Mercury 300 - PRO MAX 3.0L User Manual Download | Manualshive

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68

STORAGE

Fuel System (Continued)

1. Portable Fuel Tank – Pour the required amount of Mercury Preci-

sion Fuel System Treatment and Stabilizer (92-802875A1) (fol-
low instructions on container) into fuel tank. Tip fuel tank back
and forth to mix stabilizer with the fuel.

2. Permanently Installed Fuel Tank – Pour the required amount of

Mercury Precision Fuel System Treatment and Stabilizer
(92-802875A1) (follow instructions on container) into a separate
container and mix with approximately one quart (one liter) of
gasoline. Pour this mixture into fuel tank.

CAUTION

Prevent damage to the water pump or overheating of the en-
gine, never start or run your outboard (even momentarily)
without an adequate water supply to the engine.

3. Place the outboard in water or connect flushing attachment for

circulating cooling water. Run the engine for ten minutes to allow
treated fuel to fill the fuel system.

hid1

Protecting Internal Engine Components

NOTE: Before performing the following steps, make sure the fuel
system has been prepared for storage. Refer to Fuel System.

1. Remove the spark plugs and inject a five second spray of Mer-

cury Precision Storage Seal Rust Inhibitor (92-802878-56)
around the inside of each cylinder.

2. Rotate the flywheel manually several times to distribute the stor-

age seal in the cylinders. Reinstall spark plugs.

3. Remove the water separating fuel filter and empty contents in a

suitable container. Refer to Maintenance Section for removal
and installation of filter. Replace fuel filter annually, or every 100
hours of operation, or if large amount of fuel contamination is
present.

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Summary of Contents for 300 - PRO MAX 3.0L

Page 1: ...ng the finest quality products This has led to Mercury Racing s reputation for strict quality control excellence durability lasting performance and being the best at providing after the sale support Please read this manual carefully before operating your outboard This manual has been prepared to assist you in the operation safe use and care of your outboard All of us at Mercury Racing took pride i...

Page 2: ...0 ...

Page 3: ...rbon Monoxide Risk 9 Wave And Wake Jumping 11 Impact With Underwater Hazards 12 Selecting Accessories For Your Outboard 14 Safe Boating Suggestions 14 Recording Serial Number 16 Specifications 17 Component Identification 18 Propeller Selection 19 Transporting Trailering Boat Outboard 20 Fuel Oil Gasoline Recommendations 21 Oil Recommendation 22 Filling Fuel Tank 23 Filling Remote Oil Tank 24 Filli...

Page 4: ...perating At High Elevations 40 Setting Trim Angle While Running Engine at Idle Speed 41 Operating in Shallow Water 41 Starting The Engine 42 Gear Shifting 44 Stopping The Engine 44 Emergency Starting 45 Maintenance Outboard Care 47 Submerged Outboard 47 Selecting Replacement Parts For Your Outboard 47 EPA Emissions Regulations 47 Inspection And Maintenance Schedule 48 Flushing the Cooling System 5...

Page 5: ... Log Maintenance Log 76 The description and specifications contained herein were in effect at the time this manual was approved for printing Mercury Racing whose policy is one of continued improvement reserves the right to discontinue models at any time to change specifications designs methods or procedures without notice and without incurring obliga tion Mercury Marine Fond du Lac Wisconsin U S A...

Page 6: ...e driver is unable to operate the boat obb1 Before Operating Your Outboard Read this manual carefully Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage If you have any questions contact your dealer This manual as well as safety labels posted on the outboard use safety alerts to draw your attention to special sa...

Page 7: ...nufacturer WARNING Overpowering a Boat Can Cause Serious injury death or boat damage Loss of Boat Control Flotation Characteristics of Boat to be Altered from Placing Too Much Weight on Transom Boat to Break Apart Particularly Around the Transom Area obd2 High Speed And High Performance Boat Operation 2 If you are not familiar with high performance boat operation we recommend that you first reques...

Page 8: ...moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch A lanyard stop switch can be installed as an accessory generally on the dashboard or side adjacent to the operator s position 2 While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance de pending upon th...

Page 9: ...ntal or unintended activation of the Lanyard Stop Switch dur ing normal operation is a possibility and could cause any or all of the following potentially hazardous situations 1 Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller 2 ...

