Mercury 150 FourStroke, Operation & Installation Manual

Page 1: ...Outboard Operation Maintenance Warranty Installation Manual 2015 Mercury Marine 150 FourStroke 8M0105247 415 eng ...

Page 2: ...eng ...

Page 3: ... 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 Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Conformity assessment module used for exhaust emissions B C B D B E B F G H Conformity assessment module used for noise emiss...

Page 4: ...4 Essential requirements Standards Other normative document method Technical 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 4 owner s manual ISO 8665 2006 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s man...

Page 5: ...ill be pleasant Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the fact...

Page 6: ...a Mercury 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 manuals and parts books Employs at least one certified or master technician Provides timely service for all Mercury Marine customers Offers extended service hours and mobile service when appropriate U...

Page 7: ...tar Label 10 Warranty Policy Australia and New Zealand 11 Global Warranty Charts Outboard and Jets 15 General Information Boater s Responsibilities 20 Before Operating Your Outboard 20 Boat Horsepower Capacity 20 High Speed and High Performance Boat Operation 21 Propeller Selection 21 Outboard Remote Control Models 23 Remote Steering Notice 24 Lanyard Stop Switch 24 Protecting People in the Water ...

Page 8: ...eatures and Controls Remote Control Features 46 Warning System 46 Power Trim and Tilt 48 Operation Important Daily Inspection Before Each Use 52 Prestarting Check List 52 Operating in Freezing Temperatures 53 Operating in Saltwater or Polluted Water 53 Operating at High Elevations 53 Effects of Elevation and Weather on Performance 53 Setting Trim Angle while Running Engine at Idle Speed 54 Operati...

Page 9: ...peller Replacement 70 Spark Plug Inspection and Replacement 73 Fuse Replacement 75 Alternator Drive Belt Inspection 77 Lubrication Points 78 Checking Power Trim Fluid 80 Changing Engine Oil 80 Gearcase Lubrication 83 Storage Storage Preparation 85 Protecting External Outboard Components 85 Protecting Internal Engine Components 86 Gearcase 86 Positioning Outboard for Storage 86 Battery Storage 86 T...

Page 10: ...city 97 Start in Gear Protection 98 Fuel System 98 Installation Specifications 103 Lifting Outboard 103 Shipping Bracket Removal 104 Steering Cable Starboard Side Routed Cable 105 Steering Link Rod Fasteners if equipped 105 Determining Recommended Outboard Mounting Height 107 Drilling Outboard Mounting Holes 108 Fastening the Outboard to the Transom 109 Electrical Fuel Hose and Control Cables 114 ...

Page 11: ... s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 OUTSIDE UNITED STATES AND CANADA For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Cent...

Page 12: ...0 00 per engine to cover the transfer fee Plan coverage is not transferable from one product to another product or for noneligible applications The certified preowned engine plans are not transferable For help or assistance contact Mercury Product Protection Department at 1 888 427 5373 from 7 30 a m to 4 30 p m CST Monday Friday or e mail mpp_support mercmarine com 3 Year Limited Warranty Against...

Page 13: ...with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any co...

Page 14: ...e Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SO...

Page 15: ...er 5 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 6 Labor performed by other than an authorized dealer may be covered only under the following circumstances when performed on emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out etc and prior factory app...

Page 16: ...e use warranty whichever occurs first to the retail customer that the engine is designed built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine is free from defects in materials and workmanship that cause the engine to fail to conform with applicable regulations This emission related warranty covers all the com...

Page 17: ...igned built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code For information regarding the limited warranty for the nonemission related components of the outboard please see the limited warranty statement for your outboard WHAT IS COVERED Mercury Marin...

Page 18: ...Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury WHAT MERCURY WILL DO Mercury Marine s...

Page 19: ...DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHT...

Page 20: ...er be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days...

Page 21: ...sources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines Warranty Policy Australia and New Zealand MERCURY MARINER OUTBOARD LIMITED WARRANTY AUSTRALIA AND NEW ZEALAND POLICY This limited warranty ...

