Mercury 225 Sport XS OptiMax User Manual Download Page 70

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MAINTENANCE

Removal

or39-1

a -

O‑ring seals

b -

Filter

c -

Raised bosses

1. Disconnect the link rod.
2. Use the shaft of a screwdriver between the filter cap bosses and

unscrew the filter.

Installation

1. Lubricate the o‑ring seals with oil.
2. Install the fuel filter and tighten securely.
3. Reconnect the link rod.

IMPORTANT: Visually inspect for fuel leakage from the filter while

squeezing the primer bulb until firm, forcing fuel into the filter.

Summary of Contents for 225 Sport XS OptiMax

Page 1: ...ctured by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the factory procedure for servicing the product must be strictly followed...

Page 2: ...et forth in the Warranty Information Section of this manual The warranty statement contains a description of what is covered what is not covered the duration of coverage how to best obtain warranty coverage important disclaimers and limitations of damages and other related information Please review this important information The description and specifications contained herein were in effect at the...

Page 3: ...th service CSI Customer Satisfaction Index score for warranty service Possesses all necessary service tools test equipment manuals and parts books Employs at least one Certified or Master technician Provides timely service for all Mercury Marine customers Offers extended service hours and mobile service when appropriate Uses displays and stocks adequate inventory of genuine Mercury Precision Parts...

Page 4: ...iv ...

Page 5: ... 16 Boat Horsepower Capacity 16 Intended Boat Application 17 Outboard Remote Control Models 17 Remote Steering Notice 18 Lanyard Stop Switch 19 Protecting People In The Water 20 Exhaust Emissions 21 Passenger Safety Message Pontoon Boats And Deck Boats 22 Wave And Wake Jumping 24 Impact With Underwater Hazards 25 Selecting Accessories For Your Outboard 26 Safe Boating Suggestions 26 Recording Seri...

Page 6: ... 45 Operation Engine Break in 47 Engine Break in Fuel Mixture 47 Pre Starting Check List 47 Operating In Freezing Temperatures 48 Operating In Salt Water Or Polluted Water 48 Operating at High Elevations 48 Effects of Elevation and Weather on Performance 49 Setting Trim Angle While Running Engine at Idle Speed 50 Operating in Shallow Water 50 Starting The Engine 51 Gear Shifting 54 Stopping The En...

Page 7: ...g Trim System Fluid Level 74 Gearcase Lubricant 76 Storage Storage Preparation 78 Protecting Internal Engine Components 80 Protecting External Outboard Components 80 Gearcase 80 Positioning Outboard For Storage 81 Battery Storage 81 Troubleshooting Starter Motor Will Not Crank the Engine 82 Engine Will Not Start 82 Engine Runs Erratically 82 Performance Loss 83 Warning Horn Activates With Power Lo...

Page 8: ...TABLE OF CONTENTS viii Mercury Marine Service Offices 86 Ordering Literature 87 Maintenance Log Maintenance Log 88 ...

Page 9: ...ercury Marine will record the registration IMPORTANT Your warranty coverage begins at the time of sale but warranty claims cannot be processed until the product is registered with Mercury Marine 3 Upon processing the warranty registration Mercury Marine will send the purchaser a Mercury Owner Resource Guide The back page of this guide contains your warranty registration information and should be s...

Page 10: ...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 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 R...

Page 11: ...ich generates income for any part of the warranty period even if the product is only occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use c...

Page 12: ...p 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 routine maintenance items tune ups adjustments normal 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 Operatio...

Page 13: ...EY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHE...

Page 14: ...on repairing a corroded part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reason...

Page 15: ...yl Tin Adipate TBTA base anti fouling paints are recommended on Outboard and MerCruiser boating applications In areas where TBTA base paints are prohibited by law copper base paints can be used on the hull and transom Do not apply paint to the outboard or MerCruiser product In addition care must be taken to avoid an electrical interconnection between the warranted product and the paint For MerCrui...

