Mercury 100 EFI Fourstroke (2014) manual

eng i Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC Name of engine manufacturer: Mercury Marine Address: W6250 Pioneer Road, P.O. Box 1939 Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA Name of authorized representative: Brunswick Ma[...]

ii eng Identification of Engines Covered by This Declaration of Conformity Name of engine family Unique engine identification number: starting serial number EC Module H certificate number Verado 6 cylinder 200, 225, 250, 275, 300, 350 hp 0P401000 or 1B227000 RCD ‑ H ‑ 2 Rev 4 Verado 4 cylinder 135, 150, 175, 200 hp 0P401000 or 1B227000 RCD ‑ [...]

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 thoroughly enjoy u[...]

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.................................................................................... 38 Fuel Additives................................................................................................... 39 Avoiding Fuel Flow Restriction......................................................................... 3[...]

eng vii Maintenance Outboard Care.................................................................................................. 59 EPA Emissions Regulations............................................................................. 59 Inspection and Maintenance Schedule............................................................. 60 Flushing [...]

viii eng Owner Service Assistance Local Repair Service......................................................................................... 89 Service Away from Home................................................................................. 89 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 (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage. ! WARNING Improper fasteners[...]

GENERAL INFORMATION eng 23 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 bolts through the upper set of holes and two bolts through the lower set of holes. 27746 Propeller Selection For best all around performance from your outboard/boat combination, select a p[...]

GENERAL INFORMATION 24 eng Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyar[...]

GENERAL INFORMATION eng 25 Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's po[...]

GENERAL INFORMATION 26 eng KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat. Before each use, visually inspect the[...]

GENERAL INFORMATION eng 27 Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake,[...]

GENERAL INFORMATION 28 eng Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 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 [...]

GENERAL INFORMATION eng 29 Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from strik[...]

GENERAL INFORMATION 30 eng ! WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO)[...]

GENERAL INFORMATION eng 31 GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbo[...]

GENERAL INFORMATION 32 eng Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. IMPORTANT: Check with your dealer before installing accessories. The misuse of approved accessories or the [...]

GENERAL INFORMATION eng 33 First aid kit and instructions Waterproof storage containers Spare operating equipment, batteries, bulbs, and fuses Compass and map or chart of the area Personal flotation device (one per person onboard) Watch for signs of weather change and avoid foul weather and rough ‑ sea boating. Tell someone where you are going an[...]

GENERAL INFORMATION 34 eng Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. Watch o[...]

GENERAL INFORMATION eng 35 Specifications NOTE: 80 and 100 hp are international models. Models 75 80 90 100 115 Horsepower 75 80 90 100 115 Kilowatts 55.2 58.8 66.2 73.6 84.6 Full throttle RPM range 5000–6000 5800– 6400 Idle speed in neutral gear 1. 700 RPM Number of cylinders 4 Piston displacement 1,731 cc (105.6 cid) Cylinder bore 82 mm (3.23[...]

GENERAL INFORMATION 36 eng Models 75 80 90 100 115 Battery rating 1000 marine cranking amps (MCA), 800 cold cranking amps (CCA), or 65 ampere hour (Ah) Emission control system Electronic engine control (EC) Sound at drivers ear (ICOMIA 39‑94) dBA 82.9 Component Identification a - Top cowl b - Bottom cowl c - Water pump indicator hole d - Drivesha[...]

TRANSPORTING eng 37 Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad cros[...]

FUEL AND OIL 38 eng 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 eng 39 ! 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 40 eng EPA Pressurized Portable Fuel Tank Requirements The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following: • An air inlet that opens to allow[...]

FUEL AND OIL eng 41 Since sealed fuel tanks are not vented, they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air. This is normal. REMOVING THE FUEL CAP a - Fuel cap b - Manual vent screw c - Tab lock IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pre[...]

FUEL AND OIL 42 eng Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled. PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under nor[...]

FUEL AND OIL eng 43 4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way. 5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region). IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region[...]

FUEL AND OIL 44 eng IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer. 7. Push the dipstick back in all the way. 8. Reinstall the oil fill cap hand‑tight. 9. R[...]