Page 10: ... even with the outboard in neutral position there is sufficient force by the water to rotate the propeller This neutral propeller rotation can cause serious injury WHILE BOAT IS STATIONARY Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat WARNING Stop your engine immediately whenever anyone in the water is near your boat Serious in...

Page 11: ... monoxide is a deadly gas that is odorless colorless and tasteless and is present in the exhaust fumes of all internal combus tion engines Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizzi ness drowsiness and nausea SUFFICIENT FRESH AIR FLOW 1 Example of desired air flow through the boat a Ventilate passenger area open ...

Page 12: ...hough rare on a very calm day swimmers and passengers in an open stationary boat with a running engine or near a running engine may be exposed to a hazardous level of carbon monoxide Insufficient Air Flow Could Occur If 2 While boat is stationary a Boat moored in a confined space with the engine running b Boat is moored close to another boat with its engine running 3 While boat is moving a Running...

Page 13: ...use occupants to be thrown out of their seats or out of the boat There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches down far enough while airborne upon water contact it may pene trate under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the oc cupants...

Page 14: ...void serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater ob stacle maintain a top speed no greater than minimum planing speed Striking a floating or underwater object could result in an infinite number of situations Some of these situations could result in the fol lowing Part of the outboard or the entire outboard could break loose a...

Page 15: ...resent or suspected the outboard should be taken to an au thorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures water leaks Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat If con tinued running is necessary do so at greatly reduced speeds W...

Page 16: ...g regulations and restrictions and consider the following suggestions Use Life Jackets Have an approved life jacket of suitable size for each person aboard and have it readily accessible it is the law However we strongly recommend that everyone aboard wear their life jacket Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity p...

Page 17: ...he back stern of the boat Just shifting the outboard into neutral is not sufficient Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above idle speed Never drive your boat directly ...

Page 18: ... Serial Number 19XX XX OGXXXXXX XXXX b c d e a Record the following numbers from your engine as shown for future reference a Serial Number b Model Year c Model Designation d Year Manufactured e Certified Europe Insignia ...

Page 19: ...r 1 2 3 4 5 6 Idle Speed Pickup Timing Non Adjustable Fuel Pressure 38 40 psi 262 276 kPa Min Water Pres 7500 5500 RPM 12 psi Minimum Fleetmaster Gear Ratio Torquemaster Sportmaster 1 75 1 1 75 1 1 62 1 or 1 75 1 Recommended Gasoline Refer to Fuel Section Recommended Oil Refer to Fuel Section Recommended Gear Case Oil Mercury Precision Hi Performance Gear Lube 92 802854A1 Gear Case Lubricant Cap 2...

Page 20: ...owl Latch Rear 4 Water Pump Indicator Hose Tell Tail 5 Bottom Cowl 6 Drive Shaft Housing 7 Anti Ventilation Plate 8 Corrosion Anode s 9 Cowl Mount Trim Switch 10 Wiring Harness Fuel line and Control Cables Install thru bot tom cowl 11 Transom Brackets 12 Trim Adjustment Bolt 13 Gear Case 14 Cooling Water Intake Holes 15 Skeg ...

Page 21: ...itions such as warmer more humid weather oper ation at higher elevations increased boat load or a dirty boat bot tom gear case cause the RPM to drop below the recommended range a propeller change or boat cleaning may be required Check full throttle RPM using an accurate tachometer with the en gine trimmed out to a balanced steering condition steering effort equal in both directions without causing...

Page 22: ...ings driveways or trailer bouncing support the outboard using a sup port device Contact your local dealer for recommendations IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailer ing The outboard tilt support lever is not intended to support the outboard for trailering To prevent the propeller from spinning freely shift into forw...

Page 23: ...tion Leaded Gasoline is acceptable to use in areas where unleaded is not available However exhaust passageway corrosion may occur due to the accumulation of exhausted lead particles ALCOHOL IN GASOLINE We do not recommend gasoline containing alcohol due to the possi ble adverse effect the alcohol may have on the fuel system If only gasoline containing alcohol is available it must not contain more ...

Page 24: ...us 2 Cycle TC W3 Outboard Oil Emergency Use Only If Mercury Precision Premium Plus 2 Cycle TC W3 Outboard Oil is not available NMMA Certified 2 Cycle TC W3 Oil may be substituted Periodically consult with your dealer to get the latest gasoline and oil recommendations If Mercury Precision Premium 2 Cycle TC W3 Outboard Oil is not available substitute a 2 Cycle outboard manufacturers oil that is NMM...

