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Mercury 300R HD CMS Mechanical Operation And Maintenance Manual Download Page 74

8. Push on the end of the spark plug boot to ensure the boot is completely

engaged and seated onto the spark plug.

63315

Push the spark plug boot

9. Install the top cowl.

Fuses

IMPORTANT: An ATC fuse has the fuse element enclosed or sealed inside the

plastic housing. This type of fuse must be used for marine applications. Marine

applications are exposed to environments that may have the potential to

accumulate explosive vapors. ATO fuses have exposed elements and should

never be used in marine applications.
The electrical wiring circuits on the outboard are protected from overload with

fuses. If a fuse is open, try to locate and correct the cause of the overload. If

the cause is not found, the fuse may open again.

MAINTENANCE

  

64

eng

Summary of Contents for 300R HD CMS Mechanical

Page 1: ...Operation and Maintenance Manual 2018 Mercury Marine 300R HD CMS Mechanical 8M0140585 518 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: ...10 Exhaust Emissions 11 Selecting Accessories for Your Outboard 13 Safe Boating Recommendations 13 Recording Serial Number 16 Specifications 300R HD 17 Component Identification 19 Gearcase Identifica...

Page 8: ...ons 48 Inspection and Maintenance Schedule 49 300R HD Models Maintenance Schedule Decal 51 Flushing the Cooling System 52 Top Cowl Removal and Installation 52 Battery Inspection 54 Battery Cables and...

Page 9: ...sitioning Outboard for Storage 82 Battery Storage 82 Troubleshooting Starter Motor Will Not Crank the Engine 83 Engine Will Not Start 83 Engine Runs Erratically 83 Performance Loss 84 Battery Will Not...

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: ...s in the propulsion system An improper propeller choice can significantly affect the performance of your boat and could result in damage to the outboard engine When choosing a propeller a full selecti...

Page 13: ...gn of your outboard However when more than one diameter is available for the same pitch use a larger diameter for heavy boat applications and a smaller diameter for lighter applications Pitch The pitc...

Page 14: ...of sizes and styles that allow you to dial in the ultimate performance for your boat 3 BLADE VS 4 BLADE Available in many sizes of both aluminum and stainless 3 and 4 blade propellers have unique per...

Page 15: ...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 clip on the other end for attaching to the operator s PFD or wrist The lan...

Page 16: ...ut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recomme...

Page 17: ...ng in the water to take quick action to avoid a boat heading in his her direction even at slow speed 21604 Always slow down and exercise extreme caution any time you are boating in an area where there...

Page 18: ...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 or persons dangling their...

Page 19: ...se the boat to veer violently in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious...

Page 20: ...trol the boat speed Under these conditions boat speed should be kept to the minimum planing speed typically 24 to 40 km h 15 to 25 mph 26785 WARNING Avoid serious injury or death from all or part of a...

Page 21: ...ath If the vessel experiences any form of impact have an authorized Mercury Marine dealer inspect and repair the vessel or power package Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon...

Page 22: ...xhaust concentration but also subjects them to the possibility of injury from the boat propeller GOOD VENTILATION Ventilate the passenger area open side curtains or forward hatches to remove fumes Exa...

Page 23: ...accessories are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of nonapproved accessories can damage...

Page 24: ...Radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment batteries bulbs and fuses Compass and...

Page 25: ...hat all passengers have a proper seat and are in it before any boat movement Never operate a boat while under the influence of alcohol or drugs It is the law Alcohol or drugs can impair your judgment...

Page 26: ...uiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local...

Page 27: ...Sport Master ratio 1 75 1 137 mm 5 4 in ratio 1 75 1 Gearcase capacity Sport Master RH LH 620 mL 21 0 fl oz 137 mm 5 4 in RH 720 mL 24 4 fl oz 137 mm 5 4 in LH 680 mL 23 0 fl oz Recommended gasoline...

Page 28: ...at a higher rate Activating troll control optional accessory will override the idle charge compensation feature Battery manufacturers may rate and test their batteries to different standards MCA CCA A...

Page 29: ...ine flush d Auxiliary tilt switch e Cooling water intake holes f External steering bracket dealer installed option or factory installation available g Water pump indicator hole h Engine oil drain i Ex...

Page 30: ...in Water intake eight per side four torpedo low water L L 64308 Left hand rotation gearcase LL stamped on the end of propeller shaft Sport Master Water intake three torpedo low water 64532 L L Left ha...

Page 31: ...ice Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 66304 IMPORTANT Do not rely on the power trim tilt system...

Page 32: ...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 33: ...components Fuel Additives To minimize carbon deposit buildup in the engine it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine s fuel at each tank fill thr...

Page 34: ...If the recommended Mercury or Quicksilver NMMA FC W certified oils are not available a major outboard manufacturer s brand of NMMA FC W certified 4 Stroke outboard oil of similar viscosity may be use...

