Mercury 25 Jet FourStroke Operation, Maintenance And Installation Manual Download Page 1

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Operation

Maintenance

and

Installation

Manual

25 Jet FourStroke

8M0145522

418

eng

Summary of Contents for 25 Jet FourStroke

Page 1: ...Operation Maintenance and Installation Manual 2018 Mercury Marine 25 Jet FourStroke 8M0145522 418 eng...

Page 2: ...eng...

Page 3: ...nual 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 Throug...

Page 4: ...oved for printing Mercury Marine whose policies are based on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and witho...

Page 5: ...ort 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 Prot...

Page 6: ...eng iv...

Page 7: ...mendations 10 Recording Serial Number 13 Model Year Production Code 13 Specifications 14 Component Identification 15 Transporting Trailering Boat Outboard 17 Fuel and Oil Fuel Requirements 18 Low Perm...

Page 8: ...odels 44 Gear Shifting 47 Stopping the Engine 48 Emergency Starting 48 Maintenance Cleaning Care Recommendations 50 EPA Emission Regulations 52 Inspection and Maintenance Schedule 53 Top Cowl Removal...

Page 9: ...essive RPM 75 Performance Loss 75 Battery Will Not Hold Charge 75 Owner Service Assistance Service Assistance 76 Ordering Literature 78 Installation Installation Information 80 Top Cowl Removal and In...

Page 10: ...eng viii...

Page 11: ...g 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...

Page 12: ...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 F...

Page 13: ...out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine whe...

Page 14: ...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 accidentally falls overboard or moves wi...

Page 15: ...the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could...

Page 16: ...ojectile 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 wrapping around the impe...

Page 17: ...to launch off a wave or wake If the bow of your boat pitches down far enough while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring th...

Page 18: ...combustion engines including 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...

Page 19: ...n side curtains or forward hatches to remove fumes Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed ca...

Page 20: ...r 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 follo...

Page 21: ...lotation 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 cu...

Page 22: ...block the operator s view when the boat is above idle or planing transition speed Watch out for others the water and your wake Never drive your boat directly behind a water skier Your boat traveling a...

Page 23: ...cal lists the 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...

Page 24: ...05 0 007 in Exhaust valve 0 18 0 22 mm 0 007 0 008 in Recommended spark plug NGK DCPR6E Spark plug gap 0 8 0 9 mm 0 031 0 035 in Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fue...

Page 25: ...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 Water pump ind...

Page 26: ...ustment lever POWER TRIM REMOTE CONTROL MODEL 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 27: ...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 should be tilted u...

Page 28: ...ntly 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 ra...

Page 29: ...offered for sale in the United States The Environmental Protection Agency EPA requires that any outboard manufactured after January 1 2009 must use low permeation fuel hose for the primary fuel hose...

Page 30: ...tank exceeds 34 4 kPa 5 0 psi A hissing noise may be heard as the tank vents to the atmosphere This is normal The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering t...

Page 31: ...ys stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tank...

Page 32: ...Quicksilver SAE 25W 40 Synthetic Blend Marine 4 Stroke Engine Oil may be used at temperatures above 4 C 40 F b Mercury or Quicksilver SAE 10W 30 4 Stroke Marine Engine Oil is recommended for use in a...

Page 33: ...eration and operating in cooler climates This additional fuel and moisture that collects in the crankcase eventually ends up in the oil sump and will add to the total volume of oil that appears on the...

Page 34: ...yard 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 START h Fa...

Page 35: ...t the outboard from steering into a full turn if the tiller handle or steering wheel is released a Tighten friction b Loosen friction Warning light The warning light will turn on or flash to alert the...

Page 36: ...be tilted 180 for convenient handling during transportation and storage 28535 Tiller lock release lever Push the lever to move the tiller handle from one position to another a Tilt lock release lever...

Page 37: ...tion a Lock cap b Locking mechanism Engine stop switch 28537 Throttle grip friction knob Turn the friction knob to set and maintain the throttle at desired speed Turn the knob clockwise to tighten the...

Page 38: ...st be locked in its tilt position by moving the lock lever to the lock position WARNING Operating the engine without engaging the tilt lock lever can cause serious injury or death The outboard can til...

Page 39: ...ilt support lever LOWERING OUTBOARD TO RUN POSITION 1 Move the lock lever to the free position Tilt up the outboard slightly and release the tilt support lever Lower the outboard to the run position 2...

Page 40: ...rimming in or down Moving the outboard further away from the boat transom is called trimming out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of tra...

Page 41: ...es TILTING OPERATION To tilt the outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it re...

Page 42: ...ERATION When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce the engine speed below 2000 RPM 2 Tilt the outboard up Make...

Page 43: ...ify the following listed situations Warning System Function Sound Warning Light Description Engine Speed Limited to 2800 RPM Start up One beep On for 5 seconds Normal system test Engine over temperatu...

Page 44: ...ine and allow it to cool down This will usually allow some additional low speed idle running time before the engine starts to overheat again LOW OIL PRESSURE The warning system is activated if the oil...

