Mercury 300XS OptiMax Manual Download Page 1

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eng

Welcome

You have selected one of the finest outboards available. It incorporates

numerous design features to ensure operating ease and durability.
With proper care and maintenance, you will enjoy using this product for

many boating seasons. To ensure maximum performance and carefree

use, we ask that you thoroughly read this manual.
This manual contains specific instructions for using and maintaining your

product. We recommend that this manual remain with the product for

ready reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely hope your

boating will be pleasant!
Mercury Marine

EPA Emissions Regulations

Outboards sold by Mercury Marine in the United States are certified to the

United States Environmental Protection Agency as conforming to the

requirements of the regulations for the control of air pollution from new

outboard motors. This certification is contingent on certain adjustments

being set to factory standards. For this reason, the factory procedure for

servicing the product must be strictly followed and, wherever practicable,

returned to the original intent of the design. Maintenance, replacement, or

repair of the emission control devices and systems may be performed by

any marine engine repair establishment or individual.
Engines are labeled with an emission control information decal as

permanent evidence of EPA certification.

WARNING

The engine exhaust from this product contains chemicals known to the

state of California to cause cancer, birth defects or other reproductive

harm.

Warranty Message

The product you have purchased comes with a limited warranty from

Mercury Marine. The terms of the warranty are set forth in the

Warranty

Information

section of this manual. The warranty statement contains a

description of what is covered, what is not covered, the duration of

coverage, how to best obtain warranty coverage, important disclaimers

and limitations of damages, and other related information. Please review

this information.
The description and specifications contained herein were in effect at the

time this manual was approved for printing. Mercury Marine, whose policy

is one of continued improvement, reserves the right to discontinue models

at any time, and to change specifications, designs, methods, or

procedures without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.

300 XS OptiMax

90-8M0083353 1013

Summary of Contents for 300XS OptiMax

Page 1: ...l intent of the design Maintenance replacement or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual Engines are labeled with an emission control information decal as permanent evidence of EPA certification WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth d...

Page 2: ...ce when appropriate Uses displays and stocks an adequate inventory of genuine Mercury Precision Parts Offers a clean neat shop with well organized tools and service literature MERCURY MARINE All rights reserved Reproduction in whole or part without permission is prohibited Alpha Axius Bravo One Bravo Two Bravo Three Circle M with Waves Logo K planes Mariner MerCathode MerCruiser Mercury Mercury wi...

Page 3: ...cation Star Label 11 Warranty Policy Australia and New Zealand 12 Global Warranty Charts Outboard and Jets 16 General Information Boater s Responsibilities 21 Before Operating Your Outboard 21 Boat Horsepower Capacity 21 High Speed and High Performance Boat Operation 22 Outboard Remote Control Models 22 Remote Steering Notice 23 Lanyard Stop Switch 23 Protecting People in the Water 26 Passenger Sa...

Page 4: ...ures 48 Warning System 48 Power Trim and Tilt 50 Power Trim Operation 50 Power Tilt Operation Single Ram Systems 52 Power Tilt Operation Three Ram Trim Systems 52 Auxiliary Tilt Switch 53 Manual Tilt Operation 53 Operation Important Information 55 Engine Break in 55 Engine Break in Fuel Mixture 56 Prestarting Check List 56 Operating in Freezing Temperatures 56 Operating in Saltwater or Polluted Wa...

Page 5: ...attery Inspection 79 Charging System Fusible Link 79 Replacing the Propeller 80 Lubrication Points 82 Single Ram Trim System 83 Three Ram Trim System 86 Gearcase Lubricant 89 Submerged Power Package 91 Storage Storage Preparation 92 Protecting Internal Engine Components 93 Protecting External Outboard Components 94 Gearcase 94 Positioning Outboard for Storage 94 Battery Storage 94 Troubleshooting ...

Page 6: ...r Outboard 104 Fuel System 104 Installation Specifications 106 Lifting the Outboard 106 Steering Cable Starboard Side Routed Cable 107 Steering Link Rod Fasteners 108 Rear Mounted Steering Rams or Tie Bars 109 Determining Outboard Mounting Height 110 Drilling Outboard Mounting Holes 115 Fastening the Outboard to the Transom 116 Electrical Hoses Control Cables and Front Clamp 121 Oil Injection Set ...

Page 7: ...l number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 OUTSIDE UNITED STATES AND CANADA For products purchased outside the United States and Canada contact the distributor in your country or t...

Page 8: ...y Marine in the amount of 50 00 per engine to cover the transfer fee Plan coverage is not transferable from one product to another product or for noneligible applications The certified preowned engine plans are not transferable For help or assistance contact Mercury Product Protection Department at 1 888 427 5373 from 7 30 a m to 4 30 p m CST Monday Friday or e mail mpp_support mercmarine com 3 Ye...