Page 16: ...erning 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 with normal services 2 Factory installed jet drive unit...

Page 17: ...r 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 which could result in a failure condition responsible for noise should be corrected under the warranty 12 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard 13 Water entering e...

Page 18: ... or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board for the period of time and under the conditions identified below The cost to diagnose a warranty failure is covered under the warranty if the warranty claim is approved Damage to ...

Page 19: ...S NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal 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 General Information Specifications operation of the product in a manner inconsistent with the recommended operation proced...

Page 20: ... by the use of a non exempted add on or modified part will not be covered COMPONENTS OF THE EMISSIONS CONTROL SYSTEM 1 Fuel Metering System a Carburetor and internal parts and or pressure regulator or fuel injection system b Cold start enrichment system c Intake valves 2 Air Induction System a Intake manifold b Turbocharger or supercharger systems where applicable 3 Ignition System a Spark plugs b...

Page 21: ...he emission control system warranty on your 2001 model year and later outboard engine In California new outboard engines must be designed built and equipped to meet the State s stringent anti smog standards Mercury Marine must warrant the emission control system on your outboard engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your out...

Page 22: ...garding your warranty rights and responsibilities you should contact Mercury Marine at 1 920 929 5040 Star Label Outboards are labeled on the cowl with one of the following star labels The Symbol for Cleaner Marine Engines Means Cleaner Air and Water for a healthier lifestyle and environment Better Fuel Economy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engi...

Page 23: ...aust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines RN F T ob00711 Four Stars Super Ultra Low Emission The four Star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engin...

Page 24: ...s 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 WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or p...

Page 25: ...ng in excess of 80 miles per hour If you intend to use this engine on a boat capable of reaching or exceeding this speed an authorized Mercury Marine dealer must Install solid engine mounts Install a Sport Master gearcase Train the operator in high speed boat operation If you plan to use your outboard on a high speed or high performance boat with which you are unfamiliar Mercury Marine recommends ...

Page 26: ...ing link rod that connects the steering cable to the engine must be fastened utilizing self locking nuts These self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occ...

Page 27: ...o anyone in the boat s path as seriously as the boat would when under power ob00310 a b a Lanyard cord b Lanyard stop switch 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 e g if the operator is accidentally ejected WARNING Should the operator fall out of the boat the possibility of ...

Page 28: ...ake quick action to avoid a boat heading in their direction even at slow speeds ob00311 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 even coasting and the gear shift is in NEUTRAL there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rota...

Page 29: ...on of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes ob00316 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canva...

Page 30: ...serve the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of boat Falling over the front of the boat between the two pontoons will pos...

Page 31: ... pontoon or deck boat and being run over Stay back from the front end of the deck and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed c...

Page 32: ...ause occupants to be thrown out of their seats or out of the boat WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to a boat hand hold There is another less common hazardous result from allowing your boa...

Page 33: ...ld result in an infinite number of situations Some of these situations could result in the following Part of the outboard or the entire outboard could break loose and fly into the boat The boat could move suddenly 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 A rapid reduction in speed This will cause occupants to be thro...

Page 34: ...essories The misuse of acceptable accessories or the use of unacceptable accessories can result in serious injury death or product failure Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Sug...

Page 35: ...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 36: ...ere is complete 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 20XX XX OTXXXXXX XXXX b e a d ob00319 c a Serial number b Model year c Model designation d Year manufactured e Certified Europe Insignia as applicable Specifications 225 Pro XS an...

Page 37: ...nleaded 87 R M 2 octane 92 RON Recommended Oil Premium Plus TC W3 2 Cycle Gearcase Oil Hi Performance Gear Lube Gearcase Lubricant Capacity 710 ml 24 fl oz Battery Rating 1000 MCA Marine Cranking Amps 800 CCA Cold Cranking Amps 105 Amp Hours1 Charging System Output 50 Amps Max NOTE Where applicable specifications are derived at sea level Special Tools and Kits Description Part Number Stainless Ste...

