Mercury 25 2-Stroke Owner'S Manual Download

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TABLE OF CONTENTS

viii

ASSOCIATED PARTS

Associated Parts........................................................................98

ACCESSORIES

Accessories...............................................................................99

WIRING DIAGRAMS

Wiring Diagrams......................................................................103

OWNER SERVICE ASSISTANCE

Local Repair Service................................................................112

Service Away from Home........................................................112

Parts and Accessories Inquiries..............................................112

Service Assistance..................................................................112

Mercury Marine Service Offices...............................................113

MAINTENANCE LOG

Maintenance Log.....................................................................115

Summary of Contents for 25 2-Stroke

Page 1: ...for your confidence in Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming t...

Page 2: ...ing obligation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2008 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propell...

Page 3: ...rective 89 336 EC Generic emission standard EN 50081 1 Generic immunity standard EN 50082 1 Vehicles boats and internal combustion engine driven devices radio disturbance characteristics SAE J551 CISP...

Page 4: ...h 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 Pr...

Page 5: ...and High Performance Boat Operation 13 Outboard Remote Control Models 13 Remote Steering Notice 14 Lanyard Stop Switch 15 Protecting People in the Water 17 Passenger Safety Message Pontoon Boats and D...

Page 6: ...NTROLS Remote Control Features 56 Tilting Outboard 56 Shallow Water Operation 57 Trim Adjustment 58 Steering Friction Adjustment 59 Trim Tab Adjustment 60 OPERATION Pre Starting Check List 62 Operatin...

Page 7: ...ode 84 Propeller Replacement 85 Spark Plug Inspection and Replacement 89 Lubrication Points 90 Gearcase Lubrication 90 Submerged Outboard 92 STORAGE Storage Preparation 93 Protecting External Outboard...

Page 8: ...SORIES Accessories 99 WIRING DIAGRAMS Wiring Diagrams 103 OWNER SERVICE ASSISTANCE Local Repair Service 112 Service Away from Home 112 Parts and Accessories Inquiries 112 Service Assistance 112 Mercur...

Page 9: ...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 y...

Page 10: ...address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Dep...

Page 11: ...his limited warranty provided coverage for one 1 year from either the date the product is first sold or the date on which the product is first put into service whichever occurs first The repair or rep...

Page 12: ...efunding 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...

Page 13: ...ooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or oth...

Page 14: ...Limited Warranty Against Corrosion WHAT IS COVERED Mercury Marine warrants that each new Mercury Mariner Mercury Racing Sport Jet M2 Jet Drive Tracker by Mercury Marine Outboard Mercury MerCruiser Inb...

Page 15: ...n 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...

Page 16: ...the use of a corrosion protection system such as the Mercury Precision Parts or Quicksilver MerCathode system and or Galvanic Isolator Corrosion damage caused by improper application of copper base a...

Page 17: ...t are not covered by warranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure the International Limited Outboard W...

Page 18: ...ng circumstances When performed on emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out etc and prior factory appro...

Page 19: ...rial blocking inlet holes motor being mounted too high or trimmed too far out 15 Use of fuels and lubricants which are not suitable for use with or on the product Refer to the Maintenance section 16 O...

Page 20: ...oard 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 Th...

Page 21: ...M PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 High Speed and High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are...

Page 22: ...g 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 follo...

Page 23: ...a cord 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 lanyard cord on the other end for attaching to the operator The la...

Page 24: ...irection 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 dis...

Page 25: ...boat is moving coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can...

Page 26: ...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 o...

Page 27: ...ly 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 ca...

Page 28: ...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 the boat speed Under these con...

Page 29: ...so at greatly reduced speeds WARNING Operating a boat or engine with impact damage can result in product damage serious injury or death If the vessel experiences any form of impact have an authorized...

Page 30: ...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 e...

Page 31: ...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...

Page 32: ...r 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 di...

Page 33: ...other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record the s...

Page 34: ...on displacement 430 cc 26 2 cu in 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...

Page 35: ...GENERAL INFORMATION 27 Components 25 30M 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 MH models...

Page 36: ...rim tab 9 Secondary 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 L...

Page 37: ...29...

Page 38: ...GENERAL INFORMATION 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 EH models...

Page 39: ...ary 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 Battery cable 18 Upper oil plug 19 Cooling water intake 20...

Page 40: ...GENERAL INFORMATION 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 E models...

Page 41: ...water intake 10 Propeller 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 Con...

Page 42: ...strongly recommend that your dealer install your outboard and related accessories ot ensure proper installation and good performance If you install the outboard yourself follow instructions in the man...

Page 43: ...accordance withthe instructions below 1 Position the outboard motor at the center of the stern 37508 a 2 Position the outboard engines about 580 mm 23 in apart 580mm 37509 3 Clearance between anti ve...

Page 44: ...ove condition cannot be met due to a bottom shape of your boat please consult the dealer Installing the Remote Control Device Right Hand Steering 1 Positioning the remote control box Position the remo...

