Mercury 15 TwoStroke, Operation, Maintenance & Installation Manual

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 9 9 15 18 TwoStroke 8M0133464 617 eng ...

Page 2: ...eng ...

Page 3: ...anual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Manual included with the product The Warranty Manual contains a description...

Page 5: ...ok SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine Seria...

Page 6: ...eng iv ...

Page 7: ... Safety Instructions for Hand Tilled Outboards 10 Exhaust Emissions 10 Selecting Accessories for Your Outboard 12 Safe Boating Recommendations 12 Recording Serial Number 15 Model Year Production Code 15 Specifications 17 Component Identification 20 Associated Parts 25 Transporting Removing the Motor 26 Carrying the Motor 26 Storing the Motor 26 Trailering Boat Outboard 27 Transporting Portable Fue...

Page 8: ...ine 41 Prestarting Instructions 41 Engine Break In Procedure 42 Warming Up the Engine 43 Starting the Engine 44 Gear Shifting 47 Stopping the Engine 49 Emergency Starting 51 Maintenance Cleaning Care Recommendations 53 Outboard Care 54 Inspection and Maintenance Schedule 54 Flushing the Cooling System 56 Top Cowl Removal and Installation 57 Battery Inspection 58 Fuel System 58 Exterior Care 60 Fus...

Page 9: ... Start Models 71 Engine Will Not Start 71 Engine Runs Erratically 71 Performance Loss 72 Battery Will Not Hold Charge 72 Installation Mercury Marine Validated Engine Mounting Hardware 73 Installing Outboard 73 Installing the Remote Control Devices 75 Wire Color Code Abbreviations 80 Battery Installation 81 Propeller Selection 82 Accessories Propeller Table 83 Accessories 84 Wiring Diagrams MH Mode...

Page 10: ...Owner Service Assistance Service Assistance 94 Ordering Literature 96 Maintenance Log Maintenance Log 98 viii eng ...

Page 11: ...ng 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 WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

Page 12: ... XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device This prevents the engine from starting when the shift is actuated in any position other than neutral WARNING Starting the engine with the drive in gear can cause serious injury or death...

Page 13: ... common nuts nonlocking as they will work loose and vibrate off freeing the link rod to disengage a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote control unit...

Page 14: ...rd 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 within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boat...

Page 15: ... the 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 cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the b...

Page 16: ... 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 Passenger Safety Message Pontoon Boats and Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated f...

Page 17: ...njury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed could...

Page 18: ...change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches down far enough ...

Page 19: ... can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed Boat speed should be kept to a minimum planing speed when...

Page 20: ...tboard 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 injury or death Before operation the outboard must be correctly installed with the required mounting hardware If an obstacle is struck at planing speed and the outboard is not securely fastened to the tr...

Page 21: ...ediately behind the boat platform 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 propeller GOOD VENTILATION Ventilate the passenger area open side curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATIO...

Page 22: ...es 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 product Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maint...

Page 23: ...r 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 map or chart of the area Personal flotation device one per person onboard Watch for signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you ...

Page 24: ...that 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 and greatly reduce your ability to react quickly Know your boating area and avoid hazardous locations Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and...

Page 25: ...erial Number It is important to record the serial number and other important information for future reference Please record the serial number of the engine as indicated on the lower engine cover and the cylinder block in the space below This number will come in handy in the event of theft and it can help you to quickly identify the product type Serial number Model year Model designation Year manuf...

Page 26: ...Model Year Manufactured Code Alpha Production Code A B C D E F G H K X Corresponding Number 1 2 3 4 5 6 7 8 9 0 Examples XX 2000 HK 2089 AG 2017 GENERAL INFORMATION 16 eng ...

Page 27: ...nt 247 cc Bore x stroke 55 x 52 mm 2 1 x 2 0 in Exhaust system Through the hub exhaust Lubrication system Engine oil mixed gasoline Cooling system Thermostat controlled Starting system Manual Electric with manual backup Ignition Flywheel magneto CDI Spark plugs NGK B7HS 10 BR7HS 10 or Champion L82C RL82C gap 1 0 mm 0 039 in Trim system Manual 6 positions Engine oil mixing ratio Mercury Quicksilver...