Page 38: ...sides Propeller Selection Propping the engine at the higher end of the RPM range may increase acceleration but decrease top boat speed Conversely propping the engine at the lower end of the range may increase top boat speed but hinder acceleration Mercury Marine recommends selecting a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the ...

Page 39: ...PM change between propeller pitches ob00323 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 t...

Page 40: ...e clutch misalignment preventing the gearcase from shifting into gear Trailer your boat with the outboard tilted down in a vertical operating position If additional ground 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 b...

Page 41: ...TS OUTSIDE THE U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium 2 92 RON USING REFORMULATED OXYGENATED FUELS USA ONLY This type of fuel is required in certain areas of the U S The two 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 the Fuel Containing Alcohol section These re...

Page 42: ...g alcohol may increase Corrosion of metal parts Deterioration of rubber or plastic parts Fuel permeation through rubber fuel lines Starting and operating difficulties CAUTION When operating a Mercury engine with fuel containing alcohol avoid storing the fuel in the fuel tank for long periods of time Long storage periods common to boats create unique problems In cars alcohol blend fuels are normall...

Page 43: ...ard oil can reduce engine durability Damage from use of inferior oil may not be covered under the limited warranty Filling Remote Oil Tank Remove filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 gallons Replace filler cap and tighten securely IMPORTANT Always make sure the oil tank caps are threaded on tight An air leak will prevent oil flow to the engine or27 Filling ...

Page 44: ...om boat to refill them 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 WARNING Avoid serious injury or death from a gasoline fire or explosion Always stop the engine and do not smoke or allow open flames ...

Page 45: ...ii ob00329 a Control handle forward neutral reverse b Neutral release lever c Trim tilt switch if equipped Refer to Features Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON ST...

Page 46: ...es a warning horn inside the boat The warning horn may be located inside the remote control or under the dash connected to the ignition key switch a b ob00662 a Inside the remote control b Under the dashboard WARNING HORN SIGNALS When the key switch is turned to the ON position the horn will turn on for a moment as a test to tell you the horn is working ...

Page 47: ...dian System is activated the system must be reset before the engine will operate at higher speeds Moving throttle lever back to idle or to the required reduced throttle position resets the system Problem Horn Monitor Display Guardian Activated Percentage of Full Engine Power Available Power Up System Check Single Beep Yes N A N A During Engine Break In No No No 100 Low Oil in Engine Oil Tank 4 Bee...

Page 48: ...ctor Failure No Yes No N A SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this power package A few functions the instrument packages display are Engine RPM Coolant temp Water pressure Battery voltage Fuel consumption Engine operating hours The SmartCraft Instrument package will also aid in Engine Guardian diagnostics The SmartCraft Instrument package will di...

Page 49: ...ithin five seconds the Guardian Systems reduces available engine power To reset the Guardian System protection 1 Completely reduce throttle for two to three seconds 2 Re engage the throttle If the engine does not respond repeat step one Power Trim And Tilt NOTE Outboard position can be adjusted by pressing trim switch The trim range is used while operating your boat on plane The tilt range is used...

Page 50: ...ous firm grip on the steering wheel when this condition exists can result in loss of boat control as the outboard can turn freely The boat can now spin out or go into a very tight maximum turn which if unexpected can result in occupants being thrown within the boat or out of the boat Consider the following lists carefully Trimming in down can Lower the bow of the boat Result in quicker planing off...

Page 51: ...or death Always perform a water test to examine boat handling and steering after making any trim in limiting adjustments Operating a boat with a full trim angle without the aid of a trim in limiting device may result in undesirable or unsafe steering conditions IMPORTANT Some boat engine combinations not using a trim angle adjustment device or trimmed to the full trim in position may not exhibit a...

Page 52: ...p until the switch is released or it reaches the maximum tilt position 1 Engage the tilt support lever by pushing the metal stop and rotating the knob to bring the support lever upward b c a or33 1 a Tilt support lever b Metal stop c Knob 2 Lower the outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever un...

