Mercury 25 Jet Fourstroke (2014) manual

eng i Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Tohatsu Marine Corporation (TMC) Mercury Marine Joint Venture Address: Shimodaira 4495‑9 Town: Komagane‑City, Nagano Post Code: 399‑4101 Country: Japan Name of authoriz[...]

ii eng Identification of Engines Covered by This Declaration of Conformity Name of engine model or engine family Starting serial number EC Type–examination certificate or type–approval certificate number 2.5, 3.5 hp 0R098000 SB5 09 01 57840 033 4, 5, 6 hp 0R098000 SB5 11 04 57840 037 15, 20 hp 0R235168 SB5 07 12 57840 027 25, 30 hp EFI 0R098000[...]

eng iii Name / function: Mark D. Schwabero, President, Mercury Marine Date and place of issue: September 04, 2012 Fond du Lac, Wisconsin, USA Welcome You have selected one of the finest outboards available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will enjoy using this p[...]

iv eng Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine. The terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, i[...]

eng v WARRANTY INFORMATION Warranty Registration United States and Canada.............................................. 1 Transfer of Warranty United States and Canada................................................ 1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada....................................[...]

vi eng Fuel and Oil Fuel Recommendations.................................................................................... 37 Low Permeation Fuel Hose Requirement ........................................................ 38 EPA Pressurized Portable Fuel Tank Requirements........................................ 38 Fuel Demand Valve (FDV) Requiremen[...]

eng vii Maintenance Outboard Care.................................................................................................. 69 EPA Emission Regulations............................................................................... 69 Inspection and Maintenance Schedule............................................................. 70 Top Cowl[...]

viii eng Owner Service Assistance Local Repair Service......................................................................................... 94 Service Away from Home................................................................................. 94 Parts and Accessories Inquiries.................................................................[...]

WARRANTY INFORMATION eng 1 Warranty Registration United States and Canada To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, e‑mail, or mail. Upon receipt of this warrant[...]

WARRANTY INFORMATION 2 eng Upon processing the transfer of warranty, Mercury Marine will record the new owner's information. There is no charge for this service. OUTSIDE THE UNITED STATES AND CANADA For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest t[...]

WARRANTY INFORMATION eng 3 CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage 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 specified predelivery inspection pro[...]

WARRANTY INFORMATION 4 eng Corrosion damage caused by stray electrical currents (onshore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolato[...]

WARRANTY INFORMATION eng 5 Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us. Should you have any questions concerning warranty coverage, contact your authorized dealer. They will be pleased to answer any questions that you may have. GENERAL EX[...]

WARRANTY INFORMATION 6 eng 13. Water entering engine through the fuel intake, air intake, or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high, or trimmed too far out. 15. Use of fuels and lubrica[...]

WARRANTY INFORMATION eng 7 a. Oil pump and internal parts b. Oil injectors c. Oil meter 5. Exhaust system a. Exhaust manifold b. Exhaust valves 6. Miscellaneous items used in above systems a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensit[...]

WARRANTY INFORMATION 8 eng DURATION OF COVERAGE: This limited warranty provides coverage for the components of the emissions control systems of new, 2001 model year and later outboards, sold to retail customers in California for four (4) years from either the date the product is first sold, or first put into service, whichever occurs first, or the [...]

WARRANTY INFORMATION eng 9 Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of [...]

WARRANTY INFORMATION 10 eng Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor. MANUFACTURER'S WARRANTY COVERAGE: Select emission control parts from model year 2001 and later outboard engines are warranted for four (4) years, or for 250 hours of use, wh[...]

WARRANTY INFORMATION eng 11 42537 Two Stars ‑ Very Low Emission The Two Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards. Engines meeting these standards have 20% lower emissions than One Star ‑ Low Emission engines. 42538 Three Stars ‑ Ultra[...]

WARRANTY INFORMATION 12 eng Guarantees Under Australian Consumer Law Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or repla[...]

WARRANTY INFORMATION eng 13 How to Obtain Warranty Coverage Under This Limited Warranty The customer must provide Mercury Marine 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 th[...]

WARRANTY INFORMATION 14 eng No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional info[...]

WARRANTY INFORMATION eng 15 You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department. Global Warranty Charts Outboard and Jets UNITED [...]

WARRANTY INFORMATION 16 eng Product Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax Jet drive (200 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 (350 SCi) 2 years 3 years Outs[...]