FEATURES AND CONTROLS eng 45 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 46 eng 1. Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian system may engage and protect the engine by limiting power. You should return to port immediately and contact your servicing dealer. 2. Intermittent short beeps for six seconds: Indicates a noncritical e[...]

FEATURES AND CONTROLS eng 47 OVERSPEED REV LIMIT The overspeed rev limit is set at an RPM greater than the operating range. In the event that the engine is operated at an RPM greater than or equal to the overspeed limit, the PCM does not allow the engine to maintain the power requested by the operator. Refer to Specifications to determine this engi[...]

FEATURES AND CONTROLS 48 eng Power Trim and Tilt The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard further away from the boat transom is calle[...]

FEATURES AND CONTROLS eng 49 Consider the following lists carefully. 1. 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.[...]

FEATURES AND CONTROLS 50 eng 3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down. Lower the outboard. a - Tilt support lever b - Knob MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve mus[...]

FEATURES AND CONTROLS eng 51 AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system. a - Auxiliary tilt switch a 20886[...]

OPERATION 52 eng Important Daily Inspection Before Each Use Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom [...]

OPERATION eng 53 Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures, keep the outboard tilted down at all times so the gearcase is submerged. This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other componen[...]

OPERATION 54 eng EXAMPLE: An engine running at an elevation of 8,000 feet will have over a 30% power loss while a loss of engine power on a hot and humid day could be as much as 14%. These losses apply to normally aspirated and supercharged engines. Compensating for power robbing conditions: • Switch to lower pitch propeller. • Change gear rati[...]

OPERATION eng 55 2. Tilt the outboard up. Make sure all the cooling water intake holes stay submerged at all times. 3. Operate the engine at slow speed only. Models with a three‑ram trim system: If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range. Models with a single‑ram trim system: The outb[...]

OPERATION 56 eng 1. Check the engine oil level. 20783 2. Ensure the cooling water intake is submerged. 20765 3. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 4. Set the lanyard stop switch to RUN position. Refer to General Information ‑ Lanyard Stop Switch . 19791[...]

OPERATION eng 57 5. Shift outboard to neutral (N) position. N 26838 NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON" position for approximately one minute. This operates the fuel lift pump. Turn the ig[...]

OPERATION 58 eng WARMING UP ENGINE Before beginning operation, allow the engine to warm up at idling speed for three minutes. Gear Shifting IMPORTANT: Observe the following: • Never shift the outboard into gear unless the engine speed is at idle. • Do not shift the outboard into reverse when the engine is not running. • Your outboard has thre[...]

MAINTENANCE eng 59 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 60 eng EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. a - Idle speed b - Engine horsepower c - Piston displacement d - Engine power ‑ kilowatts e - Date of manufacture f - Family number g [...]

MAINTENANCE eng 61 • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, tighten the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of outboard transom bracket material or paint caused by movement between the outboard mountin[...]

MAINTENANCE 62 eng Description Nm lb‑in. lb‑ft Outboard mounting locknuts and bolts ‑ standard boat transom 75 55 Outboard mounting locknuts and bolts ‑ metal lift plates and setback brackets 122 90 • Check corrosion control anodes. Check more frequently when used in saltwater. See Corrosion Control Anode . • Drain and replace gearcase [...]

MAINTENANCE eng 63 Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a build‑up of deposits from clogging the internal water passages. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate[...]

MAINTENANCE 64 eng Top Cowl Removal and Installation REMOVAL 1. Pull out the front cowl latch. 20739 2. Pull down the rear cowl latch. Remove the top cowl. 20741 INSTALLATION 1. Lower the top cowl into position over the engine. 2. Pull up the rear cowl latch to lock down the rear. Push in the front cowl latch to lock down the front.[...]

MAINTENANCE eng 65 Flywheel Cover Removal and Installation REMOVAL Lift the cover off the rear mounting pin and slide the cover forward to release the cover from the front mounting pins. a - Flywheel cover b - Front mounting pins c - Rear mounting pin INSTALLATION Position the cover onto the two front pins and then secure the cover in place by push[...]

MAINTENANCE 66 eng 4. Wax the surface using a nonabrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. 5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1). Cleaning Care for the Powerhead (Saltwater Use) If the outboard is operated in salt[...]