Page 53: ...using the power trim system or54 1 a a Auxiliary tilt switch Manual Tilt Operation If the outboard cannot be tilted using the power trim tilt switch the outboard can be tilted manually 1 Turn out the manual tilt release valve three turns counter clockwise This allows manual tilting of the outboard or34 1 ...

Page 54: ...ilt the outboard to the desired position and tighten the manual tilt release valve NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation ...

Page 55: ...ng Break in 1st Hour Allow engine to warm up for 30 60 seconds Do not idle for more than 5 minutes Run the engine the majority of the time between 4000 5400 RPM approximately three quarter throttle Change engine speed approximately every two 2 minutes Avoid trimming the outboard out up beyond a vertical trim position during operation Avoid using hydraulic jack plate if equipped to raise engine dur...

Page 56: ...o the engine causing possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing The Cooling System If you keep your boat moored in the water always tilt the outboard s...

Page 57: ...power loss while a loss of engine power on a hot and humid day could be as much as 14 These losses apply to normally aspirated and supercharged engines Compensating for power robbing conditions Switch to lower pitch propeller Change gear ratio Some boat performance can be regained by dropping to a lower pitch propeller but engine performance will still remain lower In some cases a gear ratio reduc...

Page 58: ...er When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom CAUTION Avoid engine or transom damage Do not exceed 2000 RPM when the outboard is being operated in the tilt range 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the cooling water intake holes stay submerged at all times 3 Operate the engine at slow...

Page 59: ...er bulb until it feels firm 2 Turn the ignition key switch to the ON position for three seconds This operates the electric fuel pump 3 Turn the ignition key switch back to the OFF position and squeeze the primer bulb again until it feels firm Turn the ignition key switch to the ON position again for three seconds Continue this procedure until the fuel line primer bulb stays firm Before starting re...

Page 60: ...anyard stop switch to the RUN position Read the Lanyard Stop Switch safety explanation and warning in the General Information section ob00350 5 Shift the outboard to the neutral position N ob00351 6 Do not advance the neutral fast idle speed feature on the remote control for starting if equipped ob00560 ...

Page 61: ...tem will automatically prime choke the engine and increase idle speed for starting CAUTION Avoid possible engine damage If no water is coming out of the water pump indicator hole stop the engine and check the cooling water intake holes 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 outbo...

Page 62: ...ent preventing the gearcase from shifting into gear Your outboard has three gear shift positions to provide operation forward neutral out of gear and reverse N R F ob00557 When shifting always stop at neutral position and allow the engine speed to return to idle Always shift into gear with a quick motion After shifting into gear advance the lever further to increase speed Stopping The Engine Reduc...

Page 63: ... is exposed to the atmosphere to minimize internal corrosion damage to the engine Replacement Parts for Your Power Package WARNING Using a replacement part that is inferior to the original part could result in personal injury death or product failure Mercury recommends using original Mercury Precision replacement parts and lubricants EPA Emissions Regulations All new outboards manufactured by Merc...

Page 64: ... RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Inspection And Maintenance Schedule PRIOR TO EVERY USE Check that ...

Page 65: ... deterioration or leaks Visually check steering link rod fasteners for wear Lubricate all components refer to the Installation Manual for lubrication specifications Check all attachment hardware for proper torque tightness Check level and condition of gearcase lubricant Check alternator belt tension EVERY 50 HOURS OR ONCE A YEAR WHICHEVER OCCURS FIRST Lubricate all lubrication points Lubricate spl...

Page 66: ...IODS OF STORAGE Refer to Storage section Flushing the Cooling System Powerhead Flush the internal water passages of the engine with fresh water after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages a b or36 1 a Plug located on fitting b Water hose 1 Remove the plug from fitting in the bottom cowl 2 Attach a water hose ...