Page 45: ...ral N f Forward F g Reverse R h Throttle only lever 3 Determining remote control cable length A guideline for determining the proper length for a remote control cable is dimensions A plus B plus 300 m...

Page 46: ...rol box Remove the back panel by loosening two screws 37528 a a Back panel 5 Thread the remote control cables through the terminal eyes at a distance of more than 11 mm 0 43 in Securely lock the termi...

Page 47: ...he shift arm with the pin and E ring Insert a grommet supplied with the remote control box into the clamp 37527 a b c d a Grommet b Shift arm pin c E ring d Shift arm 7 Connect the throttle remote con...

Page 48: ...ALLATION 40 8 Install the back panel 37528 a a Back panel 9 Install the remote control box with three screws spacers and nuts 37464 a b c d e f a Screw b Remote control box c Hull d Spacer e Washer f...

Page 49: ...d Neck of remote control cable e Shift remote control cable f Washer g Sleeve guide B Fix remote control cable to shift lever h Shift lever i Advance arm j Ball joint k Holder cap Connect remote cont...

Page 50: ...the remote control cable to the engine 15 Throttle side Insert the throttle remote control cable into a hole of the advancer arm at the lower motor cover attach the ball joint to the holder cap at the...

Page 51: ...where the lever is latched The shift lever will be moved to the shift in position and the throttle is fully opened when shifted further Confirm the throttle lever is Fully Closed when the control lev...

Page 52: ...n the cord assembly with clamps 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 a Cord assembly b Black terminal c Brown terminal d Green terminal e Red terminal f Rectifier g Terminal holder h...

Page 53: ...t h Starter solenoid i Rectifier lead wire j Stop switch k Choke solenoid l Stop switch m Cord assembly Attaching the Steering Link Rod WARNING Improper fasteners or improper installation procedures c...

Page 54: ...ttery 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...

Page 55: ...the motor 37712 a b a Red cable b Black cable IMPORTANT Please follow the instructions below Hydrogen gas is generated when charging a battery Keep the battery in a well ventilated area during chargi...

Page 56: ...g requirements See your outboard dealer AVAILABLE PROPELLERS Light duty boat Heavy duty boat Mark 14 E 13 D 11 C 10 B 9 A 8 F Dimensions blade x diameter x pitch mm 3 x 252 x 360 3 x 252 x 332 3 x 250...

Page 57: ...he 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 trai...

Page 58: ...ting 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 tran...

Page 59: ...NG 51 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 T...

Page 60: ...d 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...

Page 61: ...r deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible...

Page 62: ...GASOLINE OIL MIXING RATIO CHART GASOLINE OIL MIXING RATIO CHART Gas Oil Ratio 3 8 liters 1 gal gas 11 5 liters 3 gal gas 23 liters 6 gal gas 25 1 4 148 ml 5 fl oz oil 473 ml 16 fl oz oil 946 ml 32 fl...

Page 63: ...e 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 o...

Page 64: ...for a description of the functions and operations of the remote control 37982 a b c d a Remote control handle Forward F Neutral N Reverse R b Throttle only lever c Ignition key switch d Lanyard stop...

Page 65: ...erse 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 SHALLOW WATER R...

Page 66: ...erse 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 s...

Page 67: ...ruising trim the trim position pin up 37883 a b c d e f a Correct trim b Trim down c Trim up d Trim position pin e Up f Down Steering Friction Adjustment Steering friction can be adjusted according to...

Page 68: ...s a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface The trim tab can help compensate for this steering torque in many cases and c...

Page 69: ...d 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 NOTE Trim tab adjustment will have little effect reduc...

Page 70: ...nspection checks listed in Maintenance Inspection and Maintenance Schedule Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing tempe...

Page 71: ...ur 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 l...

Page 72: ...ine or recommended engine oil Refer to Oil and Fuel section Starting the Engine PREPARATIONS 1 Install the fuel connector to the engine side connector 37522 2 Loosen the air vent screw on the tank cap...

Page 73: ...a sufficient supply of water to the water inlets during operation NOTE Be sure that the shift is at Neutral N when starting the engine This model is provided with start in gear protection 4 Tiller Han...

Page 74: ...e operation is necessary on warmed engine N 37521 7 Remote control models Insert the key 8 Turn the key to the ON position and push it for choke operation No need to push the key when the engine is wa...

Page 75: ...osition b Fully closed position c Throttle only lever d Ignition key switch e Lanyard stop switch SET THE LANYARD STOP SWITCH TO RUN POSITION Be sure to connect the lanyard stop switch to your body Th...

Page 76: ...ine will not start unless this switch has been properly connected and locked beforehand Refer to General Information Lanyard Stop Switch STARTING THE ENGINE 1 Pull the rewind starter slowly until you...

Page 77: ...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...

Page 78: ...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 C Turn the throttle grip to...

Page 79: ...ing water discharge port Gear Shifting FORWARD IMPORTANT It may be dangerous to attempt shifting at high RPM Be sure to slow down to trolling or idling RPM before shifting Tiller handle models Turn th...

