60 efi operation manual

If the outboard motor’s serial number plate contains the CE mark inthe lower left-hand corner, the following statement applies:

This outboard motor manufactured by Mercury Marine, Fond duLac, WI, USA or Marine Power Europe Inc. Park Industrel, dePetit-Rechain, Belgium complies with the requirements of thefollowing directives and standards, as amended:

Machinery Directive: 98/37/EC,

EMC Directive: 89/336/EC; std.EN50081-1, SAE J551(CISPR Pub. 12), EN50082-1, IEC 61000 PT4-2,IEC 61000 PT4-3

Patrick C. Mackey

President, Mercury Marine, Fond du Lac, WI USA

European Regulations Contact:

Product Environmental Engineering Department, Mercury Marine,

Fond du Lac, WI USA

EPA Emissions RegulationsOutboards manufactured by Mercury Marine in the United States arecertified to the United States Environmental Protection Agency asconforming to the requirements of the regulations for the control of airpollution from new outboard motors. This certification is contingent oncertain adjustments being set to factory standards. For this reason, thefactory procedure for servicing the product must be strictly followed and,wherever practicable, returned to the original intent of the design.Maintenance, replacement, or repair of the emission control devices andsystems may be performed by any marine engine repair establishment orindividual.Engines are labeled with an Emission Control Information decal aspermanent evidence of EPA certification.

WARNINGThe engine exhaust from this product contains chemicals known to thestate of California to cause cancer, birth defects or other reproductiveharm.

Thank Youfor your purchase of one of the finest outboards available. You have madea sound investment in boating pleasure. Your outboard has beenmanufactured by Mercury Marine, a world leader in marine technology andoutboard manufacturing since 1939. Over the years, we have committedourselves to produce the finest quality products. This led to MercuryMarine's reputation for strict quality control, excellence, durability, lastingperformance and being the best at providing after-the-sale support.Please read this manual carefully before operating your outboard. Thismanual has been prepared to assist you in the operation, safe use, andcare of your outboard.All of us at Mercury Marine took pride in building your outboard and wishyou many years of happy and safe boating.Again, thank you for your confidence in Mercury Marine.

The description and specifications contained herein were in effect at thetime this manual was approved for printing. Mercury Marine, whose policyis one of continued improvement, reserves the right to discontinue modelsat any time, to change specifications, designs, methods, or procedureswithout notice and without incurring obligation.Mercury Marine, Fond du Lac, Wisconsin U.S.A.Litho in U.S.A.

© 2004, Mercury MarineAlpha, Bravo, Cleaver, K-Planes, Mercury, Mercury Marine, MerCruiser,Mercury MerCruiser, Mercury Racing, MerCathode, Mercury PrecisionParts, Mercury Propellers, Pro Max, OptiMax, Quickleen, Quicksilver,RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury withWaves logo, and SmartCraft logo are all registered trademarks ofBrunswick Corporation. Mercury Product Protection logo is a registeredservice mark of Brunswick Corporation.

TABLE OF CONTENTS

General Information

Boater's Responsibilities........................................................................... 1Before Operating Your Outboard.............................................................. 1Boat Horsepower Capacity........................................................................1High-Speed And High-Performance Boat Operation................................ 2Lanyard Stop Switch.................................................................................. 2Protecting People In The Water................................................................ 4Wave And Wake Jumping......................................................................... 5Impact With Underwater Hazards............................................................. 6Exhaust Emissions.................................................................................... 7Selecting Accessories For Your Outboard................................................ 8Safe Boating Suggestions......................................................................... 9Recording Serial Number........................................................................ 11Specifications - 60 4-Stroke.................................................................... 11Component Identification.........................................................................13

Installation

Maximum Outboard Mounting Height...................................................... 14Steering................................................................................................... 14Propeller Selection.................................................................................. 17Installing Outboard.................................................................................. 17

Transporting

Trailering Boat/Outboard ........................................................................ 19Transporting Portable Fuel Tanks........................................................... 19

Fuel and Oil

Gasoline Recommendations................................................................... 21Filling Fuel Tank...................................................................................... 22Engine Oil Recommendations.................................................................23Checking And Adding Engine Oil............................................................ 23

Features and Controls

Warning System...................................................................................... 25

TABLE OF CONTENTS

Power Trim and Tilt (If Equipped)............................................................ 27Steering Friction Adjustment................................................................... 30Trim Tab Adjustment............................................................................... 31

Operation

Pre-Starting Check List............................................................................ 32Operating In Freezing Temperatures...................................................... 32Operating In Salt Water Or Polluted Water............................................. 32Pre-Starting Instructions..........................................................................33Engine Break-in Procedure..................................................................... 34Starting The Engine.................................................................................34Gear Shifting ........................................................................................... 37Stopping the Engine................................................................................ 37Emergency Starting ................................................................................ 37

Maintenance

Outboard Care.........................................................................................39EPA Emissions Regulations....................................................................39Inspection And Maintenance Schedule................................................... 40Flushing The Cooling System................................................................. 42Top Cowl Removal And Installation........................................................ 43Exterior Care............................................................................................ 43Battery Inspection ...................................................................................43Fuel System.............................................................................................44Corrosion Control Anode.........................................................................45Propeller Replacement............................................................................ 46Spark Plug Inspection And Replacement................................................49Fuse Replacement.................................................................................. 50Timing Belt Inspection............................................................................. 50Lubrication Points.................................................................................... 51Checking Power Trim Fluid..................................................................... 53Changing Engine Oil ............................................................................... 53Gearcase Lubrication - For 87.3 mm(3-7/16 in.) Diameter Gearcase....55Submerged Outboard.............................................................................. 57

Storage

Storage Preparation................................................................................ 58Protecting External Outboard Components............................................ 58

TABLE OF CONTENTS

Protecting Internal Engine Components................................................. 59Gearcase................................................................................................. 59Positioning Outboard For Storage...........................................................59Battery Storage........................................................................................ 59

Troubleshooting

Starter Motor Will Not Crank The Engine................................................ 60Engine Will Not Start............................................................................... 60Engine Runs Erratically........................................................................... 60Performance Loss................................................................................... 61Battery Will Not Hold Charge.................................................................. 61

Owner Service Assistance

Local Repair Service............................................................................... 62Service Away From Home.......................................................................62Parts And Accessories Inquiries.............................................................. 62Service Assistance.................................................................................. 62Mercury Marine Service Offices.............................................................. 63Ordering Literature.................................................................................. 64

Maintenance Log

Maintenance Log..................................................................................... 66

GENERAL INFORMATION

Boater's ResponsibilitiesThe operator (driver) is responsible for the correct and safe operation ofthe boat and safety of its occupants and general public. It is stronglyrecommended that each operator (driver) read and understand this entiremanual before operating the outboard.Be sure at least one additional person on board is instructed in the basicsof starting and operating the outboard and boat handling in case thedriver is unable to operate the boat.

Before Operating Your OutboardRead this manual carefully. Learn how to operate your outboard properly.If you have any questions, contact your dealer.Safety and operating information that is practiced, along with using goodcommon sense, can help prevent personal injury and product damage.This manual as well as safety labels posted on the outboard use thefollowing safety alerts to draw your attention to special safety instructionsthat should be followed.

DANGERDANGER - indicates an imminently hazardous situation that, if notavoided, will result in death or serious injury.

WARNINGWARNING - indicates a potentially hazardous situation that, if notavoided, could result in death or serious injury.

CAUTIONCAUTION - indicates a potentially hazardous situation that, if notavoided, may result in minor or moderate injury or property damage. Itmay also be used to alert against unsafe practices.

Boat Horsepower Capacity WARNING

Using an outboard that exceeds the maximum horsepower limit of aboat can: 1) cause loss of boat control 2) place too much weight at thetransom altering the designed flotation characteristics of the boat or 3)cause the boat to break apart particularly around the transom area.Overpowering a boat can result in serious injury, death or boat damage.

GENERAL INFORMATION

Do not overpower or overload your boat. Most boats will carry a requiredcapacity plate indicating the maximum acceptable power and load asdetermined by the manufacturer following certain federal guidelines. If indoubt, contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSON CAPACITY (POUNDS) XXXMAXIMUM WEIGHT CAPACITY XXX

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High-Speed And High-Performance Boat OperationIf your outboard is to be used on a high speed or high performance boatwith which you are unfamiliar, we recommend that you never operate it atits high speed capability without first requesting an initial orientation andfamiliarization demonstration ride with your dealer or an operatorexperienced with your boat/outboard combination. For additionalinformation, obtain a copy of our Hi-Performance Boat Operation booklet(part number 90-848481) from your dealer, distributor, or Mercury Marine.