WARRANTY INFORMATION eng 17 ASIA WARRANTY CHARTS–OUTBOARD 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 1 year 3 years OptiMax 1 year 3 years Verado 1 year 3 years Racing Product (R[...]

WARRANTY INFORMATION 18 eng Racing Product (Recreational only) Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application Verado 350 SCi 2 years 3 years Contact the Marine Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your cou[...]

WARRANTY INFORMATION eng 19 SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Product (Recreational only) Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2‑Stroke 2 years 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 (i[...]

GENERAL INFORMATION 20 eng Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard. Be sure that at least one additional per[...]

GENERAL INFORMATION eng 21 Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S. COAST GUARD CAP ACITY MAXIMUM HORSEPOWER XXX MAXIM[...]

GENERAL INFORMATION 22 eng Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage. ! WARNING Improper fasten[...]

GENERAL INFORMATION eng 23 The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likeli[...]

GENERAL INFORMATION 24 eng We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (if the operator is accidentally ejected). ! WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious inj[...]

GENERAL INFORMATION eng 25 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution when boating in an area where there might be people in the wat[...]

GENERAL INFORMATION 26 eng Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water. 26784 The primary concern is th[...]

GENERAL INFORMATION eng 27 ! WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. If an obstacle is struck at planing speed and the outboard [...]

GENERAL INFORMATION 28 eng Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (plat[...]

GENERAL INFORMATION eng 29 2. Examples of poor ventilation while the boat is moving: a - Operating the boat with the trim angle of the bow too high b - Operating the boat with no forward hatches open (station wagon effect) Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed an[...]

GENERAL INFORMATION 30 eng Anchor and extra anchor line Manual bilge pump and extra drain plugs Drinking water Radio Paddle or oar Spare propeller, thrust hubs, and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment, batteries, bulbs, and fuses Compass and map or chart of the area Personal f[...]

GENERAL INFORMATION eng 31 • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpecte[...]

GENERAL INFORMATION 32 eng Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. a - Serial number b - Model designation c - Year manufactured d - Certified Europe Insignia (as applicable) Specifications Models 25 Power 18.4 kw (25 hp) Full throttle RPM range 5000?[...]

GENERAL INFORMATION eng 33 Models 25 Recommended lubricant for the jet pump driveshaft bearing Refer to Maintenance Engine oil capacity 1.8 liter (1.9 US qt) Battery rating 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA) Emission control system Electronic engine control (EC)[...]

GENERAL INFORMATION 34 eng Component Identification TILLER HANDLE/GAS ASSIST MODEL a - Top cowl b - Manual start handle c - Engine stop switch d - Throttle friction adjustment knob e - Gear shift f - Tilt support lever g - Gas tilt assist lever h - Jet drive housing i - Water intake housing j - Reverse gate k - Water outlet housing l - Chaps m - Wa[...]

GENERAL INFORMATION eng 35 p - Electric start button (electric start models) q - Lanyard stop switch r - Steering friction adjustment lever POWER TRIM/REMOTE CONTROL MODEL a - Transom brackets b - Tilt support lever c - Top cowl d - Cowl latch e - Bottom cowl f - Auxiliary tilt switch g - Chaps h - Water outlet housing i - Reverse gate j - Water in[...]

TRANSPORTING 36 eng Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. 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 trailerin[...]

FUEL AND OIL eng 37 Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a majo[...]

FUEL AND OIL 38 eng ! WARNING Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation. Because of [...]

FUEL AND OIL eng 39 The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve. a - Fuel demand valve ‑ installed in the fuel hose between the fuel tank and primer bulb b - Manual release c - Vent/water drain holes Mercury Marine's Pressurized Port[...]

FUEL AND OIL 40 eng 1. Open the manual vent screw on top of the fuel cap. 2. Turn the fuel cap until it contacts the tab lock. 3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure. 4. Press down on the tab lock again and remove the cap. DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. When installing the fue[...]

FUEL AND OIL eng 41 IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended. Recommended SAE viscosity for engine oil a - Mercury or Quicksilver SAE 25[...]

FUEL AND OIL 42 eng 2. Pull out the dipstick. Wipe it with a clean rag or towel and push it back in all the way. a - Full mark b - Add mark c - Dipstick d - Oil fill cap 3. Pull the dipstick back out again and observe the oil level. Oil must be between full mark and add mark. If the oil level is low, remove the oil fill cap and fill to (but not ove[...]

FEATURES AND CONTROLS eng 43 Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. a - Control handle – forward, neutral, reverse b - Neutral release lever c - Trim/tilt switch (i[...]

