Mercury 25 Jet 4-Stroke Manual Download Page 113

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ENGINE INSTALLATION

107

Electrical Harness, Battery Connection, Fuel Tanks

REMOTE WIRING HARNESS

1. Remove the three access cover bolts. Remove the access

cover and cable rubber grommet.

10113

2. Remove the cable barrel retainer.

24857

a -

Cable barrel retainer

Summary of Contents for 25 Jet 4-Stroke

Page 1: ...corner the CE mark This outboard motor manufactured by Mercury Marine Fond du Lac Wisconsin USA or Marine Power Europe Inc Park Industriel de Petit Rechain Belgium complies with the requirements of t...

Page 2: ...eneric immunity standard EN 61000 6 1 Vehicles boats and internal combustion engine driven devices radio disturbance characteristics SAE J551 CISPR 12 Electrostatic discharge testing EN 61000 6 2 EN 6...

Page 3: ...ERAL INFORMATION Boater s Responsibilities 13 Before Operating Your Outboard 13 Boat Horsepower Capacity 14 High Speed And High Performance Boat Operation 14 Outboard Remote Control Models 15 Remote S...

Page 4: ...Starting Check List 49 Operating In Freezing Temperatures 49 Operating In Salt Water Or Polluted Water 50 Operating In Shallow Water 50 How the Jet Drive Operates 50 Stopping the Boat in an Emergency...

Page 5: ...Corrosion Control Anode 80 Spark Plug Inspection And Replacement 82 Fuse Replacement Electric Start Models 83 Timing Belt Inspection 84 Lubrication Points 84 Checking Power Trim Fluid 88 Changing Engi...

Page 6: ...vice Assistance 96 Mercury Marine Service Offices 97 ENGINE INSTALLATION Installation Information 99 Top Cowl Removal And Installation 100 Lifting Outboard 101 Determining the Mounting Height of the O...

Page 7: ...d du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no cha...

Page 8: ...e warranty registration Mercury Marine will send registration verification by mail to the purchaser of the product If this registration verification is not received within 30 days please contact your...

Page 9: ...from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you IMPORTANT Registration lists must be maintained by the factory and d...

Page 10: ...oduct Unexpired warrant coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only...

Page 11: ...ear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenanc...

Page 12: ...erage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PU...

Page 13: ...ection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation...

Page 14: ...ser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is req...

Page 15: ...een the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for ad...

Page 16: ...is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WAR...

Page 17: ...ance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or preparing for racing or oth...

Page 18: ...products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under...

Page 19: ...If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage This manual as...

Page 20: ...he manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM...

Page 21: ...eath from a sudden unexpected acceleration when starting your engine The design of this outboard requires that the remote control used with it must have a built in start in neutral only protection dev...

Page 22: ...ing nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the oper...

Page 23: ...ty Information The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator a...

Page 24: ...can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator WARNING Avoid serious injury or death from d...

Page 25: ...pump as a high speed projectile WHILE BOAT IS STATIONARY WARNING Avoid injury resulting from contacting the rotating impeller or having hair clothing or loose objects drawn into the water intake and...

Page 26: ...se 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...

Page 27: ...ury or death from being struck by a disconnected outboard Do not accelerate above idle speed in water suspected of containing underwater obstacles if the outboard is not attached to the transom correc...

Page 28: ...ain 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...

Page 29: ...gned 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 Suggestions In...

Page 30: ...d greatly reduces the ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the jet drive and boat handling in case...

Page 31: ...h fallen skiers When using the boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should...

Page 32: ...Specifications International Models 25 Horsepower 25 Kilowatts 18 Full Throttle RPM Range 5000 5500 RPM Idle Speed in Forward Gear 850 25 RPM Number of Cylinders 3 Piston Displacement 526 cc 32 09 cu...

Page 33: ...commended lubricant for the jet pump driveshaft bearing Refer to Maintenance Engine Oil Capacity 1 8 liter 1 9 quarts Battery Rating 465 Marine Cranking Amps MCA or 350 Cold Cranking Amps CCA Sound at...

Page 34: ...ne stop switch d Throttle friction adjustment knob e Gear shift f Tilt support lever g Gas tilt assist lever h Jet drive housing i Water intake housing j Reverse gate k Water outlet housing l Chaps m...

