrical accessories.
• Defective rectifier, alternator, or voltage regulator.

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Summary of Contents for 15 E

Page 1: ...r 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 the...

Page 2: ...cifications designs methods or procedures without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2009 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 Ef...

Page 3: ...Gasoline Combustion cycle 2 Stroke This declaration is issued under the sole responsibility of Mercury Marine and Brunswick Marine in EMEA Inc Name and function Mark D Schwabero President Mercury Marine Fond du Lac WI USA Date and place of issue November 20 2008 Mercury Marine Fond du Lac WI USA European Regulations Contact Regulations and Product Safety Department Mercury Marine Fond du Lac WI US...

Page 4: ...iv ...

Page 5: ...overage and Exclusions 13 GENERAL INFORMATION Boater s Responsibilities 16 Before Operating Your Outboard 16 Boat Horsepower Capacity 17 Outboard Remote Control Models 17 Remote Steering Notice 18 Lanyard Stop Switch 19 Protecting People in the Water 21 Passenger Safety Message Pontoon Boats and Deck Boats 22 Wave and Wake Jumping 23 Impact with Underwater Hazards 24 Safety Instructions for Hand T...

Page 6: ...Motor 49 Trailering Boat Outboard 50 Transporting Portable Fuel Tanks 51 FUEL AND OIL Fuel Recommendations 53 Oil Recommendation 55 Mixing Fuel and Oil 55 ENGINE BREAK IN 56 Filling Fuel Tank 56 FEATURES CONTROLS Remote Control Features 58 Tilt Up and Tilt Down 58 Shallow Water Operation 59 Trim Angle Adjustment 61 Steering Friction Adjustment 62 Throttle Grip Turning Friction Adjustment 64 Trim T...

Page 7: ...gine 71 Starting The Engine 71 Gear Shifting 75 Stopping The Engine 78 Emergency Starting 79 MAINTENANCE Outboard Care 81 Inspection and Maintenance Schedule 81 Flushing The Cooling System 82 Top Cowl Removal and Installation 84 Battery Inspection 84 Fuel System 85 Exterior Care 86 Fuse Replacement Electric Start Remote Control Models 87 Replacing the anodes 87 Propeller Replacement 88 Spark Plug ...

Page 8: ...HOOTING Starter Motor Will Not Crank The Engine Electric Start Models 99 Engine Will Not Start 99 Engine Runs Erratically 100 Performance Loss 100 Battery Will Not Hold Charge 100 OWNER SERVICE ASSISTANCE Local Repair Service 101 Service Away from Home 101 Parts and Accessories Inquiries 101 Service Assistance 101 Mercury Marine Service Offices 102 MAINTENANCE LOG Maintenance Log 104 ACCESSORIES P...

Page 9: ...TABLE OF CONTENTS ix ASSOCIATED PARTS Associated Parts 108 NOTE 109 WIRING DIAGRAMS 9 9 15 18 110 EH Models 112 E Models 114 Single Remote Control Box 116 Wire Color Code Abbreviations 117 ...

Page 10: ...x ...

Page 11: ...ax 1 920 929 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 States and Canada 1 You may change ...

Page 12: ... Outside the United States and Canada 1 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area 2 The Warranty Registration Card identifies your name and address product model and serial numbers date of sale type of ...

Page 13: ...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 registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing r...

Page 14: ... commercial use customer Warranty coverage may be terminated for used or repossessed product or product purchased at auction from a slvage yard or from an insurance company CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which...

Page 15: ...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 16: ...red by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE O...

Page 17: ... product Unexpired warranty 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 pr...

Page 18: ...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 19: ...erage 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 20: ...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 21: ...haser 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 22: ...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 23: ...n 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 24: ...tenance 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 ...

Page 25: ...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 26: ...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 27: ...ry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 Outboard Remote Control Models The remote control connected to your outboard ...

Page 28: ...ing 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 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 ...