FEATURES AND CONTROLS 44 eng ! WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment, maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released. a - Tighten friction b - Loosen [...]

FEATURES AND CONTROLS eng 45 • Tiller handle ‑ The tiller handle can be tilted 180° for convenient handling during transportation and storage. 28535 • Tiller lock release lever ‑ Push the lever to move the tiller handle from one position to another. a - Tilt lock release lever a 3274[...]

FEATURES AND CONTROLS 46 eng • Tiller handle lock cap ‑ Remove the lock cap on top of the tiller handle to lock in the up position. Push the tiller lock release lever to release the handle from the locked up position. a - Lock cap b - Locking mechanism • Engine stop switch 28537 • Throttle grip friction knob ‑ Turn the friction knob to se[...]

FEATURES AND CONTROLS eng 47 • Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch . 19791 BASIC TILTING OPERATION Models equipped with a gas assisted tilt system allows the operator to lock the outboard at any tilt position from full down to full up. This tilt system is designed to be adjusted when the outboard is idling[...]

FEATURES AND CONTROLS 48 eng TILTING OUTBOARD TO FULL UP POSITION 1. Stop the engine. Move the lock lever to the free position. Take hold of the top cowl grip and raise the outboard to the full tilt up position. Lock the outboard in place by moving the lock lever to the lock position. 10284 2. Engage the tilt support lever. 3. Lower the outboard to[...]

FEATURES AND CONTROLS eng 49 Adjust the operating angle of the outboard so that the outboard runs perpendicular to the water when the boat is at full speed. Arrange passengers and load in the boat so the weight is distributed evenly. NOTE: The outboard should be locked against the tilt pin during operation by setting the tilt lock lever to the lock[...]

FEATURES AND CONTROLS 50 eng POWER TRIM OPERATION The power trim and tilt feature of the outboard is convenient for drifting and when operating at low throttle speed in very shallow water. When under power, do not trim out the outboard in an effort to gain speed as is done with a conventional propeller driven boat. When planing, the outboard should[...]

FEATURES AND CONTROLS eng 51 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. 9976 AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim syste[...]

FEATURES AND CONTROLS 52 eng WARNING LIGHT The warning light will turn on or flash to alert the operator to the warning system situations listed the the following chart. 15732 WARNING SYSTEM OPERATION The warning horn will emit either a continuous beep or intermittent short beeps and engine speed will be limited. This alerts the operator and helps [...]

FEATURES AND CONTROLS eng 53 ENGINE OVERHEAT If the engine overheats, immediately reduce throttle speed to idle. Shift the outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. 9647 If no water is coming out of the water pump indicator hole, or flow is intermittent; stop the engine and check the c[...]

FEATURES AND CONTROLS 54 eng When the engine overspeed limiter is activated, it will reduce ignition voltage to momentarily decrease the engine speed. Excessive overspeed (above 6300 RPM) results in cutout of the cylinders to prevent operation above this limit. Replaceable Jet Drive Shear Key The jet drive is equipped with a shear key to protect it[...]

OPERATION eng 55 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 m[...]

OPERATION 56 eng Operating in Shallow Water The life of the impeller and water intake can be greatly increased by avoiding the intake of sand and gravel. The intake suction will act like a dredge when the water intake comes close to the bottom. It is better to stop the engine and drift up to shore when landing, and to shove off with an oar when lea[...]

OPERATION eng 57 The driveshaft driven impeller draws water up through the water intake and then directs it at a high pressure through the water outlet nozzle to create forward thrust. To obtain reverse, the reverse gate moves over the outlet nozzle to direct the water in the opposite direction. a - Water intake b - Water outlet nozzle c - Reverse [...]

OPERATION 58 eng Stopping the Boat in an Emergency A jet powered boat has emergency stopping capability unique to this form of propulsion. ! WARNING Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat[...]

OPERATION eng 59 Mooring the Boat Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water. Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting. Water Intake Blockage ! WARNING A rotating impelle[...]

OPERATION 60 eng Pre‑Starting Instructions 1. Connect the remote fuel line to the outboard. Ensure the connector is snapped into place. 9600 2. Check the engine oil level. 9601 3. Ensure the driveshaft bearing on the jet drive is lubricated. Refer to Maintenance ‑ Lubrication Points . 29025[...]

OPERATION eng 61 4. Tiller handle models with manual or electric start, have a quick reference decal on the tiller handle that shows the sequence for starting the engine. 52396 Tiller handle starting sequence decal Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the[...]