Page 35: ...OTE CONTROL MODEL a b c e h i j k g f d 24827 a Transom brackets b Tilt support lever c Top cowl d Cowl latch e Bottom cowl f Auxiliary tilt switch g Chaps h Water outlet housing i Reverse gate j Wate...

Page 36: ...lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering If additional ground clearance is required the outboard...

Page 37: ...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 38: ...fuel components should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation Because of possible...

Page 39: ...its temperature rises and can leak under pressure if the tank is completely filled PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level u...

Page 40: ...Viscosity for Engine Oil a NMMA FC W certified 25W 40 4 stroke outboard oil may be used at temperatures above 4 C 40 F b NMMA FC W certified 10W 30 4 stroke outboard oil is recommended for use in all...

Page 41: ...e upper oil level IMPORTANT Inspect oil for signs of contamination Oil contaminated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oi...

Page 42: ...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 Informati...

Page 43: ...right to loosen friction WARNING Avoid possible serious injury or death from loss of boat control Maintain sufficient steering friction to prevent the outboard from steering into a full turn if the ti...

Page 44: ...ES CONTROLS 38 Electric start button Electric start models Press to start the engine 15898 Tiller handle The tiller handle can be tilted 180 for convenient handling during transportation and storage o...

Page 45: ...from one position to another a 3274 Tiller handle lock cap Remove the lock cap on top of the tiller handle to lock in the up position Push the tiller lock release lever to release the handle from the...

Page 46: ...he operator to lock the outboard at any tilt position from full down to full up This tilt system is designed to be adjusted when the outboard is idling in neutral or with the engine turned off Before...

Page 47: ...engine Move the lock lever to the free position Take hold of the top cowl grip and raise the outboard to the full tilt up position Lock the outboard in place by moving the lock lever to the lock posit...

Page 48: ...lt pin for adjustments in the four holes LOCK FREE a b 10290 a Transom bracket holes b Tilt pin Adjust the operating angle of the outboard so that the outboard runs perpendicular to the water when the...

Page 49: ...nerally used when referring to adjusting the outboard further up and out of the water With the engine turned off the outboard can be tilted out of the water At low idle speed the outboard can also be...

Page 50: ...h to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating lever down 2 Lower outboard to rest on t...

Page 51: ...RY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system 9974 SHALLOW WATER OPERATION When operating your boat in shallow water you can tilt the...

Page 52: ...ollowing chart 15732 WARNING SYSTEM OPERATION The warning horn will emit either a continuous beep or intermittent short beeps and engine speed will be limited This alerts the operator and helps identi...

Page 53: ...or hole or flow is intermittent stop the engine and check the cooling water intake holes for obstruction If no obstruction is found there may be a blockage in the cooling system or a water pump proble...

Page 54: ...ws Outboard mounted too high on the transom Worn jet pump impeller or liner Incorrect jet pump impeller clearance adjustment Tilting the outboard out beyond a vertical position Cavitation of the impel...

Page 55: ...while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and...

Page 56: ...ess than 61 cm 2 ft deep but there should be more than 61 cm 2 ft of water under the boat when increasing speed to reach full plane Once the boat is on plane the boat speed will prevent the ingestion...

Page 57: ...verted to create reverse thrust This approximate balancing of forward and reverse thrust will minimize any boat movement Because the impeller is always rotating and creating thrust when the engine is...

Page 58: ...boat to be thrown forward or even out of the boat This action may result in serious injury or death In an emergency putting the jet outboard into reverse and applying reverse throttle can rapidly slow...

Page 59: ...e relatively flat bottom hulls and lack of a gearcase in the water the boat will tend to skid on turns Turns must be started early and use sufficient power to maintain steering control Mooring The Boa...

Page 60: ...ng wall especially after the engine has been stopped This will lock the driveshaft and will prevent the engine from being able to crank over for starting Following are steps for dislodging the impelle...

Page 61: ...be covered by the limited warranty 1 For the first hour of operation run the engine at varied throttle settings up to 3500 RPM or at approximately half throttle 2 For the second hour of operation run...

Page 62: ...ing of the engine NOTE If the outboard runs out of fuel or has been in storage for an extended period of time additional attempts to start the engine are required to purge the fuel system of air 1 Ope...

Page 63: ...tion If the engine fails to start in ten seconds return the key to the ON position wait 30 seconds and try again 19804 7 After the engine starts check for a steady stream of water flowing out of the w...

Page 64: ...amage to the water pump running dry or overheating of the engine NOTE If the outboard runs out of fuel or has been in storage for an extended period of time additional attempts to start the engine are...