Page 22: ...nexpired warranty coverage cannot be transferred either to or from a commercial use customer Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine spe...

Page 23: ... tear faded paint damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installat...

Page 24: ... A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY TRANSFER OF WARRANTY AUSTRALIA AND NEW ZEALAND POLICY The limited warranty is transferable to a subsequent purchaser but only for the...

Page 25: ... and 250 hp 1 year 3 years Racing Product Recreation use only Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax 250 XS 2 years 3 years OptiMax 300 XS 2 years 3 years Verado 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 Power Service Center closest to you CANADA WARR...

Page 26: ...or dealer closest to you AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS OUTBOARD AND JET Products Standard Limited Warranty Standard Limited Corrosion Warranty Light Commercial All outboard 3 years 3 years Contact the Marine Power Service Center closest to you Outside of Australia and New Zealand For product purchased outside of Australia and New Zealand contact the distributor in your country or the M...

Page 27: ...ional only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 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 EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES CIS WARRANTY CHARTS OUTBOARD AND JET Product Recreational only St...

Page 28: ...AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2 Stroke 1 year 3 years Contact the Marine Power Service Center closest to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Ve...

Page 29: ...to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Verado 400R 2 years 3 years Outside South Africa For products purchased outside of the South Africa region contact the distributor in your country or the Marine Power Service Center closest to ...

Page 30: ...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 31: ...ts in the propulsion system An improper propeller choice can significantly affect the performance of your boat and could result in damage to the outboard engine When choosing a propeller a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine To view the entire product offering and find the correct propeller that is b...

Page 32: ...ign of your outboard However when more than one diameter is available for the same pitch use a larger diameter for heavy boat applications and a smaller diameter for lighter applications Pitch The pitch is the theoretical distance in inches that a propeller travels forward during one revolution Pitch can be thought of similar to gears in a car The lower the gear the faster the car will accelerate ...

Page 33: ... of sizes and styles that allow you to dial in the ultimate performance for your boat 3 BLADE VS 4 BLADE Available in many sizes of both aluminum and stainless 3 and 4 blade propellers have unique performance characteristics In general 3 blade propellers offer good all around performance and higher top speed than 4 blade propellers However 4 blade propellers are usually faster to plane and more ef...

Page 34: ... thrown within or out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote...

Page 35: ...d 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 boats...

Page 36: ...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 bo...

Page 37: ... 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 38: ...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 39: ...hange 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 w...

Page 40: ... 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 41: ...ation include headache dizziness drowsiness and nausea WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning which can lead to unconsciousness brain damage or death Avoid exposure to carbon monoxide Stay clear from exhaust areas when engine is running Keep the boat well ventilated while at rest or underway STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmf...

Page 42: ...ce is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a Operating the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine operating 2 Examples of poor vent...

Page 43: ...yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and your state or provincial boating law enforcement agency provide c...

Page 44: ...e driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat s capacity plate Know your boat s operating and loading limitations Know if your boat will float if it is full of water When in doubt contact your authorized Mercury Marine dealer or the boat manufacturer Ensure that everyone in the boat is...

Page 45: ...r should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal in...

Page 46: ...park plug hex size 16 mm 5 8 in Spark plug torque 27 Nm 20 lb ft Gear ratio 1 92 1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity Right hand rotation 830 mL 28 1 fl oz Left hand rotation Engine oil capacity with oil filter replacement 6 0 liters 6 3 US qt Battery rating 1000 marine cranking amps MCA 800 cold cranking amps CCA or 180 amp...

Page 47: ...sh c Bottom cowl d Auxiliary tilt switch e Transom brackets f Cooling water intake holes g Gearcase h Anti ventilation plate i Driveshaft housing j Engine oil drain k Water pump indicator hole a b d e f g f h j i k c 47824 GENERAL INFORMATION eng 37 ...