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Lanyard Stop SwitchThe purpose of a lanyard stop switch is to turn off the engine when theoperator moves far enough away from the operator's position (as inaccidental ejection from the operator's position) to activate the switch. Alanyard stop switch is included as part of the ignition module/wiringharness.

GENERAL INFORMATION

While activation of the lanyard stop switch will stop the engineimmediately, a boat will continue to coast for some distance dependingupon the velocity and degree of any turn at shut down. However, the boatwill not complete a full circle. While the boat is coasting, it can cause injuryto anyone in the boat's path as seriously as the boat would when underpower.

We strongly recommend that other occupants be instructed on properstarting and operating procedures should they be required to operate theengine in an emergency (e.g. if the operator is accidentally ejected).

WARNINGShould the operator fall out of the boat, the possibility of serious injuryor death from being run over by the boat can be greatly reduced bystopping the engine immediately. Always properly connect both ends ofthe stop switch lanyard to the stop switch and the operator.

WARNINGAvoid serious injury or death from deceleration forces resulting fromaccidental or unintended stop switch activation. The boat operatorshould never leave the operator's station without first disconnecting thestop switch lanyard from the operator.

Accidental or unintended activation of the switch during normal operationis also a possibility. This could cause any, or all, of the followingpotentially hazardous situations:• Occupants could be thrown forward due to unexpected loss of forward

motion - a particular concern for passengers in the front of the boatwho could be ejected over the bow and possibly struck by the gearcase or propeller.

• Loss of power and directional control in heavy seas, strong current orhigh winds.

• Loss of control when docking.

GENERAL INFORMATION

Protecting People In The WaterWHILE YOU ARE CRUISINGIt is very difficult for a person standing or floating in the water to take quickaction to avoid a boat heading in his/her direction, even at slow speed.

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Always slow down and exercise extreme caution any time you are boatingin an area where there might be people in the water.Whenever a boat is moving (coasting) and the outboard gear shift is inneutral position, there is sufficient force by the water on the propeller tocause the propeller to rotate. This neutral propeller rotation can causeserious injury.WHILE BOAT IS STATIONARY

WARNINGStop your engine immediately whenever anyone in the water is nearyour boat. Serious injury to the person in the water is likely if contactedby a rotating propeller, a moving boat, a moving gearcase, or any soliddevice rigidly attached to a moving boat or gearcase.

Shift outboard into neutral and shut off the engine before allowing peopleto swim or be in the water near your boat.

GENERAL INFORMATION

Wave And Wake JumpingOperating recreational boats over waves and wake is a natural part ofboating. However, when this activity is done with sufficient speed to forcethe boat hull partially or completely out of the water, certain hazards arise,particularly when the boat re-enters the water.

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The primary concern is the boat changing direction while in the midst ofthe jump. In such case the landing may cause the boat to veer violently in anew direction. Such a sharp change in direction can cause occupants tobe thrown out of their seats, or out of the boat.

WARNINGAvoid serious injury or death from being thrown within or out of a boatwhen it lands after jumping a wave or wake. Avoid wave or wakejumping whenever possible. Instruct all occupants that if a wake or wavejump occurs, get low and hang on to a boat hand hold.

There is another less common hazardous result from allowing your boat tolaunch off a wave or wake. If the bow of your boat pitches down farenough while airborne, upon water contact it may penetrate under thewater surface and submarine for an instant. This will bring the boat to anearly instantaneous stop and can send the occupants flying forward. Theboat may also steer sharply to one side.

GENERAL INFORMATION

Impact With Underwater HazardsReduce speed and proceed with caution whenever you drive a boat inshallow water areas, or in areas where you suspect underwater obstaclesmay exist which could be struck by the outboard or the boat bottom. Themost important thing you can do to help reduce injury or impact damagefrom striking a floating or underwater object is to control the boat speed.Under these conditions, boat speed should be kept to a minimum planingspeed 24 to 40 km/h (15 to 25 MPH) .

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WARNINGTo avoid serious injury or death from all or part of an outboard cominginto the boat after striking a floating or underwater obstacle maintain atop speed no greater than minimum planing speed.

Striking a floating or underwater object could result in an infinite numberof situations. Some of these situations could result in the following:• Part of the outboard or the entire outboard could break loose and fly

into the boat.• The boat could move suddenly in a new direction. Such a sharp

change in direction can cause occupants to be thrown out of theirseats or out of the boat.

• A rapid reduction in speed. This will cause occupants to be thrownforward, 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 orimpact damage during an impact is control the boat speed. Boat speedshould be kept to a minimum planing speed when driving in waters knownto have underwater obstacles.After striking a submerged object, stop the engine as soon as possibleand inspect it for any broken or loose parts. If damage is present orsuspected, the outboard should be taken to an authorized dealer for athorough inspection and necessary repair.

GENERAL INFORMATION

The boat should also be checked for any hull fractures, transom fractures,or water leaks.Operating a damaged outboard could cause additional damage to otherparts of the outboard, or could affect control of the boat. If continuedrunning is necessary, do so at greatly reduced speeds.

WARNINGAvoid serious injury or death from loss of boat control. Continuedboating with major impact damage can result in sudden outboardcomponent failure with or without subsequent impacts. Have theoutboard thoroughly inspected and any necessary repairs made.

Exhaust EmissionsBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide is present in the exhaust fumes of all internalcombustion engines. This includes the outboards, sterndrives and inboardengines that propel boats, as well as the generators that power variousboat accessories. Carbon monoxide is a deadly gas that is odorless,colorless and tasteless.Early symptoms of carbon monoxide poisoning which should not beconfused with seasickness or intoxication, include headache, dizziness,drowsiness, and nausea.

WARNINGAvoid the combination of a running engine and poor ventilation.Prolonged exposure to carbon monoxide in sufficient concentration canlead to unconsciousness, brain damage, or death.

GOOD VENTILATIONVentilate passenger area, open side curtains, or forward hatches toremove fumes.

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Example of desired air flow through the boat.

GENERAL INFORMATION

POOR VENTILATIONUnder certain running and/or wind conditions, permanently enclosed orcanvas enclosed cabins or cockpits with insufficient ventilation may drawin carbon monoxide. Install one or more carbon monoxide detectors inyour boat.Although the occurrence is rare, on a very calm day, swimmers andpassengers in an enclosed area of a stationary boat that contains or isnear a running engine may be exposed to a hazardous level of carbonmonoxide.WHILE BOAT IS STATIONARY

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a - Running the engine when the boat is moored in a confinedspace.

b - Mooring close to another boat that has its engine running.

WHILE BOAT IS MOVING

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a - Running the boat with the trim angle of the bow too high.b - Running the boat with no forward hatches open.

Selecting Accessories For Your OutboardGenuine Mercury Precision or Quicksilver Accessories have beenspecifically designed and tested for your outboard. These accessories areavailable from Mercury Marine dealers.

GENERAL INFORMATION

WARNINGCheck with your dealer before installation of accessories. The misuse ofacceptable accessories or the use of unacceptable accessories canresult in serious injury, death, or product failure.

Some accessories not manufactured or sold by Mercury Marine are notdesigned to be safely used with your outboard or outboard operatingsystem. Acquire and read the installation, operation, and maintenancemanuals for all your selected accessories.

Safe Boating SuggestionsIn order to safely enjoy the waterways, familiarize yourself with local andother governmental boating regulations and restrictions, and consider thefollowing suggestions.Use flotation devices. Have an approved personal flotation device ofsuitable size for each person aboard (it is the law) and have it readilyaccessible.Do not overload your boat. Most boats are rated and certified for maximumload (weight) capacities (refer to your boat capacity plate). If in doubt,contact your dealer or the boats manufacturer.Perform safety checks and required maintenance. Follow a regularschedule and ensure that all repairs are properly made.Know and obey all nautical rules and laws of the waterways. Boatoperators should complete a boating safety course. Courses are offered inthe U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The PowerSquadron, 3) The Red Cross and 4) your state boating law enforcementagency. Inquiries may be made to the Boating Hotline, 1-800-368-5647 orthe Boat U.S. Foundation information number 1-800-336-BOAT.Make sure everyone in the boat is properly seated. Do not allow anyone tosit or ride on any part of the boat that was not intended for such use. Thisincludes the back of seats, gunwales, transom, bow, decks, raised fishingseats, any rotating fishing seat; or anywhere that an unexpectedacceleration, sudden stopping, unexpected loss of boat control, or suddenboat movement could cause a person to be thrown overboard or into theboat.Never be under the influence of alcohol or drugs while boating (it is thelaw). Alcohol or drug use impairs your judgment and greatly reduces yourability to react quickly.Prepare other boat operators. Instruct at least one other person on boardin the basics of starting and operating the outboard, and boat handling, incase the driver becomes disabled or falls overboard.

