Mercury 8 Bigfoot 4-Stroke Installation Operation Maintenance Warranty Manual Download Page 1

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Outboard

Installation

Operation

Maintenance

Warranty

Manual

8/9.9 and 9.9 Command Thrust/ProKicker FourStroke

8M0108154 615

eng

Summary of Contents for 8 Bigfoot 4-Stroke

Page 1: ...Outboard Installation Operation Maintenance Warranty Manual 2015 Mercury Marine 8 9 9 and 9 9 Command Thrust ProKicker FourStroke 8M0108154 615 eng...

Page 2: ...eng...

Page 3: ...y for exhaust emission assessment Det Norske Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Name of notified body for noise emission assessment Det Norske Ve...

Page 4: ...al file Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 engine identification B 2 exhaust emission requirements EN ISO 8178 1 1996 B 3 durability EN ISO 8178 1 1996 B...

Page 5: ...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 requirem...

Page 6: ...rcury Premier Service rating means a dealer Achieves a high 12 month service Customer Satisfaction Index CSI score for warranty service Possesses all of the necessary service tools test equipment manu...

Page 7: ...nformation 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 Steerin...

Page 8: ...em 57 Power Tilt if equipped 58 Setting The Transom Angle Of Your Outboard 60 Adjusting Transom Angle 62 Shallow Water Operation 62 Tilting Outboard 63 Trim Tab Adjustment 64 Operation Prestarting Che...

Page 9: ...nspection and Replacement 88 Timing Belt Inspection 89 Changing Engine Oil 89 Lubrication Points 91 Gearcase Lubrication 93 Checking Power Tilt Fluid 95 Submerged Outboard 96 Storage Storage Preparati...

Page 10: ...es for Your Outboard 106 Low Permeation Fuel Hose Requirement 107 Installing Outboard 107 Remote Control Installation 110 Steering Link Rod Fasteners 110 Remote Wire Harness Connection 112 Control Cab...

Page 11: ...Marine or sending a letter or fax with your name old address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also process this change of info...

Page 12: ...ge under the terms of the contract To transfer the plan to the subsequent owner contact Mercury Product Protection or an authorized dealer to receive a Request for Transfer form Submit to Mercury Prod...

Page 13: ...n warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warr...

Page 14: ...tifouling paints are recommended on Outboard and MerCruiser boating applications In areas where TBTA base paints are prohibited by law copper base paints can be used on the hull and transom Do not app...

Page 15: ...on made in connection with normal services 2 Installation errors accidents normal wear and tear and faded paint 3 Factory installed jet drive units Specific parts excluded from the warranty are the je...

Page 16: ...Refer to the Maintenance section 17 Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by...

Page 17: ...gine s emissions on any regulated pollutant California Emissions Limited Warranty The California Air Resources Board has promulgated air emission regulations for outboard engines The regulations apply...

Page 18: ...mission Control System Components and Maintenance Schedule The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its ori...

Page 19: ...acement or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual The use of non Mercury parts for nonwarranty maintenance or repairs w...

Page 20: ...personal watercraft equipped with hour meters as defined in s 2441 a 13 or their equivalent If any emission related part on your engine is defective under warranty the part will be repaired or replace...

Page 21: ...The Three Star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine...

Page 22: ...Limited Warranty of one 1 year from the date of first retail sale or one 1 year from the date on which the product was first put into service whichever occurs first Commercial use is defined as any w...

Page 23: ...www mercurymarine com au If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine at the address shown above Mercury Marine will then arrange for the...

Page 24: ...high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by...

Page 25: ...s will not apply to products used for commercial applications To transfer the warranty to the subsequent owner send or fax a copy of the Bill of Sale or Purchase Agreement new owner s name address and...

Page 26: ...tiMax 300 XS 2 years 3 years Verado 400R 2 years 3 years Outside the United States For product purchased outside the United States contact the distributor in your country or the authorized Marine Powe...

Page 27: ...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 Ze...

Page 28: ...lication Verado 400R 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 EUR...