Page 29: ... 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 30: ...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 31: ...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 32: ...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 33: ... 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 the...

Page 34: ... 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 35: ... 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 other parts of the outboard or could affect control of the boat If continued running is necessary do so at greatly reduced speeds WARNING O...

Page 36: ...cles if the outboard is not attached to the transom correctly If an obstacle is struck at planing speed and the outboard is not securely fastened to the transom it is possible the outboard could lift off the transom and land in the boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboa...

Page 37: ...s 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 level of carbon monoxide WHILE BOAT IS STATIONARY 21626 a b a Running the engine when the boa...

Page 38: ...e 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 pe...

Page 39: ...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 40: ...ther property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record the serial number and other important information for future reference Please record the serial number of the engine as indicated on the lower engine cover and the cylinder block in the space below This numb...

Page 41: ...GENERAL INFORMATION 31 NOTE ...

Page 42: ...00 5300 rpm Number of cylinders 2 Displacement 247 mL Bore x stroke 55 x 52 mm 2 1 x 2 0 in Exhaust system Through hub exhaust Lubrication system Engine oil mixed gasoline Cooling system Thermostat controlled Starting system Manual Electric w manual backup Ignition Flywheel magneto CDI Spark plugs NGK B7HS 10 BR7HS 10 or CHAMPION L82C RL82C gap 1 0 mm 0 039 in Trim system Manual 6 positions Engine...

Page 43: ...g range 5200 5800 rpm Number of cylinders 2 Displacement 247 mL 294 mL Bore x stroke 55 x 52 mm 2 1 x 2 0 in 60 x 52 mm 2 3 x 2 0 in Exhaust system Through hub exhaust Lubrication system Engine oil mixed gasoline Cooling system Thermostat controlled Starting system Manual Electric w manual back up Manual Ignition Flywheel magneto CDI Spark plugs NGK B7HS 10 BR7HS 10 or CHAMPION L82C RL82C gap 1 0 ...

Page 44: ...GENERAL INFORMATION 34 Component Identification 40465 1 2 3 4 5 6 8 9 10 11 15 16 17 18 19 21 22 23 24 12 13 14 25 27 28 29 26 30 20 7 MH Models ...

Page 45: ...tilation plate 9 Anode trim tab 10 Sub water intake 11 Propeller 12 Oil plug upper 13 Water plug 14 Oil plug lower 15 Starter handle 16 Shift lever 17 Stop switch 18 Choke knob 19 Connetor B 20 Throttle grip 21 Clamp screws 22 Transom brackets 23 Thrust rod 24 Primer bulb 25 Fuel pick up elbow 26 Fuel connector 27 Fuel tank cap 28 Air vent screw 29 Fuel tank ...

Page 46: ...GENERAL INFORMATION 36 40466 1 2 3 4 5 6 8 9 10 11 15 16 17 18 19 21 22 23 24 12 13 14 26 28 29 30 27 31 20 7 25 EH Models ...

Page 47: ...te 9 Anode trim tab 10 Sub water intake 11 Propeller 12 Oil plug upper 13 Oil plug lower 14 Water plug 15 Starter handle 16 Shift lever 17 Stop switch 18 Starter switch button 19 Choke knob 20 Connectro B 21 Throttle grip 22 Clamp screws 23 Transom brackets 24 Thrust rod 25 Primer bulb 26 Fuel pick up elbow 27 Fuel connector 28 Fuel tank cap 29 Air vent screw 30 Fuel tank ...

Page 48: ...GENERAL INFORMATION 38 40467 1 2 3 4 5 6 8 9 10 11 15 16 17 18 19 21 22 23 24 12 13 14 26 28 29 30 27 31 20 7 25 32 33 34 35 E Models ...

