Mercury 40 4-Stroke Manual Download Page 105

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TROUBLESHOOTING

• Excessive use of electrical accessories.
• Defective rectifier, alternator, or voltage regulator.

Summary of Contents for 40 4-Stroke

Page 1: ...facturer Mercury Marine W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54935 1939 USA Authorized Representative Marine Power Europe Inc Parc Industriel de Petit Rechain B 2800 Verviers Belgium Recreational Craft Directive 2003 44 EC amending 94 25 EC Applicable Requirement Standards Applied Owner s manual A 2 5 EN ISO 10240 2004 Handling characteristics A 4 EN ISO 8665 1995 Outboard engines starti...

Page 2: ... USA 135 150 1B227000 RCD H 2 Verado 6 Cylinder Belgium 200 225 250 275 0P401000 RCD H 2 Verado 6 Cylinder Fond du Lac Wisconsin USA 200 225 250 275 1B227000 RCD H 2 80 100 115 EFI Belgium 80 100 115 0P401000 RCD H 2 75 90 115 EFI Fond du Lac Wisconsin USA 75 90 115 1B366823 RCD H 2 40 3 Cylinder Belgium 40 0P401000 RCD H 2 40 50 60 4 Cylinder Belgium 40 50 60 0P401000 RCD H 2 4 5 6 hp Beligium 4 ...

Page 3: ...haracteristics SAE J551 CISPR 12 CISPR 12 EN 55012 2002 A1 2005 Electrostatic discharge testing EN 61000 6 2 EN 61000 4 2 EN 61000 4 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe Patrick C Mackey President Mercury Marine Fond du Lac WI USA on May 1 2006 European Regulations Contact Regulations and Product Safety Department Mercury Marine Fond ...

Page 4: ...iv ...

Page 5: ... Responsibilities 16 Before Operating Your Outboard 16 Boat Horsepower Capacity 17 High Speed and High Performance Boat Operation 17 Outboard Remote Control Models 17 Remote Steering Notice 18 Lanyard Stop Switch 19 Protecting People In The Water 21 Passenger Safety Message Pontoon Boats And Deck Boats 22 Wave And Wake Jumping 23 Impact With Underwater Hazards 24 Safety Instructions For Hand Tille...

Page 6: ... Models 47 Steering Friction Adjustment 47 Trim Tab Adjustment 49 OPERATION Pre Starting Check List 51 Operating In Freezing Temperatures 51 Operating In Salt Water Or Polluted Water 51 Pre Starting Instructions 52 Engine Break in Procedure 52 Starting the Engine Remote Control Models 53 Starting the Engine Tiller Handle Models 55 Gear Shifting 58 Stopping The Engine 59 Emergency Starting 60 MAINT...

Page 7: ...spection 81 Lubrication Points 82 Checking Power Trim Fluid 85 Changing Engine Oil 85 Gearcase Lubrication For 87 3 mm 3 7 16 in Diameter Gearcase 87 Gearcase Lubrication For 108 mm 4 1 4 in Diameter Gearcase 89 Submerged Outboard 91 STORAGE Storage Preparation 92 Protecting External Outboard Components 93 Protecting Internal Engine Components 93 Gearcase 93 Positioning Outboard For Storage 93 Bat...

Page 8: ...And Accessories Inquiries 98 Service Assistance 98 Mercury Marine Service Offices 99 OUTBOARD INSTALLATION Installation Information 101 Fuel Hose Connection Remote Control Models 111 Electrical Connections and Control Cable Installation 112 Propeller Installation 120 Trim Tab Adjustment 125 Trim In Stop Adjustment Power Trim Models 126 ...

Page 9: ...Fax 920 929 5893 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Warranty Registration United States And Canada 1 You may change y...

Page 10: ... Outside The United States And Canada 1 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area 2 The Warranty Registration Card identifies your name and address product model and serial numbers date of sale type of ...

Page 11: ...is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing r...

Page 12: ... commercial use customer Warranty coverage may be terminated for used or repossessed product or product purchased at auction from a slvage yard or from an insurance company CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which...

Page 13: ...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 submersion improper installation ...

Page 14: ...red by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE O...