MAINTENANCE eng 67 AIR FILTER ASSEMBLY REMOVAL 1. Remove the breather tube from the air filter. a - Air filter assembly b - Breather tube c - Air intake 2. Remove the purge vent tube from the air filter. 3. Pull the air filter assembly off the front of the air intake. NOTE: To help in the removal of the air filter assembly, use the bottom tab that [...]

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

MAINTENANCE eng 69 The engine is equipped with two fuel filters, One low‑pressure filter and one high‑pressure filter. The low‑pressure filter can be serviced as a general maintenance item, however, the high‑pressure filter is under high pressure and should only be serviced by an authorized dealer. a - Low‑pressure fuel filter b - High‑[...]

MAINTENANCE 70 eng 2. Remove the cap from the fuel vapor purge relief valve. a - Fuel vapor purge relief valve ! CAUTION Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel syste[...]

MAINTENANCE eng 71 4. Push in on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter. a - Fuel hose release tab b - Low‑pressure fuel filter Installation 1. Install the new fuel filter so the arrow points towards the engine. 2. Connect the fuel hoses to the fuel filter securely with the locking hose connections. 3. If re[...]

MAINTENANCE 72 eng Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 20761 Propeller Replacement ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, [...]

MAINTENANCE eng 73 2. Straighten the bent tabs on the propeller nut retainer. 26900 3. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 26901 4. Pull propeller straight off shaft. 5. Coat the propeller shaft with Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref No. Description Where Used Part No.[...]

MAINTENANCE 74 eng 6. Flo‑Torq I drive hub propellers ‑ Install thrust washer, propeller, continuity washer, thrust hub, propeller nut retainer, and propeller nut onto the shaft. a - Propeller nut b - Propeller nut retainer c - Rear thrust hub d - Continuity washer e - Propeller f - Forward thrust hub 7. Flo‑Torq II and Flo‑Torq III drive h[...]

MAINTENANCE eng 75 9. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 10. Reinstall spark plug leads. Spark Plug Inspection and Replacement 1. Remove top cowling. Refer to Top Cowl Removal and Installation . 2. Disconnect the wiring harness connectors from the pencil coils. 3. Remove the mounting bolts that are [...]

MAINTENANCE 76 eng 5. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode. IMPORTANT: The color of the plug may not accurately reflect its condition. To accurately diagnose a faulty plug, inspect the precious metal on the plug&apo[...]

MAINTENANCE eng 77 8. Before installing spark plugs, clean off any dirt on the spark plug seats. Install the plugs finger‑tight and then tighten an additional 1/4 turn or tighten to the specified torque. Description Nm lb‑in. lb‑ft Spark plug 27 – 20 9. Push pencil coils into place over the spark plugs using a twisting motion. 10. Secure co[...]

MAINTENANCE 78 eng Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. a - Good fuse b - Blown fuse c - Diagnostics terminal ‑ 2 amp fuse d - 14 pin remote control harness/cowl trim switch/main power relay ‑ 15 amp fuse e - SmartCraft d[...]

MAINTENANCE eng 79 Alternator Drive Belt Inspection Inspect the alternator drive belt and have it replaced by an authorized dealer if any of the following conditions are found: a - Alternator drive belt • Cracks in the back of the belt or in the base of the V grooves. • Excessive wear at the roots of the grooves. • Rubber portion swollen by o[...]

MAINTENANCE 80 eng Tube Ref No. Description Where Used Part No. 95 2-4-C with PTFE Swivel bracket, tilt support lever, tilt tube, steering cable 92-802859A 1 Extreme Grease Swivel bracket, tilt support lever, tilt tube, steering cable 8M0071842 • Swivel Bracket ‑ Lubricate through fitting. • Tilt Support Lever ‑ Lubricate through fitting. a[...]

MAINTENANCE eng 81 • Steering Link Rod Pivot Points ‑ Lubricate pivot points. 27876 Checking Power Trim Fluid 1. Tilt the outboard to the full up position and engage the tilt support lever. 27877 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 Precisio[...]