Page 49: ...er intake 11 Propeller 12 Oil plug upper 13 Water plug 14 Oil plug lower 15 Starter handle 16 Shift lever 17 Stop switch optional 18 Choke knob 19 Connector B 20 Clamp screws 21 transom brackets 22 Thrust rod 23 Battery cord 24 Primer bulb 25 Fuel pick up elbow 26 Fuel connector 27 Fuel tank cap 28 Air vent screw 29 Fuel tank 30 Remote control box 31 Main switch 32 Stop switch 33 Cord asembly ...

Page 50: ...OM IMPORTANT Most boats are rated and certified in terms of their maximum horsepower and this is shown on the boat s certification plate Do not equip your boat with an outboard that exceeds this limit If in doubt contact your dealer Do not operate the engine unit until it has been securely mounted on the boat in accordance with the instructions below 1 Single engine Position the outboard motor at ...

Page 51: ... be met due to the shape of the bottom of the boat please consult the dealer IMPORTANT If the anti ventilation plate is at a level higher than the bottom of the boat overheating may occur as a lack of cooling water flow in the cooling systems 4 Clearance between the anti ventilation plate of the motor and the bottom of the boat must be 30 50 mm 1 2 2 in If the height difference exceeds 50 mm 2 in ...

Page 52: ...r WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware Do not accelerate above idle speed in water that may contain underwater obstacles if the outboard is not attached to the transom correctly In...

Page 53: ...ox 37529 3 Installing of the remote control cable engine side and the cord assembly wiring harness Fitting of holdercap and sleeve B guide Throttle side Attach the holder cap to the end of the cable and secure it with the nut 40468 a b c d e f a Cable outer groove b Throttle cable c Nut d Spring e Holder cap f Ball holder ...

Page 54: ... it with the nut 40469 a b c d e f g a Cable outer groove b Shift cable c Nut d Sleeve B guide e Lock pin f Spring g Spring pin Fitting of remote control cable to the engine Throttle side Set the throttle cable to the cable clip and connect the holder cap to the ball joint of advancer arm ...

Page 55: ...otter pin c Spring d Sleeve B guide e Spring pin f Shift lever g CD unit h Advancer arm i Ball joint j Ball holder k Holder cap l Spring m Washer n Grommet B is installed on the lower cowl o Cable of the throttle side p Cable outer groove q Cable clip r Lower cowl s Clamp t Steering hook plate u Shift cable clip NOTE Put the control lever on the Neutral N position and the Neutral warm up lever in ...

Page 56: ...tle is fully closed when the control lever is shifted to the Neutral N position If it is not adjust the position of the ball holder Connecting Electrical Harnesses Pass the cable assembly from the remote control box through the hole in the lower cowl and connect the electric terminals Secure the cable assembly with the clamp according to the drawing below 40471 a b c a d e f g h a a Clamp b Starte...

Page 57: ... to the negative terminal of the battery Put a red cap on the positive terminal When disconnecting battery cables be sure to disconnect the black cable first and then the red cable Required battery rating 12 V battery with a recommended capacity of 40AH or more Battery cables must be long enough to allow free steering Battery cables must be arranged and protected from damage during steering With p...

Page 58: ...der average operating conditions Propeller must be selected so that the engine rpm when cruising with a wide open throttle is within the recommended range Model Wide open throttle rpm range 9 9 4500 5300 rpm 15 18 5200 5800 rpm 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 boa...

Page 59: ...er whenever you carry the motor Carrying the Motor Be sure to keep the engine vertical posture whenever you carry the motor 39485 NOTE If you carry the motor horizontal posture keep the power head higher than the propeller IMPORTANT Beware of explosion danger Spilled and vapored gasoline may easily catch fire and explode Be sure to fully discharge gasoline from the carburetors when transporting th...

Page 60: ... vertical normal running fully down position NOTE Trailering in the tilted position may cause damage to the motor boat etc If trailering with engine fully down is not available the gearcase skeg is too close to the road in a vertical position attache the motor securely using a device like a transom saver bar in the tilted position 39486 Shift the outboard to forward gear This prevents the propelle...