Page 9: ...ust provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange fo...

Page 10: ...ction 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 PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED...

Page 11: ... with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury Marine product Mercury Marine reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury Marine with a reasonable opportunity to repair and reason...

Page 12: ...o far Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income tournament fees club fees prize money or any other type of incidental or consequential damages are not covered by this warranty Expenses associated with the removal and or replacement of boat partitions or material caused by boat design for ...

Page 13: ...reated by 40 CFR Part 1045 Subpart B Mercury Marine provides a five year or 175 hours of engine use warranty whichever occurs first to the retail customer that the engine is designed built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine is free from defects in materials and workmanship that cause the engine to...

Page 14: ... the Emission Control System Components and further warrants that the outboard engine was designed built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code For information regarding the limited warranty for the nonemission related components of the outbo...

Page 15: ...ion and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury WHAT MERCU...

Page 16: ... EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY...

Page 17: ...ngine owner you should however be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists The warranty repairs will be completed in a reasonable amount o...

Page 18: ...engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines Warranty Policy Australia and New Zealand MERCURY MARINER OUTBOARD LIMITED WARRANTY AUSTRALIA AND NEW ZEALAND P...

Page 19: ...lly used for such purposes Unexpired warranty coverage cannot be transferred either to or from a commercial use customer Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only ...

Page 20: ...ne ups adjustments normal wear 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 Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submers...

Page 21: ...CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY TRANSFER OF WARRANTY AUSTRALIA AND NEW ZEALAND POLICY The limited warranty is transferable to a subsequen...

Page 22: ...ears OptiMax Jet drive 200 and 250 hp 1 year 3 years Racing Product Recreation use only Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax 250 XS 2 years 3 years OptiMax 300 XS 2 years 3 years Verado 350 SCi 2 years 3 years Outside the United States For product purchased outside the Unites States contact the distributor in your country or the authorized Marine Power Service Cent...

Page 23: ... AND JET Products Standard Limited Warranty Standard Limited Corrosion Warranty Light Commercial All outboard 3 years 3 years Contact the Marine Power Service Center closest to you Outside of Australia and New Zealand For product purchased outside of Australia and New Zealand contact the distributor in your country or the Marine Power Service Center closest to you SOUTH PACIFIC WARRANTY CHART OUTB...

Page 24: ...ion Warranty Commercial Application Verado 350 SCi 1 year 3 years None Outside of Asia For product purchased outside of the Asian region contact the distributor in your country or the Marine Power Service Center closest to you EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES CIS WARRANTY CHARTS OUTBOARD AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warran...

Page 25: ...CA WARRANTY CHARTS OUTBOARD AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2 Stroke 1 year 3 years Contact the Marine Power Service Center closest to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard L...

Page 26: ...er Service Center closest to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Verado 350 SCi 2 years 3 years Outside South Africa For products purchased outside of the South Africa region contact the distributor in your country or the Marine Pow...

Page 27: ...y Learn how to operate your outboard properly If you have any questions contact your dealer This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situati...

Page 28: ...nd that you do not operate 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 For additional information obtain a copy of our Hi Performance Boat Operation booklet from your dealer distributor or Mercury Marine Outboard Remote Control Models The remote...

Page 29: ...upants being thrown within or 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 when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and...

Page 30: ...erator accidentally falls overboard or moves within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boats high performance boats and light sensitive handling fishing boats operated by a hand tiller Falling overboard and accidental ejections are also likely to...

Page 31: ...al operation is also a possibility This could cause any or all of the following potentially hazardous situations 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 gearcase or propeller Loss of power and directional control in heavy seas strong current o...

Page 32: ...th to swimmers Stop the engine immediately whenever anyone in the water is near your boat Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats and Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated ...

Page 33: ...ve idle can cause serious injury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden re...

Page 34: ...ew 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 injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boa...

Page 35: ...a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed Boat speed should be kept to a...

Page 36: ...of seasickness and intoxication include headache dizziness drowsiness and nausea WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning which can lead to unconsciousness brain damage or death Avoid exposure to carbon monoxide Stay clear from exhaust areas when engine is running Keep the boat well ventilated while at rest or underway STAY CLEAR OF EXHAUST AREAS 41127 Engine e...

Page 37: ... boat Although the occurrence is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a Operating the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine operat...

Page 38: ...ctions and consider the following suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and your state or provincial boating law enforcement agency provide courses For more information in the U S call the Boat U S Foundation at 1 800 ...

Page 39: ... becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat s capacity plate Know your boat s operating and loading limitations Know if your boat will float if it is full of water When in doubt contact your authorized Mercury Marine dealer or the boat manufacturer Ensure that everyone in the boat is properl...