Page 67: ...ushing attachment so the nose cone cup fits tightly over the intake holes 4 Attach a water hose to the flushing attachment Turn on the water and adjust the flow so water is leaking around the rubber cups or nose cone cup to ensure the engine receives an adequate supply of cooling water 5 Start the engine and run it at idle speed in neutral shift position 6 Adjust water flow so excess water continu...

Page 68: ...t is dry will result in minor surface scratches Always wet the surface before cleaning Follow cleaning and waxing procedure CLEANING AND WAXING PROCEDURE 1 Before washing rinse the top cowl with clean water to remove dirt and dust that may scratch the surface 2 Wash the top cowl with clean water and a mild non abrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean clo...

Page 69: ...uel system completely Perform fuel system service 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 of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced WATER SEPARATING FUEL FILTER This fi...

Page 70: ... a screwdriver between the filter cap bosses and unscrew the filter Installation 1 Lubricate the o ring seals with oil 2 Install the fuel filter and tighten securely 3 Reconnect the link rod IMPORTANT Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm forcing fuel into the filter ...

Page 71: ...hose loosen the red filter to vent the chamber 3 Retighten drain screw and reattach hose ob01679 a b c a Drain hose b Side fitting c Drain screw IMPORTANT Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm forcing fuel into the chamber Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cables to the engine must be fast...

Page 72: ...hedule or79 a b c d a Special washer head bolt P N 10 849838 b Nylon Locknut used on head bolt P N 11 826709113 c Flat washer 2 d Nylon Locknut used on cable coupler P N 11 826709113 1 Assemble steering link rod to steering cable coupler with two flat washers c and a self locking nylon insert locknut d Tighten the locknut until it seats then loosen turn 2 Assemble the steering link rod to the engi...

Page 73: ...e of the overload If the cause is not found the fuse may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse 2 Replace fuse with a new fuse with the same rating The fuses and circuits are identified as follows 5 20 20 20 a b c d or41 1 a SmartCraft data bus circuit 5 amp fuse b Accessories 20 amp fuse c Ignition Coil Circuit 20 a...

Page 74: ...ficing its metal to be slowly eroded instead of other metals This model has three corrosion control anodes two above and one below the anti ventilation plate A fourth anode is located on the bottom of the clamp swivel bracket assembly or42 1 a b a Corrosion control anodes three on gearcase b Corrosion control anode one on clamp swivel bracket All anodes require periodic inspection especially in sa...

Page 75: ...er etc to remove spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off ob00375 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken or blistered or if the precious metal is not visible on the plug s electrode IMPORTANT The color of the plug may not accurately reflect its condition To accurately di...

Page 76: ...spected 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 Add water as necessary to keep the battery full 3 Make sure the battery is secure against movement 4 Battery cable terminals should be clean tight and correctly installed Positive to positi...

Page 77: ... however the run time is limited because the alternator is not charging the boat battery If the fusible link circuit becomes open contact your authorized Mercury Marine dealer 59364 Removing the Propeller WARNING Avoid possible serious injury or death Shift the outboard to the neutral position and remove spark plug leads before servicing the propeller If the propeller is rotated while the engine i...

Page 78: ...d between the gearcase and the propeller to hold the propeller and remove the propeller nut ob00377 5 Remove the propeller and associated hardware from the propeller shaft Installing the Propeller 19 Spline Shafts WARNING Avoid serious personal injury or death Remove the key from the ignition switch disconnect the lanyard stop switch and remove the spark plug leads to ensure that the engine does n...

Page 79: ...gage the safety stop switch 3 Coat the propeller shaft with Anti Corrosion Grease 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 To install a propeller for use with a 19...

Page 80: ...o 94 Anti Corrosion Grease Propeller shaft splines 92 802867A 1 3 Place a block of wood between the gearcase and propeller and torque the propeller nut or119 Description Nm lb in lb ft Propeller nut 75 55 4 Place the safety stop switch into the RUN position ...