GENERAL INFORMATION

Passenger boarding. Stop the engine whenever passengers areboarding, unloading, or are near the back (stern) of the boat. Just shiftingthe outboard into neutral is not sufficient.Be alert. The operator of the boat is responsible by law to maintain aproper lookout by sight and hearing. The operator must have anunobstructed view particularly to the front. No passengers, load, or fishingseats should block the operators view when operating the boat above idlespeed.Never drive your boat directly behind a water skier in case the skier falls.As an example, your boat traveling at 40 km/h (25 MPH) will overtake afallen skier 61 m (200 ft.) in front of you in 5 seconds.Watch fallen skiers. When using your boat for water skiing or similaractivities, always keep a fallen or down skier on the operator's side of theboat while returning to assist the skier. The operator should always havethe down skier in sight and never back up to the skier or anyone in thewater.Report accidents. Boat operators are required by law to file a BoatingAccident Report with their state boating law enforcement agency whentheir boat is involved in certain boating accidents. A boating accidentmust be reported if 1) there is loss of life or probable loss of life, 2) there ispersonal injury requiring medical treatment beyond first aid, 3) there isdamage to boats or other property where the damage value exceeds$500.00 or 4) there is complete loss of the boat. Seek further assistancefrom local law enforcement.

GENERAL INFORMATION

Recording Serial NumberIt is important to record this number for future reference. The serialnumber is located on the outboard as shown.

OTXXXXXX

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a - Serial numberb - Model yearc - Model designation

d - Year manufacturede - Certified Europe Insignia (as

applicable)

Specifications - 60 4-StrokeDescription Specification

Horsepower 60

Kilowatts 44.7

Full Throttle RPMRange

5500-6000 RPM

Idle Speed in ForwardGear

725 ± 25 RPM

Number of Cylinders 4

Piston Displacement 995 cc (60.8 cu. in.)

Cylinder Bore 65 mm (2.559 in.)

Stroke 75 mm (2.953 in.)

Valve Clearance (Cold)

Intake Valve 0.15 - 0.25mm (0.006 - 0.010 in.)

Exhaust Valve 0.25 - 0.35mm (0.010 - 0.014 in.)

GENERAL INFORMATION

Description Specification

Recommended SparkPlug

Champion RA8HC

Spark Plug Gap 1.0 mm (0.040 in.)

Gear Ratio 1.83:1

Required Gasoline Refer to Fuel & Oil

Recommended Oil Refer to Fuel & Oil

Gearcase LubricantCapacity

340 ml (11.5 fl. oz.)

Engine Oil Capacity 3.8 Liter (4 Quarts)

Battery Rating

Operation Above0 °C (32 °F)

465 Marine Cranking Amps (MCA) or 350Cold Cranking AMPS (CCA)

Operation Below 0 °C (32 °F)

1000 Marine Cranking Amps (MCA) or 750Cold Cranking AMPS (CCA)

Ampere Hours (Ah) 70 -100

GENERAL INFORMATION

Component Identification

a - Auxiliary tilt switchb - Tilt support knobc - Transom bracketsd - Primary cooling water

intakee - Gearcasef - Trim tab

g - Anti-ventilation plateh - Driveshaft housingi - Steering arm hole (optional)j - Bottom cowlk - Top cowl

INSTALLATION

Maximum Outboard Mounting HeightMonitor water pressure and engine temperature at all times. Impropermounting height may result in low water pressure and high enginetemperature.

SteeringSTEERING PLATE INSTALLATIONIMPORTANT: To install steering arms, use port and starboard bottomcowls with cut slots for steering arms (Bottom cowl, port P/N: 4020–843242–001; bottom cowl, starboard P/N: 4020–843243–001) If notutilizing steering arms, refer to Models with RideGuide Attaching Kit.1. Install the port steering arm to the port side of the engine, through the

hole in the bottom cowl (arm facing forward).NOTE: The cowls are removed in the following example for illustrationpurposes. The bottom cowls do not need to be removed to perform thisprocedure.2. Apply Loctite 271 Threadlocker to the mounting bolt threads.

a - Port steering armb - Mounting location

c - Mid sectiond - Starboard steering arm

Tube Ref. No. Description Mercury PartNumber

Quicksilver PartNumber

7 Loctite 271Threadlocker

92-809819 92-809819

INSTALLATION

3. Install three bolts to secure the arm to the mid section. Torque thebolts to the specified value.

Description Nm lb. in. lb. ft.

Steering Arm Mounting Bolt (3 perarm)

4. Repeat steps 1 through 3 for the starboard steering arm.5. Attach cable steering pulleys to the arms using the Cable Steering

Clevis Kit. Follow instructions included with the kit.

STEERING LINK ROD FASTENERSIMPORTANT: The steering link rod that connects the steering cable tothe engine must be fastened using special washer head bolt ("e" - PartNumber 10-856680) and self-locking nylon insert locknuts ("b" & "d" - PartNumber 11-826709113). These locknuts must never be replaced withcommon nuts (non-locking) as they will work loose and vibrate off, freeingthe link rod to disengage.

INSTALLATION

WARNINGDisengagement of a steering link rod can result in the boat taking a full,sudden, sharp turn. This potentially violent action can cause occupantsto be thrown overboard exposing them to serious injury or death.

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a - Spacer (12-71970)b - Nylon insert locknut (11-826709113)c - Flat washer (2)d - Nylon insert locknut (11-826709113)e - Special washer head bolt (10-856680)

Nylon insert locknut "b" 27 20

Nylon insert locknut "d" Tighten until seats then back off 1/4turn

Special washer head bolt 27 20

Assemble steering link rod to steering cable with two flat washers andnylon insert locknut. Tighten locknut until it seats, then back nut off 1/4turn.Assemble steering link rod to engine with special washer head bolt,locknut and spacer. First torque bolt, then locknut to specification.

INSTALLATION

Propeller SelectionFor best all around performance from your outboard/boat combination,select a propeller that allows the engine to operate in the upper half of therecommended full throttle RPM range with the boat normally loaded(refer to General Information - Specifications). This RPM range allows forbetter acceleration while maintaining maximum boat speed.

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If changing conditions cause the RPM to drop below the recommendedrange (such as warmer, more humid weather, operation at higherelevations, increased boat load, or a dirty boat bottom/gearcase), apropeller change or cleaning may be required to maintain performanceand ensure the outboards durability.Check full-throttle RPM, using an accurate tachometer, with the enginetrimmed out to a balanced-steering condition (steering effort equal in bothdirections) without causing the propeller to break loose.

Installing Outboard WARNING

Before operation, the outboard must be correctly installed with therequired mounting hardware as shown. Failure to correctly fastenoutboard could result in outboard ejecting off boat transom causingserious injury, death, or property damage.

We strongly recommend that your dealer install your outboard and relatedaccessories to ensure proper installation and good performance. If youinstall the outboard yourself, follow instructions in the Outboard InstallationManual which is provided with the outboard.

INSTALLATION

The outboard must be secured to the transom with the four 12.7 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two boltsthrough the upper set of holes and two bolts through the lower set ofholes.

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TRANSPORTING

Trailering Boat/OutboardTrailer your boat with the outboard tilted down in a vertical operatingposition.If additional ground clearance is required, the outboard should be tilted upusing an accessory outboard support device. Refer to your local dealer forrecommendations. Additional clearance may be required for railroadcrossings, driveways and trailer bouncing.

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IMPORTANT: Do not rely on the power trim/tilt system or tilt supportlever to maintain proper ground clearance for trailering. The outboard tiltsupport lever is not intended to support the outboard for trailering.Shift the outboard to forward gear. This prevents the propeller fromspinning freely.

Transporting Portable Fuel Tanks WARNING

Avoid serious injury or death from a gasoline fire or explosion. Followportable fuel tank transporting instructions. Transport the fuel tank in awell ventilated area away from open flame or sparks.

MANUAL VENTING TYPE FUEL TANK1. Close fuel tank air vent when transporting tank. This will prevent

escape of fuel or vapors from tank.

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TRANSPORTING

AUTO-VENTING TYPE FUEL TANK1. Disconnect the remote fuel line from tank. This will close the air vent

and prevent escape of fuel or vapors from tank.2. Install tether cap over the fuel line connector stem. This will protect the

connector stem from being accidently pushed-in, thus, allowing fuel orvapor to escape.