Page 15: ... product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only 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 after the Mercury Marine specified pr...

Page 16: ...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 submersion improper installation ...

Page 17: ...erage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR 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 ...

Page 18: ...spection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sa...

Page 19: ...haser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage ...

Page 20: ...ween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 21: ... is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection ...

Page 22: ...nance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition wh...

Page 23: ...r products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product ...

Page 24: ...board properly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage This manual as 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 DANGER Indicates a hazardous si...

Page 25: ...UM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 High Speed and High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator ...

Page 26: ...ese self locking nuts must never be replaced with common nuts non locking 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 serious injury or death due to occupants being thrown wit...

Page 27: ... cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should t...

Page 28: ...ling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat...

Page 29: ...E YOU ARE CRUISING It is very difficult for a person standing or floating 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 might be people in the water Whenever a boat is moving coasting and the outboard gear shift is in neutral position there is suff...

Page 30: ...em over the front of the boat Falling over the front of the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN OPEN FRONT DECK No one should ever be on 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 fee...

Page 31: ... 26783 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done with sufficient speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such case th...

Page 32: ... steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control th...

Page 33: ... suspected the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures or water leaks Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat If continued running is necessary do so at greatly reduced speeds WARNING O...

Page 34: ...cles if the outboard is not attached to the transom correctly If an obstacle is struck at planing speed and the outboard is not securely fastened to the transom it is possible the outboard could lift off the transom and land in the boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboa...

Page 35: ...s with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide WHILE BOAT IS STATIONARY 21626 a b a Running the engine when the boa...

Page 36: ...be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions Use flotation devices Have an approved p...

Page 37: ...ur ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the outboard into neutral is not sufficien...

Page 38: ...eds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record this number for future reference The serial number is located on the outboard as shown XX OTXXXXXX XXXX a b c d 24125 a Serial number b Model designation c Year manufactured d Certified Europe Insignia as applicable 40 50 60 4 Stroke Specifications...

Page 39: ... 33 1 Recommended Gasoline Refer to Fuel Oil Recommended Oil Refer to Fuel Oil Gearcase Lubricant Capacity 83mm 3 1 4 in Diameter Gearcase 340 ml 11 5 fl oz 108mm 4 1 4 in Diameter Gearcase 710 ml 24 0 fl oz Engine Oil Capacity 3 0 Liter 3 Quarts Battery Rating Operation Above 0 C 32 F 465 Marine Cranking Amps MCA or 350 Cold Cranking AMPS CCA Operation Below 0 C 32 F 1000 Marine Cranking Amps MCA...

Page 40: ...ransom brackets d Oil drain plug e Primary cooling water intake f Gearcase g Trim tab h Anti ventilation plate i Driveshaft housing j Water pump indicator hole k Bottom cowl l Top cowl m Shift handle n Engine stop switch o Throttle friction adjustment knob p Lanyard stop switch q Steering friction adjustment lever tiller handle models ...

Page 41: ...r railroad crossings driveways and trailer bouncing 28517 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 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion Follow the transporting i...

Page 42: ...93 AUTO VENTING TYPE FUEL TANK 1 Disconnect the remote fuel line from tank This will close the air vent and prevent escape of fuel or vapors from tank 2 Install tether cap over the fuel line connector stem This will protect the connector stem from being accidently pushed in thus allowing fuel or vapor to escape F a b 26794 a Connector stem b Tether cap ...

Page 43: ...nd of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol These Reformulated Gasolines are acceptable for use in your Mercury Mar...

Page 44: ...particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is req...

Page 45: ... tank is completely filled PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC W certified synthetic blend 25W 40 4 Stroke Outboard Oil for general all temperature use If SAE 10W 30 oil is preferred use Mercury or Qu...

Page 46: ...scosity for Engine Oil a NMMA FC W certified 10W 30 outboard oil may be used at temperatures below 4 C 40 F b NMMA FC W certified synthetic blend 25W 40 outboard oil may be used in all temperatures Checking and Adding Engine Oil IMPORTANT Do not overfill Be sure that the outboard is upright not tilted when checking oil 1 Turn the engine off Have the outboard in a level operating position Remove th...

