Mercury 2.5 TwoStroke Operation, Maintenance And Installation Manual Download Page 39

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Filling Fuel Tank

WARNING

Avoid serious injury or death from a gasoline fire or explosion. Use caution

when filling fuel tanks. Always stop the engine and do 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 completely filled.

FILLING PERMANENTLY INSTALLED TANKS

Slowly pour the correct amount of oil along with gasoline as the tank is being

filled.

FILLING PORTABLE FUEL TANKS

Remove the portable fuel tanks from the boat to refill them.
Pour the full amount of oil, along with one gallon of gasoline, into the fuel tank.

Mix thoroughly, then pour the remainder of the gasoline into the tank.

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.

FUEL AND OIL

eng

Summary of Contents for 2.5 TwoStroke

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 25 30 TwoStroke 8M0133465 717 eng ...

Page 2: ...eng ...

Page 3: ...anual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Manual included with the product The Warranty Manual contains a description...

Page 5: ...Skyhook SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine ...

Page 6: ...eng iv ...

Page 7: ...Hazards 9 Exhaust Emissions 11 Selecting Accessories for Your Outboard 13 Safe Boating Recommendations 13 Recording Serial Number 15 Model Year Production Code 16 25 30 Specifications 17 Components 18 Transporting Trailering Boat Outboard 24 Removing the Motor 24 Transporting Portable Fuel Tanks 25 Fuel and Oil Fuel Requirements 27 Oil Recommendation 28 Mixing Fuel and Oil 28 Filling Fuel Tank 29 ...

Page 8: ...d Maintenance Schedule 51 Flushing the Cooling System 52 Top Cowl Removal and Installation 54 Battery Inspection 55 Fuel System 55 Fuse Replacement Electric Start Remote Control Models 56 Corrosion Control Anode 56 Propeller Replacement 57 Spark Plug Inspection and Replacement 61 Lubrication Points 62 Gearcase Lubricant 62 Submerged Outboard 64 Storage Storage Preparation 65 Protecting External Ou...

Page 9: ...cury Marine Validated Engine Mounting Hardware 69 Installing Outboard 69 Installing the Remote Control Device 72 Attaching the Steering Link Rod 82 Battery Installation 83 Propeller Selection 84 Associated Parts Associated Parts 86 Accessories Accessories 87 Wiring Diagrams Wiring Diagrams 92 Owner Service Assistance Service Assistance 100 Ordering Literature 102 Maintenance Log Maintenance Log 10...

Page 10: ...eng viii ...

Page 11: ...ng with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

Page 12: ... performance boat with which you are unfamiliar we recommend that you do not operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat outboard combination For additional information obtain a copy of our Hi Performance Boat Operation booklet from your dealer distributor o...

Page 13: ...se 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 with common nuts nonlocki...

Page 14: ...s usually 122 152 cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator s PFD or wrist The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood o...

Page 15: ...hut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency if the operator is accidentally ejected WARNING If the ...

Page 16: ...ing in the water to take quick action to avoid a boat heading in his her direction even at slow speed 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to r...

Page 17: ...n the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can...

Page 18: ...use the boat to veer violently in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off ...

Page 19: ... control the boat speed Under these conditions boat speed should be kept to the minimum planing speed typically 24 to 40 km h 15 to 25 mph 26785 WARNING Avoid serious injury or death from all or part of an outboard or drive unit coming into the boat after striking a floating or underwater object When operating in waters where objects may be at the surface or just under the surface of the water red...

Page 20: ...ave an authorized Mercury Marine dealer inspect and repair the vessel or power package SAFETY INSTRUCTIONS FOR HAND TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion If an underwater obstacle is struck the outboard will tilt up and could seriously injure anyone occupying this area Models with Clamp Screws Some outboards come wi...

Page 21: ...ing the engines that propel boats and the generators that power boat accessories By itself CO is odorless colorless and tasteless but if you can smell or taste engine exhaust you are inhaling CO Early symptoms of carbon monoxide poisoning which are similar to the symptoms of seasickness and intoxication include headache dizziness drowsiness and nausea WARNING Inhaling engine exhaust gases can resu...