Page 40: ... up to the skier or anyone in the water Report accidents Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there i...

Page 41: ... Master 218 kg 480 lb 20 in Sport Master 229 kg 505 lb 25 in Torque Master 239 kg 527 lb 25 in Fleet Master 237 kg 522 lb 30 in Fleet Master 242 kg 533 lb Full throttle RPM range 20 in Torque Master 5000 6200 RPM 20 in Sport Master 5000 6200 RPM 25 in Sport Master 5400 5800 RPM 30 in Sport Master 5400 5800 RPM 25 in Fleet Master 5400 5800 RPM 30 in Fleet Master 5400 5800 RPM ...

Page 42: ...2 075 mm 3 625 in Stroke 78 9 mm 3 110 in Spark plug NGK IZFR7M Spark plug gap 0 81 mm 0 032 in Firing order 1 2 3 4 5 6 Maximum timing Controlled by PCM Idle timing Controlled by PCM Fuel pressure 655 13 8 kPa 95 2 psi Air pressure 758 13 8 kPa 110 2 psi Gear ratio Torque Master 1 62 1 1 75 1 Sport Master 1 62 1 1 75 1 Fleet Master 1 75 1 Required fuel Premium unleaded 91 R M 2 octane 96 RON Reco...

Page 43: ... to different standards MCA CCA Ah and reserve capacity RC are the ratings recognized by Mercury Marine Manufacturers that use standards different than these such as equivalent MCA do not meet Mercury Marine battery requirements Special Tools and Kits Description Part Number Stainless Steel Tilt Pin Three Ram Trim Systems 17 49930A1 Oil Syringe 91 803976T Flushing Attachment for Torque Fleet Maste...

Page 44: ... acceleration Mercury Marine recommends selecting a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded refer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed All L models 20 in driveshaft are capable of operating at engine speeds in excess of 6...

Page 45: ... RPM change between propeller pitches 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboard s durability Check full throttle RPM using an accurate tachometer with ...

Page 46: ...ice Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 2722 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This p...

Page 47: ...hanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the f...

Page 48: ...ne oil Premium Plus 2 Cycle Outboard Oil Mercury Racing 2 Stroke Oil is recommended for OptiMax engines that are used in applications of extreme loads associated with commercial work or extended periods of high RPM The added lubrication and protection properties with Mercury Racing 2 Stroke oil maximizes engine horsepower while protecting against heat reduces wear and carbon deposit build up OptiM...

Page 49: ...ressurized Portable Fuel Tank Requirements The Environmental Protection Agency EPA requires portable fuel systems that are produced after January 1 2011 for use with outboard engines to remain fully sealed pressurized up to 34 4 kPa 5 0 psi These tanks may contain the following An air inlet that opens to allow air to enter as the fuel is drawn out of the tank An air outlet that opens vents to the ...

Page 50: ... a click This signals that the fuel cap is fully seated A built in device prevents overtightening The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal Since sealed fuel tanks are not vented they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air This is normal REMOVING THE...

Page 51: ...ters 3 gallons Replace the filler cap and tighten securely IMPORTANT Always make sure the oil tank caps are threaded on tight An air leak will prevent oil flow to the engine 2723 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 1 Remove the top cowl 2 Loosen the fill cap on the engine oi...

Page 52: ...ks in the area while filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tanks from the boat to refill them Always stop the engine before filling the tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is c...

Page 53: ...ase lever c Trim tilt switch if equipped Refer to Features and Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard 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 Fast idle lever Refer to Operation Starting the Engine i...

Page 54: ...on does not require immediate attention You may continue using your boat however depending on the nature of the problem the engine s power may be limited by the Engine Guardian system see Engine Guardian System following to protect the engine You should contact your servicing dealer at your earliest convenience It is important to note that in either of the above scenarios the horn will only sound ...

Page 55: ...ected before Engine Guardian will allow the engine to reach a normal operating RPM OVERSPEED REV LIMIT The overspeed rev limit is set at an RPM greater than the operating range In the event that the engine is operated at an RPM greater than or equal to the overspeed limit the PCM does not allow the engine to maintain the power requested by the operator Refer to Specifications to determine this eng...

Page 56: ...m generally refers to the adjustment of the outboard within the first 20 range of travel 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 water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation Power Trim Operation With most boats...

Page 57: ...ions at planing speeds WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer resulting in the operator losing control of the boat Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner WARNING On some boats increased trim in range can cause handling problems at high speeds resultin...

Page 58: ...ting if any cooling water intake holes are above the water line Power Tilt Operation Single Ram Systems To tilt the outboard shut off the engine and press the trim tilt switch or the auxiliary tilt switch to the up position The outboard tilts up until the switch is released or it reaches the maximum tilt position The hydraulic system is fully capable of supporting the outboard during normal tiltin...