OPERATION 62 eng 2. Squeeze the fuel line primer bulb several times until it feels firm. 19779 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after engine has warmed up. 3. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch . 19791 4. Shift the outboard to the neu[...]

OPERATION eng 63 7. After the engine starts, check for a steady stream of water flowing out of the water pump indicator hole. 9647 IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. [...]

OPERATION 64 eng 3. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch . 19791 4. Set the tiller handle grip to the neutral start position. START N ST ART N 24834 . 5. Set the gear shift to the neutral "N" position. R N F 24835 6. Position the tilt lock lever to the lock posit[...]

OPERATION eng 65 7. Manual starting models ‑ Pull the starter rope slowly until the starter engages, then pull rapidly to crank the engine. Allow the rope to return slowly. Repeat until the engine starts. 10173 8. Electric starting models ‑ Push the starter button and crank the engine. Release the button when the engine starts. Do not operate t[...]

OPERATION 66 eng Gear Shifting NOTE: The propeller continues to rotate while the engine is in neutral. Although the approximate balancing of forward and reverse thrust will minimize boat movement, the boat may tend to move slowly forward and backward. This is normal for a direct‑drive jet driven boat. The operator should be aware of this and use [...]

OPERATION eng 67 Stopping the Engine Reduce the engine speed and shift the outboard to neutral position. Push in the stop switch or move the lanyard stop switch to the "OFF" position. 26776 Emergency Starting If the starter system fails, the engine can be started using the spare starter rope (provided). Refer to the following procedure fo[...]

OPERATION 68 eng ! WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. 3. Electric start models ‑ Turn the ignition key to the "ON" position. 26846 ! WARNING High [...]

MAINTENANCE eng 69 Outboard Care To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule . We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. Reco[...]

MAINTENANCE 70 eng EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. a - Piston displacement b - Maximum emission output for the engine family c - Percent of fuel line permeation d - Timing specification e - F[...]

MAINTENANCE eng 71 • Make sure the driveshaft bearing on the jet drive is lubricated. See Lubrication Points . AFTER EACH USE AND AFTER EVERY 10 HOURS OF OPERATION • Lubricate the driveshaft bearing on the jet drive. See Lubrication Points . AFTER EACH USE • If operating in saltwater, wash off all salt deposits and flush out the exhaust outle[...]

MAINTENANCE 72 eng Top Cowl Removal and Installation REMOVAL 1. Unlock the rear latch by pulling lever up. 10190 2. Lift rear of cowl and disengage front hook. 10191 INSTALLATION 1. Lower the top cowl over the engine. Bring the front of the cowl down first and engage the front hook, then lower the cowl into its seated position with the bottom cowl.[...]

MAINTENANCE eng 73 • An increase in engine RPM at wide‑open throttle IMPORTANT: Do not sharpen or alter the top side lifting angle. Check the impeller blades occasionally for damage. Use a flat file to sharpen the leading edges. Sharpen to a 0.8 mm (1/32 in.) radius by removing material from bottom side only. a - Leading edge b - Top side lifti[...]

MAINTENANCE 74 eng Impeller Removal and Installation ! WARNING Rotating the driveshaft may cause the engine to crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating impeller, always turn the ignition key or lanyard stop switch to the "OFF" position and r[...]

MAINTENANCE eng 75 5. Straighten the bent tabs on the impeller nut retainer and remove the impeller nut. a - Tabs b - Impeller nut 6. Pull the impeller straight off the shaft. If the impeller is tight, use a hammer and a block of wood to rotate the impeller clockwise on the shaft until the keyway is directly above the flat on the shaft. This will f[...]

MAINTENANCE 76 eng 4. Temporarily install the water intake housing in order to check for impeller clearance. The clearance between the impeller and liner should be 0.8 mm (0.03 in.). Shim washers can be transferred to either side of the impeller to raise or lower the impeller to the correct clearance setting. The water intake housing can be shifted[...]

MAINTENANCE eng 77 6. Install the water intake housing with six bolts. Check clearance around the impeller to ensure the water intake housing is centered and not rubbing against the liner. Tighten the mounting bolts to the specified torque. 29081 Description Nm lb‑in. lb‑ft Water intake housing mounting bolts 13 120 – Shift Link Rod Adjustmen[...]

MAINTENANCE 78 eng 2. Adjust the length of the shift link rod so the roller is at the full end of travel (bottom) in the shift cam when the shift handle is in forward. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which ac[...]