Page 22: ...side curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATION Under certain 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 an...

Page 23: ...ur selected accessories Safe Boating Recommendations To safely enjoy the waterways familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Pow...

Page 24: ...flotation devices Federal law requires that there be a U S Coast Guard approved life jacket personal flotation device correctly sized and readily accessible for every person onboard plus a throwable cushion or ring We strongly advise that everyone wear a life jacket at all times while in the boat Prepare other boat operators Instruct at least one person onboard in the basics of starting and operat...

Page 25: ... Your boat traveling at 40 km h 25 mph will overtake a fallen skier who is 61 m 200 ft in front of you in five seconds Watch fallen skiers When using your boat for waterskiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in sight and never back up to the skier or any...

Page 26: ...he year of manufacture as an alpha code This code can be deciphered into a corresponding number utilizing the following table XXXXXXXXX XXXXXXXX XXXX AG 62972 Serial number decal alpha code Model Year Manufactured Code Alpha Production Code A B C D E F G H K X Corresponding Number 1 2 3 4 5 6 7 8 9 0 Examples XX 2000 HK 2089 AG 2017 GENERAL INFORMATION 16 eng ...

Page 27: ...26 2 in3 Cylinder bore 68 mm 2 68 in Piston stroke 59 mm 2 32 in Exhaust system Through hub exhaust Cooling system Water cooled Starting system Manual Electric Manual Battery rating Minimum reserve capacity rating of 100 minutes and 350 cold cranking amps CCA Ignition CD ignition Spark plug NGK B7HS 10 or Champion L82C NGK BPR7HS 10 Spark plug gap 1 0 mm 0 035 in Alternator 12 V 80 W 6 7 amps Fuel...

Page 28: ...Components 37417 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 4 5 GENERAL INFORMATION 18 eng ...

Page 29: ... water intake 10 Propeller 11 Starter rope handle 12 Shift lever 13 Throttle grip 14 Clamp screw 15 Clamp bracket 16 Trim position pin 17 Upper oil plug 18 Cooling water intake 19 Lower oil plug 20 Connector B 21 Stop switch 22 Choke knob 23 Fuel tank 24 Primer valve 25 Fuel connector 26 Fuel tank cap 27 Air vent screw 28 Fuel pickup elbow GENERAL INFORMATION eng 19 ...

Page 30: ...37461 26 27 28 29 30 25 1 2 3 4 5 6 7 8 9 10 11 12 15 16 14 18 19 20 13 21 22 23 24 17 GENERAL INFORMATION 20 eng ...

Page 31: ... Propeller 11 Starter rope handle 12 Shift lever 13 Throttle grip 14 Clamp screw 15 Clamp bracket 16 Trim position pin 17 Battery cable 18 Upper oil plug 19 Cooling water intake 20 Lower oil plug 21 Connector B 22 Main switch 23 Stop switch 24 Choke knob 25 Fuel tank 26 Primer valve 27 Fuel connector 28 Fuel tank cap 29 Air vent screw 30 Fuel pickup elbow GENERAL INFORMATION eng 21 ...

Page 32: ...37463 26 27 28 29 30 25 1 2 3 4 5 6 7 8 9 10 11 12 14 15 13 17 18 19 20 16 21 22 23 24 GENERAL INFORMATION 22 eng ...

Page 33: ...peller 11 Starter rope handle 12 Shift lever 13 Clamp screw 14 Clamp bracket 15 Trim position pin 16 Battery cable 17 Upper oil plug 18 Cooling water intake 19 Lower oil plug 20 Connector B 21 Remote control box 22 Main switch 23 Stop switch 24 Cord assembly 25 Fuel tank 26 Primer valve 27 Fuel connector 28 Fuel tank cap 29 Air vent screw 30 Fuel pickup elbow GENERAL INFORMATION eng 23 ...