Page 59: ... support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever until it locks Lower the outboard Auxiliary Tilt Switch This switch can be used to tilt the outboard up or down using the power trim system a Auxiliary tilt switch Manual Tilt Operation If the outboard cannot be tilted using the power trim tilt switch the outboard can be tilted ma...

Page 60: ...clockwise This allows manual tilting of the outboard 2728 2 Tilt the outboard to the desired position and tighten the manual tilt release valve NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation ...

Page 61: ...tart up Prime the oil injection pump on new or rebuilt engines or after performing maintenance on the oiling system Refer to Priming the Oil Injection Pump for instructions FUEL REQUIREMENTS Do not use premixed gas and oil in this engine The engine automatically receives extra oil during engine break in Use a fresh supply of the recommended gasoline during engine break in and after engine break in...

Page 62: ...k in cycle Next 3 Hours Change engine speed every 10 minutes Engine Break in Fuel Mixture The propulsion control module PCM controls oil and fuel mixture during engine break in Prestarting Check List Engine lowered to run position with all water intake holes submerged Fuel tank vent cap open or fuel drain valve on Fuel supply OK Lanyard stop switch in RUN position and cord connected Remote control...

Page 63: ... metal surfaces Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes Operating at High Elevations Your engine automatically compensates for high elevation changes A different pitch propeller may help reduce some normal performance loss resulting from reduced oxygen in the air Consult your dealer Effects of Elevation and Weather on Performance The following c...

Page 64: ... and fouled spark plugs If this condition exists trim outboard up until exhaust relief hole is out of the water a Relief hole submerged wrong b Relief hole above waterline correct Operating in Shallow Water When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom NOTICE Operating the engine with the outboard in the tilt range can d...

Page 65: ... tank Removal of the vent cap may damage the threads in the oil reservoir tank Damaged threads may result in future oil leakage 2 Check the oil level in the engine mounted oil reservoir tank The tank must contain at least 118 ml 4 oz of oil prior to starting the engine 3 If the oil level is less than 118 ml 4 oz loosen the vent cap Use a squirt can and fill the tank with at least 118 ml 4 oz of th...

Page 66: ...ump b Oil supply hose IMPORTANT Fill the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel pump will run without fuel during the priming process and may be damaged Prime the oil injection pump as follows 1 Fill the engine fuel tank with fuel 2 Position the fuel primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel hose primer bulb unti...

Page 67: ...engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation INITIAL STARTING PROCEDURE NOTE For initial start up of a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled according to the following procedure 1 Squeeze the fuel line primer bulb until it feels ...

Page 68: ...es are submerged 26837 2 Open fuel tank filler cap vent screw manual venting fuel tanks 19748 3 Squeeze the fuel line primer bulb several times until it feels firm 19779 4 Set the lanyard stop switch to the RUN position Read the Lanyard Stop Switch safety explanation and warning in the General Information section 19791 ...

Page 69: ...Turn the ignition key to the START position Release the key when the engine starts If the engine fails to start in ten seconds return the key to the OFF position wait one second and try again 19804 8 Check for water coming out of the water pump indicator hole 2746 NOTE The electronic starting system will automatically prime choke the engine and increase idle speed for starting ...

Page 70: ... Gear Shifting IMPORTANT Never shift into gear unless the engine is at idle Never shift into reverse without the engine running Your outboard has three gear shift positions to provide operation forward neutral out of gear and reverse N R F 27237 When shifting always stop at neutral position and allow the engine speed to return to idle Always shift into gear with a quick motion After shifting into ...

Page 71: ... Save all maintenance work orders and receipts Replacement Parts for Your Power Package Mercury recommends using original Mercury Precision replacement parts and lubricants EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution...

Page 72: ... manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule PRIOR TO EVERY USE Check that the lanyard stop switch stops the engine Check the steering system for binding or loose components Check the outboard for tightness on the transom Check the propeller blades for damage Visually inspect all hoses clam...

Page 73: ...oper torque tightness Check the level and condition of the gearcase lubricant Check the alternator belt condition EVERY 50 HOURS OR ONCE A YEAR WHICHEVER OCCURS FIRST Lubricate the splines on the driveshaft Lubricate the entire length of the driveshaft with Extreme Grease Lubricate the splines on the propeller shaft Refer to Lubrication Points Drain and replace the gearcase lubricant Check the spa...

Page 74: ...engine with fresh water after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages a Plug located on fitting b Water hose 1 Remove the plug from fitting in the bottom cowl 2 Attach a water hose to the fitting Turn on the water and flush for three to five minutes NOTE The engine can be stopped or operated at idle speed when ...