Page 80: ...sition NOTE Forward running is not possible unless the throttle only lever is at the lower position 37531 a b c d e g b a f d c h a Fully opened position b Fully closed position c Throttle d Shift e N...

Page 81: ...d F to Reverse R first idle the engine and shift into Neutral N With the engine still running slowly engage and gradually increase the reverse speed NOTE Confirm that the reverse lock lever is at the...

Page 82: ...OPERATION 74 3 Press the stop switch until the engine stops completely or pull the stop switch lock 1 Remote control models Place the remote control lever at Neutral N and idle the engine 37882 N...

Page 83: ...low After the engine stops tighten the air vent screw on the tank cap Disconnect the fuel connector from the engine For the EH and E types disconnect the cables from the battery when not in use for ex...

Page 84: ...t 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 engin...

Page 85: ...Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection A...

Page 86: ...ecification d Recommended spark plug and gap e Valve clearance if applicable f Family number g Maximum emission output for the engine family h Piston placement i Date of manufacture OWNER RESPONSIBILI...

Page 87: ...rication Points Inspect and clean spark plugs See Spark Plug Inspection and Replacement Check fuel line filter for contaminants See Fuel System Check carburetor adjustments if required See Carburetor...

Page 88: ...Use a Mercury Precision or Quicksilver Accessory or equivalent flushing attachment IMPORTANT The engine must be run during flushing in order to open the thermostat and circulate water through the wat...

Page 89: ...water intake and secondary water intake located at the gearcase with tape 37515 a a Flushing plug 3 With the shift lever in Neutral N run the engine at a low speed so that water flushes out the coolin...

Page 90: ...attery is secure against movement 3 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative 4 Make sure the battery is equipped with a nonco...

Page 91: ...or 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 ENGINE FUEL FILTER Inspect the sight bowl...

Page 92: ...an SFE 20 apm 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 w...

Page 93: ...re the engine will not start then check and replace 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 pee...

Page 94: ...ING PROPELLER 1 Remote control model Shift outboard to Neutral N position 37882 N 2 Tiller handle model Move shift lever to Neutral N position 38030 3 Remove the spark plug leads to prevent the engine...

Page 95: ...thrust holder f Propeller shaft 6 Pull propeller straight off the propeller shaft If the propeller is seized to the propeller shaft and cannot be removed have the propeller removed by an authorized de...

Page 96: ...to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed INSTALLING PROPELLER 1 Install the propeller thrust holder propeller washer nut and c...

Page 97: ...ng in serious injury or death from a fire or explosion To avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Remove the spark plug boots Twi...

Page 98: ...pply and pump in grease Grease fittings Yes Yes Apply and pump in grease Gearcase Lubrication When adding or changing gearcase lubricant visually check for the presence of water in the lubricant If wa...

Page 99: ...elow the outboard 3 Remove the oil plugs upper and lower and drain the gear oil completely 37849 4 Place the lubricant tube into the fill drain hole and add the lubricant until it appears at the upper...

Page 100: ...ediate attention 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...

Page 101: ...ne being used contains alcohol it is advisable to drain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system Fill the fuel tank and engine fuel syst...

Page 102: ...urfaces 92 802878 55 Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceding IMPORTANT Refer to Maintenance Spark Plug Inspect...

Page 103: ...tboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze...

Page 104: ...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 i...

Page 105: ...ent 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 Exce...

Page 106: ...1 21 mm Socket wrench handle 1 Screwdriver 1 Spare parts Starter rope 1 1000 mm Spark plug 1 NGK B7HS 10 or Campion L82C Gap 1 0 mm 0 035 in Cotter pin 1 Other Fuel tank 1 Primer bulb 1 set Remote co...

Page 107: ...f g h i j k l 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 i Touch up spray paint...

Page 108: ...ACCESSORIES 100 37540 a b a Turnbuckle plate b Twin remote control turnbuckle assembly 37506 a b a Steering spacer b Steering link assembly standard EP type...

Page 109: ...ACCESSORIES 101 37493 a b c d e f g 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...

Page 110: ...ACCESSORIES 102 37504 a a Clutch lever reverse lock kit...

Page 111: ...WIRING DIAGRAMS 103 Wiring Diagrams 37842 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20...

Page 112: ...tension cord light optional 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...

Page 113: ...105...

Page 114: ...WIRING DIAGRAMS 106 37843 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 115: ...Tachometer lead wire 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...

Page 116: ...WIRING DIAGRAMS 108 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...

Page 117: ...coil 12 Flywheel magneto 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 118: ...WIRING DIAGRAMS 110 REMOTE CONTROL BOX 37845 1 2 3 4 5...

Page 119: ...WIRING DIAGRAMS 111 1 Neutral switch 2 Main switch 3 Stop switch 4 Cord assembly 5 Meter lead wire optional...

Page 120: ...e 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...

Page 121: ...bsite 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...

Page 122: ...an 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 W...

Page 123: ...MAINTENANCE LOG 115 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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