Page 65: ...gear shift to the neutral N position R N F 24835 6 Position the tilt lock lever to the lock position LOCK FREE 10251 7 Manual starting models Pull the starter rope slowly until the starter engages the...

Page 66: ...and check cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard...

Page 67: ...e the engine speed to idle before shifting START N START N 24834 R N F 24835 Remote control models When shifting always stop at the neutral position and allow the engine speed to return to idle N R F...

Page 68: ...rd stop switch to the OFF position ob00361 Emergency Starting If the starter system fails the engine can be started using the spare starter rope provided Refer to the following procedure for instructi...

Page 69: ...n key to the ON position ob00364 WARNING To prevent getting an electrical shock do not touch any ignition component wiring or spark plug wire when starting or running the engine WARNING The exposed mo...

Page 70: ...OPERATION 64 5 Pull the starter rope to start the engine 10006...

Page 71: ...outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury death or product failure Re...

Page 72: ...spark plug and gap OWNER RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner ope...

Page 73: ...oints Change the engine oil and replace the oil filter The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling See Changing Engine Oil Repla...

Page 74: ...wl sound reduction foam if equipped to make sure foam is intact and not damaged Check that the intake silencer if equipped is in place Check that the idle relief muffler if equipped is in place Check...

Page 75: ...securely fastened by pulling up on the back of the cowl Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes Worn Dull Impell...

Page 76: ...bottom side only ob01409 b a a Leading edge b Top side lifting angle Impeller Clearance Adjustment The impeller should be adjusted so there is approximately 0 8 mm 0 03 in clearance between the impell...

Page 77: ...te and measure the clearance between the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation Impeller Removal and Installation WARNING If the driveshaft is rot...

Page 78: ...n R N F 24835 2 Position the key switch or lanyard stop switch to the OFF position 3 Remove the spark plug leads to prevent the engine from starting ob00375 4 Remove the six screws securing the water...

Page 79: ...er nut 6 Pull the impeller straight off the shaft If the impeller is tight use a hammer and a block of wood to rotate the impeller clockwise on the shaft until the keyway is directly above the flat on...

Page 80: ...nut ob01413 a b c d e f a Plastic sleeve b Impeller c Shear key d Shims e Nut retainer f Impeller nut 3 Turn the nut tight on the shaft to remove any play between the impeller and shaft If the tabs on...

Page 81: ...f the impeller to raise or lower the impeller to the correct clearance setting The water intake housing can be shifted sideways a small amount in order to center the liner ob01410 b a a Shims b Cleara...

Page 82: ...und the impeller to ensure the water intake housing is centered and not rubbing against the liner Torque mounting bolts to specifications ob01411 Description Nm lb in lb ft Water intake housing mounti...

Page 83: ...Roller d Reverse gate ADJUSTING SHIFT LINK ROD 1 Place the shift handle into full forward shift position 2 Adjust the length of the shift link rod so the roller is at the full end of travel bottom in...

Page 84: ...ately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of...

Page 85: ...from the filter by squeezing the primer bulb until firm forcing fuel into the filter Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be...

Page 86: ...392 10 c Spacer 23 853826001 d Nylon insert locknut 11 16147 3 e Install steering link rod into side hole f Nylon insert locknut 11 16147 3 tighten until seats then back off 1 4 turn Description Nm lb...

Page 87: ...or apply a protective coating on the anode as this will reduce effectiveness of the anode One anode is installed in the engine block Remove the anode at the location shown Fasten the anode to the cove...

Page 88: ...aused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal t...

Page 89: ...cement Electric Start Models IMPORTANT Always carry spare SFE 20 AMP fuses The electric starting circuit is protected from overload by an SFE 20 AMP fuse If the fuse is blown the electric starter moto...

Page 90: ...ricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Driveshaft bearing...

Page 91: ...increase in moisture content indicates seal wear If the grease begins to turn dark or dirty gray the driveshaft bearing and seals should be inspected and replaced if necessary Some discoloration of t...

Page 92: ...MAINTENANCE 86 Swivel bracket Lubricate through fitting 24839 Tilt tube Lubricate through fittings 15915 Lubricate the threads on the transom clamp screws if equipped 15914...

Page 93: ...he steering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically...

Page 94: ...ion Lubricants Power Trim Steering Fluid If not available use automotive ATF automatic transmission fluid 9701 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim s...