Page 75: ...tach the Dual Water Flush Seal over the nose inlets 3 Sport Master gearcases Install the appropriate flushing attachment so the nose cone cup fits tightly over the intake holes 4 Attach a water hose to the flushing attachment Turn on the water and adjust the flow so water is leaking around the rubber cups or nose cone cup to ensure the engine receives an adequate supply of cooling water 5 Start th...

Page 76: ... the dirt and dust that may scratch the surface 2 Wash the top cowl with clean water and a 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 Remove the applied wax by hand using a soft clean cloth Fuel System FUEL SYSTEM SERVICE INFORMATION WARNING Fuel i...

Page 77: ...SPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced WATER SEPARATING FUEL FILTER This filter removes moisture and debris from the fuel If the filter becomes filled with water the water can be removed If the filter becomes plugged with d...

Page 78: ...crewdriver between the filter cap bosses and unscrew the filter Installation 1 Lubricate the O ring seals with oil 2 Install the fuel filter and tighten securely 3 Connect the link rod IMPORTANT Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm forcing fuel into the filter ...

Page 79: ...r chamber a Drain hose b Aft hose fitting c Filter drain screw 1 Remove the drain hose from the aft hose fitting right side of the chamber Hold the unattached end of the hose over a suitable container 2 Loosen the filter drain screw left side of the chamber and allow the contents to drain NOTE If little or no liquid drains from the hose loosen the red filter to vent the chamber 3 Tighten the drain...

Page 80: ...omponents and follow instructions and torque procedures WARNING Worn loose or seized steering components can lead to loss of boat control Inspect all steering attachment components for wear lubricate all attachment hardware and check all fasteners for proper tightness in accordance with the inspection and maintenance schedule a Special washer head bolt P N 10 849838 b Nylon insert locknut P N 11 8...

Page 81: ...e 2 15 and 20 amp fuses The electrical wiring circuits on the engine are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload before replacing the fuse If the cause is not found the fuse may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If the band is broken replace the fuse 2 Replace the fuse ...

Page 82: ...jector PCM and electric fuel pump circuits 20 amp fuse g Diagnostic circuit 2 amp fuse Corrosion Control Anode NOTICE Anodes made of insufficiently pure aluminum alloys may not adequately protect critical drive components from corrosion We recommend using anodes sold through Mercury Precision Parts only Anodes help protect the power package against galvanic corrosion by sacrificing its metal to be...

Page 83: ...ctive coating on the anode as effectiveness of the anode will be reduced Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Remove the spa...

Page 84: ...gap c If an adjustment is necessary do not pry or apply any force on the center electrode This is critical with any type of spark plug that has a wear surface such as platinum or iridium added to either the ground electrode or the center electrode d When it is necessary to widen the gap use a tool that only pulls back on the ground electrode without touching the center electrode the porcelain or t...

Page 85: ... to negative 4 Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals Charging System Fusible Link This model has a 100 amp fusible link between the alternator and the 12 volt stud This fusible link protects the alternator from damage due to accidental reverse battery connection If the battery cables are reversed the fusible link creates an o...

Page 86: ...the keys from the ignition and engage the safety stop switch 3 Straighten the bent tabs on the propeller nut retainer if applicable 4 Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut 26901 5 Remove the propeller and associated hardware from the propeller shaft INSTALLING THE PROPELLER NOTICE Operating the engine with the wrong propelle...

Page 87: ... propeller hub assembly propeller washer Belleville washer washer and propeller nut onto the propeller shaft a Propeller hub assembly b Propeller c Washer d Belleville washer e Washer f Propeller nut Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft splines 8M0071842 3 Place a block of wood between the gearcase and propeller and torque the propeller nut 2691 Description Nm ...

Page 88: ...h PTFE 5517 94 95 95 95 Tube Ref No Description Where Used Part No Extreme Grease Trim rod ball ends propeller shaft 8M0071842 95 2 4 C with PTFE Swivel bracket tilt support lever tilt tube 92 802859A 1 NOTE Turn the ball ends to work the lubricant into the ball sockets Lubricate through fittings ...

Page 89: ...ENERAL INFORMATION The single ram heavy duty trim pump is installed in a remote location usually inside the engine motor well It is available on all offshore models The heavy duty trim system Is intended for offshore applications Is not integrated into the engine like the three ram system Requires the heavy duty offshore transom bracket and midsection Includes a trim stop pin to limit the degree o...

Page 90: ...ming beyond a neutral steering condition The outboard can be operated beyond the 20 trim limit if operating outboard in shallow water as long as the engine RPM is kept below 1200 RPM WARNING Operating a boat in a trim up position can cause severe equipment damage or loss of boat control This product may not have a trim out limiting device or trim indicator Never trim up beyond the unit s side supp...