Page 25: ...ortable fuel tanks must be removed from the boat and placed directly on the ground for filling 1 Fill fuel tanks outdoors away from heat sparks and open flames 2 Remove portable fuel tanks from boat to refill them 3 Always stop engine before refilling tanks 4 Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its tem perature rise...

Page 26: ...d of the break in period visually check to see if the oil level in the remote oil supply tank has dropped Oil usage indicates the oil injection system is functioning correctly Filling Engine Mounted Oil Reservoir Tank NOTE Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated 2 Remove top cowl Loosen engine mounted oil reservoir tank fill...

Page 27: ...er c Trim Tilt Switch d Lanyard Stop Switch Read the Lanyard Stop Switch safety explanation and Warning in the General Information Section e Lanyard Read the lanyard stop switch safety explanation and warning in the General Information Section f Throttle Friction Adjustment g Ignition Key Switch Choke h Fast Idle Lever Raising lever will increase engine idle speed in neutral i Throttle Only Button...

Page 28: ...ation following Engine overheat see explanation following Water in fuel filter reaches full level see explanation following 2 When the ignition key is initially turned on the warning horn will sound for a moment as a test to tell you the system is working Failure of this test indicates a problem Have the outboard checked by your dealer NOTE If you are in a stranded situation stopping the engine an...

Page 29: ...ank located beneath the top cowl along with the remote oil tank will have to be refilled refer to Fuel Oil Section The low oil level warning system works as follows 3 The warning horn will begin a series of four beeps If you contin ue to operate the outboard the horn will beep every two min utes The engine has to be shut off to reset the warning system CAUTION To avoid engine damage caused by runn...

Page 30: ...tor hole a CAUTION Operating the engine while overheated will cause engine damage The overheat problem must be corrected before you can resume normal operation a If no water is coming out of the water pump indicator hole a or flow is intermittent Stop engine and check cooling water intake holes for obstruction If no obstruction is found this may indicate a blockage in the cool ing system or a wate...

Page 31: ...peller is being used or the propeller is faulty If engine over speed continues have the outboard checked by your dealer ELECTRICAL SENSOR NOT FUNCTIONING The warning system is activated if an electrical engine sensor is not functioning or is out of its operating range The warning system works as follows 7 The warning horn begins beeping Have the outboard checked by your dealer WATER SEPARATING FUE...

Page 32: ... the outboard further away from the boat transom called trimming out or up The term trim Generally refers to the adjustment of the outboard within the first 20 range of travel b The term tilt Generally refers to adjusting the outboard further up out of the water With the engine turned off the outboard can be tilted out of the wa ter At low idle speed the outboard can also be tilted up past the tri...

Page 33: ...oat control as the out board 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 or Down Can Lower the bow of the boat Result in quicker planing off Generally improve the ride in choppy water Increase steering torque or pull to th...

Page 34: ... the steering wheel 1 The trim in limit may be set by inserting the tilt pin a into the de sired transom bracket hole Trimming Out or Up can Lift the bow higher out of the water Generally increase top speed Gain clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a normal installation height with the normal right hand rotation propeller In excess ca...

Page 35: ...eased or it reaches its maximum tilt position 1 Engage the tilt support lever a by pushing in and rotating knob b to bring support lever upward 2 Lower 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 down Lower the outboard osc1 Auxiliary Tilt Switch 4 This switch c can be used to tilt the outboard u...

Page 36: ...s its maximum tilt position 1 Push in on the tilt support release knob 2 Move tilt support lever into locking position and lower 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 up until it locks Lower the outboard osc1 Auxiliary Tilt Switch 4 This switch c can be used to tilt the outboard up or down ...

Page 37: ... can be manually tilted 1 Turn out the manual tilt release valve 3 turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve NOTE The manual tilt release valve must be tightened before op erating the outboard to prevent the outboard from tilting up during reverse operation ...

Page 38: ...ith a cloth to collect any fluid which may be dis pelled during the following operations 1 TILTING DOWN IN Loosen the starboard right facing engine from front hydraulic connection at the front of the swivel bracket Slowly lower the engine to the desired position and reconnect the hydraulic connection 2 TILTING UP OUT Loosen the port left facing engine from front hydraulic connec tion at the front ...