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ba - Connector stem b - Tether cap

FUEL AND OIL

Gasoline RecommendationsUNITED STATES AND CANADAUse a major brand of automotive unleaded gasoline with a minimumposted octane rating of 87. Mid-grade automotive gasolines that containfuel injector cleaner are preferred for added internal engine cleanliness.Leaded gasoline is not recommended.INTERNATIONALUse a major brand of automotive unleaded gasoline with a minimumposted octane rating of 90RON. Automotive gasolines that contain fuelinjector cleaner are preferred for added internal engine cleanliness.Leaded gasoline is acceptable in areas where unleaded gasoline is notavailable.USING REFORMULATED (OXYGENATED) FUELS - UNITEDSTATES ONLYThis type of fuel is required in certain areas of the United States. The twotypes of reformulated ingredients in these fuels are alcohol (Ethanol) orEther (MTBE or ETBE). If Ethanol is the oxygenates that is used in thegasoline, refer to Alcohol in Gasoline.These reformulated fuels are acceptable for use in the Mercury engine.ALCOHOL IN GASOLINEWe do not recommend the use of gasoline which contains alcoholbecause of the possible adverse effect the alcohol may have on the fuelsystem. In general, if only gasoline containing alcohol is available, it mustnot contain more than 10% ethanol or 5% methanol, and the addition of awater separating fuel filter is recommended.If gasoline containing alcohol is used or if you suspect the presence ofalcohol in your gasoline, increase your inspection of the fuel system,visually checking for fuel leaks or abnormalities.Gasoline containing alcohol may cause the following problems to youroutboard and fuel system:• Corrosion of metal parts• Deterioration of elastomers and plastic parts• Wear and damage of internal engine parts• Starting and operating difficulties• Vapor lock or fuel starvationSome of these adverse effects are due to the tendency of gasolinecontaining alcohol to absorb moisture from the air, resulting in a phase ofwater and alcohol which separates from the gasoline in the fuel tank.

FUEL AND OIL

The adverse effects of alcohol are more severe with methanol and areworse with increasing content of alcohol.

Filling Fuel Tank WARNING

Avoid serious injury or death from a gasoline fire or explosion. Alwaysstop the engine and do not smoke or allow open flames or sparks in thearea while filling fuel tanks.

Fill fuel tanks outdoors away from heat, sparks, and open flames.Remove portable fuel tanks from boat to refill them.Always stop engine before refilling tanks.Do not completely fill the fuel tanks. Leave approximately 10% of the tankvolume unfilled. Fuel will expand in volume as its temperature rises andcan leak under pressure if the tank is completely filled.PORTABLE FUEL TANK PLACEMENT IN THE BOATPlace the fuel tank in the boat so the vent is higher than the fuel levelunder normal boat operating conditions.

FUEL AND OIL

Engine Oil RecommendationsWe recommend the use of Mercury or Quicksilver SAE 10W-30multi-viscosity 4-stroke outboard oil for general, all-temperature use. IfSAE 25W-40 multi-viscosity oil is preferred, use Mercury MerCruiser4-cycle engine oil or Quicksilver sterndrive & inboard 4-cycle engine oil.Never use 4-cycle engine oil that is not certified to meet or exceed anyone or combination of the following American Petroleum Institute (API)Service Classification SH, SG, SF, CF-4, CE, CD, CDII. Severe enginedamage may result from use of an inferior oil.

F° C°

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Recommended SAE Viscosity for Engine Oila - SAE 25W-40 viscosity oil may be used at temperatures above

4 °C (40 °F)b - SAE 10W-30 viscosity oil is recommended for use in all

temperatures.

Checking And Adding Engine OilIMPORTANT: Do not overfill. Be sure that the outboard is upright (nottilted) when checking oil.1. Turn the engine off. Have the outboard in a level operating position.

Remove the top cowl.

FUEL AND OIL

2. Flip the handle up and pull out the dipstick. Wipe it with a clean rag ortowel and push it back in all the way.

3. Pull the dipstick back out again and observe the oil level. If the oillevel is low, remove the oil filler cap and fill to (but not over) the upperoil level with the recommended oil.

IMPORTANT: Inspect oil for signs of contamination. Oil contaminatedwith water will have a milky color to it; oil contaminated with fuel will have astrong fuel smell. If contaminated oil is noticed, have the engine checkedby your dealer.4. Push the dipstick back in all the way, then flip the handle down to lock

the dipstick in place. Reinstall the oil filler cap and hand tightensecurely.

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a - Dipstick b - Oil filler cap

FEATURES AND CONTROLS

Warning SystemThe warning system on this engine does not have a warning horn. Insteadthe warning system consists of a warning light, located on the ignitionmodule.WARNING LIGHT SIGNALSThe warning light alerts the operator and helps identify the following listedsituations:

Function Description

Start Up Normal System Test

Engine Fault The light illuminates when there maybe a problem with one of the enginefunctions. Have your dealer checkthe engine soon.

Engine Fault Engine problem has occurred.Engine will run rough and/or stall.Engine may not start. Advancing theremote control neutral fast idlefeature or advancing the tiller handlethrottle grip half way may assiststarting. Have your dealer check theengine

Engine Fault Engine problem has occurred.Engine will not run. Have yourdealer check the engine

Cooling System Problem Engine Guardian System isactivated. Power limit will vary withlevel of overheat. Shift outboard intoneutral and check for a steadystream of water coming out of thewater pump indicator hole. If nowater is coming out of the waterpump indicator hole or flow isintermittent, stop engine and checkwater intake holes for obstruction.

Function Description

Low Oil Pressure Engine Guardian System isactivated. Power will be limited to2000 RPM. First, stop the engineand check the oil level. Add oil ifnecessary.

Engine Overspeed The warning light illuminates anytime engine speed exceeds themaximum allowable RPM. Thesystem will limit the engine speed towithin the allowable range. Engineoverspeed indicates a condition thatshould be corrected. Overspeedcould be caused by incorrectpropeller pitch, engine height, trimangle, etc.

Battery Voltage to High or to Low Engine Guardian System isactivated. Power limit will restrictengine speed to 75%.

Coolant Sensor Failure Engine Guardian System isactivated. Power limit will restrictengine speed to 50%.

ENGINE GUARDIAN SYSTEMThe Engine Guardian System monitors the critical sensors on the enginefor any early indications of problems. The system will respond to a problemby illuminating the warning light or reducing engine power to provideengine protection.If the Guardian System activates, reduce throttle speed. The light will turnoff when throttle speed is within the allowable limit.

Power Trim and Tilt (If Equipped)Your outboard has a trim/tilt control called power trim. This enables theoperator to easily adjust the position of the outboard by pressing the trimswitch. Moving the outboard in closer to the boat transom is calledtrimming in or down. Moving the outboard further away from the boattransom is called trimming out or up. The term trim generally refers to theadjustment of the outboard within the first 20° range of travel. This is therange used while operating your boat on plane. The term tilt is generallyused when referring to adjusting the outboard further up out of the water.With the engine turned off, the outboard can be tilted out of the water. Atlow idle speed, the outboard can also be tilted up past the trim range topermit, for example, shallow water operation.

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a - Remote control trim switchb - Panel mount trim switch

c - Tilt range of traveld - Trim range of travel

POWER TRIM OPERATIONWith most boats, operating around the middle of the trim range will givesatisfactory results. However, to take full advantage of the trimmingcapability there may be times when you choose to trim your outboard allthe way in or out. Along with an improvement in some performanceaspects comes a greater responsibility for the operator, and this is beingaware of some potential control hazards.The most significant control hazard is a pull or torque that can be felt onthe steering wheel or tiller handle. This steering torque results from theoutboard being trimmed so that the propeller shaft is not parallel to thewater surface.

WARNINGAvoid possible serious injury or death. When the outboard is trimmed inor out beyond a neutral steering condition, a pull on the steering wheelor tiller handle in either direction may result. Failure to keep acontinuous firm grip on the steering wheel or tiller handle when thiscondition exists can result in loss of boat control as the outboard canturn freely. The boat can now spin out or go into a very tight maximumturn which, if unexpected, can result in occupants being thrown withinthe boat or out of the boat.

Consider the following lists carefully.Trimming In or Down Can:• Lower the bow.• Result in quicker planing off, especially with a heavy load or a stern

heavy boat.• Generally improve the ride in choppy water.• Increase steering torque or pull to the right (with the normal right hand

rotation propeller).• In excess can lower the bow of some boats to a point where they

begin to plow with their bow in the water while on plane. This canresult in an unexpected turn in either direction (called bow steering orover-steering) if any turn is attempted, or if a significant wave isencountered.