Page 35: ...an hour 1 Before starting a cold engine tilt the outboard out up past vertical to allow trapped oil to drain back to the oil sump Allow the outboard to remain tilted for approximately one minute 2 Ti...

Page 36: ...een the beads are part of the dipstick assembly When checking the oil level if oil is on any of the five oil range beads or four crosshatch the oil level is within the safe operating range When the oi...

Page 37: ...e of the beads shows the oil level remove the oil filler cap and add 1 8 Liter 2 US qt of the specified outboard motor oil 7 Allow a few minutes for the oil to drain into the sump and insert the oil d...

Page 38: ...e speed control is active from idle RPM up to max rated RPM however can only maintain engine speed when the throttle is less than wide open Remote Control Features Your boat may be equipped with one o...

Page 39: ...itions are as follows Water in the engine mounted fuel filter Refer to Maintenance Low Pressure Fuel Filter Cooling system water pressure or engine temperature problem Stop the engine and check the wa...

Page 40: ...Engine Guardian diagnostics The SmartCraft instrument package will display critical engine alarm data and potential problems EXHAUST GAS OVER TEMPERATURE When the Engine Guardian system detects the ex...

Page 41: ...forward gear Power Trim and Tilt The outboard has a trim tilt control called power trim This enables the operator to easily adjust the position of the outboard by pressing the trim switch Moving the...

Page 42: ...hazards The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle This steering torque results from the outboard being trimmed so the propeller s...

Page 43: ...out or up can Lift the bow higher out of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a normal i...

Page 44: ...cket 2 Remove the pins from and install them into the desired adjustment holes 3 Install and tighten the nuts OPERATING IN SHALLOW WATER When operating your boat in shallow water you can tilt the outb...

Page 45: ...NOTE Exceeding 4250 RPMs the engine PCM will begin Engine Guardian protection FEATURES AND CONTROLS eng 35...

Page 46: ...um load capacity Look at the boat capacity plate Fuel supply OK Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where y...

Page 47: ...ays tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearca...

Page 48: ...ain lower In some cases a gear ratio reduction may be more beneficial To optimize engine performance prop the engine to allow it to operate at or near the top end of the recommended maximum RPM range...

Page 49: ...ne PRIMING THE FSM WITH A PURGE TOOL The use of a purge tool for priming the FSM is the preferred method but is not always practical The objective is to purge the air entrained in the fuel system thro...

Page 50: ...already primed If a primer bulb is installed it can be used during the priming event to shorten the amount of time required to start the engine NOTE In most cases the priming procedure can be accompli...

Page 51: ...ICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 1 Push dow...

Page 52: ...the engine oil level Refer to Fuel and Oil Checking and Adding Engine Oil a Service access door b Oil fill cap c Dipstick 3 Ensure that the cooling water intake is submerged 66310 b c a 63305 OPERATIO...

Page 53: ...For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled as follows Turn the ignition key switch to the ON position for approxima...

Page 54: ...engine idle speed could cause damage to the gearcase Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed Shifting into reverse at higher boat spe...

Page 55: ...Stopping the Engine Reduce the engine speed and shift the outboard to neutral position Turn the ignition key to OFF position 26843 OFF ON S T A R T OPERATION eng 45...

Page 56: ...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 57: ...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 58: ...FICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at the time of manufacture a Idle speed b Engine...

Page 59: ...n Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 3 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 Visually inspect the fuel system...

Page 60: ...ten the fasteners to the specified torque dealer service Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 3 Outboard mounting locknuts and bolts metal lift p...

Page 61: ...Lubricate more frequently when used in saltwater Refer to Lubrication Points Replace water pump impeller dealer service 1 Lubricate the splines on the upper driveshaft dealer service Check wiring and...

Page 62: ...emove the flush connector from the bottom cowl 3 Remove the cover from the flush connector and thread a water hose into the flush connector 64241 4 Turn on the water tap 1 2 maximum and let the water...

Page 63: ...ort side of the service access door to unlock and open the door 64230 Push here to unlock 3 Press on the red lock button and lift the handle a Service access door b Red lock button c Handle b c a 6330...

Page 64: ...ll have a gap that is larger than the other side NOTE It may be necessary to slightly lift the larger gap side of the cowl to correctly position the alignment guides 3 Gently push down on the cowl 4 P...

Page 65: ...he clean power harness wires must be secured to the engine starting battery with nuts Wing nuts are not acceptable The clean power harness must be secured to one of the battery cables with a cable tie...

Page 66: ...gative ground When connecting the engine battery hex nuts must be used to secure the battery leads to the battery posts Tighten the hex nuts to the specified torque Description Nm lb in lb ft Battery...

Page 67: ...r signs of deterioration or damage If any of these conditions are found the fuel line must be replaced LOW PRESSURE FUEL FILTER The low pressure fuel filter can be serviced as a general maintenance it...