Page 39: ...arter throttle Short bursts of full throttle for periods up to 10 seconds are acceptable Vary engine speed 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 during break in cycle NEXT 3 HOURS Change engine speed every 10 minutes CAUTION It is the boat...

Page 40: ...s 11 5 L 6 Gallons Gas 23 L 30 US Gal Gas 114 L 25 1 4 5 fl oz 148 ml Oil 15 fl oz 444 ml Oil 31 fl oz 917 ml Oil 4 75 US qt 4 5 L Oil GASOLINE RECOMMENDATION Use a major brand of automotive unleaded gasoline with a minimum posted octane rating R M 2 of 92 OIL RECOMMENDATION Use Mercury Precision Premium Plus 2 Cycle TC W3 Outboard Oil ...

Page 41: ...y and everyone is seated in a proper seat j Tell someone where you are going and when you expect to return j It is illegal to operate a boat while under the influence of alcohol or drugs j Know the waters and area you will be boating tides currents sand bars rocks and other hazards j Engine lowered to run position with all water intake holes sub merged j Fuel tank vent cap open or fuel petcock On ...

Page 42: ... out board with fresh water after each use in salt or polluted water to pre vent a buildup of deposits from clogging the water passages Refer to Flushing The Cooling System procedure in the Maintenance Section If you keep your boat moored in the water always tilt the outboard so the gear case is completely out of water except in freezing tem perature when not in use Wash down the outboard exterior...

Page 43: ...ed spark plugs If this condition exists trim outboard up until exhaust relief hole is out of the water b onk2 Operating in Shallow Water 2 When operating in shallow water you can tilt the outboard be yond the maximum trim range to prevent hitting bottom a Operate the engine at slow speed only Do Not exceed 1200 RPM with the outboard trimmed beyond the side supports of the swivel bracket b Tilt out...

Page 44: ...nt damage to the water pump running dry or overheating of the engine 1 Lower the outboard to the run position Make sure all the cooling water intake holes are submerged 2 Open fuel tank filler cap vent screw manual venting fuel tanks 3 Squeeze the fuel line primer bulb several times until it feels firm 4 Set the lanyard stop switch to RUN position Read the Lanyard Stop Switch safety explanation an...

Page 45: ...he key to ON position wait 30 seconds and try again NOTE Starting Flooded Engine Advance the neutral high idle speed feature on the remote control to the full high speed position Crank engine for 10 seconds wait 30 seconds and repeat until en gine starts 7 Check for a steady stream of water flowing out of the water pump indicator hole allow approximately 10 15 seconds for the water flow to start I...

Page 46: ...e without the engine run ning 1 Your outboard has three gear shift positions to provide opera tion Forward F Neutral out of gear and Reverse R 2 When shifting always stop at neutral position and allow the en gine speed to return to idle 3 Always shift outboard into gear with a quick motion Stopping The Engine 4 Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF pos...

Page 47: ... condition the engine cannot be manually started 1 Remove flywheel cover a Refer to Maintenance Section 2 Shift outboard to neutral N position WARNING When using emergency starter rope to start engine the start in gear protection provided by the remote control is inopera tive Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear Sudden unexpected accelerat...

Page 48: ...ep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is run ning 4 Place the rope knot into the flywheel notch and wind the rope clockwise around the flywheel under the alternator belt 5 Pull the starter rope to start the engine 6 After engine has started do not reinstall the ...

Page 49: ...ize internal corrosion damage to the engine Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision replacement parts and Lubricants WARNING Using a replacement part that is inferior to the original part could result in personal injury death or product failure oti1 EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the Un...

Page 50: ...for damage AFTER EACH USE 1 Flush out the outboard cooling system if operating in salt or pol luted water 2 If operating in salt water wash off salt deposits and flush propel ler and gear case exhaust outlet with fresh water EVERY 50 HOURS OF USE 1 Lubricate all lubrication points More frequently in salt water 2 Inspect and clean replace spark plugs 3 Check corrosion control anodes More frequently...

Page 51: ... more frequent service may be needed 4 Torque Master and Sport Master Gearcases Lubricate entire length of driveshaft with Mercury Precision anti corrosion grease 92 802867A1 If used in salt water more frequent ser vice may be needed 5 Inspect fiberglass reeds for chipping or cracks 6 Use Mercury Precision QuicKleen 92 802877A1 in fuel EVERY 300 HOURS OR USE OR THREE YEARS 1 Replace water pump imp...