Page 47: ...igns of contamination Oil contaminated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 4 Push the dipstick back in all the way then flip the handle down to lock the dipstick in place Reinstall the oil filler cap and hand tighten securely a b c d 28412 a Full mark b Add mark c Dip...

Page 48: ...andle forward neutral reverse b Neutral release lever c Trim tilt switch if equipped Refer to Features Controls Power Trim and Tilt d Lanyard stop switch Refer to General 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 ...

Page 49: ...System may engage and protect the engine by limiting it s power You should return to port immediately and contact your servicing dealer 2 Intermittent short beeps for six seconds Indicates a non critical engine condition This condition 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...

Page 50: ...r have to be concerned about whether or not you are protected The system will respond to a problem by sounding the warning horn for six seconds and or reducing engine power in order to provide engine protection If the Guardian System has been activated reduce throttle speed The problem will need to be identified and corrected if possible The system must be reset before the engine will operate at h...

Page 51: ...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 d a b c 28520 a Remote control trim switch b Panel mount trim switch c Tilt range of travel d Trim range of travel POWER TRIM OPERATION With most boats oper...

Page 52: ...se steering torque or pull to the right with the normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered WARNING Operating the boat at hig...

Page 53: ...ON To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Press the knob in and rotate it to engage the tilt support lever 2 Lower outboard to rest on the tilt support lever 3 To disengage the tilt support lever raise the outboard off the support...

Page 54: ...l tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system a 28534 a Auxiliary tilt switch SHALLOW WATER OPERATION When operating the boat in shallow water the outboard can be tilted beyond the maximum tri...

Page 55: ...ent Tiller Handle Models Throttle Grip Friction Knob Turn friction knob to set and maintain the throttle at desired speed Turn knob clockwise to tighten friction and turn knob counterclockwise to loosen friction a b 19807 a Loosen friction b Tighten friction Steering Friction Adjustment TILLER HANDLE MODELS Steering Friction Adjustment Adjust this lever to achieve the desired steering friction dra...

Page 56: ...1 a Tighten friction b Loosen friction c Locknut REMOTE STEERING MODELS WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control When setting the friction adjustment maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released ...

Page 57: ... with the propeller shaft parallel to the water surface The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort 26816 NOTE Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 50 mm 2 in or more above the boat bottom M...

Page 58: ...etighten bolt and retest MODELS WITH POWER TRIM Operate your boat at normal cruising speed trimmed to desired position Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easi...

Page 59: ...nspection checks listed in Maintenance Inspection and Maintenance Schedule Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at all times so the gearcase is submerged This prevents trapped water in gearcase from freezing and causing possible damage to the water pump and other components...

Page 60: ...ray on corrosion control anodes as this will reduce the effectiveness of the anodes Pre Starting Instructions 1 Check the engine oil level 28525 2 Make sure the cooling water intake is submerged NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a sufficient supply of water at the water inlets during operation 26837 Engine Break i...

Page 61: ...le for more than five minutes at a time Starting the Engine Remote Control Models Before starting read the pre starting check list special operating instructions and engine break in procedure in the Operation section NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a sufficient supply of water at the water inlets during operatio...

Page 62: ...e throttle only lever to the fully closed position or press the throttle only button a b a b 26840 a Fully closed position b Maximum fast idle speed position 6 Starting a flooded engine Advance the throttle only lever or control handle to the maximum throttle only position and continue to crank the engine for starting Immediately reduce engine speed after engine starts ...

Page 63: ...or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage WARMING UP ENGINE Before beginning operation allow the engine to warm up at idling speed for three minutes Starting the Engine Tiller Handle Models Before starting read the pre starting check list special operat...

Page 64: ... the outboard Make sure the connector is snapped into place 28526 3 Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm 27348 4 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 ...

Page 65: ...RT ST 0 100 START START a b 19799 a Start position b Half way position 8 Turn the ignition key to the START position If the engine fails to start in ten seconds return the key to the ON position wait 30 seconds and try again 19804 WARNING Rapid acceleration can result in serious injury or death from being thrown within or out of the boat Decrease engine speed before shifting into gear ...