WARNINGAvoid possible serious injury or death. Adjust outboard to anintermediate trim position as soon as boat is on plane to avoidpossible ejection due to boat spin out. Do not attempt to turn boatwhen on plane if outboard is trimmed extremely in or down and thereis a pull on the steering wheel or tiller handle.

• In rare circumstances, the owner may decide to limit the trim in. Thiscan be accomplished by repositioning the tilt stop pins into whateveradjustment holes in the transom brackets are desired.

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 left at a normal installation

height (with the normal right hand rotation propeller).

• In excess can cause boat porpoising (bouncing) or propellerventilation.

• Cause engine overheating if any cooling water intake holes are abovethe water line.

TILTING OPERATIONTo tilt outboard, shut off the engine and press the trim/tilt switch orauxiliary tilt switch to the up position. The outboard will tilt up until theswitch is released or it reaches its maximum tilt position.1. Engage the tilt support lever, by rotating knob to bring the support

lever upward.2. Lower outboard to rest on the tilt support lever.3. Disengage the tilt support lever, by raising the outboard off the

support lever and rotating the lever down. Lower the outboard.

b ob00336

a - Tilt support lever b - Knob

MANUAL TILTINGIf the outboard cannot be tilted using the power trim/tilt switch, theoutboard can be manually tilted.1. Turn out the manual tilt release valve 3 turns counterclockwise. This

allows manual tilting of the outboard. Tilt the outboard to the desiredposition and tighten the manual tilt release valve.

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NOTE: The manual tilt release valve must be tightened before operatingthe outboard to prevent the outboard from tilting up during reverseoperation.

AUXILIARY TILT SWITCHThe auxiliary tilt switch can be used to tilt the outboard up or down usingthe power trim system.

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a - Auxiliary tilt switch

SHALLOW WATER OPERATIONWhen operating the boat in shallow water, the outboard can be tiltedbeyond the maximum trim range to prevent hitting bottom.

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1. Reduce engine speed below 2000 RPM.2. Tilt 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 trimrange.

Steering Friction Adjustment WARNING

Avoid possible serious injury or death from loss of boat control. Maintainsufficient steering friction to prevent the outboard from steering into afull turn if the tiller handle is released.

Steering Friction Adjustment - Adjust this screw to achieve the desiredsteering friction (drag) on the steering wheel. Turn screw clockwise totighten friction or turn counterclockwise to loosen friction.

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a - Loosen friction b - Tighten friction

Trim Tab AdjustmentPropeller steering torque will cause your boat to pull in one direction. Thissteering torque is a normal thing that results from your outboard not beingtrimmed so the propeller shaft is parallel to the water surface. The trim tabcan help to compensate for this steering torque in many cases and can beadjusted within limits to reduce any unequal steering effort.

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NOTE: Trim tab adjustment will have little effect reducing steering torqueif the outboard is installed with the anti-ventilation plate approximately50 mm (2 in.) or more above the boat bottom.Operate your boat at normal cruising speed, trimmed to desired position.Turn your boat left and right and note the direction the boat turns moreeasily.If adjustment is necessary, loosen trim tab bolt and make smalladjustments at a time. If the boat turns more easily to the left, move thetrailing edge of trim tab to the left. If the boat turns more easily to the rightmove the trailing edge of trim tab to the right. Retighten bolt and retest.

OPERATION

Pre-Starting Check List• Operator knows safe navigation, boating, and operating procedures.• An approved personal flotation device of suitable size 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 expect to return.• It is illegal to operate a boat while under the influence of alcohol or

drugs.• Know the waters and area you will be boating; tides, currents, sand

bars, rocks, and other hazards.• Make inspection checks listed in Maintenance - Inspection and

Maintenance Schedule.

Operating In Freezing TemperaturesWhen using your outboard or having your outboard moored in freezing ornear freezing temperatures, keep the outboard tilted down at all times sothe gearcase is submerged. This prevents trapped water in gearcase fromfreezing and causing possible damage to the water pump and othercomponents.If there is a chance of ice forming on the water, the outboard should beremoved and drained completely of water. If ice should form at the waterlevel inside the outboard driveshaft housing, it will block water flow to theengine causing possible damage.

Operating In Salt Water Or Polluted WaterWe recommend that you flush the internal water passages of youroutboard with fresh water after each use in salt or polluted water. This willprevent a buildup of deposits from clogging the water passages. Refer toMaintenance - Flushing The Cooling System.If you keep your boat moored in the water, always tilt the outboard so thegearcase is completely out of water (except in freezing temperatures)when not in use.

OPERATION

Wash down the outboard exterior and flush out the exhaust outlet of thepropeller and gearcase with fresh water after each use. Each month,spray Mercury Precision or Quicksilver Corrosion Guard on externalmetal surfaces. Do not spray on corrosion control anodes as this willreduce the effectiveness of the anodes.

Pre-Starting Instructions1. Connect the remote fuel line to the outboard. Make sure connector is

snapped into place.

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2. Check the engine oil level.

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OPERATION

3. Make sure the cooling water intake is submerged.

CAUTIONNever start or run your outboard (even momentarily) without watercirculating through the cooling water intake in the gearcase toprevent damage to the water pump (running dry) or overheating ofthe engine.

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Engine Break-in Procedure CAUTION

Severe damage to the engine can result by not complying with theEngine Break-in Procedure.

1. For the first hour of operation, run the engine at varied throttle settingsup to 3500 RPM or at approximately half throttle.

2. For the second hour of operation, run the engine at varied throttlesettings up to 4500 RPM or at three-quarter throttle, and during thisperiod of time, run it at full throttle for approximately one minute everyten minutes.

3. For the next eight hours of operation, avoid continuous operation atfull throttle for more than five minutes at a time.

Starting The EngineBefore starting, read the Pre-Starting Check List, Special OperatingInstructions, and Engine Break-in in the Operation section.

CAUTIONNever start or run your outboard (even momentarily) without watercirculating through all the cooling water intake holes in the gearcase toprevent damage to the water pump (running dry) or overheating of theengine.

OPERATION

1. Open the fuel tank vent screw (in the filler cap) on manual venting typefuel tanks.

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2. Squeeze the fuel line primer bulb several times until it feels firm.

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3. Set the lanyard stop switch to the "RUN" position. Refer to GeneralInformation - Lanyard Stop Switch.

4. Shift outboard to neutral (N) position.5. Move the neutral fast idle speed feature to the fully closed position (if

applicable).

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a - Fully closed position b - Maximum fast idle speedposition

Starting Flooded Engine - Advance the neutral fast idle speed featureto the maximum fast idle speed position and continue to crank theengine for starting. Immediately reduce engine speed after the enginestarts.

6. Flip the ignition switch to "ON."

OPERATION

NOTE: The red pilot light illuminates when the harness is energized andready to start the engine, or if the engine goes into Guardian mode. Sincethis system does not include a warning horn, the pilot light acts as a visiblewarning system.

START ON

a - Ignition moduleb - lanyard switchc - Ignition/warning pilot light

d - Ignition switche - Start switch

7. Depress the start switch to "START."8. After the engine starts, check for a steady stream of water flowing out

of the water pump indicator hole.

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IMPORTANT: If no water is coming out of the water pump indicator hole,stop the engine and check the cooling water intake for obstruction. Noobstruction may indicate a water pump failure or blockage in the coolingsystem. These conditions will cause the engine to overheat. Have theoutboard checked by your dealer. Operating the engine while overheatedwill cause engine damage.

OPERATION

WARMING UP THE ENGINEBefore beginning operation, allow the engine to warm up at idling speedfor 3 minutes.

Gear ShiftingIMPORTANT: Observe the following:• Never shift the outboard into gear unless engine speed is at idle.• Do not shift the outboard into reverse when the engine is not running.• Your outboard has three gear shift positions to provide operation:

Forward (F), Neutral (out of gear), and Reverse (R).

• When shifting, always stop at neutral position and allow the enginespeed to return to idle.

• Always shift the outboard into gear with a quick motion.• After shifting the outboard into gear, advance the remote control lever

to increase speed.

Stopping the EngineTo stop the engine, flip the ignition switch to "OFF."

Emergency StartingIf the starter system fails, use the spare starter rope (provided) and followthis procedure.1. Remove the flywheel cover or manual starter assembly.

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OPERATION

2. Shift the outboard to neutral (N) position.

WARNINGWhen using emergency starter rope to start engine, the start in gearprotection device is inoperative. Make sure to set the outboard gearshift into neutral to prevent outboard from starting in gear. Suddenunexpected acceleration could result in serious injury or death.