Page 48: ...cal dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 47333 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propell...

Page 49: ...lines Containing Alcohol These Reformulated Gasolines are acceptable for use in your Mercury Marine engine GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can als...

Page 50: ... washed protective oil films from internal components Fuel Additives To minimize carbon deposit buildup in the engine it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine s fuel at each tank fill throughout the boating season Use additive as directed on container Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or of...

Page 51: ...ertain portable outboard models SPECIAL FEATURES OF THE PORTABLE FUEL TANK The fuel tank has a two way valve which allows air to enter the tank 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 atmosphere This is normal The fuel tank includes a fuel demand valve...

Page 52: ... for operation and cap removal Close the manual vent screw for transportation 3 For fuel hoses that have quick disconnects disconnect the fuel line from the engine or fuel tank when not in use 4 Follow Filling Fuel Tank instructions for fueling Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion Use caution when filling fuel tanks Always stop the engine and do...

Page 53: ...y oils other than Mercury or Quicksilver NMMA FC W certified oil or a major brand NMMA FC W certified oil synthetic oils low quality oils or oils that contain solid additives are not recommended 58246 6 0 L 6 3 U S qt C 100 80 60 40 20 0 38 27 16 4 7 18 F 120 49 25W 40 Engine Oil 10W 30 Checking and Adding Engine Oil IMPORTANT Do not overfill Tilt outboard out up past vertical for approximately on...

Page 54: ...rating range between the top bar and bottom bar a Oil level operating range b Top bar c Bottom bar d Upper 1 3 level 6 If the oil level is below the bottom bar remove the oil filler cap and add approximately 500 ml 16 oz of the specified outboard motor oil Allow a few minutes for the oil to drain to the oil sump and recheck the dipstick If necessary add additional oil to bring the oil level within...

Page 55: ... will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 7 Push the dipstick back in all the way 8 Install the oil fill cap hand tight 9 Install the top cowl FUEL AND OIL eng 45 ...

Page 56: ...ns to alert the operator of an active problem within the engine s operating system 1 Continuous six second beep Indicates a critical engine condition Depending on the condition the Engine Guardian system may engage and protect the engine by limiting power You should return to port immediately and contact your servicing dealer 2 Intermittent short beeps for six seconds Indicates a noncritical engin...

Page 57: ... in order to provide engine protection If Engine Guardian has been activated reduce the engine speed The problem will need to be identified and corrected The system must be reset before the engine will operate at higher speeds Moving the throttle lever back to the idle position will reset the Engine Guardian system If the Engine Guardian system has determined the reset has not corrected the proble...

Page 58: ...g out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating the boat on plane The term tilt is generally used when referring to adjusting the outboard further up out of the water With the engine turned off and ignition switch turned on the outboard can be tilted out of the water At low idle speed the outboa...

Page 59: ...plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or oversteering if any turn is attempted or if a significant wave is encountered 2 Trimming out or up can Lift the bow higher out of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the ...

Page 60: ...utboard from tilting up during reverse operation Turn out the manual tilt release valve three turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 47663 AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system a Auxiliary tilt switch SHALLOW WATER OPERAT...

Page 61: ...he outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range FEATURES AND CONTROLS eng 51 ...

Page 62: ... for each person aboard and readily accessible it is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know your boats maximum load capacity Look at the boat capacity plate Fuel supply OK Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where you are going and when you expe...

Page 63: ...s tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use Wash the outboard exterior and flush out the exhaust 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 anodes as this will reduce the effective...

Page 64: ...r ratio changes Reduces the possibility of detonation Enhances overall reliability and durability of the engine Setting Trim Angle while Running Engine at Idle Speed a Relief hole submerged wrong b Relief hole above waterline correct Operating in Shallow Water When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom NOTICE Operatin...

