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Mercury 8/9.9 BigFoot Manual Download Page 144

ENGINE INSTALLATION

  

132

eng

Assemble steering link rod to steering cable with flat washer and

nylon insert locknut. Tighten locknut until it seats, then back nut

off 1/4 turn.
Assemble steering link rod to engine with bolt, locknut and

spacer and flat washers. Torque locknut to specifications.

Remote Wire Harness Connection

1. Remove the cover and cable receptacle bracket from the

bottom cowl.

a -

Cover

a -

Cable receptacle bracket

a

28003

a

28107

Summary of Contents for 8/9.9 BigFoot

Page 1: ...fidence in 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 requir...

Page 2: ...tion Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2012 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Marine...

Page 3: ...of engine manufacturer Tohatsu Marine Corporation TMC Mercury Marine Joint Venture Address Shimodaira 4495 9 Town Komagane City Nagano Post Code 399 4101 Country Japan Name of Authorized Representativ...

Page 4: ...ic Compatibility Directive 2004 108 EC Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle z or sterndrive without integral exhaust Diesel 2 stroke Outboard engine...

Page 5: ...manual ISO 8665 1995 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s manual This declaration of conformity is issued under the sole responsibility of the ma...

Page 6: ...vi eng...

Page 7: ...ourStroke Outboard Limited Warranty 7 FourStroke Outboard Limited Warranty 11 3 Year Limited Warranty Against Corrosion 15 Warranty Coverage and Exclusions 18 U S EPA Emissions Limited Warranty 20 Emi...

Page 8: ...36 Wave and Wake Jumping 37 Impact with Underwater Hazards 38 Exhaust Emissions 40 Selecting Accessories for Your Outboard 42 Safe Boating Suggestions 42 Recording Serial Number 44 8 9 9 FourStroke Sp...

Page 9: ...g System 71 Power Tilt if equipped 71 Setting The Transom Angle Of Your Outboard 73 Adjusting Transom Angle 75 Shallow Water Operation 75 Tilting Outboard 76 Trim Tab Adjustment 77 Operation Prestarti...

Page 10: ...ontrol Anode 102 Propeller Replacement 102 Fuse Replacement Electric Start Models 104 Spark Plug Inspection and Replacement 105 Timing Belt Inspection 106 Changing Engine Oil 107 Lubrication Points 10...

Page 11: ...Service Assistance 122 Mercury Marine Service Offices 123 Engine Installation Boat Horsepower Capacity 125 Start in Gear Protection 125 Selecting Accessories for Your Outboard 126 Low Permeation Fuel...

Page 12: ...xii eng...

Page 13: ...aler on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required You may change your address at any time including at time of warranty cla...

Page 14: ...du Lac WI 54936 1939 920 929 5054 Fax 1 920 929 5893 Upon processing the transfer of warranty Mercury Marine will record the new owner s information There is no charge for this service OUTSIDE THE UN...

Page 15: ...ot transferable from one product to another product or for non eligible applications The Certified Pre Owned engine plans are not transferable For help or assistance contact Mercury Product Protection...

Page 16: ...n proper reregistration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer Warranty coverage may be terminated for used repossessed product or...

Page 17: ...r warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer...

Page 18: ...ke air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine...

Page 19: ...F 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...

Page 20: ...overage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper reregistration of the product Unexpired warranty coverage cannot be transferred eith...

Page 21: ...r warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer...

Page 22: ...take air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engin...

Page 23: ...RRANTIES 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 DISC...

Page 24: ...he 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...

Page 25: ...s limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engin...

Page 26: ...arding the product other than those contained in this limited warranty and if made shall not be enforceable against Mercury Marine For additional information regarding events and circumstances covered...

Page 27: ...quent noncommercial use purchaser upon proper reregistration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers tha...

Page 28: ...ated 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 tha...

Page 29: ...een 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 ad...

Page 30: ...on 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...

Page 31: ...ntenance 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...

Page 32: ...he 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 which cause the engine to fail to conform with...