Page 61: ...the outboard in the tilted position when trailering Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion Follow the transporting instructions supplied with the portable fuel tank Transport the fuel tank in a well ventilated area away from open flame or sparks MANUAL VENTING TYPE FUEL TANK Close fuel tank air vent when transporting tank This will ...

Page 62: ...ING 52 2 Install tether cap over the fuel line connector stem This will protect the connector stem from being accidently pushed in thus allowing fuel or vapor to escape F a b 26794 a Connector stem b Tether cap ...

Page 63: ...rand 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 M...

Page 64: ...at contains more than 10 ethanol or more than 5 methanol Damages resulting from the use of gasolines that contain alcohol acetone or benzene are not covered under the limited warranty WARNING Fuel leakage is a fire or explosion hazard which can cause serious injury or death Periodically inspect all fuel system components for leaks softening hardening swelling or corrosion particularly after storag...

Page 65: ...ed TC W3 2 Cycle oil Mercury or Quicksilver Premium TC W3 2 Cycle oil is recommended for this engine For added protection and lubrication Mercury or Quicksilver Premium Plus TC W3 2 Cycle oil is recommended If Mercury or Quicksilver outboard oil is not available substitute another brand of 2 cycle outboard oil that is NMMA Certified TC W3 Severe engine damage may result from use of an inferior oil...

Page 66: ...nks 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 Always stop engine before refilling tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is...

Page 67: ...FUEL AND OIL 57 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 ...

Page 68: ...the outboard to the full up position When running the outboard keep the tilt lever in the release position This allows the outboard to return to the running position if the outboard should hit an underwater obstacle and be lifted up Moving the tilt lever to the tilt position will allow the outboard to lock into the shallow water drive position or the full up position IMPORTANT When tilting up or d...

Page 69: ...e engine slightly and then allow gravity to lower it for you 39484 a b c a Tilt down position b Tilt up position c Reverse lock lever Shallow Water Operation IMPORTANT When shallow water operation be careful not to place your hand between the swivel bracket and the stern bracket Besure to tilt the outboard down slowly NOTE Slow down to trolling speed and shift to the Neutral N before shallow water...

Page 70: ...tion and tilt up the engine to put the engine in the shallow water running position 37535 a a Reverse lock lever 3 Tilt down Pull the reverse lock lever in the tilt down position slightly lift up the engine then put it down 39484 a b c a Tilt down position b Tilt up position c Reverse lock lever ...

Page 71: ...djustment The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the adjustment holes provided Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort The following instructions explain how to set the best angle of the boat The tilt pin should be adjusted so the outboard is positioned to run perpendicula...

Page 72: ...r position Trim up If the trim angle is too small the bow will dip into water the speed will decrease and water may enter the boat In this case the trim angle should be increased by setting the trim position pin in a higher position 37883 a b c d e f a Correct trim b Trim down c Trim up d Trim position pin e Move pin to raise bow up f Move pin to lower bow down Steering Friction Adjustment Steerin...

Page 73: ...eering into a full turn if the tiller handle or steering wheel is released Adjust the steering co pilot to achieve desired steering friction Turn clockwise for more friction Turn counterclockwise for less friction 40867 a a Steering co pilot NOTE The steering adjust bolt is used to adjust the sliding load of the steering but not to correct the steering If excess tightening given to the bolt may ca...

Page 74: ...y unequal steering effort Operate the boat at normal cruising speed with the outboard set at the desired operating angle position Turn the boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen the trim tab bolt and make small adjustments at a time After adjustment securely tighten the trim tab bolt NOTE Check for looseness of the bolt and the trim ...

Page 75: ...irection of B If the boat steers toward the right set the trim tab in the direction of C 37494 a b c d e a Trim tab b Steers toward the left set the trim tab in the direction of B c Steers toward the right set the trim tab in the direction of C d Turning left e Turning right REMOTE CONTROL LEVER FRICTION Throttle friction adjustment screw ...