Page 65: ...t three quarter throttle and at full throttle for approximately one minute every ten minutes 2 For the next eight hours of operation avoid continuous operation at full throttle for more than five minutes at a time Starting the Engine Before starting read the Prestarting Check List and Engine Break in Procedure in this section NOTICE Without sufficient cooling water the engine the water pump and ot...

Page 66: ...yard Stop Switch 19791 5 Shift outboard to neutral N position N 58237 6 Ignition key starting Turn ignition key to the START position and release the key The electronic starting system will automatically crank the engine for starting If the engine fails to start the engine will stop cranking Turn the key to the START position again until engine starts OPERATION 56 eng ...

Page 67: ...of water flowing out of the water pump indicator hole IMPORTANT If no water is coming out of the water pump indicator hole stop the engine and check the 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 Operating the engine while overheat...

Page 68: ...ide operation forward F neutral N and reverse R When shifting always stop at the neutral position and allow the engine speed to return to idle Always shift the outboard into gear with a quick motion After shifting the outboard into gear advance the lever further to increase speed N R F 58239 Stopping the Engine Reduce the engine speed and shift the outboard to neutral position Turn the ignition ke...

Page 69: ...or Quicksilver replacement parts and Genuine Lubricants EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory standards For this r...

Page 70: ...in emission levels within prescribed certification standards The owner 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 BEFORE EACH USE Check engine oil level See Fuel and Oil Checking and Adding Engine Oil Check that lanyard stop switch stops the engi...

Page 71: ...utboard cooling system if operating in salt polluted or muddy water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater If operating in saltwater inspect the powerhead and powerhead components for salt buildup See Cleaning Care for the Powerhead Saltwater Use EVERY 100 HOURS OF USE OR O...

Page 72: ...d Spark plug threads 92 898101385 Check wiring and connectors Check tightness of bolts nuts and other fasteners Check cowl seals to ensure seals are intact and not damaged Check internal cowl sound reduction foam if equipped to ensure foam is intact and not damaged Check that the intake silencer if equipped is in place Check that the idle relief muffler if equipped is in place Check for loose hose...

Page 73: ...eral description of the maintenance schedule decal located on the engine 58260 Icon Definition Icon Definition 58249 Replace 58250 Inspect 58251 Engine oil and filter 58252 Gearcase lubricant 58253 Spark plugs 58254 Thermostat 58255 Low pressure fuel filter 58256 Anodes MAINTENANCE eng 63 ...

Page 74: ...ition during flushing 1 With the engine turned off place the outboard in either the operating position vertical or in a tilted position 2 Remove the flush connector from the bottom cowl 3 Remove the cover from the flush connector and thread a water hose into the flush connector 47592 4 Turn on the water tap maximum and let the water flush through the cooling system for about 15 minutes 5 When flus...

Page 75: ...e cowl to lock it in place Ensure the cowl is securely fastened by trying to pull up on the back of the cowl 47633 Cleaning Care for Top and Bottom Cowls IMPORTANT Dry wiping wiping the plastic surface when it is dry will result in minor surface scratches Always wet the surface before cleaning Do not use detergents containing hydrochloric acid Follow the cleaning and waxing procedure CLEANING AND ...

Page 76: ...e powerhead and powerhead components Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys IMPORTANT Do not allow lubricant or Corrosion Guard spray to come in contact with the alternator drive belt or the belt pulleys The alternator drive belt could slip and be damaged if it becomes coated with any lubricant or Corrosion Guard spray Tube Ref No D...

Page 77: ... fuel must be disposed of in an approved receptacle Before servicing any part of the fuel system 1 Stop engine and disconnect the battery 2 Perform fuel system service in a well ventilated area 3 Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line for cracks swelling leaks hardness or other signs of deterioration or damage If any of these...

Page 78: ...pull the fuel filter out of its opening If necessary move the fuel hose so that it clears the bracket while lifting the fuel filter 4 Push in on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter 5 Place the lower hose into the hose holder to prevent it from dropping into the filter hole 47535 a b MAINTENANCE 68 eng ...