Page 52: ...ssages NOTE Engine should not be running when flushing the cooling system Do not flush engine using a water system that exceeds 45 psi 1 Remove plug a from valve body b in the bottom cowl port side 2 Attach coupling assembly 22 852400 c to the valve body b located in the bottom cowl port side 3 Attach a water hose to the coupling assembly c 4 Turn water supply on and flush engine for 3 to 5 minute...

Page 53: ...is leaking around the flushing attachment to ensure the engine receives an adequate supply of cooling water 3 Start the engine and run it at idle speed in neutral shift position 4 Adjust water flow so excess water continues leaking out from around the flushing attachment to ensure the engine is receiving an adequate supply of cooling water 5 Check for a steady stream of water flowing out of the wa...

Page 54: ...emoval a Rotate rear latching handle clockwise b Pull out on front latching handle and at the same time lift front of cowl c Lift cowl from engine 2 Installation d Lower top cowl into position over engine e Rotate the rear latch counterclockwise to secure the rear cowl latch f Pull out on front latching handle and push down on the front of the cowl to engage the front latch ...

Page 55: ...e servicing any part of the fuel system Before servicing any part of the fuel system Stop engine and disconnect the battery Drain the fuel system completely Fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage IMPORTANT Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain...

Page 56: ...plugged with debris the filter must be replaced with a new filter Remove and replace filter as follows Turn ignition key switch to OFF position Disconnect wire a at bottom of filter Remove filter by turning the filter in the direction of the arrow clockwise Tip the filter to drain fluid in a suitable container Lubricate the sealing ring on the filter with oil Thread on the filter and tighten secur...

Page 57: ...se vibrate off freeing 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 ac tion can cause occupants to be thrown overboard exposing them to serious injury or death Assemble steering link rod to steering cable with two flat washers d and self locking nylon insert locknut b Part Number 11 34863 Tighten ...

Page 58: ...nodes IMPORTANT Anodes help protect the metal of the outboard from galvanic corrosion by sacrificing their metal to be slowly eroded instead of the outboard metals being eroded All anodes require periodic inspection especially in salt water Replace any anodes before they are completely eroded Never paint or apply protective coating on the anode as effectiveness of the anode will be reduced 2 Your ...

Page 59: ...y a rotating propeller always shift outboard to neutral position and remove spark plug leads before you service the propeller 1 Shift outboard to neutral N position 2 Remove spark plug leads to prevent engine from starting 3 Straighten the bent tabs on the propeller nut retainer 4 Place a block of wood between gear case and propeller to hold propeller and remove propeller nut 5 If propeller is sei...

Page 60: ...vals and also each time the propeller is removed 7 Rubber Hub Propellers Install thrust washer a propeller b continuity washer c splined washer d propeller nut retainer e and propeller nut f onto the shaft 8 Replaceable Hub Propellers Using Flo Torq II Hub Assembly Kit P N 835258A1 or 835258A2 Install forward thrust hub a replaceable drive sleeve b propeller c drive sleeve adaptor d propeller nut ...

Page 61: ...ction 4 Before reinstalling spark plugs clean away dirt on the spark plug seats Install plugs finger tight and tighten 1 4 turn or torque to 20 lb ft 27 N m Battery Inspection The battery should be periodically inspected 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...

Page 62: ...should be periodically inspected for condition and ten sion 1 Check belt tension by pressing in on the belt at the point shown Proper tension allows the belt to be pressed in 1 2 in 12 7mm 2 If adjustment is required loosen bolts and adjust belt Re torque adjustment bolts to 40 lb ft 55 N m ...

Page 63: ...l Lubricant 101 92 802865A1 1 Fleet Master and Torque Master Models Only Trim Rod Ball Ends Turn the ball ends to work the lubricant into the ball sockets 2 Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft continued on next page ...

Page 64: ...peller Shaft Refer to Propeller Replacement for re moval and installation WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant thru grease fitting Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked An hy draulically locked steering cable could cause loss of steering control po...

Page 65: ...the full up position and engage the tilt support lock 4 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add Mercury Precision Pow er Trim Steering Fluid 92 802880A1 If not available use au tomotive ATF automatic transmission fluid continued on next page ...