Page 91: ...and Steering Fluid until the level in the reservoir reaches the MIN level mark It is acceptable to fill the reservoir beyond the MIN level mark but do not overfill past the MAX level mark 114 15033 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Trim pump reservoir 92 858074K01 4 Trim the outboard down to bleed air out of the system The fluid level may drop Add more Po...

Page 92: ...omatically stop the outward trim travel at 20 when engine RPM is approximately 2000 RPM or higher outboard also has to be in water and in gear The outboard can be operated beyond the 20 trim limit for operating outboard in shallow water if engine RPM is kept below approximately 2000 RPM POWER TRIM OPERATION THREE RAM SYSTEM WARNING Trimming the outboard beyond a neutral steering condition may resu...

Page 93: ...oat in a safe manner Some boats particularly some bass boats are built with a greater than normal transom angle which will allow the outboard to be trimmed further in or under This greater trim under capability is desirable to improve acceleration reduce the angle and time spent in a bow high boat during planing off and in some cases may be necessary to plane off a boat with aft live wells given t...

Page 94: ...osition and engage the tilt support lock a Tilt support lock Tube Ref No Description Where Used Part Number 114 Power Trim and Steering Fluid Fill hole 92 802880A1 2 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add fluid if required a 114 or47 1 ...

Page 95: ...move the vent plug upper plug and sealing washer 3 Remove the fill drain plug lower plug 4 Quickly place lubricant tube into the fill hole 5 Slowly add lubricant until it flows from the upper vent hole 6 Stop adding lubricant Install the upper vent plug and sealing washer before removing the lubricant tube IMPORTANT Replace sealing washers if damaged NOTE Examine the magnetic fill drain plug for m...

Page 96: ...earcase DRAINING THE GEARCASE a Sport Master gearcase vertical operating position b Fleet Master Torque Master gearcase vertical operating position c Vent plug and sealing ring d Fill drain plug and sealing ring e Drain pan 1 Place the outboard in a vertical operating position 2 Place a drain pan below the outboard gearcase 3 Remove the vent plug upper plug and sealing ring 4 Remove the fill drain...

Page 97: ...er Package A submerged power package requires prompt service by an authorized dealer after recovery This immediate attention is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine ...

Page 98: ... line and engine fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on their respective containers to the fuel tank before the final operation of the boat prior to storage Fuel Stabilizer helps prevent the formation of varnish and gum in the fuel Quickleen helps cl...

Page 99: ... or 2 teaspoons of Mercury Precision Quickleen lubricant 8 cc 0 3 oz or 2 teaspoons of Mercury Precision Fuel Stabilizer 9 Remove the fuel filter Refer to Fuel System in the Maintenance section of this manual 10 Pour the mixture into the fuel filter opening 11 Install the fuel filter 12 Prime the fuel system as described in the Starting the Engine in the Operation section of this manual 13 Place t...

Page 100: ...rt No 120 Corrosion Guard External metal surfaces 92 802878 55 Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected...

Page 101: ... engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose Ignition system component failure Spa...

Page 102: ...nd the remote oil tank Refer to Fuel and Oil for details Battery voltage is out of limits Throttle position sensor failure Continuous horn sound The oil level in the engine mounted oil reservoir tank is critically low Refill the reservoir tank and the remote oil tank Refer to Fuel and Oil for details The oil pump has failed halting the oil supply to the engine High engine temperature or low block ...

Page 103: ...E CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator Open circuit in the alternator output wire fused link ...

Page 104: ...cury outboard powered boat take it to your authorized dealer Only authorized dealers specialize in Mercury products and have factory trained mechanics special tools and equipment and genuine Quicksilver parts and accessories to properly service your engine NOTE Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package SERVICE AWAY FROM HOME If...

Page 105: ...nuine Quicksilver parts and accessories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring about parts and accessories the dealer requires the engine model and serial numbers to order the correct parts RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us If you ever have a problem question or concern ...

Page 106: ...1 3 9791 5822 Brunswick Asia Pacific Group 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar ...

Page 107: ...4 USA only Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54935 1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service 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 Road P O Box 1939 ...

Page 108: ...OWNER SERVICE ASSISTANCE 102 eng Quantity Item Stock Number Price Total Total Due ...

Page 109: ...ded with the outboard For example do not mount a 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 outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have...

Page 110: ...th a start in neutral only protection device This prevents the engine from starting in gear Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system Acquire and...

Page 111: ...drawn out of the tank An air outlet that opens vents to the atmosphere if pressure exceeds 34 4 kPa 5 0 psi FUEL DEMAND VALVE FDV REQUIREMENT Whenever a pressurized fuel tank is used a fuel demand valve is required to be installed in the fuel hose between the fuel tank and primer bulb The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or pos...