Page 28: ...c Bore x stroke 60 x 52 mm 2 3 x 2 0 in Exhaust system Through the hub exhaust Lubrication system Engine oil mixed gasoline Cooling system Thermostat controlled Starting system Manual Electric with manual backup Ignition Flywheel magneto CDI Spark plugs NGK B7HS 10 BR7HS 10 or Champion L82C RL82C gap 1 0 mm 0 039 in Trim system Manual 6 positions Engine oil mixing ratio Mercury Quicksilver 2 Strok...

Page 29: ...60 x 52 mm 2 3 x 2 0 in Exhaust system Through the hub exhaust Lubrication system Engine oil mixed gasoline Cooling system Thermostat controlled Starting system Manual Ignition Flywheel magneto CDI Spark plugs NGK B7HS 10 BR7HS 10 or Champion L82C RL82C gap 1 0 mm 0 039 in Trim system Manual 6 positions Engine oil mixing ratio Mercury Quicksilver 2 Stroke engine oil Unleaded gasoline 1 50 Gear oil...

Page 30: ...Component Identification 40465 1 2 3 4 5 6 8 9 10 11 15 16 17 18 19 21 22 23 24 12 13 14 25 27 28 29 26 30 20 7 GENERAL INFORMATION 20 eng ...

Page 31: ...water intake 11 Propeller 12 Oil drain plug upper 13 Water plug 14 Oil drain plug lower 15 Starter handle 16 Shift lever 17 Stop switch 18 Starter switch button 19 Choke knob 20 Fuel hose connector 21 Throttle grip 22 Clamp screws 23 Transom brackets 24 Thrust rod 25 Primer bulb 26 Fuel pickup elbow 27 Fuel connector 28 Fuel tank cap 29 Air vent screw 30 Fuel tank GENERAL INFORMATION eng 21 ...

Page 32: ...40466 1 2 3 4 5 6 8 9 10 11 15 16 17 18 19 21 22 23 24 12 13 14 26 28 29 30 27 31 20 7 25 GENERAL INFORMATION 22 eng ...

Page 33: ...ake 11 Propeller 12 Oil drain plug upper 13 Water plug 14 Oil drain plug lower 15 Starter handle 16 Shift lever 17 Stop switch 18 Starter switch button 19 Choke knob 20 Fuel hose connector 21 Throttle grip 22 Clamp screws 23 Transom brackets 24 Thrust rod 25 Battery cables 26 Primer bulb 27 Fuel pickup elbow 28 Fuel connector 29 Fuel tank cap 30 Air vent screw 31 Fuel tank GENERAL INFORMATION eng ...

Page 34: ...40467 1 2 3 4 5 6 8 9 10 11 15 16 17 18 19 21 22 23 24 12 13 14 26 28 29 30 27 31 20 7 25 32 33 34 35 GENERAL INFORMATION 24 eng ...

Page 35: ...ery cables 26 Primer bulb 27 Fuel pickup elbow 28 Fuel connector 29 Fuel tank cap 30 Air vent screw 31 Fuel tank 32 Remote control box 33 Main switch 34 Lanyard stop switch 35 Harness assembly Associated Parts Name Qty Dimensions Service tools Tool bag 1 Pliers 1 Socket wrench 1 10 x 13 mm Socket wrench 1 21 mm Socket wrench handle 1 Screwdriver 1 Screwdriver handle 1 Spare parts Starter rope 1 10...

Page 36: ...osition whenever you carry the motor 39485 NOTE If you carry the motor in a horizontal position keep the powerhead higher than the propeller IMPORTANT Beware of explosion danger Spilled and vapored gasoline may easily catch fire and explode Be sure to fully discharge gasoline from the carburetors when transporting the engine Wipe off spilled gasoline with a rag Storing the Motor Keep the motor in ...

Page 37: ...om saver bar in the tilted position 39486 Shift the outboard to the forward gear This prevents the propeller from spinning freely If additional ground clearance is required the outboard should be tilted up using an accessory outboard support device Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing IMPORTANT The...

Page 38: ... TANK Close the fuel tank air vent when transporting tank This will prevent escape of fuel or vapors from tank 26793 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 accidentally pushed in allowing ...