Page 45: ...ts in cutout of the cylinders to prevent operation above this limit Replaceable Jet Drive Shear Key The jet drive is equipped with a shear key to protect it in the event of a lodged impeller The shear...

Page 46: ...Check steering for free operation Check for debris around the rudder and reverse gate which may jam or hinder operation Before launching examine the jet drive water intake for obstructions which may...

Page 47: ...debris from the bottom The suction is still present but the water intake passes too quickly over the bottom to allow debris to be drawn into the water intake When boating through shallow water areas...

Page 48: ...ne is running the boat may tend to move slowly forward or backward This is normal for a direct drive jet driven boat The operator should be aware of this and use caution whenever the engine is running...

Page 49: ...Steering the vessel in a tight turn can result in loss of boat control In some cases the boat can spin out or roll over causing serious injury or death Avoid steering beyond the capabilities of the v...

Page 50: ...w the debris to fall off the intake grate allowing full power to be restored If debris does not fall off the intake grate the engine must be shut off and debris physically removed from the grate Clear...

Page 51: ...emote fuel line to the outboard Ensure the connector is snapped into place 9600 2 Check the engine oil level 9601 3 Ensure the driveshaft bearing on the jet drive is lubricated Refer to Maintenance Lu...

Page 52: ...uring this period of time run it at full throttle for approximately one minute every ten minutes 3 For the next eight hours of operation avoid continuous operation at full throttle for more than five...

Page 53: ...o the neutral N position N 26838 5 Move the neutral fast idle speed feature to the fully closed position NOTE To start a flooded engine advance the neutral fast idle speed feature to the maximum fast...

Page 54: ...e Tiller Handle Models Before starting read the Prestarting Check List Prestarting Instructions and Engine Break in Procedure in the Operation section NOTICE Without sufficient cooling water the engin...

Page 55: ...l Information Lanyard Stop Switch 19791 4 Set the tiller handle grip to the neutral start position START N START N 24834 5 Set the gear shift to the neutral N position R N F 24835 6 Position the tilt...

Page 56: ...nds at a time If the engine fails to start in ten seconds wait 30 seconds and try again 10187 9 Check for a steady stream of water flowing out of the water pump indicator hole 9647 IMPORTANT If no wat...

Page 57: ...use caution whenever the engine is running The outboard has three gear shift positions to provide operation forward F neutral N and reverse R Tiller handle models Reduce the engine speed to idle befor...

Page 58: ...witch to the OFF position 26776 Emergency Starting If the starter system fails the engine can be started using the spare starter rope provided Refer to the following procedure for instructions 1 Remov...

Page 59: ...n starting or operating the engine Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests WARNING The exposed moving flywheel can cause ser...

Page 60: ...lure 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...

Page 61: ...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 Remo...

Page 62: ...LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture a Piston displacement b Maximum em...

Page 63: ...ANNUALLY OR 100 HOURS Grease the engine if applicable Change the engine oil and filter if equipped Inspect the thermostat saltwater or brackish water only Add Quickleen to the fuel tank once per year...

Page 64: ...LATION 1 Lower the top cowl over the engine Bring the front of the cowl down first and engage the front hook then lower the cowl into its seated position with the bottom cowl 2 Apply some downward pre...

Page 65: ...the impeller edge and liner Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades and the clearance will start to exceed 0 8 mm 0 03 in As the blades wea...

Page 66: ...ignition key or lanyard stop switch to the OFF position and remove the spark plug leads from the spark plugs while servicing the impeller 1 Shift the outboard to the neutral position R N F 24835 2 Pos...

Page 67: ...allow removal INSTALLATION 1 Lubricate the driveshaft shear key and impeller bore 2 Place the plastic sleeve inside the impeller and install impeller shear key shims nut retainer and impeller nut a P...

Page 68: ...liner a Shims b Clearance between impeller edge and liner 5 After setting the impeller height tighten the impeller nut snug with a wrench Secure impeller nut by bending tabs against the flats on the i...

Page 69: ...ry or death from occupants being thrown within or out of the boat Adjust the shift link rod to lock the reverse gate preventing it from interfering with water flow CHECKING SHIFT LINK ROD ADJUSTMENT C...

Page 70: ...e work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of th...

Page 71: ...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 fastened...

Page 72: ...urn Description Nm lb in lb ft Nylon insert locknut d 27 20 Nylon insert locknut f Tighten until it seats then back off turn Corrosion Control Anode Your outboard has corrosion control anodes at diffe...

Page 73: ...n lb ft Flange screw 6 53 Screw 6 53 The second anode is on the water intake housing and the third anode is installed on the transom brackets a Water intake housing anode b Transom bracket anode Spark...

Page 74: ...ore installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten to the specified value Description Nm lb in lb ft Spark plug 20 177 Fuse Replacement E...

Page 75: ...ng belt and have it replaced by an authorized dealer if any of the following conditions are found Cracks in the back of the belt or in the base of the belt teeth Excessive wear at the roots of the cog...

Page 76: ...greasing a Grease fitting b Vent hose NOTE After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give an indication of cond...

Page 77: ...Swivel bracket Lubricate through fitting 24839 Tilt tube Lubricate through fittings 15915 Lubricate the threads on the transom clamp screws if equipped 15914 MAINTENANCE eng 67...