Page 29: ...ND 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 Fou...

Page 30: ...o 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 War...

Page 31: ...g with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to...

Page 32: ...t 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 Fo...

Page 33: ...r 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 wh...

Page 34: ...stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves wi...

Page 35: ...he operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could c...

Page 36: ...Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Pass...

Page 37: ...jury 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...

Page 38: ...ange 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...

Page 39: ...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 a...

Page 40: ...board for more complete installation information WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage serious inju...

Page 41: ...rm dragging teak body surfing This dangerous practice not only places a person in an area of high engine exhaust concentration but also subjects them to the possibility of injury from the boat propell...

Page 42: ...s are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of nonapproved accessories can damage the produ...

Page 43: ...Radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment batteries bulbs and fuses Compass and...

Page 44: ...hat all passengers have a proper seat and are in it before any boat movement Never operate a boat while under the influence of alcohol or drugs It is the law Alcohol or drugs can impair your judgment...

Page 45: ...he serial number is located on the outboard as shown a Serial number b Model designation c Year manufactured d Certified Europe Insignia as applicable 8 9 9 FourStroke Specifications Models 8 9 9 9 9...

Page 46: ...oz Gearcase lubricant capacity 320 ml 10 8 fl oz 370 ml 12 5 fl oz Battery rating electric start models 465 marine cranking amps MCA or 350 cold cranking amps CCA Emission control system Engine modif...

Page 47: ...e 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 Water inlet j Gear lubrican...

Page 48: ...VIEW a Choke fast idle knob b Oil pressure light c Fuel line connector d Start switch electric tiller handle e Lanyard safety switch f Copilot tension adjustment a b c d e f 57671 GENERAL INFORMATION...

Page 49: ...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 GENERAL INFORMATION eng 39...

Page 50: ...ter inlet e Gear lubricant fill drain plug f Secondary water inlet g Anti ventilation plate h Engine flush plug i Water pump indicator hole j Cowl latch k Oil drain screw l Power tilt m Kicker strap n...

Page 51: ...is will drain fuel from the carburetor Install the protector cap over the fuel connector a Protector cap 2 Remove outboard and hold it upright until the water is drained out Keep the outboard in an up...

Page 52: ...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 ge...

Page 53: ...Shift the outboard to forward gear This prevents the propeller from spinning freely TRANSPORTING eng 43...

Page 54: ...in your area refer to Gasolines Containing Alcohol These reformulated gasolines are acceptable for use in your Mercury Marine engine GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains...

Page 55: ...rom internal components Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or offered for sale in the United States The Environmental Protection Agency EPA requires...

Page 56: ...tank exceeds 34 4 kPa 5 0 psi A hissing noise may be heard as the tank vents to the atmosphere This is normal The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering t...

Page 57: ...ys stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tank...

Page 58: ...T 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 the dipstick Wipe...

Page 59: ...4 Install the oil filler cap and tighten securely a Dipstick b Oil filler cap 4914 a b FUEL AND OIL eng 49...

Page 60: ...g so will inject fuel into the engine and cause a possible hard starting flooded condition A decal on the tiller handle is a quick reference guide for starting a cold or hot engine 57622 Tiller handle...

Page 61: ...ndle lock cap Remove the lock cap on top of the tiller handle to lock in the up position Push the tiller lock release lever to release the handle from the locked up position a Lock cap b Locking mecha...

Page 62: ...witch Push to tilt engine up down 4639 Throttle grip friction knob Turn the friction knob to set and maintain the throttle at desired speed Turn the knob clockwise to tighten friction or turn the knob...

Page 63: ...is in neutral disables the gear shift control of the tiller handle 28550 Throttle grip Controls the engine speed and shifting a Reverse gear throttle b Forward gear throttle Choke Pull out when start...

Page 64: ...tion 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 fu...

Page 65: ...Locks the engine in the full tilt position 28564 Trim position knob Presets the trim position 28551 Kicker strap power tilt models Prevents the engine from turning while tilted up 4676 FEATURES AND C...