Page 39: ...ently in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittin...

Page 40: ... oil films from internal components Oil Recommendation Recommended Oil Mercury or Quicksilver Premium 2 Cycle TC W3 Outboard Oil IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Mercury or Quicksilver Premium TC W3 2 Cycle oil is recommended for this engine For added protection and lubrication Mercury or Quicksilver Premium Plus TC W3 2 Cycle oil is recommended If Mercury or Quicksilver outb...

Page 41: ...ng fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Always stop engine before refilling tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled FILLING FUEL TANKS PERMANENTLY INSTALLED Slowly pour the correct amount of oil ...

Page 42: ...tilt the outboard to the full up position When running the outboard keep the tilt lever in the release position This allows the outboard to return to the running position if the outboard should hit an underwater obstacle and be lifted up Moving the tilt lever to the tilt position will allow the outboard to lock into the shallow water drive position or the full up position IMPORTANT When tilting up...

Page 43: ...wn until it stops This is the tilt up position 4 Tilt the engine all the way up until it locks in place a Reverse lock lever 5 Tilt down Pull the reverse lock lever upward until it stops This is the tilt down position 6 Lift the engine up slightly and then allow gravity to lower it for you a Tilt down position b Tilt up position c Reverse lock lever 37535 a 39484 a b c FEATURES AND CONTROLS eng 33...

Page 44: ...tral N before operating in shallow water 1 Stop the engine 2 Tilt up Put the reverse lock lever in the tilt up position and tilt up the engine to put the engine in the shallow water running position a Reverse lock lever 3 Tilt down Pull the reverse lock lever in the tilt down position slightly lift up the engine then put it down a Tilt down position b Tilt up position c Reverse lock lever 37535 a ...

Page 45: ...at to achieve optimum performance stability and minimize steering effort The following instructions explain how to set the best angle of the boat The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed This allows the boat to be driven parallel to the water Arrange passengers and load in the boat so the weight is distri...

Page 46: ...ing Friction Adjustment Steering friction can be adjusted according to your preference with the steering co pilot 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 Ad...

Page 47: ...oosen friction a Tighten friction b Loosen friction c Throttle adjustment screw Trim Tab Adjustment Propeller steering torque will cause the boat to pull in one direction This steering torque is a normal result from the outboard not trimmed with the propeller shaft parallel to the water surface The trim tab can help compensate for this steering torque in many cases and can be adjusted within limit...

Page 48: ...teers toward the right set the trim tab in the direction of C a Trim tab b Steers toward the left set the trim tab in the direction of B c Steers toward the right set the trim tab in the direction of C d Turning left e Turning right IMPORTANT The trim tab also acts as an anode to prevent galvanic corrosion Do not apply any paint grease or other material to the surface of the trim tab NOTE Trim tab...

Page 49: ...the throttle friction adjustment screw on the front of the remote control box Turn clockwise to increase the friction and counterclockwise to decrease it a Turn counterclockwise to decrease the friction b Turn clockwise to increase the friction c Throttle friction adjustment screw 38385 a b c FEATURES AND CONTROLS eng 39 ...

Page 50: ...o 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 water the outboard should be removed and drained completely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possibl...

Page 51: ...the air causing an overly rich fuel mixture Operating Outboard as an Auxiliary Engine If the outboard is used as an auxiliary engine stop the engine and tilt the outboard out of the water when using the main power source IMPORTANT The outboard must be restrained from bouncing while operating the boat using the main power source Bouncing can damage the outboard and boat transom Prestarting Instruct...

Page 52: ...Make sure the cooling water intake is submerged 43116 Engine Break 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 ENGINE OIL Use Mercury or Quicksilver engine oil or the other recommended oil TC W3 37714 a c b OPERATION 42 eng ...

Page 53: ...g at a constant speed for more than two minutes and avoid sustained wide open throttle Time 0 9 min 10 59 min 1 00 1 59 hrs 2 00 9 59 hrs 10 hrs Method of operation Idling or trolling Throttle open less than of the way about 3000 RPM Throttle open less than 3 4 of the way about 4000 RPM Throttle open 3 4 of the way about 4000 RPM Normal operating Conditions Cruising at no more than minimum speed A...