Page 68: ...th a water in fuel sensor installed the sensor harness would be connected to the boat mounted filter a Fuel hose release tabs b Water in fuel sensor harness 6 Rotate the filter clockwise approximately...

Page 69: ...t the fuel hoses to the fuel filter securely with the locking hose connections 5 Turn the key to the RUN position and inspect for fuel leaks Repair any fuel leaks if necessary Corrosion Control Anode...

Page 70: ...e lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Shift the outboard into neutral position 2 Place a block of...

Page 71: ...nstall the propeller hub propeller washer Belleville washer washer and propeller nut onto the shaft a Propeller nut b Washer c Belleville washer d Washer e Propeller f Propeller hub 6 Place a block of...

Page 72: ...rk plug if the electrode is worn the insulator is rough cracked broken or blistered or if the precious metal is not visible on the spark plug electrode IMPORTANT The color of the plug may not accurate...

Page 73: ...gap use a tool that only pulls back on the ground electrode without touching the center electrode the porcelain or the wear portion of the ground electrode e When it is necessary to close the gap gen...

Page 74: ...is type of fuse must be used for marine applications Marine applications are exposed to environments that may have the potential to accumulate explosive vapors ATO fuses have exposed elements and shou...

Page 75: ...er on the port side of the engine and remove the cover from the fuse holder 63317 2 Remove the suspected open fuse and look at the silver band inside the fuse If the band is broken open replace the fu...

Page 76: ...tor drive belt is located under the flywheel shroud intake air induction plenum The alternator drive belt inspection must be completed by an authorized Mercury dealer at the recommended interval Refer...

Page 77: ...eller shaft 92 802859A 1 Lubricate the tilt lock through the grease fitting Lubricate the swivel bracket through the grease fitting a Tilt lock grease fitting b Swivel bracket grease fitting Lubricate...

Page 78: ...r package at high speeds when the engine is trimmed out When the engine is trimmed up or down the swivel bracket thrust guide will rub against the thrust guide wear pads which are mounted on the trans...

Page 79: ...ck the fluid level in the trim pump reservoir The level should be between the minimum MIN and the maximum MAX level on the reservoir 3 If necessary remove the yellow fill cap and add Power Trim and St...

Page 80: ...l of fluid to ensure the steering helm will not introduce air into the steering system A hydraulic steering system which has entrained air will have spongy or unresponsive steering control which could...

Page 81: ...e minute to allow any trapped oil to drain back to the oil sump OIL CHANGE ON LAND PROCEDURE 1 Tilt the outboard out up past vertical for approximately one minute to allow any trapped oil to drain bac...

Page 82: ...ighten the oil drain valve to the specified torque Clean up any oil in the valve area Description Nm lb in lb ft Oil drain valve 15 132 7 IMPORTANT Overtightening the oil drain valve can damage the oi...

Page 83: ...cess door to unlock and open the door 64230 Push here to unlock 4 Remove the dipstick 5 Install the oil drain hose onto the crankcase oil pump Verify the hose is securely attached a Crankcase oil pump...

Page 84: ...ify the pump is securely attached to the tube by pulling it up lightly a Oil drain hose b Lock button 7 Place the drain tube of the crankcase oil pump into an appropriate container The container shoul...

Page 85: ...ilter b Drain hose 3 Allow the oil in the trough to drain 4 Clean the remaining oil from the oil trough and filter mounting base area 5 Remove the hose and install the plug 6 Apply a film of clean oil...

Page 86: ...mple DIPSTICK BEAD OIL LEVEL OVERVIEW New oil level may be difficult to identify which is why the crosshatch between the beads are part of the dipstick assembly When checking the oil level if oil is o...

Page 87: ...on or once a year whichever occurs first 1 Remove the top cowl Refer to Top Cowl Removal and Installation 2 Remove the hose from the exhaust water spray inlet assembly Press on the hose lock and pull...

Page 88: ...e the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase l...

Page 89: ...l plug Install the lubricant level plug 4 Remove the tube and install the fill drain plug 5 Tighten the plugs to the specified torque Description Nm lb in lb ft Plugs 11 3 100 Checking Lubricant Level...

Page 90: ...5 Remove the lubricant tube and install the fill drain plug and sealing washer 6 Tighten the plugs to the specified torque Description Nm lb in lb ft Plugs 11 3 100 MAINTENANCE 80 eng...

Page 91: ...engine s fuel system other than the fuel tank will remain stable during normal storage periods without the addition of fuel treatment stabilizers Fill the fuel tank and engine fuel system with treate...

Page 92: ...s and the high tension spark plug leads Gearcase Drain and refill the gearcase lubricant Refer to Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position t...

Page 93: ...pty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Ignition system compo...

Page 94: ...tment or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or cor...

Page 95: ...s in the recovery of stolen power packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer...

Page 96: ...rial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geo...

Page 97: ...Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Ma...

Page 98: ...Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Q...

Page 99: ...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 eng 89...

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