Page 33: ...y The California Air Resources Board has promulgated air emission regulations for outboard engines The regulations apply to all outboard engines sold to retail consumers in California and which were m...

Page 34: ...a warranted part will also be repaired under warranty DURATION OF COVERAGE This limited warranty provides coverage for the components of the emissions control systems of new 2001 model year and later...

Page 35: ...s warranty is limited to at our expense and at our option repairing or replacing defective parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercur...

Page 36: ...Regulations or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim at the discretion of Mercury Marine Failures of warranted parts caused...

Page 37: ...semblies Where a warrantable condition exists Mercury Marine will repair your outboard engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission con...

Page 38: ...he symbol for a cleaner marine engine means Cleaner air and water for a healthier lifestyle and environment Better fuel economy burns up to 30 40 percent less gas and oil than conventional carbureted...

Page 39: ...haust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines 42539 Four Stars Super Ultra Low Emission The Four Star label identifies engines tha...

Page 40: ...tboard 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...

Page 41: ...guidelines 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 High Speed and...

Page 42: ...neutral 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 26779 Remote Steering Notice The...

Page 43: ...ents 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 t...

Page 44: ...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 the operator choose to mo...

Page 45: ...ing at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel or tiller handle that is pulling in one direction drinking alcohol or consuming drugs or daring hig...

Page 46: ...engers 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 or high winds Loss...

Page 47: ...a boat is moving coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation c...

Page 48: ...he 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 K...

Page 49: ...t 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...

Page 50: ...o 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...

Page 51: ...r 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...

Page 52: ...bstacle 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 CA...

Page 53: ...ts 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...

Page 54: ...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 e...

Page 55: ...he boat Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly Prepare other boat oper...

Page 56: ...fe or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is com...

Page 57: ...0 035 in Gear ratio 2 08 1 2 42 1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Engine oil capacity 800 ml 27 0 fl oz Gearcase lubricant capacity 320 ml 10 8 fl oz...

Page 58: ...VIEW a Cowl latch b Throttle only button c Throttle friction adjustment knob d Water pump indicator hole e Oil drain plug f Transom angle preset knob g Engine flush plug h Gear lubricant level plug i...

Page 59: ...TION eng 47 FRONT VIEW a Choke fast idle knob b Fuel primer c Oil pressure light d Fuel line connector e Start switch electric tiller handle f Lanyard safety switch g Trim tilt position indicator a b...

Page 60: ...GENERAL INFORMATION 48 eng PORT VIEW a Tiller lock release lever b Start switch electric tiller handle model c Steering friction adjustment lever tiller model only d Tilt lock knob a b c d 38571...

Page 61: ...nsom bracket b Tilt support lever c Gear lubricant level plug d Primary water inlet e Gear lubricant fill drain plug f Secondary water inlet g Anti ventilation plate h Engine flush plug i Water pump i...

Page 62: ...GENERAL INFORMATION 50 eng l Power tilt m Kicker strap n Throttle only button o Throttle grip friction knob p Power tilt button...

Page 63: ...rd to avoid the possibility of oil leaks 1 With the outboard still in the water disconnect the remote fuel line and run engine until it stops This will drain fuel from the carburetor Install the prote...

Page 64: ...re or transport the outboard in the two positions shown Engine damage could result from oil draining out of the crankcase a Tiller handle up b Front side up Transporting Portable Fuel Tanks WARNING Av...

Page 65: ...e 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 accidenta...

Page 66: ...hift the outboard to forward gear This prevents the propeller from spinning freely Trailering Boat Outboard Models without Power Tilt Trailer your boat with the outboard tilted down in a vertical oper...

Page 67: ...brand 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 ethano...

Page 68: ...on 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 tha...

Page 69: ...ank Requirements The Environmental Protection Agency EPA will require portable fuel systems that are produced after January 1 2011 for use with outboard engines to remain fully sealed pressurized up t...