Page 54: ...aving the battery leads connected to a battery Damage to the charging system could result IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operati...

Page 55: ... the mark on the grip faces the triangular mark on the steering handle 28847 3 Pull the choke knob out all the way The choke operation is not necessary when the engine is warm 38349 4 MH models Pull the starter handle slowly until you feel resistance Then pull it quickly a Pull slowly b Pull quickly 37523 a b OPERATION eng 45 ...

Page 56: ...k when the engine has started 7 E Models Insert the main switch key 8 Set the control lever in the Neutral N position Raise the Neutral N warm up lever a Fully opened b Fully closed c Neutral warm up lever d Ignition key e Lanyard stop switch 9 Turn the main switch key to the start position Then continuously push the key to operate the choke 39481 a 37715 N c d e a b OPERATION 46 eng ...

Page 57: ...d the starter motor Operate the starter motor for a maximum of three seconds If the engine does not start wait five seconds before engaging the starter motor again Do not engage the starter motor after the engine has started Gear Shifting IMPORTANT Observe the following Never shift the outboard into gear unless the engine speed is at idle Do not shift the outboard into reverse when the engine is n...

Page 58: ...ected while lifting up on the lock button located at the bottom of the control lever grip Further shifting will open the throttle 2 Reverse Quickly pull the control lever to the Reverse R position at 32 where the gear is connected while lifting up on the lock button located at the bottom of the control lever grip Further shifting will open the throttle NOTE The control lever is inoperative unless ...

Page 59: ...eutral N f Reverse R g Fully closed h Neutral warm up lever i Lock button Stopping the Engine MH and EH Models 1 Turn the throttle grip to the low speed position 2 Put the shift lever into the Neutral N position Run the engine for 2 3 minutes at idling speed if it has been running at full speed 39483 a b g d d g f c a h i e OPERATION eng 49 ...

Page 60: ...3 Push the stop switch to stop the engine 37877 E Models 1 Put the shift lever into the Neutral N position and run the engine for 2 3 minutes at idling speed 37882 N OPERATION 50 eng ...

Page 61: ...ctor of the engine or the fuel tank Disconnect the battery cable of the EH or E type engine if the engine will not be used for more than three days Emergency Starting If the starter system fails use the spare starter rope provided and follow the procedure Remove the top cowl and use the spare starter rope provided and follow the procedure 1 Pull directly on the starter rope by hand 2 Use a 10 mm s...

Page 62: ...r 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 cover or top cowl when engine is running OPERATION 52 eng ...

Page 63: ...ilure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product CLEANING GAUGES IMPORTANT Never use high pressure water to clean gauges Routine cleaning of the gauges is recommended to prevent a buildup of salt and other environmental debris Crystalized s...

Page 64: ...ter to remove dirt and dust that may scratch the surface 2 Wash the cowls with clean water and a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth 5 To remove minor scratches use Mercury Marine Cowl ...

Page 65: ...Inspect the corrosion control anodes Lubricate the propeller shaft splines Replace all filters on the suction side of the fuel system dealer item Lubricate the driveshaft splines dealer item Check the tightness on all the fasteners dealer item Check the torque of the outboard mounting hardware dealer item Check the battery condition and tightness of the battery cable connection if equipped dealer ...

Page 66: ...opellers 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 Place a block of wood between the propeller blade and the anti ventilation plate 1 Remove the propeller Refer to Propeller Replacement Install th...

Page 67: ...r 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 water 27260 5 Check for a steady stream of water flowing out of the water pump indicator hole Continue flushing the outboard for 3 to 5 minutes carefully monitoring water supply at all times 6 Stop the engine turn off the water and remove the flushin...

Page 68: ...ccidental shorting of battery terminals Fuel System WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the eng...

Page 69: ...bulb must be replaced ENGINE FUEL FILTER Inspect the sight bowl for water accumulation and inspect the filter element for sediment Clean the filter as follows Cleaning the fuel filters and the fuel tank Fuel filters are provided inside the fuel tank and engine 1 Fuel tank filter Loosen the fuel pickup elbow shown remove it and clean the fuel filter a Filter b Fuel pickup elbow 37711 b a MAINTENANC...