Page 79: ...f necessary 4 Install the fuel filter back into the opening Position the lift handle so that the locking tab is secured under the bracket Corrosion Control Anode The outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals Each anode requires periodic inspe...

Page 80: ...ever 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 Shift outboard to the neutral N position N 58237 2 Straighten the bent tabs on the propeller nut retainer ...

Page 81: ... PTFE 47623 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 time the ...

Page 82: ...uts a Forward thrust washer b Drive sleeve c Propeller d Drive sleeve adapter e Locknut retainer f Locknut g Raised pins h Tabs bent against the locknut Description Nm lb in lb ft Propeller nut 75 55 3 FLO TORQ IV PROPELLERS 1 Install the propeller onto the shaft with the supplied components as shown 2 Tighten the locknut to the specified torque 45232 c d e f a b g h MAINTENANCE 72 eng ...

Page 83: ...washer b Drive sleeve c Propeller d Drive sleeve adapter e Locknut retainer f Locknut g Tabs bent into grooves Description Nm lb in lb ft Propeller nut 75 55 3 Spark Plug Inspection and Replacement 1 Remove the spark plug leads Pull the rubber boots off the spark plugs 47660 c d e f a b g 45248 MAINTENANCE eng 73 ...

Page 84: ...ous metal is not visible on the spark plug electrode IMPORTANT The color of the plug may not accurately reflect its condition To accurately diagnose a faulty plug inspect the precious metal on the plug s electrode If no precious metal is visible replace the plug a Precious metal 4 Set the spark plug gap Refer to Specifications 27848 a 9381 MAINTENANCE 74 eng ...

Page 85: ...portion of the ground electrode e When it is necessary to close the gap gently tap the plug ground electrode on a hard surface 5 Saltwater use Apply a thin coating of Anti Seize Compound only on threads of spark plugs Tube Ref No Description Where Used Part No 81 Anti Seize Compound Spark plug threads 92 898101385 6 Before installing spark plugs clean off any dirt on the spark plug seats Install t...

Page 86: ...e with the same rating a Cover b Spare fuse holders c Fuse holder d Fuse 4 IGN 20 amp ignition system e Fuse 2 FUEL 20 amp fuel delivery f Fuse 1 DIAG 2 amp diagnostics vessel accessory harness g Fuse 3 HELM 15 amp 14 pin remote control harness cowl trim switch h Good fuse i Blown fuse h i 47408 20 20 2 15 a b c d e f g MAINTENANCE 76 eng ...

Page 87: ...by an authorized dealer if any of the following conditions are found Cracks in the back of the belt or in the base of the V grooves Excessive wear at the roots of the grooves Rubber portion swollen by oil Belt surfaces roughened Signs of wear on edges or outer surfaces of belt 4 Install the flywheel cover with three screws Tighten the screws to the specified torque Description Nm lb in lb ft Flywh...

Page 88: ...ller shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 47623 2 Lubricate the following with 2 4 C with PTFE or Extreme Grease Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Steering cable 92 802859A 1 Extreme Grease Steering cable 8M007...

Page 89: ... Fitting b Steering cable end WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant 3 Lubricate the following with lightweight oil Steering link rod pivot points Lubricate pivot points 47652 b a 47651 MAINTENANCE eng 79 ...

Page 90: ...ATF Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim reservoir 92 858074K01 47647 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 6 liter 6 3 US qt IMPORTANT Tilt the outboard out up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump OIL CHANGING PROCEDURE 1 Tilt the outboard out up p...

Page 91: ...ten the oil drain valve clockwise and remove the oil drain hose 7 Tighten the oil drain valve to the specified torque Clean up any oil in the valve area Description Nm lb in lb ft Oil drain valve 15 133 IMPORTANT Over tightening the oil drain valve can damage the oil sump a Oil drain valve b Drain hose c Loosen 2 1 2 turns maximum CHANGING OIL FILTER 1 Remove the plug from the oil trough and attac...