Page 70: ...ank as the fuel is drawn to the engine and also opens to vent to the atmosphere if internal pressure in the tank exceeds 34 4 kPa 5 0 psi A hissing noise may be heard as the tank vents to the atmosphe...

Page 71: ...ing the fuel tank cap turn the cap to the right until you hear a click This signals that the fuel cap is fully seated A built in device prevents overtightening 2 Open the manual vent screw on top of t...

Page 72: ...EL 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 Mercur...

Page 73: ...ORTANT 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 the top cowl 2 Remove dipstick Wip...

Page 74: ...FUEL AND OIL 62 eng 4 Reinstall the oil filler cap and tighten securely a Dipstick b Oil filler cap 4914 a b...

Page 75: ...not running Doing so will inject fuel into the engine and cause a possible hard starting flooded condition Tiller handle Handle can be tilted 180 for convenient handling during transportation and stor...

Page 76: ...o lock in up position Push tiller lock release lever to release the handle from the locked up position a Lock cap b Locking mechanism Starter rope Pulling the starter rope cranks the engine over for s...

Page 77: ...Push to tilt engine up down 4639 Throttle grip friction knob Turn friction knob to set and maintain the throttle at desired speed Turn knob clockwise to tighten friction or turn knob counterclockwise...

Page 78: ...s in neutral disables the gear shift control of the tiller handle 28550 Throttle grip Controls engine speed and shifting a Reverse b Forward Choke Pull out when starting a cold engine 28544 Fuel prime...

Page 79: ...will not exceed 3000 RPM 28549 Electric start button electric start models Press button to start engine 28532 WARNING Insufficient friction adjustment can cause serious injury or death due to loss of...

Page 80: ...achieve the desired steering friction drag on the tiller handle Move lever to the left to tighten or move lever to the right to loosen a Tighten b Loosen Tilt lock knob Locks the engine in the full ti...

Page 81: ...FEATURES AND CONTROLS eng 69 Kicker strap power tilt models Prevents the engine from turning while tilted up 4676...

Page 82: ...se 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...

Page 83: ...will be limited to 3000 The Engine Guardian System will also limit RPM of the engine in the event of an over speed condition due to cavitation no load on propeller and or under propped Power Tilt if e...

Page 84: ...tboard will tilt up until the switch is released or it reaches its maximum tilt position Tiller handle models have a kicker strap located on each side of the outboard preventing the outboard from turn...

Page 85: ...ging the position of the preset tilt knob in one of the three adjustment holes provided Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort NOTE Ref...

Page 86: ...the outboard close to the boat transom can Lower the bow Result in quicker planing off especially with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering t...

Page 87: ...the outboard into forward Raise the engine to one of the tilt release positions Change the preset knob position and lower the outboard to the preset transom angle position 2 Repeat step number one if...

Page 88: ...t release positions c Water Intake Tilting Outboard 1 Stop the engine Shift the outboard into the forward gear position 2 Take hold of the top cowl grip and raise the outboard to the full up position...

Page 89: ...ard 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 un...

Page 90: ...en 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 easily to the right move the trail...

Page 91: ...ile under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Ma...

Page 92: ...aust outlet of the propeller and gearcase with fresh water after each use Each month spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces Do not spray on corrosion control...

Page 93: ...in Procedure IMPORTANT Failure to follow the engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures 1...

Page 94: ...ne break in procedure in the Operation section 1 Open the fuel tank vent on manual venting type tanks 19748 2 Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squ...

Page 95: ...rimer if engine is warm This will inject fuel into the engine and may cause a hard starting flooded condition 28548 6 Cold engine Pull out the choke knob for starting Push in the choke knob after engi...

Page 96: ...ine Release button when the engine starts Do not operate the starter motor continuously for longer than ten seconds at a time If the engine fails to start wait 30 seconds and try again 9 Flooded engin...

Page 97: ...Before beginning operation allow the engine to warm up at idling speed for three minutes Starting the Engine Remote Control Models Before starting read the pre starting check list special operating in...