3. Turn the ignition switch to the "ON" position.

WARNINGTo prevent getting an electrical shock, DO NOT touch any ignitioncomponent, wiring, or spark plug wire when starting or running theengine.

WARNINGThe exposed moving flywheel can cause serious injury. Keep yourhands, hair, clothing, tools, and other objects away from enginewhen starting or running the engine. Do not attempt to reinstall theflywheel cover or top cowl when engine is running.

4. Place the starter rope knot into the flywheel notch and wind the ropeclockwise around the flywheel.

5. Pull the starter rope to start the engine.

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MAINTENANCE

Outboard CareTo keep your outboard in the best operating condition, it is important thatyour outboard receive the periodic inspections and maintenance listed inthe Inspection and Maintenance Schedule. We urge you to keep itmaintained properly to ensure the safety of you and your passengers, andretain its dependability.

WARNINGNeglected inspection and maintenance service of your outboard orattempting to perform maintenance or repair on your outboard if you arenot familiar with the correct service and safety procedures could causepersonal injury, death, or product failure.

Record maintenance performed in Maintenance Log at the back of thisbook. Save all maintenance work orders and receipts.SELECTING REPLACEMENT PARTS FOR YOUROUTBOARDWe recommend using original Mercury Precision or Quicksilverreplacement parts and Genuine Lubricants.

WARNINGUsing a replacement part that is inferior to the original part could resultin personal injury, death, or product failure.

EPA Emissions RegulationsAll new outboards manufactured by Mercury Marine are certified to theUnited States Environmental Protection Agency, as conforming to therequirements of the regulations for the control of air pollution from newoutboard motors. This certification is contingent on certain adjustmentsbeing set to factory standards. For this reason, the factory procedure forservicing the product must be strictly followed and, wherever practicable,returned to the original intent of the design. Maintenance, replacement, orrepair of the emission control devices and systems may be performed byany marine spark ignition (SI) engine repair establishment or individual.

MAINTENANCE

EMISSION CERTIFICATION LABELAn emission certification label, showing emission levels and enginespecifications directly related to emissions, is placed on the engine at timeof manufacture.

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a - Idle speedb - Engine horsepowerc - Piston displacementd - Date of manufacturee - Valve clearance (if

applicable)

f - Family numberg - Maximum emission output for

the engine familyh - Timing specificationi - Recommended spark plug

and gap

OWNER RESPONSIBILITYThe owner/operator is required to have routine engine maintenanceperformed to maintain emission levels within prescribed certificationstandards.The owner/operator is not to modify the engine in any manner that wouldalter the horsepower or allow emissions levels to exceed theirpredetermined factory specifications.

Inspection And Maintenance ScheduleBEFORE EACH USE• Check engine oil level. See Fuel & Oil - Checking and Adding Engine

Oil.• Check that lanyard stop switch stops the engine.• Visually inspect the fuel system for deterioration or leaks.• Check outboard for tightness on transom.• Check steering system for binding or loose components.

MAINTENANCE

• Visually check steering link rod fasteners for proper tightness. SeeSteering Link Rod Fasteners.

• Check propeller blades for damage.AFTER EACH USE• Flush out the outboard cooling system if operating in salt or polluted

water. See Flushing the Cooling System.• Wash off all salt deposits and flush out the exhaust outlet of the

propeller and gearcase with fresh water if operating in salt water.EVERY 100 HOURS OF USE OR ONCE YEARLY,WHICHEVER OCCURS FIRST• Lubricate all lubrication points. Lubricate more frequently when used in

salt water. See Lubrication Points.• Change engine oil and replace the oil filter. The oil should be changed

more often when the engine is operated under adverse conditionssuch as extended trolling. See Changing Engine Oil.

• Replace spark plugs at first 100 hours or first year. After that, inspectspark plugs every 100 hours or once yearly. Replace spark plugs asneeded. See Spark Plug Inspection and Replacement.

• Inspect thermostat visually for corrosion and broken spring. Make surethermostat closes completely at room temperature.1.

• Check engine fuel filter for contaminants. See Fuel System.• Check engine timing setup.1.

• Check corrosion control anodes. Check more frequently when used insalt water. See Corrosion Control Anodes.

• Drain and replace gear case lubricant. See Gearcase Lubrication.• Lubricate splines on the drive shaft.1.

• Check and adjust valve clearance, if necessary.1.

• Check power trim fluid. See Checking Power Trim Fluid.• Inspect battery. See Battery Inspection.• Check control cable adjustments.1.

• Inspect timing belt. See Timing Belt Inspection.• Check tightness of bolts, nuts, and other fasteners.EVERY 300 HOURS OF USE OR THREE YEARS• Replace water pump impeller (more often if overheating occurs or

reduced water pressure is noted).1.

1. These items should be serviced by an authorized dealer.

MAINTENANCE

BEFORE PERIODS OF STORAGE• Refer to Storage procedure. See Storage section.

Flushing The Cooling SystemFlush the internal water passages of the outboard with fresh water aftereach use in salt, polluted, or muddy water. This will help prevent a buildupof deposits from clogging the internal water passages.IMPORTANT: The engine must be run during flushing in order to openthe thermostat and circulate water through the water passages.

WARNINGTo avoid possible injury when flushing, remove the propeller. Refer toPropeller Replacement, following.

1. Place the outboard in either the operating position (vertical) or in atilted position.

2. Remove propeller. Refer to Propeller Replacement.3. Thread a water hose into the rear fitting. Partially open the water tap

(1/2 maximum). Do not open the water tap all the way, as this allows ahigh pressure flow of water.

IMPORTANT: Do not run engine above idle when flushing.4. Shift outboard into neutral. Start the engine and flush the cooling

system for at least 5 minutes. Keep engine speed at idle.5. Stop the engine. Turn off the water and remove hose. Reinstall the

propeller.

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MAINTENANCE

Top Cowl Removal And InstallationREMOVAL1. Unlock the rear latch by pushing lever down.

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2. Lift rear of cowl and disengage front hook.

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INSTALLATION1. Engage the front hook and push cowl back over the cowl seal.2. Push cowl down and move the rear latch lever up to lock.

Exterior CareYour outboard is protected with a durable baked enamel finish. Clean andwax often using marine cleaners and waxes.

Battery InspectionThe battery should be inspected at periodic intervals to ensure properengine starting capability.IMPORTANT: Read the safety and maintenance instructions whichaccompany your battery.1. Turn off the engine before servicing the battery.2. Add water as necessary to keep the battery full.3. Make sure the battery is secure against movement.4. Battery cable terminals should be clean, tight, and correctly installed.

Positive to positive and negative to negative.5. Make sure the battery is equipped with a nonconductive shield to

prevent accidental shorting of battery terminals.

MAINTENANCE

Fuel System WARNING

Avoid serious injury or death from gasoline fire or explosion. Carefullyfollow all fuel system service instructions. Always stop the engine and donot smoke or allow open flames or sparks in the area while servicingany part of the fuel system.

Before servicing any part of the fuel system, stop engine and disconnectthe battery. Drain the fuel system completely. Use an approved containerto collect and store fuel. Wipe up any spillage immediately. Material usedto contain spillage must be disposed of in an approved receptacle. Anyfuel system service must be performed in a well ventilated area. Inspectany completed service work for sign of fuel leakage.FUEL LINE INSPECTIONVisually inspect the fuel line and primer bulb for cracks, swelling, leaks,hardness, or other signs of deterioration or damage. If any of theseconditions are found, the fuel line or primer bulb must be replaced.ENGINE FUEL FILTERCheck the fuel filter for water accumulation or sediment. If water is in thefuel, remove the sight bowl and drain the water. If the filter appears to becontaminated, remove and replace.REMOVAL1. Read Fuel System servicing information and Warning proceeding.2. Pull out the filter assembly from mount. Hold onto the cover to prevent

it from turning and remove the sight bowl. Empty contents into anapproved container.

MAINTENANCE

3. Pull out the filter element and replace it if necessary.

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a - Coverb - Filter element

c - O-ring seald - Sight bowl

INSTALLATIONIMPORTANT: Visually inspect for fuel leakage from the filter bysqueezing the primer bulb until firm, forcing fuel into the filter.1. Push the filter element into the cover.2. Place the O-ring seal into its proper position on the sight bowl, and

screw the sight bowl hand tight into the cover.3. Push filter assembly back into mount.