Page 78: ...ubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant 3 Lubricate the following wi...

Page 79: ...id 9701 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim system 92 858074K01 Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Engine oil 1 8 liter 1 9...

Page 80: ...NG OIL FILTER 1 Place a rag or towel below the oil filter to absorb any spilled oil 2 Unscrew the old filter by turning the filter to the left 9735 3 Clean the mounting base Apply a film of clean oil...

Page 81: ...cap Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing deale...

Page 82: ...wing instructions Portable fuel tank Pour the required amount of gasoline stabilizer follow the instructions on container into the fuel tank Tip the fuel tank back and forth to mix the stabilizer with...

Page 83: ...se 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 the outboard NOTICE Storing the outbo...

Page 84: ...stop switch not in RUN position Incorrect starting procedure Refer to Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching the engine Fuel tank...

Page 85: ...clearance adjustment Tilting the outboard out beyond a vertical position Cavitation of the impeller due to rough water or obstruction in the boat hull Blockage of the water intake Performance Loss PO...

Page 86: ...e model and serial numbers and to whom the recovery is to be reported This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power pack...

Page 87: ...vice manager Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your deale...

Page 88: ...FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabecho Sakai ku Sakai shi Osaka 590 0984 Japan Fax 072 233 8833 Asia Singapore Telephone 65 65466160 Brunswick A...

Page 89: ...e center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Ro...

Page 90: ...outboard For example do not mount tow sport bars or boarding ladders onto the boat using the mounting hardware included with the outboard Installing other products onto the boat that utilize the outb...

Page 91: ...specifically designed and tested for your outboard These accessories are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved ac...

Page 92: ...pressure Top Cowl Removal and Installation TOP COWL REMOVAL 1 Unlock the cowl latch located at the rear of the engine by lifting the latch up 2 Lift up on the rear of the cowl and disengage the front...

Page 93: ...owever because of different boat hull designs the setting should be checked by test running the boat Refer to Water Testing Installing the outboard too high on the transom will allow the water intake...

Page 94: ...som so that the front edge of the water intake housing is in line with the horizontal line made in step 1 Temporarily clamp the outboard to the transom at this position 3 Fasten the outboard to the tr...

Page 95: ...ation the outboard must be correctly installed with the required mounting hardware This product must be secured to the transom with the required mounting hardware If the outboard strikes an under wate...

Page 96: ...ontinues to turn without the torque reading on the dial increasing it is an indication that the transom is yielding The load area can be increased by using a larger washer or a transom reinforcement p...

Page 97: ...t clamp screws c Washer 4 d Locknut 4 Description Nm lb in lb ft Outboard mounting locknuts and bolts 75 55 Steering Bracket Steering Cable Installation 1 Install the steering bracket with two washers...

Page 98: ...stened using the steering link rod fastening hardware supplied with the engine Never replace the locknuts with nonlocking nuts Nonlocking nuts may loosen and vibrate off allowing the link rod to disen...

Page 99: ...ed hole 59496 2 Assemble the steering link rod onto the steering bracket with the bolt two washers spacer and a locknut Do not tighten the bolt or locknut at this time a Bolt b Washer c Spacer d Steer...

Page 100: ...ly and then back the nut off 1 4 turn a Washer b Locknut 4 Tighten the link rod bolt to the specified torque 5 Secure the link rod bolt so it does not loosen and tighten the locknut to the specified t...

Page 101: ...ith two cable ties to prevent contact with the steering components 59502 Electrical Harness Battery Connection Fuel Tanks REMOTE WIRING HARNESS 1 Remove the three access cover bolts Remove the access...

Page 102: ...rrel retainer a Cable barrel retainer 3 Loosen the harness retainer Route the remote harness into the cowl as shown and below the harness retainer a Harness retainer b Remote harness a 24857 a b 24858...

Page 103: ...ed torque Description Nm lb in lb ft Harness retainer bolt 6 53 BATTERY CABLE CONNECTIONS IMPORTANT To prevent damage to the engine charging system when the battery cables are not connected to a batte...

Page 104: ...within the engine fuel line length limitations and secure the tank in place Permanent Fuel Tank Permanent fuel tanks should be installed in accordance with industry and federal safety standards which...

Page 105: ...and cotter pin retainer 3 Adjust the throttle cable barrel so when barrel is installed into the throttle cable barrel support no play can be felt when lightly pushing the throttle cam with your finger...

Page 106: ...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 Cable barrel retainer b Cable barrel retainer bolt c...

Page 107: ...y or death from occupants being thrown within or out of the boat Adjust the shift cable to prevent the reverse gate from interfering with water flow off the rudder 1 Attach the shift cable to the shif...

Page 108: ...n The reverse gate should not move when pushed toward the neutral position IMPORTANT The forward locking of the reverse gate must be met If not readjust the shift cable Water Testing CHECKING FOR CAVI...

Page 109: ...to try is lowering the outboard mounting height If cavitation still exists after lowering the outboard it may be helpful to seek advice from the boat manufacturer Another option to further reduce cavi...

Page 110: ...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 100 eng...

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