Page 34: ... clearance is required the outboard should be tilted up using an accessory outboard support device Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing Shift the outboard to forward gear This prevents the propeller from spinning freely Removing the Motor 1 Stop the engine 2 Disconnect the fuel connector from the m...

Page 35: ...upplied 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 the fuel tank air vent when transporting tank This will prevent escape of fuel or vapors from tank 26793 AUTO VENTING TYPE FUEL TANK 1 Disconnect the remote fuel line from tank This will close the air vent and prevent escape of fuel or vapors from...

Page 36: ... tether cap over the fuel line connector stem This will protect the connector stem from being accidentally pushed in allowing fuel or vapor to escape a Connector stem b Tether cap F a b 26794 TRANSPORTING 26 eng ...

Page 37: ...ently in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittin...

Page 38: ...oard Oil IMPORTANT Oil must be NMMA certified 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 da...

Page 39: ...l expand in volume as its temperature rises and can leak under pressure if the tank is completely filled FILLING PERMANENTLY INSTALLED TANKS Slowly pour the correct amount of oil along with gasoline as the tank is being filled FILLING PORTABLE FUEL TANKS Remove the portable fuel tanks from the boat to refill them Pour the full amount of oil along with one gallon of gasoline into the fuel tank Mix ...

Page 40: ...IC TILTING OPERATION The tilt feature allows the operator to tilt the outboard to a higher tilt angle for operation in shallow water or tilt 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 t...

Page 41: ...it down Reverse lock is done automatically a Reverse lock lever Shallow Water Operation The outboard is equipped with a shallow water tilt feature that allows you to tilt the outboard to a higher tilt angle to prevent hitting bottom IMPORTANT Before tilting the outboard into the shallow water drive position reduce engine speed to idle and shift engine into neutral gear 37535 a 37537 a FEATURES AND...

Page 42: ... drive position do not operate the outboard in reverse Operate the outboard at slow speed and keep the cooling water intake submerged Trim Adjustment Trim of the motor can be adjusted to suit the transom angle and loading conditions of your boat Be sure to maintain the anti ventilation plate parallel to the water level during cruising Correct trim Maintain the trim position pin perpendicular to th...

Page 43: ...g to your preference with the steering co pilot WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control When setting the friction adjustment maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released Adjust the steering co pilot to achieve desired steering friction Tu...

Page 44: ...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 tab at regular intervals Due to corrosion the trim tab will wear down over time IMPORTANT The trim tab also acts as an anode to prevent galvanic corrosion Do not apply any paint grease or other material...

Page 45: ...trim tab in the direction of C 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 37494 a b c d e FEATURES AND CONTROLS eng 35 ...

Page 46: ...o the gearcase is submerged This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other components If there is a chance of ice forming on the water the outboard should be removed and drained completely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possibl...

Page 47: ...reak in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures Break in running time 10 hours Time 0 min 10 min 1 hr 2 hrs 10 hrs Method of break in Trolling or idling Throttle opening 1 2 about 3 000 RPM Throttle opening 3 4 about 4 000 RPM Throttle opening 3 4 about 4 000 RPM Normal running Running conditions Crui...

Page 48: ...ank cap For tanks with a fuel tank auto air vent optional There is no need to loosen the air vent screw An air vent opens automatically when the connector is attached to the tank 37518 3 Feed fuel to the carburetor by squeezing the primer valve until firm a To fuel tank b To outboard c Fuel flow direction 37714 a c b OPERATION 38 eng ...

Page 49: ...els Set the shift lever to neutral position NOTE Be sure that the shift is at Neutral N when starting the engine This model is provided with start in gear protection 5 Turn the throttle grip until the bar mark on the grip faces the triangle mark on the steering handle 6 Pull out the choke knob fully No choke operation is necessary on warmed engine N 37521 7 Remote control models Insert the key OPE...