MAINTENANCE 82 eng Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 5 liter (5.3 US quart). OIL CHANGING PROCEDURE 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricat[...]

MAINTENANCE eng 83 2. Idle engine for five minutes and check for leaks. Stop the engine. Allow a few minutes for the oil to drain to the oil sump and recheck the oil on the dipstick. Add oil if necessary. 20714 Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is pre[...]

MAINTENANCE 84 eng GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 665 ml (22.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place the outboard in a vertical operating position. 2. Remove the front vent plug and [...]

STORAGE eng 85 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 86 eng Protecting Internal Engine Components IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacement for correct procedure for removing spark plugs. • Remove pencil coils and spark plugs. • Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole. Tube Ref No. Description Where Used [...]

TROUBLESHOOTING eng 87 Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 15 amp fuse. Check 14 pin remote control harness/cowl trim switch/main power relay fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connecti[...]

TROUBLESHOOTING 88 eng Performance Loss POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Throttle not opening fully. • Damaged propeller or improper propeller size. • Incorrect engine timing, adjustment, or setup. • Boat overloaded or load improperly distributed. • Excessive water in b[...]

OWNER SERVICE ASSISTANCE eng 89 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 90 eng 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 eng 91 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 92 eng 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 eng 93 Quantity Item Stock Number Price Total . . Total Due .[...]

OUTBOARD INSTALLATION 94 eng Mercury Marine Validated Engine Mounting Hardware IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability [...]

OUTBOARD INSTALLATION eng 95 ! WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque. ACCEPTABLE ACCESSORY MOUNTING[...]

OUTBOARD INSTALLATION 96 eng • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. Figure 1 a - Minimum clearance 3.175 mm (0.125 in.) b - Edge of accessory bracket c - Transom clamp bracket wall d - Radius e - Engine supplied mounting fa[...]

OUTBOARD INSTALLATION eng 97 UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition. Refer to Figure 2. 54625 Figure [...]

OUTBOARD INSTALLATION 98 eng 3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4. Figure 4 a - Boat transom or jack plate b - Transom clamp bracket c - Wedge/plate Important Information Rigging boats, which includes proper engine installation has become more complex over the years[...]

OUTBOARD INSTALLATION eng 99 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 MAX[...]

OUTBOARD 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 [...]

OUTBOARD INSTALLATION eng 101 FILLING THE FUEL SYSTEM NOTE: For initial start of a new engine, or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON" position for approximately one minute. This operates the fuel lift pump. Turn the ignition key sw[...]

OUTBOARD INSTALLATION 102 eng 5. Lift the outboard and place it on the transom. a - Lifting base b - Lifting eye Flywheel Puller/Lifting Ring 91‑895343T02 14869 Removes flywheel from engine. Used for lifting powerhead/engine. Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate the O‑ring seal and the entire cable end. 3724 95 Tube Ref N[...]

OUTBOARD INSTALLATION eng 103 2. Insert the steering cable into the tilt tube. 3725 3. Tighten the nut to the specified torque. 3727 Description Nm lb‑in. lb‑ft Nut 47.5 – 35 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a"[...]

OUTBOARD INSTALLATION 104 eng ! WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and f[...]

OUTBOARD INSTALLATION eng 105 Determining Recommended Outboard Mounting Height a - The solid line is recommended to determine the outboard mounting height b - The broken lines represent the extremes of known successful outboard mounting height dimensions c - This line may be preferred to determine outboard mounting height dimension, if maximum spee[...]

OUTBOARD INSTALLATION 106 eng NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions. Exhaust restrictions will result in poor p[...]

OUTBOARD INSTALLATION eng 107 Transom Drilling Fixture 91‑98234A2 5489 Aids in engine installation by acting as a template for engine mounting holes. 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Descri[...]

OUTBOARD INSTALLATION 108 eng Available Outboard Mounting Bolts Part Number Description 67755‑2 ½‑20 x 6.50 in. long (2.75 in. thread) 8M0028080 ½‑20 x 7.50 in. long (2.75 in. thread) 8M0032860 ½‑20 x 8.00 in. long (2.75 in. thread) CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mou[...]

OUTBOARD INSTALLATION eng 109 Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate. a - Large transom washer b - Transom[...]