Page 98: ...d starting flooded condition N 26838 IMPORTANT Outboards with battery charging capabilities must not be operated with battery cables disconnected from the battery Damage to the charging system may res...

Page 99: ...thly 19804 7 Check for a steady stream of water flowing out of the water pump indicator hole 27240 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling wa...

Page 100: ...Do not shift outboard into reverse when the engine is not running Your outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R Tiller Handle Models Reduce engin...

Page 101: ...n ignition key to OFF position 26776 Emergency Starting If the starter system fails use the spare starter rope provided and follow this procedure WARNING The neutral speed protection device is inopera...

Page 102: ...d 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 fly...

Page 103: ...OPERATION eng 91 8 Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 28616 9 Pull the starter rope quickly...

Page 104: ...Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Emission Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Pr...

Page 105: ...ner operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule...

Page 106: ...e more frequently when used in saltwater See Lubrication Points Change engine oil and replace the oil filter The oil should be changed more often when the engine is operated under adverse conditions s...

Page 107: ...e Check for loose hose clamps and rubber boots if equipped on the air intake assembly EVERY 300 HOURS OF USE OR THREE YEARS Replace water pump impeller more often if overheating occurs or reduced wate...

Page 108: ...anyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Remove propeller Refer to Propeller Replacement Install the fl...

Page 109: ...ANT Do not run engine above idle when flushing 4 Adjust water flow if necessary so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply o...

Page 110: ...front of cowl 3 Push in latch to secure top cowl Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and mai...

Page 111: ...rt the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system completely Use an approved containe...

Page 112: ...by squeezing the primer bulb until firm forcing fuel into the filter Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using...

Page 113: ...thrown within or out of the boat Always use required components and follow instructions and torque procedures a Bolt 12 71970 b Flat washer c Spacer d Nylon insert locknut 11 16147 3 e Steering brack...

Page 114: ...the outboard metals The anode requires periodic inspection especially in salt water which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is comple...

Page 115: ...nd remove propeller nut 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer IMPORTANT To prevent the propel...

Page 116: ...PTFE Propeller shaft 92 802859A 1 7 Install front thrust washer propeller rear thrust hub and propeller nut onto the shaft 8 Place a block of wood between gearcase and propeller to prevent rotation an...

Page 117: ...r colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same rating Identifying a blown fuse a Good fuse b Blown fuse Spark Plug Inspection and Replacem...

Page 118: ...d 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark plug gap 1 0 mm 0 040 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight...

Page 119: ...1 Lock the outboard in the full tilt up position 2 Position outboard so the drain hole is facing downward 3 Remove drain plug and drain engine oil into an appropriate container IMPORTANT Do not use a...

Page 120: ...lted when checking oil 1 Remove the oil fill cap and refill with 800 ml 27 0 fl oz of oil Reinstall the oil fill cap 28617 2 Idle engine for five minutes and check for leaks Stop engine and check oil...

Page 121: ...ng cable grease fitting 92 802865Q02 95 2 4 C with PTFE Swivel bracket transom clamp screws tilt tube throttle and shift cables steering cable grease fitting 92 802859A 1 Swivel bracket Lubricate fitt...

Page 122: ...to the outboard tilt tube Lubricate through fitting a Steering cable grease fitting b Steering cable end WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death...

Page 123: ...visually check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving...

Page 124: ...ill drain plug GEARCASE LUBRICANT CAPACITY Standard model gearcase Approximately 320 ml 10 8 fl oz Bigfoot model gearcase Approximately 370 ml 12 5 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Q...

Page 125: ...ant until it appears at the vent hole 28659 IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lu...

Page 126: ...ver or Mercury Precision Lubricants Power Trim Steering Fluid If not available use automotive ATF automatic transmission fluid 4531 Submerged Outboard A submerged outboard will require service within...

Page 127: ...oline being used contains alcohol it is advisable to drain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system Fill the fuel tank and engine fuel s...

Page 128: ...rcury Precision Lubricants Corrosion Guard on external metal surfaces except corrosion control anodes Tube Ref No Description Where Used Part No 120 Corrosion Guard External metal surfaces 92 802878 5...