Page 92: ...This will bring the oil level within the midpoint of the operating range 2 Idle engine for five minutes and check for leaks Stop the engine For an accurate oil level reading allow the engine to cool for at least an hour before checking the oil level Refer to Fuel and Oil Checking and Adding Engine Oil NOTE Checking the oil level within five minutes of engine shutdown can falsely read up to 1 liter...

Page 93: ...l gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEARCASE 1 Place the outboard in a vertical operating position 2 Remove the propeller Refer to Propeller Replacement 3 Place the drain pan below the outboard 4 Remove the vent plug and fill drain plug and drain lubricant a Vent plug b Fil...

Page 94: ...ars at the vent hole a Vent hole b Fill hole IMPORTANT Replace the sealing washers if damaged 4 Stop adding the lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove the lubricant tube and install cleaned fill drain plug and sealing washer a b 22693 MAINTENANCE 84 eng ...

Page 95: ...ystem other than the fuel tank will remain stable during normal storage periods without the addition of fuel treatment stabilizers 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 amount of Fuel System Treatment and Stabilizer follow instructions on contai...

Page 96: ...nstall the spark plugs Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the ...

Page 97: ...nk is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erratically POSSIBLE CAUSES Overheating Warning horn not working Low oil pressure Check oil level Spark pl...

Page 98: ...at 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 Open circuit in the alternator output wire fused link ...

Page 99: ...rs 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 possibility of serious engine damage REPLACEMENT SERVICE PARTS WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine produ...

Page 100: ...erial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geographic office in your area Please include your daytime telephone number with mail and fax correspondence United States Canada Telephone English 1 920 929 5040 Français 1 905 636 4751 Mercury Marine ...

Page 101: ...e Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O ...

Page 102: ...s 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 Price Total Total Due OWNER SERVICE ASSISTANCE 92 eng ...

Page 103: ...t 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 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories such as emergency bo...

Page 104: ...ESSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 1 The following list provides additional guidelines for mounting accessories to the transom clamp bracket The ...

Page 105: ...amp bracket Refer to Figure 1 Figure 1 a Minimum clearance 3 175 mm 0 125 in b Edge of accessory bracket c Transom clamp bracket wall d Radius e Engine supplied mounting fasteners f Fasteners supplied by the accessory manufacturer installed through unused engine mounting bracket holes b c d a f 54624 e OUTBOARD INSTALLATION eng 95 ...

Page 106: ...ecuring the engine to the boat 1 Do not mount an accessory to the transom clamp bracket in an unsupported condition Refer to Figure 2 54625 Figure 2 2 Do not attach an accessory to the boat by use of the engine mounting hardware Refer to Figure 3 Figure 3 a Engine supplied mounting fasteners b Transom clamp bracket c Accessory 53523 a b c OUTBOARD INSTALLATION 96 eng ...

Page 107: ... disregard this recommendation and install the engine yourself please make sure to read and comply with these instructions Failure to comply with these installation instructions could lead to serious injury or death NOTE Do not install an accessory electric fuel pump onto the fuel system for this engine Boat Horsepower Capacity WARNING Exceeding the boat s maximum horsepower rating can cause serio...

Page 108: ... in gear Fuel System ACCESSORY ELECTRIC FUEL PUMP IMPORTANT Do not install an accessory electric fuel pump onto the fuel system for this engine AVOIDING FUEL FLOW RESTRICTION IMPORTANT Adding components to the fuel supply system filters valves fittings etc may restrict the fuel flow This may cause engine stalling at low speed and or a lean fuel condition at high RPM that could cause engine damage ...

Page 109: ...l hose between the fuel tank and the engine b Manual release c Vent water drain holes FUEL TANKS Portable Fuel Tank Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place Permanent Fuel Tank Permanent fuel tanks should be installed in accordance with industry and federal safety standards which include recommendations applicable to groundi...