Page 95: ...e container Lubricate the seal on the drain plug with oil and reinstall a 24854 a Drain plug CHANGING OIL FILTER 1 Place a rag or towel below the oil filter to absorb any spilled oil 2 Unscrew the old...

Page 96: ...oil level on the dipstick Add oil if necessary 9737 a a Oil fill cap Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recove...

Page 97: ...of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of va...

Page 98: ...et Drive Pump extra grease into the jet drive bearing to purge out moisture Positioning Outboard For Storage Store outboard in an upright vertical position to allow water to drain out of outboard CAUT...

Page 99: ...storage for an extended period of time additional attempts to start the engine will be required to purge the fuel system of air Lanyard stop switch not in RUN position Incorrect starting procedure Re...

Page 100: ...valve located on permanently built in type fuel tanks d Fuel line is kinked or pinched Fuel pump failure Ignition system component failure Engine Over Speed Excessive RPM POSSIBLE CAUSES Outboard mou...

Page 101: ...irty 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 acce...

Page 102: ...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 103: ...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 104: ...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 105: ...ndicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY...

Page 106: ...ome 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 maintenanc...

Page 107: ...rd The following outboard mounting height settings will work good for most applications however because of different boat hull designs the setting should be rechecked by test running the boat Refer to...

Page 108: ...b 22401 a Horizontal line b Width of the leading edge on the water intake housing 2 Place center the outboard on the boat transom Set the height of the outboard on the boat transom so that the front...

Page 109: ...om at this position 2 Fasten outboard to the transom at this height Refer to Fastening the Outboard 22403 Fastening the Outboard 1 Drill four 13 5 mm 17 32 in mounting holes 2 Install the outboard so...

Page 110: ...e lower set of mounting slots a b c d 10175 a Bolt b Transom clamp bolt c Washer d Nut Steering Bracket Steering Cable Installation 1 Lubricate entire cable end with 2 4 C with Teflon 10261 Tube Ref N...

Page 111: ...must be fastened using the steering link rod fastening hardware supplied with engine Never replace the locknuts 11 16147 3 with common nuts non locking as they will work loose and vibrate off freeing...

Page 112: ...b f 9691 a Bolt 10 898101018 b Flat washer 12 95392 10 c Spacer 23 853826001 d Nylon insert locknut 11 16147 3 e Install steering link rod into side hole f Nylon insert locknut 11 16147 3 tighten unti...

Page 113: ...ctrical Harness Battery Connection Fuel Tanks REMOTE WIRING HARNESS 1 Remove the three access cover bolts Remove the access cover and cable rubber grommet 10113 2 Remove the cable barrel retainer a 24...

Page 114: ...e harness retainer a b 24858 a Harness retainer b Remote harness 4 Connect the remote harness to the engine harness connector a 24859 a Harness connector 5 Fasten the remote harness to the cowl with t...

Page 115: ...TANT To prevent damage to the engine charging system when the battery cables are not connected to a battery ensure the battery cable ends are thoroughly insulated Single Outboard a b c or86 a Red slee...

Page 116: ...sleeve negative c Ground cable d Cranking battery FUEL TANKS Portable Fuel Tank Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place Perm...

Page 117: ...box out of neutral 2 Install the throttle cable to the throttle actuating lever Secure with a washer and cotter pin retainer 3 Adjust the throttle cable barrel so when barrel is installed into the thr...

Page 118: ...e cam b Cam roller 7 Install the cable grommet 8 Secure the throttle cable barrel with the cable barrel retainer 9 Tighten the cable barrel retainer bolt to the specified torque a b c 24903 a Cable ba...

Page 119: ...vation of the reverse gate will cause sudden unexpected stopping of the boat Sudden stopping may cause occupants to be thrown within the boat or even out of the boat This action may result in serious...

Page 120: ...t a b c d 24905 a Roller b Shift cam c Shift cable d Shift cable adjustment barrel 5 Recheck the shift cable adjustment in forward shift position The correct shift adjustment will position the cam far...

Page 121: ...a vertical position reduces the scoop angle and can cause impeller slippage and cavitation IMPORTANT If the angle of the boat transom does not allow the driveshaft housing to be positioned vertical a...

Page 122: ...g in windy rough water conditions where air is sucked into the water intake when jumping waves Install a 0 8 mm 1 32 in metal plate that extends from the hull bottom to the top of the water intake hou...

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