Page 66: ...e the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated may cause serious engine damage WARMING UP ENGINE Before beginning operation allow the engine to warm up at idling speed for three minutes Gear Shifting IMPORTANT Observe the following Never shift outboard into gear unless engine speed is at idle Do not shift outboard into reverse when the engin...

Page 67: ...ngine speed to idle before shifting 26842 Always shift the outboard into gear with a quick motion After shifting the outboard into gear advance the remote control lever or rotate the throttle grip tiller handle to increase speed Stopping The Engine 1 Remote Control Models Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position 26843 ...

Page 68: ...r turn ignition key to OFF position 26776 Emergency Starting If the starter system fails use the spare starter rope provided and follow procedure NOTE EFI models Engine must have a fully charged battery to start the engine 1 Remove flywheel cover or manual starter assembly 26844 2 Shift outboard to neutral N position N N 28528 ...

Page 69: ...me the key is turned on especially when starting or operating the engine Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel co...

Page 70: ...OPERATION 62 5 Pull the starter rope to start the engine 26848 ...

Page 71: ...ntenance work orders and receipts SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture e d c b a f g h ...

Page 72: ...ess on transom Check steering system for binding or loose components Visually check steering link rod fasteners for proper tightness See Steering Link Rod Fasteners Check propeller blades for damage AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller ...

Page 73: ...ck cowl seals to make sure seals are intact and not damaged Check internal cowl sound reduction foam if equipped to make sure foam is intact and not damaged Check that the intake silencer if equipped is in place Check that the idle relief muffler if equipped is in place Check for loose hose clamps and rubber boots if equipped on the air intake assembly EVERY 300 HOURS OF USE OR THREE YEARS Replace...

Page 74: ...ling or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting 1 Place the outboard in either the operating position vertical or in a tilted position 2 Remove the propeller Refer to Propeller Replacement 3 Thread a water hose into the rear fitting Partially open the water tap 1 2 maximum Do not open the water tap all the way as t...

Page 75: ... Lower the cowl into its seated position and apply downward pressure to the back of the cowl to lock it in place Gently pull up on the back of cowl to make sure it is securely fastened 28445 Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes Battery Inspection The battery should be inspected at periodic intervals to ensur...

Page 76: ...ed exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved recep...

Page 77: ...ilter by squeezing the primer bulb until firm forcing fuel into the filter 1 Push the filter element into the cover 2 Place the O ring seal into its proper position on the sight bowl and screw the sight bowl hand tight into the cover 3 Push the filter assembly back into the mount Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fast...

Page 78: ...95 a Spacer 12 71970 b Nylon insert locknut 11 826709113 c Flat washer 2 d Nylon insert locknut 11 826709113 e Special washer head bolt 10 856680 Description Nm lb in lb ft Nylon insert locknut b 27 20 Nylon insert locknut d Tighten until seats then back off 1 4 turn Special washer head bolt 27 20 Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten l...

Page 79: ...etely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode ANODE LOCATION MODELS WITH 87 3 MM 3 7 16 IN GEARCASES One of the anodes is the trim tab installed on the gearcase Another anode is installed on the bottom of the transom bracket assembly a b 28884 a Anode on the transom bracket assembly b Trim tab ANODE LOCATION MODELS WITH 108 MM 4 ...

Page 80: ...rotating propeller always turn the ignition key or lanyard stop switch to the OFF position and remove the spark plug leads from the spark plugs while servicing 1 Shift the outboard to the neutral N position N N 28528 2 Remove the spark plug leads to prevent engine from starting 26899 3 Straighten the bent tabs on the propeller nut retainer 26900 4 Place a block of wood between the gearcase and pro...

Page 81: ...orrosion Grease or 2 4 C with Teflon 26902 Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C with Teflon Propeller shaft 92 802859A1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended...

Page 82: ... the forward thrust hub propeller replaceable drive sleeve rear thrust hub propeller nut retainer and propeller nut onto the shaft a b c d e f 26904 a Propeller nut b Propeller nut retainer c Rear thrust hub d Replaceable drive sleeve e Propeller f Forward thrust hub 9 Place the propeller nut retainer over the pins Place a block of wood between the gearcase and the propeller and tighten the propel...