Page 66: ...olding the throttle only button in move the throttle handle forward to assist in starting the engine Lanyard stop switch if equipped The purpose of a lanyard stop switch is to shut down the engine whe...

Page 67: ...th a quick motion After shifting into gear advance the lever further to increase speed N R F 58239 Warning System The warning system on this engine does not have a warning horn Instead there is an oil...

Page 68: ...les the operator to easily adjust the position of the outboard by pressing the tilt switch With the engine turned off the outboard can be tilted out of the water At low idle speed the outboard can als...

Page 69: ...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 turning when tilted up 4676 38581...

Page 70: ...et 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 Refer to the following lists whe...

Page 71: ...steering torque or pull to the right 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 e...

Page 72: ...ber one if the transom angle needs further adjustment a Transom angle settings b Tilt release position Shallow Water Operation There are three 3 shallow water drive positions that enable the outboard...

Page 73: ...the top cowl grip and raise the outboard to the full up position 3 Pull out on the tilt lock knob and move it to the lock position The outboard cannot be lowered while the tilt lock knob is in the lo...

Page 74: ...e effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 50 mm 2 inches or more above the boat bottom Operate your boat at normal cruising speed tri...

Page 75: ...the gearcase is submerged This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other components If there is a chance of ice forming on the w...

Page 76: ...source Bouncing can damage the outboard and boat transom Prestarting Instructions 1 Connect the remote fuel line to the outboard Make sure connector is snapped into place 27231 2 Check the engine oil...

Page 77: ...ely one minute every ten minutes 3 For the next eight hours of operation avoid continuous operation at full throttle for more than five minutes at a time Starting the Engine Tiller Handle Models Befor...

Page 78: ...ed in this position After the engine is running push the choke knob in one detent The choke is partially open in this position After the engine starts to warm up push the choke knob in The choke is op...

Page 79: ...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 8 Flooded engine If the engine wi...

Page 80: ...operation allow the engine to warm up at idling speed for three minutes Starting the Engine Remote Control Models Before starting read the Prestarting Check List special operating instructions and En...

Page 81: ...ging capabilities must not be operated with the battery cables disconnected from the battery Damage to the charging system may result 5 Do not use the throttle only feature on the remote control for i...

Page 82: ...ditions 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...

Page 83: ...at the neutral position and allow the engine speed to return to idle N R F 27237 Always shift the outboard into gear with a quick motion After shifting the outboard into gear advance the remote contr...

Page 84: ...s use the spare starter rope provided and follow this procedure WARNING The neutral speed protection device is inoperative when starting the engine with the emergency starter rope Set the engine speed...

Page 85: ...hen 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 s...

Page 86: ...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 OPERATION 76 eng...

Page 87: ...or Quicksilver replacement parts and Genuine Lubricants EPA Emission Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as...

Page 88: ...spection and Maintenance Schedule BEFORE EACH USE Check engine oil level See Fuel and Oil Checking Engine Oil Check that lanyard stop switch stops the engine Visually inspect the fuel system for deter...

Page 89: ...m temperature 1 Check fuel line filter for contaminants See Fuel System Check corrosion control anodes Check more frequently when used in saltwater See Corrosion Control Anode Check and adjust valve c...

Page 90: ...water passages 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 dri...

Page 91: ...ine above idle when flushing 4 Adjust the water flow if necessary so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling wate...

Page 92: ...ttery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine be...

Page 93: ...e performed in a well ventilated area Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness...

Page 94: ...on insert locknut 11 16147 3 e Steering bracket Install steering link rod into side hole f Nylon insert locknut 11 16147 3 tighten until seats then back off 1 4 turn Description Nm lb in lb ft Nylon i...

Page 95: ...ore it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode 28623 Propeller Replacement WARNING Rotating propellers can cause seri...

Page 96: ...peller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especial...

Page 97: ...he propeller nut Secure the propeller nut to the shaft with the cotter pin a Cotter pin b Propeller nut c Rear thrust washer d Propeller e Front thrust washer Fuse Replacement Electric Start Models IM...