Page 70: ...tored for a long period over three months IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes Fuse Replacement Electric Start Remote Control Models IMPORTANT Always carry spare SFE 20 amp fuses 4...

Page 71: ...control anode installed on the gearcase An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals Two anodes are fitted at the gearcase and the mount bracket When the anodes has been eroded more than 2 3 replace it immediately a Anode trim tab IMPORTANT Please follow the instructions below 1 Never grease or paint the ...

Page 72: ...n neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Shift outboard to Neutral N position 38347 2 Remove the spark plug leads to prevent the engine from starting 26899 3 Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut 27296 M...

Page 73: ... 4 C with PTFE 27305 Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each ...

Page 74: ...onto the propeller shaft a Cotter pin b Nut c Washer d Propeller e Forward thrust hub f Propeller shaft 7 Place a block of wood between the gearcase and propeller and tighten the propeller nut 27341 8 Install the spark plug leads 37520 a b c d e f MAINTENANCE 64 eng ...

Page 75: ...spark plug leads Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace the spark plug if the electrode is worn or the insulator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap 0 9 1 0 mm 26947 Spark Plug NGK B7HS 10 or BPR7HS 10 or recommended ones Champion L82 or RL 82C with 1 0 mm gap 4 Before installing spark plugs clean off an...

Page 76: ...low the outboard 3 Remove the oil plugs upper and lower and drain the gear oil completely a Upper oil drain plug b Lower oil drain plug c Water strainer 4 Insert the oil tube nozzle into the lower oil drain plug hole and fill with gear oil by squeezing the oil tube until oil flows out of the upper plug hole a Upper oil drain plug b Lower oil drain plug c Water strainer 5 Install the upper oil drai...

Page 77: ...bmerged 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 MAINTENANCE eng 67 ...

Page 78: ...t cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation FUEL SYSTEM IMPORTANT Gasoline containing alcohol ethanol or methanol can cause a formation of acid during storage and can damage the fuel system If the gasoline being used contains alcohol it is advisable to drain as much of the r...

Page 79: ... Place the outboard in water or connect flushing attachment for circulating cooling water Start the engine and let it run in neutral to warm up With engine running at fast idle stop the fuel flow by disconnecting the remote fuel line When engine begins to stall quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel Remove the spa...

Page 80: ...urer s instructions for storage and charging Remove the battery from the boat and check water level Charge if necessary Store the battery in a cool dry place Periodically check the water level and charge the battery during storage STORAGE 70 eng ...

Page 81: ...ection 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 to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance secti...

Page 82: ...p Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator TROUBLESHOOTING 72 eng ...

Page 83: ...utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have the following decal on the transom clamp 51965 Installing Outboard NOTE If outboard is a remote control electric start model follow instructions in the outboard installation manual provided with th...

Page 84: ...ransom a Equal distance from the center 3 Transom matching Be sure that the anti ventilation plate of the outboard is below the water surface when running with the throttle wide open If the above condition cannot be met due to the shape of the bottom of the boat please consult the dealer IMPORTANT If the anti ventilation plate is at a level higher than the bottom of the boat overheating may occur ...

Page 85: ...perly and safely secure the outboard to the transom Use a marine waterproofing sealer in holes and around bolts to make the installation water tight a Clamp bracket screw WARNING Failure to correctly fasten 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...

Page 86: ...ontrol cable engine side and the harness assembly wiring harness a Fitting of throttle cable and shift cable guide Throttle side Attach the throttle cable adapter to the end of the cable and secure it with the nut a Cable outer groove b Throttle cable c Nut d Spring e Throttle cable adapter f Ball holder 40468 a b c d e f INSTALLATION 76 eng ...

Page 87: ...ter groove b Shift cable c Nut d Shift cable adapter e Lock pin f Spring g Spring pin b Fitting of remote control cable to the engine Throttle side Set the throttle cable to the cable clip and connect the throttle cable adapter to the ball joint of the advancer arm 40469 a b c d e f g INSTALLATION eng 77 ...

Page 88: ...le of the shift side b Lock pin c Spring d Shift cable adapter e Spring pin f Shift lever g CDU h Advancer arm i Ball joint j Ball holder k Throttle cable adapter l Spring m Washer n Grommet is installed on the lower cowl o Cable of the throttle side p Cable outer groove 40470 a b c d e f g h i j k l m n o p q r s t u INSTALLATION 78 eng ...