MAINTENANCE eng 79 2. Loosen the hex nut and remove the filter assembly from the mount. Hold on to the cover to prevent it from turning and remove the sight bowl. Empty the contents into an approved container. 3. Inspect the filter element. If replacement is necessary, replace the filter assembly. a - Cover b - Filter element c - O‑ring seal d - [...]

MAINTENANCE 80 eng Assemble steering link rod to steering cable with flat washer and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with bolt, locknut, spacer, and flat washers. Tighten the locknut to the specified torque. a - Bolt (10‑898101018) b - Flat washer (12‑95392?[...]

MAINTENANCE eng 81 One anode is installed in the engine block. Remove the anode at the location shown. Fasten the anode to the cover with a bolt. Tighten the bolt to the specified torque. Install the cover with new gasket. Tighten the bolts to the specified torque. a - Cover b - Anode Description Nm lb. in. lb. ft. Anode bolt 8 71 Cover bolt (2) 8 [...]

MAINTENANCE 82 eng Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots. 1. Remove the [...]

MAINTENANCE eng 83 Fuse Replacement ‑ Electric Start Models IMPORTANT: Always carry spare SFE 20 amp fuses. The electric starting circuit is protected from overload by an SFE 20 amp fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may [...]

MAINTENANCE 84 eng • Signs of wear on edges or outer surfaces of belt. 9697 Lubrication Points 1. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref No. Description Where Used Part No. Extreme Grease Driveshaft bearing 8M0071842 95 2-4-C with PTFE Driveshaft bearing 92-802859A 1 • Driveshaft bearing IMPORTANT: It is im[...]

MAINTENANCE eng 85 NOTE: After 30 hours of operation, pump in extra grease to purge out any moisture. Visually inspecting the purged grease at this time will give an indication of conditions inside the bearing housing. A gradual increase in moisture content, indicates seal wear. If the grease begins to turn dark or dirty gray, the driveshaft bearin[...]

MAINTENANCE 86 eng • Lubricate the threads on the transom clamp screws (if equipped). 15914 • Steering cable grease fitting (If equipped) ‑ Rotate the steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. a - Fitting b - Steering cable end ! WARNING Incorrect cable lubrication can cause[...]

MAINTENANCE eng 87 Checking Power Trim Fluid 1. Tilt the outboard to the full up position and engage the tilt support lock. 9703 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use aut[...]

MAINTENANCE 88 eng 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove the drain plug and drain the engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and install. a - Drain plug CHANGING OIL FILTER 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unsc[...]

MAINTENANCE eng 89 2. Idle the engine for five minutes and check for leaks. Stop the engine and check oil level on the dipstick. Add oil if necessary. a - Oil fill cap Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a s[...]

STORAGE 90 eng Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without su[...]

STORAGE eng 91 • Rotate the flywheel manually several times to distribute the oil in the cylinders. Install the spark plugs. • Change the engine oil. Jet Drive • Pump extra grease into the jet drive bearing to purge out moisture. Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of t[...]

TROUBLESHOOTING 92 eng Starter Motor will not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Blown fuse in the starting 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 connect[...]

TROUBLESHOOTING eng 93 • Incorrect setup and adjustments. • 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. • Ignit[...]

OWNER SERVICE ASSISTANCE 94 eng Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Servic[...]

OWNER SERVICE ASSISTANCE eng 95 REPLACEMENT SERVICE PARTS ! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with the[...]

OWNER SERVICE ASSISTANCE 96 eng 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 W6250 Pione[...]

OWNER SERVICE ASSISTANCE eng 97 Ordering Literature 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 Telepho[...]

OWNER SERVICE ASSISTANCE 98 eng Quantity Item Stock Number Price Total . . Total Due .[...]

INSTALLATION eng 99 Installation Information BOAT HORSEPOWER CAPACITY ! WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating. Do not ov[...]

INSTALLATION 100 eng LOW PERMEATION FUEL HOSE REQUIREMENT Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to t[...]

INSTALLATION eng 101 Lifting Outboard Use the lifting eye located aft of the flywheel to support the engine when installing the outboard. 101 1 1 Determining the Mounting Height of the Outboard Jet The following outboard mounting height settings will work good for most applications, however, because of different boat/hull designs, the setting shoul[...]

INSTALLATION 102 eng BOATS WITH A "V" BOTTOM HULL 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line on the transom up from the "V" bottom the same length as the width of the water intake housing. a - Horizontal line b - Width of the leading edge on the water intake housing 2. Place (cen[...]