Page 110: ...o the outboard is restrictive contains an anti siphon valve or holds a relatively large volume of fuel because of a long fuel supply line or water separating fuel filter If a primer bulb is installed it can be used during the priming event to shorten the amount of time required to start the engine 1 Verify the engine is in a level vertical position 2 Verify the vessel fuel supply line is connected...

Page 111: ...ignition key cycle until the purged fuel is relatively clear of air bubbles NOTE If the outboard fuel system does not prime within 15 key on events check for leaks in the fuel supply line to the outboard Repair as needed If no leak is found the fuel supply system to the outboard may be too restrictive Correct the condition and try again 7 Remove the fuel pressure gauge 8 Turn the ignition key on W...

Page 112: ...ine is connected to the outboard fuel system inlet fitting 3 Turn the ignition key on The fuel pumps will run for approximately three to five seconds 4 Turn the ignition key to the start position and release the key The ECM controls the activation of the starter The starter may continue cranking for up to eight seconds NOTE When priming a drained fuel system residual fuel may cause the engine to f...

Page 113: ...ting Outboard 1 Remove the top cowl 2 Install the lifting base to the flywheel using three bolts Tighten the bolts securely 3 Thread the lifting eye into the lifting base 4 Connect a hoist that has a minimum lift capacity of 450 kg 1000 lb to the lifting eye 5 Lift the outboard and place it on the transom a Lifting base b Lifting eye 18552 a a b a b 47706 OUTBOARD INSTALLATION eng 103 ...

Page 114: ... Bracket Removal 1 Remove the two top screws and loosen the two bottom screws 2 Slide the shipping bracket off the bottom screws 3 Tighten the bottom screws to the specified torque a Shipping bracket b Top screws c Bottom screws Description Nm lb in lb ft Bottom screws 7 9 70 c b c a 47720 OUTBOARD INSTALLATION 104 eng ...

Page 115: ...que 47708 Description Nm lb in lb ft Nut 47 5 35 Steering Link Rod Fasteners if equipped IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt a Part Number 10 856680 and self locking nylon insert locknuts c and d Part Number 11 826709113 These locknuts must never be replaced with common nuts nonlocking as they will work lo...

Page 116: ...0 b Flat washers c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighten until it seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn Assem...

Page 117: ...ly objective d This line may be preferred to determine outboard mounting height dimension for dual outboard installation e Outboard mounting height height of outboard mounting brackets from bottom of boat transom For heights over 56 0 cm 22 in a propeller that is designed for surfacing operation is usually preferred f Maximum boat speed MPH anticipated 20 in 21 in 22 in 23 in 24 in 25 in 19 in 10 ...

Page 118: ... 25 in for L models 76 cm 30 in for XL models Mounting the outboard higher may cause damage to the gearcase components Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause propeller to break loose during planing Drilling Outboard Mounting Holes IMPORTANT Before drilling any mounting holes carefully read Determining Recommended Outboard...

Page 119: ...on 8M0071543 Outboard mounting bolt 20 x 5 00 in long 3 25 in thread 826711 17 Nylon insert locknut 20 28421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in thread 67755 1 20 x 4 50 in long 2 25 in thread 8M0...

Page 120: ...th of the boat transom The outboard mounting locknuts and bolts should be able to hold 75 Nm 55 lb ft of torque without the boat transom yielding or cracking If the boat transom yields or cracks under this torque the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under...

Page 121: ...ransom reinforcement plate a Large transom washer b Transom reinforcement plate FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT The transom mounting surface must be flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between transom clamp and boat transom not al...

Page 122: ...ensure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting hardware Tighten the locknuts to the specified torque IMPORTANT Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be drawn ti...

Page 123: ...875 in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 a c d c a d 40952 b e OUTBOARD INSTALLATION eng 113 ...