Page 76: ...tle friction adjustment screw on the front of the remote control box Turn clockwise to increase the friction and counterclockwise to decrease it 38385 a b c a Turn counterclockwise to decrease the friction b Turn clockwise to increase the friction c Throttle friction adjustment screw ...

Page 77: ...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 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 component...

Page 78: ...wer elevation unless the jets are changed again to correspond to the new elevation Operating your outboard at an elevation higher than 750 m 2500 ft above sea level may require a carburetor jet change and or different pitch propeller Consult your dealer This will reduce the normal performance loss experienced as a result of reduced oxygen in the air causing an overly rich fuel mixture Operating Ou...

Page 79: ...r damage Provide a sufficient supply of water to the water inlets during operation 2 Loosen the air vent screw on the tank cap 37518 3 Feed fuel to the carburetor by squeezing the primer bulb until it is firm 37714 a c b a To fuel tank b To engine c Fuel flow direction 4 Make sure the cooling water intake is submerged 27029 ...

Page 80: ... recommended engine oil TCW 3 1 ENGINE BREAK IN FUEL MIXTURE Use a 1 25 oil gasoline mixture in the first tank of fuel Use Mercury or Quicksilver engine oil or the recommended oil TCW 3 BREAK IN Break in period 10 hours Vary the throttle setting during the first hour of operation During the first hour of operation avoid remaining at a constant speed for more than two minutes and avoid sustained wi...

Page 81: ...without water discharging from the water pump cooling water hole or idle hole the engine may overheat 40472 a b a Water pump cooling water hole b Idle hole Engine speeds Idling speed after warming up Clutch in Clutch off 800 rpm 950 rpm Starting The Engine Before starting read the Pre Starting Check List Special Operating Instructions and Engine Break in Procedure in the Operation Section Electric...

Page 82: ... your dealer Operating the engine while overheated will cause serious engine damage 1 9 9 15 18 EH Models Place the shift lever in the Neutral N position 38030 NOTE Be sure that the shift is in Neutral N when starting the engine This model is provided with a function that prevents starting in gear protection IMPORTANT If the motor somehow does start in gear do not use it Contact your authorized de...

Page 83: ... the engine is warm N 37521 4 9 9 15 18 Pull the starter handle slowly until you feel resistance Then pull it quickly 37523 a b a Pull slowly b Pull quickly 5 EH Models Push the starter switch button 6 Release pushing the button when the engine has started 39481 a a Starter switch button ...

Page 84: ...odels Insert the main switch key 8 Set the control lever in the Neutral N position Raise the Neutral N warm up lever 37715 N c d e a b a Fully opened b Fully closed c Neutral warm up lever d Ignition key e Stop switch 9 Turn the main switch key to START position Then continuously push the key to operate the choke ...

Page 85: ...ift in Forward F or Reverse R NOTE E and EH Models Continuous operation of the starter motor shorter battery and starter motor life Operate the starter motor for a maximum of 3 seconds If the engine does not start wait 5 seconds before engaging the starter motor again Do not engage the starter motor after the engine has started Gear Shifting IMPORTANT Observe the following Never shift outboard int...

Page 86: ...he throttle grip to reduce engine speed When the engine reaches trolling speed quickly pull the shift lever to the Forward position 2 Reverse As when shifting to Forward reduce the engine speed when the engine reaches trolling speed quickly push the shift lever to the Reverse position ...

Page 87: ...tton located at the bottom of the control lever grip Further shifting will open the throttle 5 Reverse Quickly pull the control lever to the Reverse R position at 32 where the gear is connected while lifting up on the lock button located at the bottom of the control lever grip Further shifting will open the throttle NOTE The control lever is inoperative unless the Neutral warm up lever is in the f...

Page 88: ...osition 2 Put the shift lever into Neutral position Run the engine for 2 3 minutes at idling speed if it has been running at full speed 3 Push the stop switch to stop the engine 37877 E Models 1 Put the shift lever into Neutral N position and run the engine for 2 3 minutes at idling speed 37882 N ...