Corrosion Control AnodeYour outboard has corrosion control anodes at different locations. Ananode helps protect the outboard against galvanic corrosion by sacrificingits metal to be slowly corroded instead of the outboard metals.Each anode requires periodic inspection, especially in salt water whichwill accelerate the erosion. To maintain this corrosion protection, alwaysreplace the anode before it is completely eroded. Never paint or apply aprotective coating on the anode as this will reduce effectiveness of theanode.

MAINTENANCE

This model has two anodes. One is installed on the bottom of the transombracket assembly. The other is the trim tab.

a - Anode on transom bracketassembly

b - Trim tab anode

Propeller Replacement WARNING

If the propeller shaft is rotated while the engine is in gear, there is thepossibility that the engine will crank over and start. To prevent this typeof accidental engine starting and possible serious injury caused frombeing struck by a rotating propeller, always shift outboard to neutralposition and remove spark plug leads when you are servicing thepropeller.

1. Shift outboard to neutral (N) position.

2. Remove the spark plug leads to prevent engine from starting.

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MAINTENANCE

3. Straighten the bent tabs on the propeller nut retainer.

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4. Place a block of wood between gearcase and propeller to holdpropeller and remove propeller nut.

5. Pull propeller straight off shaft. If propeller is seized to the shaft andcannot be removed, have the propeller removed by an authorizeddealer.

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6. Coat the propeller shaft with Quicksilver or Mercury PrecisionLubricants Anti-Corrosion Grease or 2-4-C with Teflon.

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IMPORTANT: To prevent the propeller hub from corroding and seizing tothe propeller shaft (especially in salt water), always apply a coat of therecommended lubricant to the entire propeller shaft at the recommendedmaintenance intervals, and also each time the propeller is removed.

MAINTENANCE

7. Install the forward thrust hub, propeller, propeller nut retainer, andpropeller nut onto the shaft.

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a - Propeller nutb - Propeller nut retainer

c - Propellerd - Forward thrust hub

8. Place the propeller nut retainer over the pins. Place a block of woodbetween the gearcase and propeller and tighten the propeller nut tothe specified value.

Propeller Nut 75 55

9. Align the flat sides of the propeller nut with the tabs on the propellernut retainer.

10. Secure the propeller nut by bending the tabs up and against the flatson the propeller nut.

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a - Pins b - Tabs

11. Reinstall the spark plug leads.

MAINTENANCE

Spark Plug Inspection And Replacement WARNING

Avoid serious injury or death from fire or explosion caused by damagedspark plug boots. Damaged spark plug boots can emit sparks. Sparkscan ignite fuel vapors under the engine cowl. To avoid damaging sparkplug boots, do not use any sharp object or metal tool such as pliers,screwdriver, etc. to remove spark plug boots.

1. Remove the spark plug leads. Twist the rubber boots slightly and pulloff.

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2. Remove the spark plugs to inspect. Replace spark plug if electrode isworn or the insulator is rough, cracked, broken, blistered or fouled.

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3. Set the spark plug gap. See General Information - Specifications.

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4. Before installing spark plugs, clean off any dirt on the spark plugseats. Install plugs finger tight, and then tighten 1/4 turn or torque tospecifications.

Spark plug 27 20

MAINTENANCE

Fuse ReplacementIMPORTANT: Always carry spare 20 AMP fuses.The electrical wiring circuits on the outboard are protected from overloadby fuses in the wiring. If a fuse is blown, try to locate and correct the causeof the overload. If the cause is not found, the fuse may blow again.Open the fuse holder and look at the silver colored band inside the fuse. Ifband is broken, replace the fuse. Replace fuse with a new fuse with thesame rating.

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a - SmartCraft data bus circuit - 15 AMP fuseb - Fuel pump/idle air control/fuel injector circuits - SFE 20 AMP

fusec - Main relay/accessories - 20 AMP fused - Ignition coil circuit - 20 AMP fusee - Spare 20 AMP fusef - Good fuseg - Blown fuse

Timing Belt Inspection1. Inspect the timing belt and have it replaced by an authorized dealer if

any of the following conditions are found.a. Cracks in the back of the belt or in the base of the belt teeth.b. Excessive wear at the roots of the cogs.c. Rubber portion swollen by oil.

MAINTENANCE

d. Belt surfaces roughened.e. Signs of wear on edges or outer surfaces of belt.

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Lubrication Points1. Lubricate the following with Quicksilver or Mercury Precision

Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.• Propeller Shaft - Refer to Propeller Replacement for removal and

installation of the propeller. Coat the entire propeller shaft withlubricant to prevent the propeller hub from corroding and seizing tothe shaft.

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2. Lubricate the following with Quicksilver or Mercury PrecisionLubricants 2-4-C with Teflon or Special Lubricant 101.• Tilt Support Lever - Lubricate through fitting.

MAINTENANCE

• Swivel Bracket - Lubricate through fitting.

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a - Tilt support lever b - Swivel bracket

• Tilt Tube - Lubricate through fitting.

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WARNINGThe end of the steering cable must be fully retracted into theoutboard tilt tube before adding lubricant. Adding lubricant tosteering cable when fully extended could cause steering cable tobecome hydraulically locked. A hydraulically locked steeringcable will cause loss of steering control, possibly resulting inserious injury or death.

• Steering Cable Grease Fitting (If equipped) - Rotate steeringwheel to fully retract the steering cable end into the outboard tilttube. Lubricate through fitting.

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a - Fitting b - Steering cable end

MAINTENANCE

3. Lubricate the following with light weight oil.• Steering Link Rod Pivot Points - Lubricate points.

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Checking Power Trim Fluid1. Tilt outboard to the full up position and engage the tilt support lock.

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2. Remove fill cap and check fluid level. The fluid level should be evenwith the bottom of the fill hole. Add Quicksilver or Mercury PrecisionLubricants Power Trim & Steering Fluid. If not available, useautomotive (ATF) automatic transmission fluid.

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Changing Engine OilCHANGING THE OIL1. Tilt the outboard up to the trailer position.

MAINTENANCE

2. Turn the steering on the outboard so that the drain hole is facingdownward. Remove drain plug and drain engine oil into an appropriatecontainer. Lubricate the seal on the drain plug with oil and reinstall.

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CHANGING THE OIL FILTER1. Place a rag or towel below the oil filter to absorb any spilled oil.2. Unscrew old filter by turning the filter to the left.3. Clean the mounting base. Apply film of clean oil to filter gasket. Do

not use grease. Screw new filter on until gasket contacts base, thentighten 3/4 to 1 turn.

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FILLING THE SYSTEM1. Remove the oil fill cap and add oil to proper operating level.

MAINTENANCE

2. Idle engine for five minutes and check for leaks. Stop engine andcheck oil level on dipstick. Add oil if necessary.

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a - Oil fill cap

Gearcase Lubrication - For 87.3 mm (3-7/16 in.)Diameter GearcaseWhen adding or changing gearcase lubricant, visually check for thepresence of water in the lubricant. If water is present, it may have settledto the bottom and will drain out prior to the lubricant, or it may be mixedwith the lubricant, giving it a milky colored appearance. If water is noticed,have the gearcase checked by your dealer. Water in the lubricant mayresult in premature bearing failure or, in freezing temperatures, will turn toice and damage the gearcase.Examine the drained gearcase lubricant for metal particles. A smallamount of fine metal particles indicates normal gear wear. An excessiveamount of metal filings or larger particles (chips) may indicate abnormalgear wear and should be checked by an authorized dealer.DRAINING GEARCASE1. Place outboard in a vertical operating position.2. Place a drain pan below outboard.

MAINTENANCE

3. Remove vent plug and fill/drain plug and drain lubricant.

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a - Drain panb - Vent plug

c - Fill/drain plug

GEARCASE LUBRICANT CAPACITYGearcase lubricant capacity is approximately 340 ml (11.5 fl. oz.).CHECKING GEARCASE LUBRICANT LEVEL AND REFILLINGGEARCASE1. Place outboard in a vertical operating position.2. Remove vent plug.3. Place lubricant tube into the fill hole and add lubricant until it appears

at the vent hole.IMPORTANT: Replace sealing washers if damaged.4. Stop adding lubricant. Install the vent plug and sealing washer before

removing the lubricant tube.

MAINTENANCE

5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealingwasher.

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a - Vent holeb - Vent plug

c - Fill/drain plug

Submerged OutboardA submerged outboard will require service within a few hours by anauthorized dealer once the outboard is recovered from the water. Thisimmediate attention by a servicing dealer is necessary once the engine isexposed to the atmosphere to minimize internal corrosion damage to theengine.