OUTBOARD INSTALLATION 110 eng IMPORTANT: Clearance must be maintained between the vessel transom and the outboard transom bracket relief radius area. Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure[...]

OUTBOARD INSTALLATION eng 111 NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. a - 0.500 in. diameter outboard mounting bolt (4) b - 0.875 in. flat washer (4) c - Nylon insert locknut (4) d - 1.500 in. flat washer (4) e - Marine sealer – apply to the shank of the bolts, not the threa[...]

OUTBOARD INSTALLATION 112 eng A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Electrical, Fuel Hose, and Control Cables FRONT COWL GROMMET Installation IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses[...]

OUTBOARD INSTALLATION eng 113 1. Pull up the cowl seal. Remove the access cover from the bottom cowl. a - Access cover b - Front grommet c - Fuel hose opening d - Remote wiring harness opening e - Throttle cable opening f - Battery cable opening g - Speedometer tube opening h - SmartCraft harness or additional harness opening i - Shift cable openin[...]

OUTBOARD INSTALLATION 114 eng REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front grommet. Connect the remote harness to the 14 pin connector on the engine harness. a - 14 pin connector b - Remote 14 pin boat harness SMARTCRAFT HARNESS CONNECTION If SmartCraft gauges are being used with the outboard, route the SmartCraft wi[...]

OUTBOARD INSTALLATION eng 115 BATTERY CABLE CONNECTIONS Single Outboard a - Red sleeve ‑ Positive (+) b - Black sleeve ‑ Negative (–) c - Cranking battery 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 slee[...]

OUTBOARD INSTALLATION 116 eng FUEL HOSE CONNECTION Fasten the remote fuel hose to fitting with hose clamp. Fuel Hose Size Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with separate fuel hose/fuel tank pickup for each engine. NOTE: An optional fuel hose fitting is available that will adapt the engine fuel hose which has an inside diamet[...]

OUTBOARD INSTALLATION eng 117 NOTE: The high‑pressure fuel hose can be moved out of the way for additional access. a - Access cover b - High‑pressure fuel hose 2. Position the shift mechanism into the neutral position. N 20820 3. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote co[...]

OUTBOARD INSTALLATION 118 eng c. Make a center mark "c", midway between marks "a" and "b". Align the cable end guide against this center mark when installing the cable to the engine. 6098 b c a 4. Fit the shift cable through the front grommet. 6099 5. Position remote control into neutral. 6. Align the shift cable end g[...]

OUTBOARD INSTALLATION eng 119 7. Secure shift cable to the anchor pin with hairpin retainer. a - Center mark b - Barrel insert c - Cable barrel d - Hairpin retainer e - Anchor pin f - Barrel holder 8. Lock barrel in place with cable latch. a - Cable latch 9. Check shift cable adjustments as follows: a. Shift remote control into forward. The propell[...]

OUTBOARD INSTALLATION 120 eng b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b . c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable e[...]

OUTBOARD INSTALLATION eng 121 NOTE: The high‑pressure fuel hose can be moved out of the way for additional access. a - Access cover b - High‑pressure fuel hose 2. Position remote control into neutral. N 26838 3. Install the throttle cable to the throttle arm with the retainer clip. 4. Adjust the cable barrel so that the installed throttle cable[...]

OUTBOARD INSTALLATION 122 eng 6. Place cable barrel into barrel retainer. a - Throttle cable opening b - Flat washer c - Retainer clip d - Cable barrel 7. Lock the cable in place with the cable latch. a - Cable latch a d b c 20827 20828 a[...]

OUTBOARD INSTALLATION eng 123 8. If the shift cable is already installed, place the high‑pressure fuel hose back into the hose retainers. Reinstall the access cover. a - Fuel hose retainer b - High‑pressure fuel hose Trim In Pin ! WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, r[...]

OUTBOARD INSTALLATION 124 eng Stainless Steel Tilt Pin 17‑49930A 1 2749 Limits the down trim angle of the power trim equipped engines, or aids in determining the trim out angle on non‑power trim engines. The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in[...]

MAINTENANCE LOG eng 125 Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours[...]