Page 89: ...he air vent screw on the tank cap Disconnect the fuel connector of the engine or the fuel tank Disconnect the battery cable of the EH or E type engine if the engine will not be used for more than 3 days Emergency Starting If the starter system fails use the spare starter rope provided and follow procedure Remove the top cowl and use the spare starter rope provided and follow procedure 1 Pull direc...

Page 90: ...e engine Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running ...

Page 91: ...n and Maintenance Schedule BEFORE EACH USE Check that lanyard stop switch stops the engine Visually inspect the fuel system for deterioration or leaks Check outboard for tightness on transom Check steering system for binding or loose components Remote control models Visually check steering link rod fasteners for proper tightness See Steering Link Rod Fasteners Check propeller blades for damage AFT...

Page 92: ... 1 Remove engine deposits with Mercury Precision or Quicksilver Power Tune Engine Cleaner Check tightness of bolts nuts and other fasteners Clean fuel tank pick up filter EVERY 300 HOURS OF USE OR THREE YEARS Replace water pump impeller more often if overheating occurs or reduced water pressure is noted 1 BEFORE PERIODS OF STORAGE Refer to Storage procedure See Storage section Flushing The Cooling...

Page 93: ...and screw in the flushing attachment hose adapter 2 Connect a hose to the flushing attachment to flush out the inside of the motor with water Be sure to seal the water strainer and sub water strainer located in the gear case with tape 39488 3 With the shift lever in Neutral N run the engine at a low speed while flushing the cooling system to ensure all sea water and mud are removed 4 Check for a s...

Page 94: ...e battery should be inspected at periodic 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 Make sure the battery is secure against movement 3 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative ...

Page 95: ...oved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs ...

Page 96: ...uel filter 3 Fuel tank Water or dirt in the fuel tank may cause engine trouble Clean the tank at specified times or after the motor has been store for a long period over three months IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wa...

Page 97: ... electric starter motor will not operate Try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Replace fuse with a fuse of the same rating 3036 Replacing the anodes The outboard has a corrosion control anode installed on the gearcase An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of...

Page 98: ...lt as it is likely to be subjected to electrolytic corrosion Propeller Replacement WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller...

Page 99: ...of wood between gearcase and propeller to hold propeller and remove propeller nut 27296 4 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 38055 a c d e b a Cotter pin b Nut c Washer d Propeller e Thrust hub ...

Page 100: ...o 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C with Teflon Propeller shaft 92 802859A 1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water 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 ...

Page 101: ...st hub propeller nut and cotter pin onto the shaft 37520 a b c d e f a Cotter pin b Nut c Washer d Propeller e Propeller thrust hub f Propeller shaft 7 Place a block of wood between gearcase and propeller and tighten propeller nut 27341 8 Reinstall spark plug leads ...

Page 102: ...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 blistered or fouled 26946 3 Set the spark plug gap 0 9 1 0 mm 26947 Spark Plug NGK B7HS 10 or BR7HS 10 or recommended ...

Page 103: ...tion Points Only let an authorized Mercury service shop perform service or maintenance on this product Be sure to use genuine parts genuine lubricants or recommended lubricants Changing gear oil 1 Place the outboard in a vertical operating position 2 Place a drain pan below the outboard 3 Remove the oil plugs upper and lower and drain the gear oil completely 40473 b a c a Upper oil plug b Lower oi...

Page 104: ...ube nozzle and install the lower oil plug IMPORTANT Use Mercury Quicksilver gear oil or the recommended one APL GL 5 SAE 80 to 90 Required volume Approximate 370 ml 0 10 gal 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 servicing dealer is necessary once the engine ...

Page 105: ...ation in preparing your outboard for storage is to protect it from rust corrosion and damage caused by freezing of trapped water The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage two months or longer NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide...