Page 50: ...ine is warm a Off b On c Push for choke operation 9 Place the control lever at Neutral N and move the throttle only lever to the open position a Fully opened position b Fully closed position c Throttle only lever d Ignition key switch e Lanyard stop switch 37466 a b c 37715 N c d e a b OPERATION 40 eng ...

Page 51: ...yard is disconnected Tiller handle models a Lanyard stop switch b Stop switch lock c Hook Remote control models a Hook b Off c On d Lanyard stop switch NOTE The engine will not start unless this switch has been properly connected and locked beforehand Refer to General Information Lanyard Stop Switch 37465 a b c 37716 a b c d OPERATION eng 41 ...

Page 52: ...Slowly b Rapidly IMPORTANT Before starting read the Prestarting Check List special operating instructions and Engine Break in Procedures in the Operation section 2 Tiller handle models Push the starter button 3 After the engine starts release the button 37524 4 Remote control models Insert push and turn the key to the start position 37523 a b OPERATION 42 eng ...

Page 53: ...thrown from their seats or out of the boat causing injury or death STARTING GUIDELINE Temperature Starting procedure Over 25 C 77 F Turn the throttle grip to the original position Pull the choke knob and rewind starter once Turn the throttle grip to start position push the choke knob back then pull the rewind starter until the engine starts 15 C 25 C 59 F 77 F Turn the throttle grip to start posit...

Page 54: ...o or out of gear unless the engine speed is at idle Shifting at higher than engine idle speed could cause damage to the gearcase Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed Shifting into reverse at higher boat speeds could cause the engine to stall and in some situations this could cause water to be drawn into the cylinders resulting i...

Page 55: ...e or rotate the throttle grip tiller handle to increase the engine speed Tiller handle models Turn the throttle grip to the slow position and move the shift lever to Forward F position swiftly when the engine speed drops to its lowest level a Reverse R b Forward F Remote control models Move the throttle only lever to the lower position then shift the control lever to Forward F position 37713 a b O...

Page 56: ... Shift range e Neutral N f Forward F g Reverse R h Throttle only lever REVERSE Tiller handle models Move the shift lever to the Reverse R position swiftly when the engine speed drops to its lowest level NOTE Confirm that the reverse lock lever is at the lock position a Reverse lock lever R Release L Lock 37531 a b c d e f g a b c d h 37538 a OPERATION 46 eng ...

Page 57: ...y increase the reverse speed NOTE Confirm that the reverse lock lever is at the lock position a Reverse lock lever R Release L Lock Stopping the Engine 1 Tiller handle models Reduce the speed to trolling speed by turning the throttle grip to the slow position 2 Place the shift lever at Neutral N 3 Press the stop switch until the engine stops completely or pull the lanyard stop switch 37877 37538 a...

Page 58: ...he instructions below After the engine stops tighten the air vent screw on the tank cap Disconnect the fuel connector from the engine For electric start models disconnect the cables from the battery when not in use for extended periods Emergency Starting If the starter system fails use the spare starter rope provided and follow procedure 1 Ensure the lanyard stop switch is in run position 37716 a ...

Page 59: ...the key switch is in the on position NOTE Confirm that the shift lever is in Neutral N 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 rewind starter assembly or top cowl when engine is running OPERATION eng 49 ...

Page 60: ...ilure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product CLEANING GAUGES IMPORTANT Never use high pressure water to clean gauges Routine cleaning of the gauges is recommended to prevent a buildup of salt and other environmental debris Crystalized s...

Page 61: ...procedure Cleaning and Waxing Procedure 1 Before washing rinse the cowls with clean water to remove dirt and dust that may scratch the surface 2 Wash the cowls with clean water and a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remove the applied wax...

Page 62: ...place the spark plugs Replace the water pump impeller dealer item Inspect the carbon fiber reeds if equipped dealer item Inspect the wire harness connectors dealer item Check the remote control cable adjustment if equipped dealer item Replace the high pressure fuel filter if equipped dealer item Replace the accessory drive belt if equipped dealer item Check the power trim fluid level if equipped d...