Page 89: ... box to its first position in Forward F or Reverse R about 32 and whether the throttle of the carburetor is fully open when shifting the lever further Confirm whether the carburetor s throttle is fully closed when the control lever is shifted to the Neutral N position If it is not adjust the position of the ball holder c Connecting Electrical Harnesses Pass the cable assembly from the remote contr...

Page 90: ...ectifier f From the remote control box g Battery cable h Cable assembly Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN or ORG Orange PNK Pink PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark 40471 a b c a d e f g h a INSTALLATION 80 eng ...

Page 91: ...g Battery cables must be arranged and protected from damage during steering With poor cable connections the starter will fail to start Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative Battery must be fully charged before running the motor a Red cable b Black cable IMPORTANT Please follow the instructions below Hydrogen gas is gener...

Page 92: ...e humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboard s durability Check full throttle RPM using an accurate tachometer with the engine trimmed out to a balanced steering condition steering effort equal in both directions without causing the propeller to break...

Page 93: ... 5800 RPM Transom height S short L long XL extra long Propeller Chart Standard Equipment Propeller size 235 x 203 mm 9 2 x 8 in 235 x 229 mm 9 2 x 9 in 9 9 HP L XL S 15 HP L XL S 18 HP XL S L Propeller Chart Propeller size 234 x 155 mm 9 2 x 6 in 234 x 254 mm 9 2 x 10 in 234 x 292 mm 9 2 x 11 5 in 9 9 HP Optional Optional Optional 15 HP Optional Optional Optional 18 HP Optional Optional Optional A...

Page 94: ...Accessories OPTIONAL ACCESSORIES 40476 a b c d e g h f ACCESSORIES 84 eng ...

Page 95: ...rcury Quicksilver grease 250 g d Mercury Quicksilver gear oil 500 ml e Touch up paint f Mercury Quicksilver engine oil 0 4 L 1 L 4 L 20 L g Flushing attachment h Extension cord for light lights are available on the market ACCESSORIES eng 85 ...

Page 96: ...MH Models 39493 a b c d e f g h i j k l m o p q r n WIRING DIAGRAMS 86 eng ...

Page 97: ...t optional g Receptacle plug optional h Lamp 12V 80W AC sold separately i Tachometer optional j Tachometer lead wire optional k Separate cord yellow optional l Separate cord white optional m Flywheel magneto n Spark plug o Ignition coil p CD unit q Lanyard stop switch r Stop cord optional WIRING DIAGRAMS eng 87 ...

Page 98: ...EH Models 39494 a b c d e f g h i j k l m n o p q WIRING DIAGRAMS 88 eng ...

Page 99: ...solenoid f Fuse g Rectifier h Tachometer i Tachometer lead wire optional j Separate cord yellow optional k Separate cord white optional l Flywheel magneto m Spark plugs n Ignition coil o CDU p Lanyard stop switch q 12V 40AH or 12V 70AH sold separately WIRING DIAGRAMS eng 89 ...

Page 100: ...E Models 39495 a b c d e k j i q h g f l m n o p t r s WIRING DIAGRAMS 90 eng ...

Page 101: ...ire optional f Fuse 15A g Starter solenoid h Rectifier i Flywheel magneto j Separate cord white optional k Separate cord yellow optional l Spark plugs m Ignition coil n CD unit o Lead wire black p Lead wire brown q Starter motor r Choke solenoid s Battery cables t Lanyard stop switch optional WIRING DIAGRAMS eng 91 ...

Page 102: ...Single Remote Control Box 39496 a b c d WIRING DIAGRAMS 92 eng ...

Page 103: ...a Neutral switch b Main switch c Stop switch d Cord assembly WIRING DIAGRAMS eng 93 ...

Page 104: ...he 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 packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer is required to reduce the possibilit...

Page 105: ...rvice 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 dealership please contact the Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the Cus...

Page 106: ...r 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 Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789 Ordering Literature Before ordering literature have the following information about your power ...

Page 107: ...ce center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Quantity Item Stock Number P...

Page 108: ...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 98 eng ...