Page 98: ...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...

Page 99: ...27 20 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 of the...

Page 100: ...ower the outboard Wait a minute to allow the remaining oil that was trapped in the engine to return to the drain Return the outboard to the full tilt position and drain the remaining oil 5 Lubricate t...

Page 101: ...shift cables steering cable grease fitting 8M0071842 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 bracke...

Page 102: ...te 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 from loss of boat control Comple...

Page 103: ...bottom and will drain out prior to the lubricant or 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 lu...

Page 104: ...r Quicksilver Premium or High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place the outboard in a vertical operating position 2 Remove the vent plug from the vent hole...

Page 105: ...he full up position and engage the tilt lock lever 4530 2 Remove the fill cap and check the fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Preci...

Page 106: ...tboard 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 on...

Page 107: ...stem Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with the following instructions Portable fuel tank Pour the required am...

Page 108: ...times to distribute the oil in the cylinders Install spark plugs Change the engine oil Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage N...

Page 109: ...e a Tiller handle up b Front side up Battery Storage Follow the battery manufacturer s instructions for storage and charging Remove the battery from the boat and check water level Charge if necessary...

Page 110: ...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 Mainte...

Page 111: ...Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will No...

Page 112: ...model and serial numbers and to whom the recovery is to be reported This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packa...

Page 113: ...vice manager Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your deale...

Page 114: ...FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabecho Sakai ku Sakai shi Osaka 590 0984 Japan Fax 072 233 8833 Asia Singapore Telephone 65 65466160 Brunswick A...

Page 115: ...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 Roa...

Page 116: ...he 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 outboard must be equipped with a start...

Page 117: ...the outboard could result in the outboard propelling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the requi...

Page 118: ...prevents the outboard from propelling off the transom A decal on the swivel bracket reminds the installer of the potential hazard Avoid serious injury or death Secure engine to transom with bolts WAR...

Page 119: ...cket 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 bracket clamp screws and four mounting bolts Drill two 7 9 mm...

Page 120: ...hten the steering cable nut to the specified torque a Steering cable nut Description Nm lb in lb ft Steering cable nut 47 5 35 Steering Link Rod Fasteners IMPORTANT The steering link rod that connects...

Page 121: ...nsert locknut 11 16147 3 e Steering bracket Install steering link rod into side hole f Nylon insert locknut 11 16147 3 tighten until seats then back off 1 4 turn g Seal Description Nm lb in lb ft Nylo...

Page 122: ...ess Connection 1 Remove the cover and cable receptacle bracket from the bottom cowl a Cover a Cable receptacle bracket 2 Route the remote wiring harness through the rubber grommet a 28003 a 28107 INST...

Page 123: ...harness Push the clamp down and secure the remote wiring harness into the bottom cowl a Clamp b Remote wiring harness c 8 pin connector d Rubber grommet 4 Install the cable receptacle bracket with tw...

Page 124: ...oving the control box out of neutral 2 Attach the throttle cable end guide to the throttle lever with a washer and cotter pin retainer 3 Adjust the cable barrel so that the installed throttle cable wi...

Page 125: ...end guide g Barrel receptacle h Rubber grommet SHIFT CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control 1 Locate the center point...

Page 126: ...gn the end guide with this center mark when installing cable to the engine 6098 b c a 2 Manually shift the outboard into neutral propeller will rotate freely 3 Position the remote control handle into...

Page 127: ...bber 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 h Barrel receptacle 28096...

Page 128: ...h 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 guide Repeat steps a through c Battery Installation Electric...

Page 129: ...e 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 Plac...

Page 130: ...se and propeller to prevent rotation and tighten propeller nut Secure propeller nut to the shaft with the cotter pin a Cotter pin b Propeller nut c Rear thrust washer d Propeller e Front thrust washer...

Page 131: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 121...

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Mercury 8 Bigfoot 4-Stroke, Installation Operation Maintenance Warranty Manual

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