Page 66: ...cessary add Mercury Precision Power Trim Steering Fluid 92 802880A1 or SAE 10W 30 or 10W 40 motor oil thru the fill vent screw hole to bring level up to the FULL mark on the dip stick DO NOT OVERFILL 3 To purge system of air raise the outboard 2 or 3 times Recheck oil level and add oil if necessary 4 Reinstall fill vent screw by turning it all the way in then back it out one and a half 1 1 2 turns...

Page 67: ...small amount of metal filings or fine metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips should be checked by an authorized dealer d Quickly place lubricant tube into the fill hole e Slowly add lubricant until it flows from the upper vent hole IMPORTANT Replace sealing washers if damaged f Stop adding lubricant Install the upper vent plug and ...

Page 68: ... Result in premature bearing failure In freezing temperatures turn to ice and damage gearcase Draining Gear Case 1 Torquemaster Sportmaster 2 Fleetmaster a Place outboard in a vertical operating position b Place drain pan below outboard c Remove upper vent plug and sealing ring d Remove lower fill drain plug sealing ring drain lubricant GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is ...

Page 69: ...temperature water may enter the propeller exhaust outlet in the gear case and could freeze causing damage to the outboard oib11 Fuel system IMPORTANT Gasoline containing alcohol ethanol or metha nol can cause a formation of acid during storage and can dam age the fuel system If the gasoline being used contains alco hol it is advisable to drain as much of the remaining gasoline as possible from the...

Page 70: ... supply to the engine 3 Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for ten minutes to allow treated fuel to fill the fuel system hid1 Protecting Internal Engine Components NOTE Before performing the following steps make sure the fuel system has been prepared for storage Refer to Fuel System 1 Remove the spark plugs and inject a five seco...

Page 71: ...78 55 on external metal surfaces Do not apply on corrosion control anodes oie1 Gear Case 1 Drain and refill the gear case lubricant refer to maintenance pro cedure BATTERY STORAGE 1 Follow the battery manufacturers instructions for storage and re charging 2 Remove the battery from the boat and check water level Re charge if necessary 3 Store the battery in a cool dry place 4 Periodically check the...

Page 72: ...lenoid failure 2 ENGINE WILL NOT START POSSIBLE CAUSES Lanyard stop switch not in RUN position Incorrect starting procedure Refer to Operating Section Old or contaminated gasoline Engine flooded Refer to Operating Section Fuel is not reaching the engine a Fuel tank is empty b Fuel tank vent not open or restricted c Fuel line is disconnected or kinked d Fuel filter is obstructed Refer to Maintenanc...

Page 73: ... Water separating filter or In Line filter clogged d Stuck anti siphon valve on built in fuel tank e Fuel line is kinked or pinched f Reed valve open or broken Fuel pump failure Ignition system component failure 4 PERFORMANCE LOSS POSSIBLE CAUSES Throttle not opening fully Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed...

Page 74: ...ry Excessive use of electrical accessories Defective alternator or voltage regulator 6 ENGINE OVERHEATING CONTINUOUS HORN SOUND POSSIBLE CAUSES Cooling system clogged Engine overloaded cannot attain recommended RPM Incorrect ignition timing Incorrect transom height water pickups not getting adequate water supply Not enough oil in fuel mixture Lean fuel mixture ...

Page 75: ...73 NOTES ...

Page 76: ...BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LT Light DK Dark 7 8 9 10 11 12 1 Fuel Injector 1 2 Fuel Injector 2 3 Fuel Injector 3 4 Fuel Injector 4 5 Fuel Injector 5 6 Fuel Injector 6 7 Ignition Coil 1 8 Ignition Coil 2 9 Ignition Coil 3 10 Ignition Coil 4 11 Ignition Coil 5 12 Ignition Coil 6 13 MAP Sensor 14 Throttle Position Sensor 1...

Page 77: ...6 18 17 19 20 21 22 23 24 1 2 345 67810 911 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 21 30 31 32 2 1 34 567 8 10 911 12 13 14 15 16 18 17 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 B A C B A C A B C BLK PPL GRY BLK BLK BLK BLK RED 1 2 3 4 5 6 7 8 BLK YEL PPL TAN LT BLU BLK GRY YEL RED RED DK BLU WHT A B 86 87 85 30 87a PPL RED RED BLU YEL PPL RED A B...

Page 78: ...76 ok MAINTENANCE LOG Record here all maintenance performed on your outboard Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

Page 79: ...77 ok MAINTENANCE LOG Date Maintenance Performed Engine Hours ...

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