Page 124: ... the transom bracket Electrical Fuel Hose and Control Cables RIGGING GROMMET Installation IMPORTANT Sufficient slack must exist in wiring harnesses battery cables and hoses that are routed between the rigging grommet and engine attachment points to relieve stress and prevent hoses from being kinked or pinched OUTBOARD INSTALLATION 114 eng ...

Page 125: ...harness opening f Battery cable opening g Accessory harness opening h Shift cable opening i Fuel hose opening j SmartCraft harness or additional harness opening k Throttle cable opening 2 Fasten the rigging grommet and rigging adapter with two screws Tighten the screws to the specified torque 3 Hold the wiring hoses and cables together with a cable tie a b c d e f g i j k 47374 h OUTBOARD INSTALLA...

Page 126: ...on Nm lb in lb ft Screws for attaching the rigging adapter 6 53 REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the rigging grommet Connect the remote harness to the 14 pin connector on the engine harness Fasten the harness with the retainer a Remote 14 pin boat harness b Retainer c 14 pin connector a 47753 47717 a b c OUTBOARD INSTALLATION 116 eng ...

Page 127: ...ery cables If battery cables longer than the factory supplied cables are required the wire gauge size must increase Refer to the following chart for the correct gauge according to the length IMPORTANT Only copper battery cables should be used Do not use aluminum power cables in any marine installation a Wire gauge size b Cable length IMPORTANT The battery cable length specified in the following ch...

Page 128: ...erican Wire Gauge AWG Maximum Length Meter Feet 1 0 19 6 m 64 ft 2 0 24 4 m 80 ft Single Outboard a Red sleeve positive b Black sleeve negative c Cranking battery b a c 15496 OUTBOARD INSTALLATION 118 eng ...

Page 129: ...tive c Ground cable d Cranking battery FUEL HOSE CONNECTION Fasten the remote fuel hose to fitting with a hose clamp Position the hose clamp so that it will not chafe or cut into an adjacent wiring harness NOTICE Inspect the position of the hose clamp to ensure that it will not chafe or cut into the adjacent wiring harnesses a a b b c d d 15497 OUTBOARD INSTALLATION eng 119 ...

Page 130: ...nstructions provided with the remote control NOTE Install the shift cable to the engine first The shift cable is the first cable to move when the remote control handle is moved out of neutral 1 Position the remote control and outboard into neutral position 2 Center the shift cable anchor pin with the neutral detent alignment mark a Shift cable anchor pin b Neutral detent alignment mark a b 47751 4...

Page 131: ...tion Slowly return the handle back to the neutral position Place a mark b on the cable against the cable end guide c Make a center mark c midway between marks a and b Align the cable end guide against this center mark when installing the cable to the engine 6098 b c a 4 Fit the shift cable through the rigging grommet 47738 5 Position the remote control into neutral 6 Place the barrel cup into the ...

Page 132: ...cure the shift cable to the anchor pin with the bow tie clip retainer a Shift cable end guide b Bow tie clip retainer c Center mark d Cable barrel e Barrel cup c d e b a 47743 OUTBOARD INSTALLATION 122 eng ...

Page 133: ...way from the cable end Repeat steps a and b c Shift remote control into reverse while turning propeller The propeller shaft should be locked in gear If not adjust the barrel away from the cable end Repeat steps a through c d Shift remote control back to neutral The propeller shaft should turn freely without drag If not adjust the barrel closer to the cable end Repeat steps a through d THROTTLE CAB...

Page 134: ...throttle cable through the rigging grommet 47739 3 Install the throttle cable to the throttle arm with the bow tie clip retainer 4 Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop OUTBOARD INSTALLATION 124 eng ...

Page 135: ...e the cable barrel and barrel cup into the barrel retainer a Bow tie retainer b Throttle cable end guide c Cable barrel d Barrel cup 6 Lock the cable in place with the cable latch a Cable latch b c d 47747 a 47748 a OUTBOARD INSTALLATION eng 125 ...

Page 136: ...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 126 eng ...