Page 81: ...n Where Used Part No 34 Special Lubricant 101 Trim Rod Ball Ends 92 802865A1 95 2 4 C Marine Lubricant with Teflon Prop Shaft Swivel Bracket Tilt Support Lever Tilt Tube 92 802859A1 NOTE Turn the ball ends to work the lubricant into the ball sockets Lubricate through fittings ...

Page 82: ...ly resulting in serious injury or death 7727 95 95 95 110 110 Tube Ref No Description Where Used Part No 95 2 4 C Marine Lubricant with Teflon Steering cable and grease fitting on belt tensioner pulley 92 802859A1 110 4 Stroke 10W30 Outboard Oil Steering cable 92 802833A1 Checking Trim System Fluid Level CAUTION Avoid possible injury Oil in the trim system is under pressure when the outboard is in...

Page 83: ...he bottom of the fill hole If necessary add Power Trim Steering Fluid If this is not available use automotive transmission fluid ATF a 7729 114 a Fill cap Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Trim system fill hole 92 802880A 1 3 Re install the fill cap 4 Trim the outboard through the entire trim and tilt range several times to remove any air from the system ...

Page 84: ...l operating position 2 Remove the vent plug upper plug and sealing washer 3 Remove the fill drain plug lower plug 4 Quickly place lubricant tube into the fill hole 5 Slowly add lubricant until it flows from the upper vent hole 6 Stop adding lubricant Install the upper vent plug and sealing washer before removing the lubricant tube IMPORTANT Replace sealing washers if damaged NOTE Examine the magne...

Page 85: ...damage gearcase DRAINING THE GEARCASE or50 1 a b c c d e a SportMaster Gearcase vertical operating position b Fleet Torque Master gearcase vertical operating position c Vent plug and sealing ring d Fill Drain plug and sealing ring e Drain pan 1 Place the outboard in a vertical operating position 2 Place a drain pan below outboard 3 Remove the vent plug upper plug and sealing ring 4 Remove the fill...

Page 86: ... remote fuel line and engine fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on their containers to the fuel tank before the last operation of the boat Adding Fuel Stabilizer will help prevent the formation of varnish and gum in the gasoline The Mercury Precisio...

Page 87: ...ew b Drain hose c Right side fitting 4 Re tighten drain screw and re attach hose 5 Pull the drain hose off the left side fitting Hold the open end of the hose over a container and loosen drain screw and drain the float chamber Re tighten drain screw and re attach hose c a ob01589 b a Left side fitting b Drain screw c Drain hose ...

Page 88: ... for storage Refer to Fuel System preceeding IMPORTANT Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark plug leads 1 Remove the spark plugs and add approximately 30 ml 1 oz of engine oil into each spark plug hole 2 Rotate the flywheel manually several times to distribute the oil in the cylinders 3 Re install spark plugs Protecting External Outboard Components...

Page 89: ...water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard 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 du...

Page 90: ...minated fuel Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose ...

Page 91: ...gine block pressure sensor or coolant temperature sensor failure Guardian is activated Restricted fuel system or filter loss of fuel or air pressure Warning Horn Activates With Power Loss POSSIBLE CAUSES Intermittent horn sound The oil level in the engine mounted oil reservoir tank is low Refill the reservoir tank and the remote oil tank Refer to Fuel and Oil for details Battery voltage is out of ...

Page 92: ...clogged Incorrect transom height water pickups not getting adequate water supply Warning Horn Activates No Power Loss POSSIBLE CAUSES Warning horn activates on start up This is normal operation Water is detected in the water separating fuel filter Refer to Maintenance for procedures on removing water from the filter Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corr...

Page 93: ...arts 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 any authorized Mercury Marine dealership If additio...

Page 94: ...o 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 Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 744 3513 M...

Page 95: ...ditional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact MERCURY MARINE Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest dealer or Marine Power Service Cente...

Page 96: ...MAINTENANCE LOG 88 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

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