Page 129: ...ed by oil entering the cylinders from the sump only store the outboard in one of the three positions shown a Upright position b Tiller handle down c Front side down Never carry store or transport the...

Page 130: ...STORAGE 118 eng Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage...

Page 131: ...ES Lanyard stop switch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel tank is empty...

Page 132: ...ilt in type fuel tanks d Fuel line is kinked or pinched Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Low oil pressure Check oil level Throttle not fully open Da...

Page 133: ...TROUBLESHOOTING eng 121 Defective rectifier alternator or voltage regulator...

Page 134: ...local authorized dealer The 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...

Page 135: ...936 1939 Fax English 920 929 5893 Fran ais 905 636 1704 Website www mercurymarine com Australia Pacific Telephone 61 3 9791 5822 Brunswick Asia Pacific Group 41 71 Bessemer Drive Dandenong South Victo...

Page 136: ...OWNER SERVICE ASSISTANCE 124 eng Asia Singapore Telephone 65 65466160 Brunswick Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789...

Page 137: ...mum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWE...

Page 138: ...anuals for all your selected accessories Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or offered for sale in the United States The Environmental Protection Ag...

Page 139: ...your boat The boat bottom should be aligned or be within 25 mm 1 in above the anti ventilation plate of the outboard a Anti ventilation plate INSTALLING OUTBOARD ON TRANSOM 1 Place the outboard on th...

Page 140: ...cket clamp screws 2 Description Nm lb in lb ft Transom bracket mounting bolts 13 5 10 4 Power tilt models To prevent a loss of the outboard secure the outboard to the transom with the two transom brac...

Page 141: ...nd with Mercury Precision or Quicksilver 2 4 C with PTFE 28722 Tube Ref No Description Where Used Part No 95 2 4 C Marine Lubricant with PTFE Steering cable end 92 802859A 1 2 Insert the steering cabl...

Page 142: ...ink rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine Never replace the locknuts 11 16147 3 with common nuts non l...

Page 143: ...thrown within or out of the boat Always use required components and follow instructions and torque procedures a Bolt 12 71970 b Flat washer c Spacer d Nylon insert locknut 11 16147 3 e Steering bracke...

Page 144: ...en locknut until it seats then back nut off 1 4 turn Assemble steering link rod to engine with bolt locknut and spacer and flat washers Torque locknut to specifications Remote Wire Harness Connection...

Page 145: ...p the clamp in the bottom cowl and position the remote wiring harness below the clamp Connect the 8 pin connector to the engine harness Push the clamp down and secure the remote wiring harness into th...

Page 146: ...full forward throttle position NOTE The throttle cable is the second cable to move when moving the control box out of neutral 2 Attach the throttle cable end guide to the throttle lever with a washer...

Page 147: ...mote wiring harness a Cotter pin retainer b Flat washer c Full Throttle stop d Throttle lever e Cable barrel f Throttle cable end guide g Barrel receptacle h Rubber grommet SHIFT CABLE INSTALLATION In...

Page 148: ...ack to the neutral Place a mark b on the cable next to the end guide c Make a center mark c midway between marks a and b Align the end guide with this center mark when installing cable to the engine 6...

Page 149: ...e shift cable into the rubber grommet and place the cable barrel into the barrel receptacle a Flat washer b Cotter pin retainer c End guide d Center mark e Rubber grommet f Shift cable g cable barrel...

Page 150: ...rd The propeller shaft should be locked in gear If not adjust the barrel closer to the cable guide b Shift remote control into reverse while turning propeller The propeller shaft should be locked in g...

Page 151: ...ic starting outboards must have the battery cables connected to a battery whenever the engine is running even if started manually as damage to the charging system could result Battery Connections CONN...

Page 152: ...of the propeller liberally coat the propeller shaft splines with one of the following Mercury Quicksilver products Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft s...

Page 153: ...MAINTENANCE LOG eng 141 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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