Page 63: ...ement Install the flushing attachment so the rubber cups fit tightly over the cooling water intake 27256 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 2 Attach a water hose to the flushing attachment Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure t...

Page 64: ...p indicator hole Continue flushing the outboard for 3 to 5 minutes carefully monitoring water supply at all times 6 Stop the engine turn off the water and remove the flushing attachment Install the propeller Top Cowl Removal and Installation REMOVAL 1 Unlock the rear latch by pushing lever down 29054 2 Lift rear of cowl and disengage front hook 26851 INSTALLATION 1 Engage the front hook and push c...

Page 65: ...ks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be ...

Page 66: ...ting circuit is protected from overload by an SFE 20 amp fuse If the fuse is blown the 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 Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase and in the cylinder An anode help...

Page 67: ...place the anode If the anode is worn out or no anode is fitted on the outboard motor aluminum parts will corrode more rapidly which can cause paint to peel off and damage the surface 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 ...

Page 68: ...se and the propeller to hold the propeller and remove the propeller nut 27296 4 Remove the propeller from the shaft If the propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer a Cotter pin b Nut c Washer d Propeller e Thrust hub 38055 a c d e b MAINTENANCE 58 eng ...

Page 69: ... 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed MAINTENANCE eng 59 ...

Page 70: ...onto the propeller shaft a Cotter pin b Nut c Washer d Propeller e Forward thrust hub f Propeller shaft 7 Place a block of wood between the gearcase and propeller and tighten the propeller nut 27341 8 Install the spark plug leads 37520 a b c d e f MAINTENANCE 60 eng ...

Page 71: ...he spark plug boots 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 to specification 26947 Spark Plug Spark plug gap 1 0 mm 0 035 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger ...

Page 72: ...e 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 temperatures will turn to ice and damage the gearcase Remove the fill drain pl...

Page 73: ...ear oil completely 37849 4 Place the lubricant tube into the fill drain hole and add the lubricant until it appears at the upper oil plug hole a Upper oil plug hole 5 Install the upper oil plug before removing the lubricant tube 37848 a MAINTENANCE eng 63 ...

Page 74: ... by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine Following are the emergency measures to be taken on the submerged outboard 1 Immediately take it out of the water and wash it with fresh water to remove salt or dirt 2 Remove the spark plugs and completely drain the water from the engine by pulling the rewind starter...

Page 75: ... prevent formation of varnish and gum Proceed with the following instructions Portable fuel tank Pour the required amount of gasoline stabilizer follow instructions on container into the fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently installed fuel tank Pour the required amount of gasoline stabilizer follow instructions on container into a separate container and...

Page 76: ...of storage seal around the inside of the cylinder Rotate the flywheel manually several times to distribute the storage seal in the cylinder Install the spark plug Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubricant Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a til...

Page 77: ...ection 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 f Fuel filter is obstructed Refer to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance secti...

Page 78: ...p 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 TROUBLESHOOTING 68 eng ...

Page 79: ...at utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have the following decal on the transom clamp 51965 Installing Outboard We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good per...

Page 80: ...apart Refer to General Information 25 30 Specifications for the transom height a Transom height 3 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 30 50 mm 1 2 2 in engine power performance is likely to be reduced as a result of increased water resistance to the gearcase assembly 37508 a 580 mm 37509 a a...

Page 81: ...lamp bracket Secure the engine with the supplied bolts and nuts Be sure to use the washers a Trim position pin holes b Bolt c Clamp screw d Nut TRANSOM MATCHING NOTE Be sure that the anti ventilation plate of the outboard is below the water surface when running at wide open throttle In case the above condition cannot be met due to a bottom shape of your boat please consult the dealer 30 50 mm 1 2 ...

Page 82: ... of the control levers and switches Confirm there is no obstacle in the passage of the remote control cables 37529 2 Remote control features a Fully opened position b Fully closed position c Throttle range d Shift range e Neutral N f Forward F g Reverse R h Throttle only lever 37531 a b c d e f g a b c d h ENGINE INSTALLATION 72 eng ...