Page 106: ...his mixture into fuel tank Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for ten minutes to fill the engine fuel system Flushing Device 91 44357Q 2 9192 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the engine Protecting External Outboard Components Lubricate all outboard compo...

Page 107: ...to carburetor until engine stops from lack of fuel Remove the spark plugs and inject a five second spray of storage seal around the inside of the cylinder Rotate the flywheel manually several times to distribute the storage seal in the cylinder Reinstall spark plug Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage Store outboard in an u...

Page 108: ...STORAGE 98 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 109: ... Engine Will Not Start POSSIBLE CAUSES Lanyard stop switch not in RUN position Incorrect starting procedure Refer to Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching the engine a Fuel tank is empty b Fuel tank vent not open or restricted c Fuel line is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty ...

Page 110: ... or pinched Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not fully open Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low elec...

Page 111: ...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 112: ...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 113: ...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 ...

Page 114: ...MAINTENANCE LOG 104 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

Page 115: ... 5200 to 5800 RPM Light boats Heavy boats Size as indicated on propeller 10 9 8 5 8 7 6 Propeller size diameter x pitch 234x250 mm 9 2x9 8 in 234x231 mm 9 2x9 1 in 234x224 mm 9 2x8 8 in 234x199 mm 9 2x7 8 in 234x174 mm 9 2x6 9 in 234x155 mm 9 2x6 1 in Model 18 optional S L UL optional optional 15 optional optional S L UL optional 9 9 optional optional S L UL optional S short L long UL extra long T...

Page 116: ...ACCESSORIES 106 Accessories OPTIONAL ACCESSORIES 40476 a b c d e g h f ...

Page 117: ... b Tachometer c Mercury Quicksilver grease 250 g d Mercury Quicksilver gear oil 500 mL e Touch up paint f Mercury Quicksilver engine oil 0 4 L 1 L 4 L 20 L g Flushing attachment h Extension cord for light Lights are available on the market ...

Page 118: ...et wrench 1 21 mm Socket wrench handle 1 Screwdriver 1 Spare parts Starter rope 1 1000 mm Spark plug 1 NGK B7HS 10 or Champion L82C Gap 1 0 mm Cotter pin 1 Other Fuel tank 1 Primer bulb 1 set Remote control box 1 set E Models only Remote control attachment 1 set E Models only Not included as standard accessories in some markets ...

Page 119: ...ASSOCIATED PARTS 109 NOTE ...

Page 120: ...WIRING DIAGRAMS 110 9 9 15 18 39493 a b c d e f g h i j k l m o p q r n ...

Page 121: ...xtension cord for light optional g Receptacle plug optional h Lamp 12V 80W AC available on the market i Tachometer optional j Tachometer lead wire optional k Separate cord white optional l Separate cord white optional m Flywheel magneto n Spark plug o Ignition coil p CD unit q Stop switch r Stop cord optional ...

Page 122: ...WIRING DIAGRAMS 112 EH Models 39494 a b c d e f g h i j k l m n o p q ...

Page 123: ...arter cord e Starter solenoid f Fuse g Rectifier h Tachometer i Tachometer lead wire optional j Separate cord yellow optioal k Separate cord white optioal l Flywheel magneto m Spark plugs n Ignition coil o CD unit p Stop switch q 12V 40AH or 12V 70AH abilable on the market ...

Page 124: ...WIRING DIAGRAMS 114 E Models 39495 a b c d e f g h n f g f j j k l m q o p ...

Page 125: ...able on the market c Tachometer d Battery cord e Tachometer lead wire optional f Fuse 15A g Starter solenoid h Flywheel magneto i Spark plugs j Ignition coil k CD unit l Lead wire black m Lead wire brown n Starter moter o Choke solenoid p Battery cord q Stop switch optional ...

Page 126: ...WIRING DIAGRAMS 116 Single Remote Control Box 39496 a b c d ...

Page 127: ...tch c Stop switch d Cord assembly Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN or ORG Orange PNK Pink PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark ...

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