Page 83: ...opeller Replacement 108 mm 4 1 4 in Diameter Gearcase WARNING Rotating the propeller shaft may cause the engine to crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller always turn the ignition key or lanyard stop switch to the OFF position and remove the spark plug leads from the spark plugs while servi...

Page 84: ... on the propeller nut retainer 26900 4 Place a block of wood between gearcase and propeller to keep the propeller from turning Remove the propeller nut 5 Pull the propeller straight off the shaft If the propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 26901 ...

Page 85: ...ller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and each time the propeller is removed 7 Flo Torq I drive hub propellers Install the thrust washer propeller continuity washer thrust hub propeller nut retainer and propeller nut onto the shaft a ...

Page 86: ...llation of a Flo Torq III drive hub propeller for stainless steel applications 9 Flo Torq III drive hub propellers Install the forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft 3223 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 10 Place a block...

Page 87: ...s 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 spark plug boots Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blis...

Page 88: ...ugs finger tight and then tighten 1 4 turn or torque to specifications Description Nm lb in lb ft Spark plug 27 20 Fuse Replacement IMPORTANT Always carry spare 20 amp fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again ...

Page 89: ... Main circuit 25 amp fuse e Spare 20 amp fuse f Main relay accessories 15 amp fuse g Ignition coil circuit 25 amp fuse h Fuel pump idle air control fuel injector circuits SFE 20 amp fuse i Blown fuse j Good fuse Timing Belt Inspection 1 Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found a Cracks in the back of the belt or in the base o...

Page 90: ...02867Q 1 95 2 4 C with Teflon Propeller shaft 92 802859A1 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Tilt support lever swivel bracket tilt tube steering cable grease fitting 92 802859A1 34 Special Lubricant 101 Tilt support lever swivel bracket tilt tube co pi...

Page 91: ... through fitting a b 28466 a Tilt support lever b Swivel bracket Tilt Tube Lubricate through fitting 28461 Co pilot shaft tiller handle models Lubricate through fitting Move the steering friction lever back and forth while lubricating 28823 ...

Page 92: ... the end of the steering cable before applying lubricant Steering Cable Grease Fitting If equipped Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting b a 28468 a Fitting b Steering cable end 3 Lubricate the following with light weight oil Steering Link Rod Pivot Points Lubricate points 28471 ...

Page 93: ... Fluid If not available use automotive ATF automatic transmission fluid 28476 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim reservoir 92 858074K0 1 Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Engine oil 3 0 Liter 3 U S Quarts Mercury Precision Parts or Quicksilver Synthetic Blend 25W 40 4 Stroke Outboard Oil Mercury Precision Parts or Quick...

Page 94: ...n plug b Drain hole CHANGING OIL FILTER 1 Place a rag or towel below the oil filter to absorb any spilled oil 2 Unscrew the old filter by turning the filter to the left 3 Clean the mounting base Apply a film of clean oil to the filter gasket Do not use grease Screw the new filter on until the gasket contacts the base then tighten 3 4 to 1 turn 28417 OIL FILLING 1 Remove the oil fill cap and add oi...

Page 95: ...it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have 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 lubricant for metal particles A small amount of fine metal particles indicates normal gear wear An excessi...

Page 96: ...ly 340 ml 11 5 fl oz CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug 3 Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube ...

Page 97: ...ixed with the lubricant giving it a milky colored appearance If water is noticed have 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 lubricant for metal particles A small amount of fine metal particles indicates normal gear wear An excessive amount o...

Page 98: ...LING GEARCASE 1 Place outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug 3 Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole At this time install the front vent plug and sealing washer 4 Continue adding lubricant until it appears at the rear vent hole 5 Stop adding lubricant Install the rear vent plug and sealin...

Page 99: ...le d Rear vent plug e Fill drain plug and sealing washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine ...

Page 100: ...nk remote fuel line and engine fuel system Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with following instructions Portable Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently Installed Fuel Ta...