STORAGE

Storage PreparationThe major consideration in preparing your outboard for storage is toprotect it from rust, corrosion, and damage caused by freezing of trappedwater.The following storage procedures should be followed to prepare youroutboard for out of season storage or prolonged storage (two months orlonger).

CAUTIONNever start or run your outboard (even momentarily) without watercirculating through the cooling water intake in the gearcase to preventdamage to the water pump (running dry) or overheating of the engine.

FUEL SYSTEMIMPORTANT: Gasoline containing alcohol (ethanol or methanol) cancause a formation of acid during storage and can damage the fuelsystem. If the gasoline being used contains alcohol, it is advisable to drainas much of the remaining gasoline as possible from the fuel tank, remotefuel line, and engine fuel system.Fill the fuel tank and engine fuel system with treated (stabilized) fuel tohelp prevent formation of varnish and gum. Proceed with followinginstructions.• Portable Fuel Tank - Pour the required amount of gasoline stabilizer

(follow instructions on container) into fuel tank. Tip fuel tank back andforth to mix stabilizer with the fuel.

• Permanently Installed Fuel Tank - Pour the required amount ofgasoline stabilizer (follow instructions on container) into a separatecontainer and mix with approximately one quart (one liter) of gasoline.Pour this mixture into fuel tank.

• Remove the fuel filter sight bowl and empty contents in a suitablecontainer. Refer to Maintenance- Fuel System for removal andinstallation of filter. Add 3 cc (1/2 tsp.) of gasoline stabilizer into thefuel filter sight bowl and reinstall.

• Place the outboard in water or connect flushing attachment forcirculating cooling water. Run the engine for 15 minutes to fill theengine fuel system.

Protecting External Outboard Components• Lubricate all outboard components listed in Maintenance - Inspection

and Maintenance Schedule.

STORAGE

• Touch up any paint nicks. See your dealer for touch-up paint.• Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on

external metal surfaces (except corrosion control anodes).

Protecting Internal Engine Components• Remove the spark plugs and inject a small amount of engine oil inside

of each cylinder.• Rotate the flywheel manually several times to distribute the oil in the

cylinders. Reinstall spark plugs.• Change the engine oil.

Gearcase• Drain and refill the gearcase lubricant (refer to Maintenance -

Gearcase Lubrication).

Positioning Outboard For StorageStore outboard in an upright (vertical) position to allow water to drain outof outboard.

CAUTIONIf outboard is stored tilted up in freezing temperature, trapped coolingwater or rain water that may have entered the propeller exhaust outlet inthe gearcase could freeze and cause damage to the outboard.

Battery Storage• Follow the battery manufacturer's instructions for storage and

recharging.• Remove the battery from the boat and check water level. Recharge if

necessary.• Store the battery in a cool, dry place.• Periodically check the water level and recharge the battery during

storage.

TROUBLESHOOTING

Starter Motor Will Not Crank The EnginePOSSIBLE CAUSES• Open 20 Amp fuse in or main power relay/accessories circuit. Refer to

Maintenance section.• Outboard is not shifted to neutral position.• Weak battery or battery connections are loose or corroded.• Ignition key switch failure.• Wiring or electrical connection faulty.• Starter motor or starter solenoid failure.

Engine Will Not StartPOSSIBLE CAUSES• Lanyard stop switch not in "RUN" position.• Incorrect starting procedure. Refer to Operation section.• Old or contaminated gasoline.• Engine flooded. Refer to Operation section.• Fuel is not reaching the engine.• Fuel tank is empty.• Fuel tank vent not open or restricted.• Fuel line is disconnected or kinked.• Primer bulb not squeezed.• Primer bulb check valve is faulty.• Fuel filter is obstructed. Refer to Maintenance section.• Fuel pump failure.• Fuel tank filter obstructed.

• Open 20 Amp fuse. Refer to Maintenance section.• Ignition system component failure.• Wiring or electrical connection faulty.• Spark plugs fouled or defective. Refer to Maintenance section.

Engine Runs ErraticallyPOSSIBLE CAUSES• Low oil pressure. Check oil level.• Spark plugs fouled or defective. Refer to Maintenance section.• Incorrect setup and adjustments.

TROUBLESHOOTING

• Fuel is being restricted to the engine.a. Engine fuel filter is obstructed. Refer to Maintenance section.b. Fuel tank filter obstructed.c. Stuck anti-siphon valve located on permanently built-in type fuel

tanks.d. Fuel line is kinked or pinched.

• Fuel pump failure.• Ignition system component failure.• Fuel injection component failure.

Performance LossPOSSIBLE CAUSES• Low oil pressure. Check oil level.• Throttle not fully open.• Damaged or improper size propeller.• Incorrect engine timing, adjustments, or setup.• Boat overloaded or load improperly distributed.• Excessive water in bilge.• Boat bottom is dirty or damaged.

Battery Will Not Hold ChargePOSSIBLE 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.

OWNER SERVICE ASSISTANCE

Local Repair ServiceAlways return your outboard to your local authorized dealer should theneed for service arise. Only he has the factory trained mechanics,knowledge, special tools, equipment, and genuine parts and accessoriesto properly service your engine should the need occur. He knows yourengine best.

Service Away From HomeIf you are away from your local dealer and the need arises for service,contact the nearest authorized dealer. Refer to the Yellow Pages of thetelephone directory. If, for any reason, you cannot obtain service, contactthe nearest Mercury Marine Service Office.

Parts And Accessories InquiriesAll inquiries concerning genuine replacement parts and accessoriesshould be directed to your local authorized dealer. The dealer has thenecessary information to order parts and accessories for you. Wheninquiring on parts and accessories, the dealer requires the model andserial number to order the correct parts.

Service AssistanceYour satisfaction with your outboard product is very important to yourdealer and to us. If you ever have a problem, question or concern aboutyour outboard product, contact your dealer or any authorized MercuryMarine dealership. If additional assistance is required, take these steps.1. Talk with the dealership's sales manager or service manager. If this

has already been done, then contact the owner of the dealership.2. Should you have a question, concern, or problem that cannot be

resolved by your dealership, please contact Mercury Marine ServiceOffice for assistance. Mercury Marine will work with you and yourdealership to resolve all problems.

The following information will be needed by the service office:• Your name and address• Daytime telephone number• Model and serial number of your outboard• The name and address of your dealership• Nature of problem

Mercury Marine Service OfficesFor assistance, call, fax, or write. Please include your daytime telephonenumber with mail and fax correspondence.

United States

Telephone Fax Mercury MarineW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939

(920) 929-5040 (920) 929-5893

United States (Mercury Racing)

Telephone Fax Mercury RacingN7480 County Rd. UUFond du Lac, WI 54935-9585(920) 924-2088 (920) 924-2096

Canada

Telephone Fax Mercury Marine Ltd.2395 Meadowpine Blvd.Mississauga, Ontario L5N 7W6Canada

(905) 567-6372 (905) 567-8515

Australia, Pacific

Telephone Fax Mercury Marine Australia132-140 Frankston RoadDandenong, Victoria 3164Australia

(61) (3) 9791-5822 (61) (3) 9793-5880

Europe, Middle East, Africa

Telephone Fax Marine Power - Europe,Inc.Parc Industriel de Petit-Rechain B-4800Verviers,Belgium

(32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65

Mexico, Central America, South America, Caribbean

Telephone Fax Mercury Marine11650 Interchange Circle NorthMiramar, FL 33025U.S.A.

(954) 744-3513 (954) 744-3535

Telephone Fax Mercury Marine - Japan283-1 Anshin-cho HamamatsuShizuoka, 435-0005Japan

81-53-423-2500 81-53-423-2510

Asia, Singapore

Telephone Fax Mercury Marine Singapore72 Loyang WaySingapore, 5087625466160 5467789

Ordering LiteratureBefore ordering literature, please have the following information aboutyour power package available:

EngineModel: Horsepower:

SerialNumber: Model year:

UNITED STATES AND CANADAFor information on additional literature that is available for your particularMercury/MerCruiser power package and how to order that literaturecontact your nearest dealer or contact:

MERCURY MARINE

Telephone Fax Mail

(920)929-5110

(920)929-4894

Mercury MarineAttn: Publications Department

P.O. Box 1939Fond du Lac, WI 54936-1939 ,

OUTSIDE THE UNITED STATES AND CANADAContact your nearest dealer or Marine Power Service Center forinformation on additional literature that is available for your particularMercury/MerCruiser power package and how to order that literature.

MAINTENANCE LOG

Maintenance LogRecord all maintenance performed on your outboard here. Be sure to saveall work orders and receipts.

Date Maintenance Performed Engine Hours

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