Page 112: ... to the ON position again for three seconds Continue this procedure until the fuel line primer bulb stays firm Installation Specifications a Minimum transom opening b Engine centerline for dual engine 66 0 cm 26 in Minimum Transom Opening Single engine 84 8 cm 33 3 8 in Dual engine 151 8 cm 59 3 4 in Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engi...

Page 113: ...boat transom Lifting Eye 91 90455 1 2756 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing or to lift entire engine for removal installation Steering Cable Starboard Side Routed Cable 1 Lubricate the O ring seal and the entire cable end 3724 95 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE O ring seal and entire cable end 92 802859A 1 a 28495 ...

Page 114: ...38 and self locking nylon insert locknuts P N 11 826709113 Never replace locknuts with common nuts nonlocking as they will work loose and vibrate off freeing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected loss of boat control resulting in serious injury or ...

Page 115: ... c and a self locking nylon insert locknut d Tighten the locknut until it seats then loosen turn 2 Assemble the steering link rod to the engine with the special washer head bolt a and self locking nylon insert locknut b 3 Torque the head bolt then the locknut to specifications Description Nm lb in lb ft Cable coupler nylon insert locknut d Tighten locknut until it seats then loosen turn Head bolt ...

Page 116: ...op speed and more propeller cavitation particularly noticeable when planing off or when operating with a heavy load Observe the following Monitor water pressure and engine temperature at all times Improper mounting height may result in reduced available power due to low water pressure and high temperature Prevent exhaust restriction which could result in poor idle performance by mounting the outbo...

Page 117: ...t the distance between the underside of transom bracket hooks and the bottom of the boat measurement c in the diagram below falls between the recommended mounting height range Ensure that this measurement is to the actual bottom of the boat not to any steps or notches in the hull IMPORTANT The recommended mounting height is based on performance testing with single engine applications on hulls with...

Page 118: ...loser than 25 mm 1 in from the top of the boat transom not including any shims used to increase transom mouting height Never install the upper mounting bolts through these shims Install the outboard to a height so that the distance between the underside of transom bracket hooks and the bottom of the boat measurement c in the diagram below falls between the recommended mounting height range Ensure ...

Page 119: ...oats with Sport Master gearcases try to mount the outboard so the propeller shaft centerline is even with the bottom of the boat as this gearcase is designed for surfacing applications a Underside of transom bracket hooks b Bottom of the boat c Distance between a and b d Propeller shaft centerline Item Model1 Recommended Mounting Height Range c 20 in driveshaft models 685 732 mm 27 30 in 28 45 in ...

Page 120: ...t the distance between the underside of transom bracket hooks and the bottom of the boat measurement c in the diagram below falls between the recommended mounting height range Ensure that this measurement is to the actual bottom of the boat not to any steps or notches in the hull IMPORTANT The recommended mounting height is based on performance testing with single engine applications on hulls with...

Page 121: ...g any mounting holes carefully read Determining Recommended Outboard Mounting Height and install outboard to the nearest recommended mounting height 1 Mark four mounting holes on the transom using the transom drilling fixture a Drill guide holes b Transom drilling fixture c Transom centerline Transom Drilling Fixture 91 98234A2 5489 Aids in engine installation by acting as a template for engine mo...

Page 122: ...ocknut 20 28421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in thread 67755 1 20 x 4 50 in long 2 25 in thread 8M0033366 20 x 5 00 in long 3 25 in thread 67755 003 20 x 5 50 in long 3 25 in thread 67755 2 20...

Page 123: ...he transom may not be adequate The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom strength If the bolt or nut continues 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...

Page 124: ...transom mounting surface must be flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between transom clamp and boat transom not allowed a b 51817 ...

Page 125: ...ng fixture may be required to ensure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting hardware Tighten the locknuts to the specified torque IMPORTANT Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightenin...

Page 126: ... outboard mounting bolt 4 b 0 875 in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 a c d c a d 40952 b e ...

Page 127: ...rd to the transom before each use 51985 Decal on the transom bracket Electrical Hoses Control Cables and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl Connect remote harness to the 14 pin connector on the engine harness a 14 pin connector a 28742 ...

Page 128: ...ANT Battery cable size and length is critical Refer to engine installation manual for size requirements The decal needs to be placed on or near the battery box for future service reference One 5 16 in and one 3 8 in hex nut is supplied per battery for wing nut replacement Metric hex nuts are not supplied NOTICE DTS OptiMax Engines DO NOT USE DEEP CYCLE BATTERIES DTS Digital Throttle and Shift appl...

Page 129: ...ive b Black sleeve negative c Cranking battery Dual Outboards Connect a common ground cable wire size same as engine battery cables between negative terminals on starting batteries a Red sleeve positive b Black sleeve negative c Ground cable d Cranking battery b a c 15496 a a b b c d d 15497 ...