Page 101: ... or inject a five second spray of storage seal into each spark plug hole Rotate the flywheel manually several times to distribute the oil in the cylinders Reinstall spark plugs Change the engine oil Gearcase Drain and refill the gearcase lubricant refer to Maintenance Gearcase Lubrication Positioning Outboard For Storage Store outboard in an upright vertical position to allow water to drain out of...

Page 102: ...STORAGE 94 Remove the battery from the boat and check water level Recharge if necessary Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage ...

Page 103: ...USES Lanyard stop switch not in RUN position Incorrect starting procedure Refer to Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching the engine a Fuel tank is empty b Fuel tank vent not open or restricted c Fuel line is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty f Fuel filter is obstructed Refer ...

Page 104: ...type fuel tanks d Fuel line is kinked or pinched Fuel pump failure Ignition system component failure Fuel injection component failure EFI Models Performance Loss POSSIBLE CAUSES Engine Guardian System activated Refer to Features Controls Warning System Throttle not fully open Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distribu...

Page 105: ...TROUBLESHOOTING 97 Excessive use of electrical accessories Defective rectifier alternator or voltage regulator ...

Page 106: ...he dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or a...

Page 107: ...ebsite www mercurymarine com Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9793 5880 Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Recha...

Page 108: ...pan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Singapore 508762 Fax 5467789 ...

Page 109: ...lines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 START IN GEAR PROTECTION WARNING Starting the engine with the drive in gear can cause serious injury or death Never operate a boat that does not have a neutral safety protection device The remote control connected to the...

Page 110: ...nd read the installation operation and maintenance manuals for all your selected accessories ELECTRIC FUEL PUMP If an electric fuel pump is used the fuel pressure must not exceed 27 58 kPa 4 PSI at the engine If necessary install a pressure regulator to regulate the pressure INSTALLATION SPECIFICATIONS A A B 2763 a Minimum transom opening b Engine center line for dual engines Minimum Transom Openi...

Page 111: ...OUTBOARD INSTALLATION 103 LIFTING OUTBOARD Use the lifting eye on the engine 28510 ...

Page 112: ...s 1 Mark four mounting holes on the transom using the transom drill fixture or69 1 a a b c a Drill guide holes b Transom drilling fixture c Transom center line Transom Drilling Fixture 91 98234A2 5489 Aids in engine installation by acting as a template for engine mounting holes ...

Page 113: ...or cracks under this torque the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased 18961 a b a Transom yielding under bolt torque b Transom cracking under bolt torque When first determining transom strength use a dial torque wrench If the bolt or nut continues to turn without the torque reading on the dial increasing it is an i...

Page 114: ...art Number Large transom washer 67 896392 Transom reinforcement plate 67 896305 Fastening the Outboard to the Transom 1 Install the outboard so that the anti ventilation plate is in line or within 25 mm 1 in below the bottom of the boat a b 8045 a Anti ventilation plate b 25 mm 1 in 2 Apply marine sealer to the shanks of bolts not the threads 3 Fasten the outboard with the provided mounting hardwa...

Page 115: ...ts 28481 b c a a 1 2 in diameter bolt 4 b Flat washer 4 c Locknut 4 Description Nm lb in lb ft Outboard mounting locknuts and bolts 75 55 STEERING CABLE STARBOARD SIDE ROUTED CABLE 1 Lubricate the entire cable end 10261 Tube Ref No Description Where Used Part No 95 2 4 C Marine Lubricant with Teflon Steering cable end 92 802859A1 ...

Page 116: ...e 28507 3 Tighten the nut to the specified torque 29506 Description Nm lb in lb ft Nut 47 5 35 STEERING CABLE SEAL 1 Mark tilt tube 6 4 mm 0 25 in from end Install seal components 2 Thread cap to the mark a b c d 8041 a a 6 4 mm 1 4 in b Plastic spacer c O ring seal d Cap ...

Page 117: ...eering cable to the engine must be fastened using special washer head bolt e Part Number 10 856680 and self locking nylon insert locknuts b d Part Number 11 826709113 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage ...

Page 118: ...njury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures a c b 28479 f d e a Special washer head bolt 10 856680 b Nylon insert locknut 11 826709113 c Spacer 12 71970 d Flat washer 2 e Nylon insert locknut 11 826709113 f Use middle hole steer outboard to the side to gain hole access Description Nm lb in lb ft...