Page 83: ...ions A plus B plus 300 mm 1 foot a Center of transom NOTE The minimum bend radius for a remote control cable is typically 203 mm 8 in Avoid making sharp bends 4 Connecting remote control cables to the remote control box Remove the back panel by loosening two screws a Back panel 37530 a A B 37528 a ENGINE INSTALLATION eng 73 ...

Page 84: ...yes b Locknut 6 Press the neck of the shift remote control cable down into the clamp on the housing of the remote control box Connect the terminal eye to the shift arm with the pin and E ring Insert a grommet supplied with the remote control box into the clamp a Grommet b Shift arm pin c E ring d Shift arm 11 mm a b 37497 37527 a b c d ENGINE INSTALLATION 74 eng ...

Page 85: ...control cable to the throttle arm in a manner similar to the shift remote control cable a Throttle cable b Shift cable c Throttle arm d Shift arm 8 Install the back panel a Back panel 37526 a b c d 37528 a ENGINE INSTALLATION eng 75 ...

Page 86: ...9 Install the remote control box with three screws spacers and nuts a Screw b Remote control box c Hull d Spacer e Washer f Nut 37464 a b c d e f ENGINE INSTALLATION 76 eng ...

Page 87: ...leeve guide B Connect remote control cable to shift lever h Shift lever i Advance arm j Ball joint k Holder cap Connect remote control cable to ball joint l Remove grommet from lower motor cover m Throttle remote control cable n Neck of remote control cable o Spacer p Clip q Stop switch harness 11 Attach a holder cap and a sleeve guide B 37495 a c d e f g b h i j k l m n o p q ENGINE INSTALLATION ...

Page 88: ...15 Throttle side Insert the throttle cable into a hole of the advancer arm at the lower cowl attach the ball joint to the holder cap at the tip of the remote control cable and fasten the remote control cable with a clip Attach a grommet to the lower cowl NOTE Place the control lever in Neutral N and the idling lever in the fully closed position 16 Shift side Insert the lock pin at the sleeve guide...

Page 89: ...owl as illustrated Fasten the cord assembly with clamps a Cord assembly b Black terminal c Brown terminal d Green terminal e Red terminal f Rectifier g Terminal holder h Fuse i Clamps j Blue terminal k Starter solenoid l CD unit m Choke solenoid 37505 a b c b c d f j i h j i g k l m n o r s p q e d ENGINE INSTALLATION eng 79 ...

Page 90: ...n Starter solenoid bracket o Lower cowl p Grommet q To remote control box r Clamp s Screw ENGINE INSTALLATION 80 eng ...

Page 91: ...Magnet lead wire c Cord assembly d Fuse wire e CD unit f Cord assembly g CD unit h Starter solenoid i Rectifier lead wire j Stop switch k Choke solenoid l Stop switch m Cord assembly YEL WHT RED BRN BLU BLK GRN YEL WHT RED BRN BLU BLK GRN RED 37500 a b c d e f g h i j k l m i ENGINE INSTALLATION eng 81 ...

Page 92: ...k Attaching the Steering Link Rod WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected loss of boat control resulting in serious injury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures ENGINE INST...

Page 93: ... k Washer A l Seal ring Battery Installation MOUNTING BATTERY Follow the battery manufacturer s instructions carefully Mount battery securely to the hull in a place free from splashing water NOTE Electric starting outboards must have the battery cables connected to a battery whenever the engine is running even if started manually as damage to the charging system could result a b c d e f a d g h d ...

Page 94: ... a battery Keep the battery in a well ventilated area during charging Remove the battery from the boat this will protect your hull and interior from damage Electric sparks cigarette smoking and other sources of fire must be avoided in the charging area to prevent explosion of the battery The battery fluid electrolyte contains sulfuric acid If electrolyte is spilled on the skin or clothes wash with...

Page 95: ...ng 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 outboard s durability Check full throttle RPM using an accurate tachometer with the engine trimmed out to a balanced steering conditi...