Page 130: ... to the engine hose connections Fasten hose connections with cable ties Water Pressure and Speedometer Hose or Tubing NOTE This applies to models without SmartCraft gauges This outboard has a speedometer water pickup located in the leading edge of the gearcase If you want to use this water pickup for the speedometer disconnect the water pickup tubing from the speedometer sensor and route tubing ou...

Page 131: ...hose with blue stripe k Oil hose without blue stripe l Cable tie INSTALLING THE SHIFT CABLE IMPORTANT The shift cable is the first cable to move when the remote control handle is moved out of neutral so install connect it to the engine first Locating the Center Point of the Shift Cable IMPORTANT Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustmen...

Page 132: ...the cable end guide a Forward position mark 2 Mark the reverse position as follows a Move the remote control handle into reverse and advance the handle to the full speed position Ensure the throttle control lever is touching the throttle control lever stop screw b Slowly return the handle back to the neutral detent position c Place a mark on the shift cable against the cable end guide a Reverse po...

Page 133: ... felt then slide the anchor pin toward the rear until resistance is felt 7 Center the anchor pin between these resistance points a Anchor pin Adjusting the Shift Cable 1 Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable a Center mark 2 Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips free...

Page 134: ...s a and b c Shift the remote control into reverse while turning the propeller shaft If the propeller shaft does not lock solidly in gear adjust the barrel away from the cable end guide Repeat steps a through c d Return the remote control handle to neutral If the propeller shaft does not turn freely without drag adjust the barrel closer to the cable end guide Repeat steps a through d INSTALLING THE...

Page 135: ...as follows a Shift the outboard into gear a few times to activate the throttle linkage Rotate the propeller shaft while shifting into reverse b Return the remote control to neutral c Place a thin piece of paper between the idle adjustment screw and the idle stop The adjustment is correct when the paper can be removed without tearing but has some drag on it IMPORTANT The idle stop screw must be tou...

Page 136: ...s battery cables fuel hose and oil hoses between clamp and engine attachment point to relieve stress and prevent hoses from being kinked or pinched 1 Place the lower half of the front clamp into the bottom cowl opening 2 Place the neoprene wrap around the wiring hoses and control cables and place into the lower half of the front clamp a Neoprene wrap b Lower half of the front clamp a b 29073 ...

Page 137: ...he front clamp with the bottom half Secure both halves together with cables ties a Top half of the front clamp b Cable ties 4 Secure the front clamp into the bottom cowl with the retainer and two screws 5 Install the cowl seal a Retainer a b 29074 a 29075 ...

Page 138: ...IL SYSTEM 1 Fill the remote oil tank with the recommended oil listed in the Operation and Maintenance Manual Tighten the fill cap a Fill cap 2 Remove the cap and fill the engine oil tank with oil Install the fill cap a Engine oil tank b Fill cap a 2683 a b 7745 ...

Page 139: ... injection pump IMPORTANT Fill the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel pump will run without fuel during the priming process and may be damaged 1 Fill the fuel system a Connect fuel hose b Fill the fuel system by squeezing the primer bulb c Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line ...

Page 140: ...the remote control handle from neutral into forward This will automatically start the priming process PURGING AIR FROM THE ENGINE OIL TANK 1 Loosen the fill cap on the engine oil tank 2 Start the engine 3 Operate the engine until all the air has vented out and oil starts to flow out of the tank 4 Tighten the fill cap Engine Well Inlet Cover Installation Models with Remote Trim Pump 1 Select a loca...

Page 141: ...ver IMPORTANT The power trim hoses must be able to extend to the rear edge of the transom to connect to the engine 2 Make hydraulic connections to the remote pump assembly according to the instructions included with the pump 3 Using the inlet cover gasket as a template mark and drill four 3 16 in mounting holes a c b b d 15870 ...

Page 142: ...b Nut 4 c Lockwasher 4 d Cover e Gasket 5 Route the trim pump harness end through the cover and cowl and attach the harness to the pump and the main engine harness 6 Install the grommet to protect the harness 7 Route the trim hoses through the two holes provided in the cover and install the two grommets a Grommet 2 b Cover 15871 a b d e c 15886 a b ...

Page 143: ...mit pin in a position that prevents excessive trim under and operate the boat in a safe manner Some boats particularly some bass boats are built with a greater than normal transom angle which will allow the outboard to be trimmed further in or under This greater trim under capability is desirable to improve acceleration reduce the angle and time spent in a bow high boat during planing off and in s...

Page 144: ... Stainless Steel Tilt Pin 17 49930A 1 2749 Limits the down trim angle of the power trim equipped engines or aids in determining the trim out angle on non power trim engines The owner may decide to limit the trim in This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired A nonstainless steel ship...

Page 145: ...MAINTENANCE LOG eng 139 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

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