INSTALLATION eng 103 2. Fasten outboard to the transom at this height. Refer to Fastening the Outboard . 22403 Fastening the Outboard ! WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly[...]

INSTALLATION 104 eng IMPORTANT: Determine the strength 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 [...]

INSTALLATION eng 105 4. Fasten the outboard with provided mounting hardware shown. Tighten the locknuts to the specified torque. The outboard must be secured to the transom with the two transom bracket clamp screws and four 13 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of mounting holes and t[...]

INSTALLATION 106 eng 4. Install the steering cable and tighten the steering cable nut to the specified torque. a - Steering cable nut b - Steering bracket bolt and washer (2) c - Cable seal Description Nm lb. in. lb. ft. Steering cable nut 47.5 35 Steering bracket bolt 30 22.13 Steering Link Rod Fasteners IMPORTANT: The steering link rod that conne[...]

INSTALLATION eng 107 Assemble steering link rod to engine with bolt, locknut, spacer, and flat washers. Tighten the locknut to the specified torque. a - Bolt (10‑898101018) b - Flat washer (12‑95392‑10) c - Spacer (23‑853826001) d - Nylon insert locknut (11‑16147‑‑3) e - Install steering link rod into side hole f - Nylon insert locknu[...]

INSTALLATION 108 eng Electrical Harness, Battery Connection, Fuel Tanks REMOTE WIRING HARNESS 1. Remove the three access cover bolts. Remove the access cover and cable rubber grommet. 101 13 2. Remove the cable barrel retainer. a - Cable barrel retainer a 24857[...]

INSTALLATION eng 109 3. Loosen the harness retainer. Route the remote harness into the cowl as shown and below the harness retainer. a - Harness retainer b - Remote harness 4. Connect the remote harness to the engine harness connector. a - Harness connector 5. Fasten the remote harness to the cowl with the harness retainer. Tighten the bolt to the [...]

INSTALLATION 110 eng BATTERY CABLE CONNECTIONS IMPORTANT: To prevent damage to the engine charging system when the battery cables are not connected to a battery, ensure the battery cable ends are thoroughly insulated. Single Outboard a - Red sleeve ‑ positive (+) b - Black sleeve ‑ negative (–) c - Cranking battery (+) (-) b a c 15496[...]

INSTALLATION eng 111 Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. a - Red sleeve ‑ positive (+) b - Black sleeve ‑ negative (–) c - Ground cable d - Cranking battery FUEL TANKS Portable Fuel Tank Select a suitable location in the boat within the [...]

INSTALLATION 112 eng 1. Move the remote control handle from neutral into forward and advance the handle to full speed position. NOTE: The throttle cable is the second cable to move when moving the control box out of neutral. 2. Install the throttle cable to the throttle actuating lever. Secure with a washer and cotter pin retainer. 3. Adjust the th[...]

INSTALLATION eng 113 6. Adjust the throttle cable barrel if the cam roller is touching the cam. a - Cam roller b - Throttle cam 7. Install the cable grommet. 8. Secure the throttle cable barrel with the cable barrel retainer. 9. Tighten the cable barrel retainer bolt to the specified torque. a - Cable barrel retainer b - Cable barrel retainer bolt [...]

INSTALLATION 114 eng 10. Install the access cover and secure with three bolts. Tighten bolts to the specified torque. 15858 Description Nm lb. in. lb. ft. Access cover bolt (3) 10 88 SHIFT CABLE INSTALLATION ! WARNING If not properly installed, the reverse gate can interfere with water coming off the rudder, suddenly and unexpectedly slowing the bo[...]

INSTALLATION eng 115 4. Attach the shift cable adjustment barrel to the bracket with a bolt and locknut. Tighten the bolt until it seats against the adjustment barrel, then back‑off the bolt 1/4 turn. Hold the bolt from turning, and tighten the locknut on the bolt. The adjustment barrel must be free to pivot. a - Roller b - Shift cam c - Shift ca[...]

INSTALLATION 116 eng IMPORTANT: If the angle of the boat transom does not allow the driveshaft housing to be positioned vertical, a wedge kit should be installed behind the transom brackets to increase the tilt‑in angle. NOTE: Slight cavitation in sharp turns and rough water is acceptable, but excessive cavitation is harmful to the outboard and s[...]

MAINTENANCE LOG eng 117 Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours[...]