Page 96: ... handle 1 Screwdriver 1 Spare parts Starter rope 1 1000 mm Spark plug 1 NGK B7HS 10 or Champion L82C Gap 1 0 mm 0 035 in Cotter pin 1 Other Fuel tank 1 Primer bulb 1 set Remote control box 1 set Remote control attachment 1 set Steering link 1 set Flushing plug 1 Not included as standard accessories in some markets ASSOCIATED PARTS 86 eng ...

Page 97: ...ACCESSORIES a Speedometer 50 MPH b Speedometer 75 MPH c Fuel meter d Tachometer e Hour meter f Genuine engine oil g Genuine grease 50 g 250 g h Genuine gear oil 260 cc 500 cc 37846 a c b d e f g h i j k l ACCESSORIES eng 87 ...

Page 98: ...i Touch up spray paint 300 ml j Stop switch k Extension cord light l Meter lamp switch a Turnbuckle plate b Twin remote control turnbuckle assembly 37540 a b ACCESSORIES 88 eng ...

Page 99: ...a Steering spacer b Steering link assembly standard EP type 37506 a b ACCESSORIES eng 89 ...

Page 100: ...a Twin remote control box kit b 3 screws included in kit c 3 spacers included in kit d 6 spacers e Hull f 6 washers g 3 nuts 37493 a b c d e f g ACCESSORIES 90 eng ...

Page 101: ...a Automatic reverse lock kit 37504 a ACCESSORIES eng 91 ...

Page 102: ...Wiring Diagrams 37842 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 WIRING DIAGRAMS 92 eng ...

Page 103: ...ptional 8 Receptacle plug optional 9 Lamp 12 V 80 W AC 10 Tachometer optional 11 Separate cord yellow optional 12 Separate cord white optional 13 Flywheel magneto 14 Ignition coil 15 Spark plug 16 CD unit 17 Stop switch optional 18 Stop switch 19 Remote control stop cord optional 20 Remote control stop switch WIRING DIAGRAMS eng 93 ...

Page 104: ...37843 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 WIRING DIAGRAMS 94 eng ...

Page 105: ...re optional 6 Tachometer optional 7 Separate cord yellow optional 8 Separate cord white optional 9 Flywheel magneto 10 Ignition coil 11 Spark plug 12 CD unit 13 Stop switch optional 14 Stop switch 15 Battery 12 V 70 AH optional 16 Neutral switch 17 Main switch WIRING DIAGRAMS eng 95 ...

Page 106: ...37844 1 2 3 4 5 6 7 8 15 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 9 WIRING DIAGRAMS 96 eng ...

Page 107: ...neto 13 Exciter coil 14 Choke solenoid 15 CD unit 16 Ignition coil 17 Spark plug 18 Stop switch optional 19 Meter lead wire optional 20 Cord assembly 21 Remote control box see next page 22 Battery 12 V 70 AH 23 Battery cord black 24 Battery cord red 25 Assist cord blue optional 26 Assist cord red optional 27 Meter lamp switch optional 28 Voltmeter optional 29 Speedometer optional 30 Hour meter opt...

Page 108: ...37845 1 2 3 4 5 WIRING DIAGRAMS 98 eng ...

Page 109: ...1 Neutral switch 2 Main switch 3 Stop switch 4 Cord assembly 5 Meter lead wire optional WIRING DIAGRAMS eng 99 ...

Page 110: ...s in the recovery of stolen power packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer is required to reduce the possibility of serious engine damage REPLACEMENT SERVICE PARTS WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine produc...

Page 111: ...erial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geographic office in your area Please include your daytime telephone number with mail and fax correspondence United States Canada Telephone English 1 920 929 5040 Français 1 905 636 4751 Mercury Marine ...

Page 112: ...e Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O ...

Page 113: ...s Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Quantity Item Stock Number Price Total Total Due OWNER SERVICE ASSISTANCE eng 103 ...

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

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Mercury 2.5 TwoStroke, Operation, Maintenance And Installation Manual

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