Page 119: ...ble steering link rod to engine with special washer head bolt locknut and spacer First torque bolt then torque locknut to specifications Fuel Hose Connection Remote Control Models REMOTE FUEL HOSE SIZE Minimum fuel hose inside diameter ID is 8 mm 5 16 in Use a separate fuel hose fuel tank pickup for each engine FUEL HOSE CONNECTION Fasten the remote fuel hose to the fitting with a metal hose clamp...

Page 120: ...BOARD INSTALLATION 112 Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover a 28505 a Access cover Route the remote wiring harness through the rubber grommet ...

Page 121: ...OUTBOARD INSTALLATION 113 Connect the 14 pin connector to the engine harness and fasten the harness with the retainer a b c 28482 a Remote wiring harness b Retainer c 14 pin connector ...

Page 122: ...OUTBOARD INSTALLATION 114 BATTERY CABLE CONNECTIONS Single Outboard a b c or86 a Red sleeve positive b Black sleeve negative c Cranking battery ...

Page 123: ...ranking battery SHIFT CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control 1 Locate the center point of the slack or lost motion that exists in the shift cable as follows a Move the remote control handle from neutral into forward and advance the handle to full speed position Slowly return the handle back to the neutral Place a ma...

Page 124: ... back to the neutral Place a mark b on the cable next to the cable end guide c Make a center mark c midway between marks a and b Align the cable end guide with this center mark when installing cable to the engine 6098 b c a 2 Manually shift the outboard into neutral The propeller will rotate freely 3 Position the remote control handle into neutral N 26838 ...

Page 125: ... to the shift lever with a cotter pin retainer 6 Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle b a d e a c 28487 a Cable end guide b Cotter pin retainer c Center mark d Cable barrel e Barrel latch 7 Place the cable barrel into the barrel receptacle ...

Page 126: ...verse while turning propeller The propeller shaft should be locked in gear If not adjust the barrel away from the cable end guide Repeat steps a through c c Shift remote control back to neutral The propeller shaft should turn freely without drag If not adjust the barrel closer to the cable end guide Repeat steps a through c THROTTLE CABLE INSTALLATION Install the cables into the remote control fol...

Page 127: ...er with a cotter pin retainer 4 Adjust cable barrel until the barrel slips onto the mounting stud 5 Fasten the throttle cable to the mounting stud with a flat washer and locknut Tighten the locknut to the specified torque 28494 b a c d e a Throttle cable b Cotter pin retainer c Flat washer d Locknut e Cable barrel Description Nm lb in lb ft Throttle cable locknut 6 53 ...

Page 128: ...cover bolt 10 89 Propeller Installation PROPELLER INSTALLATION 108 MM 4 1 4 IN DIAMETER GEARCASE WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting ...

Page 129: ...T To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 2 Flo Torq I Drive Hub Propellers Install thrust washer propeller continuity washer thrust hub propeller nut retainer and propelle...

Page 130: ...ess Steel Applications Installation of a Flo Torq III drive hub propeller is recommended 4 Flo Torq III Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft 3223 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 5 Place a ...

Page 131: ...ith a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting 1 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C Marine Lubricant with Teflon 26902 Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft 92 ...

Page 132: ...ller nut retainer and propeller nut onto the shaft a b c d 26903 a Propeller nut b Propeller nut retainer c Propeller d Forward thrust hub 3 Flo Torq II Drive Hub Propellers Install forward thrust hub propeller replaceable drive sleeve rear thrust hub propeller nut retainer and propeller nut onto the shaft a b c d e f 26904 a Propeller nut b Propeller nut retainer c Rear thrust hub d Replaceable d...

Page 133: ...rmal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort 26816 NOTE Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation plat...

Page 134: ...the left If the boat turns more easily to the right move the trailing edge of trim tab to the right Retighten bolt and retest Trim In Stop Adjustment Power Trim Models If an adjustment is required to the trim in stop reposition the tilt stop pins in the desired holes Tighten the tilt stop pins to the specified torque a 28538 a Tilt stop pins Description Nm lb in lb ft tilt stop pins 24 4 18 ...

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