Mercury 150 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.................................................................................... 39 Fuel Additives................................................................................................... 40 Low Permeation Fuel Hose Requirement ........................................................ 40 EPA Pres[...]

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

viii eng Owner Service Assistance Local Repair Service......................................................................................... 87 Service Away from Home................................................................................. 87 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 IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. [...]

GENERAL INFORMATION eng 23 • Upgrading from a 3‑blade propeller to a 4‑blade propeller will generally decrease full throttle RPM by 50 to 100 IMPORTANT: Avoid damage to the engine. Never use a propeller that allows the engine to exceed the recommended full throttle RPM range when under normal full throttle operation. PROPELLER MATERIAL Most p[...]

GENERAL INFORMATION 24 eng Remote Steering Notice Models with steering link rod ‑ 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 disen[...]

GENERAL INFORMATION eng 25 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 26 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 27 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 any time you are boating in an area where there might be peopl[...]

GENERAL INFORMATION 28 eng Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 ! WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay [...]

GENERAL INFORMATION eng 29 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 30 eng 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 eng 31 ! 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 32 eng 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 eng 33 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 34 eng 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 eng 35 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 36 eng Specifications Models 150 Horsepower 150 Kilowatts 110 Full throttle RPM range 5000–5800 Idle speed in neutral gear 1. 650 RPM Number of cylinders 4 Piston displacement 3.0 L (183 cid) Cylinder bore 101.6 mm (4.0 in.) Stroke 92 mm (3.62 in.) Valve clearance Intake 0.075 mm (0.003 in.) Exhaust 0.25 mm (0.010 in.) Recomme[...]

GENERAL INFORMATION eng 37 Component Identification a - Top cowl b - Engine flush c - Bottom cowl d - Auxiliary tilt switch e - Transom brackets f - Cooling water intake holes g - Gearcase h - Anti‑ventilation plate i - Driveshaft housing j - Engine oil drain k - Water pump indicator hole a b d e f g f h j i k c 47824[...]

TRANSPORTING 38 eng 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 eng 39 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 40 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 41 Fuel Demand Valve (FDV) Requirement Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and the engine. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage. The fuel deman[...]

FUEL AND OIL 42 eng 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 pressure before opening. 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 fue[...]

FUEL AND OIL eng 43 PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions. Engine Oil Recommendations Mercury or Quicksilver NMMA FC‑W certified SAE 10W‑30 Marine 4‑Stroke Engine Oil is recommended for general all‑temperature use. As an optio[...]

FUEL AND OIL 44 eng 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 (between the top bar and bottom bar). IMPORTANT: Do not try to fill the oil level to the top bar. Oil level is correct as l[...]

FUEL AND OIL eng 45 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. Install the oil fill cap hand‑tight. 9. Ins[...]

FEATURES AND CONTROLS 46 eng 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 eng 47 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 48 eng 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 eng 49 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 50 eng 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) • In excess, can lower the bow of some b[...]

FEATURES AND CONTROLS eng 51 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 must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve three turns c[...]

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 Models with a single‑ram trim system: The outboard will remain at the selected tilt position, regardless of engine RPM. Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in pr[...]

OPERATION 56 eng 3. Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch . 19791 5. Shift outboard to neutral (N) position. N 26838 NOTE: For initial start of a new engine or for an engine that ran o[...]

OPERATION eng 57 6. Ignition key starting ‑ Turn ignition key to the "START" position and release the key. The electronic starting system will automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking. Turn the key to the "START" position again until engine starts. 19804 7. After [...]

OPERATION 58 eng Stopping the Engine Reduce the engine speed and shift the outboard to neutral position. Turn the ignition key to "OFF" position. 26843[...]

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, retorque 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 mounti[...]

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 NOTE: The outboard can be tilted or in the vertical operating position during flushing. 1. With the engine turned off, place the outboard in either the operating position (vertical) or in a tilted position. 2. Remove the flush connector from the bottom cowl. 3. Remove the cover from the flush connector and thread a water hose int[...]

MAINTENANCE 64 eng INSTALLATION 1. Lower the top cowl over the engine. 2. Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply pressure to the back of the cowl to lock it in place. Ensure the cowl is securely fastened by trying to pull up on the back of the cowl. 47633 Cleaning Car[...]

MAINTENANCE eng 65 Cleaning Care for the Powerhead (Saltwater Use) If the outboard is operated in saltwater, remove the top cowl and flywheel cover. Inspect the powerhead and powerhead components for salt buildup. Wash off any salt buildup from the powerhead and powerhead components with fresh water. Keep water spray out of the air filter/intake an[...]

MAINTENANCE 66 eng IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately. Material used to contain spilled fuel must be disposed of in an approved receptacle. Before servicing any part of the fuel system: 1. Stop engine and disconnect the battery. 2. Perform fuel system service in a well‑ventilated area.[...]

MAINTENANCE eng 67 6. Remove the fuel filter from the lift handle. a - Fuel hose release tab b - Low‑pressure fuel filter c - Hose holder Installation 1. Place the lift handle onto the fuel filter. 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 connec[...]

MAINTENANCE 68 eng Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 47569 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 69 3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. 26901 4. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. Coat the propeller shaft with Extreme Grease [...]

MAINTENANCE 70 eng 2. Place the locknut retainer over the raised pins on the drive sleeve adapter and tighten the locknut to the specified torque. 3. Secure the locknut by bending the tabs up against the locknuts. a - Forward thrust washer b - Drive sleeve c - Propeller d - Drive sleeve adapter e - Locknut retainer f - Locknut g - Raised pins h - T[...]

MAINTENANCE eng 71 3. Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter. a - Forward thrust washer b - Drive sleeve c - Propeller d - Drive sleeve adapter e - Locknut retainer f - Locknut g - Tabs bent into grooves Description Nm lb‑in. lb‑ft Propeller nut 75 55 Spark Plug Inspection and Replacement 1.[...]

MAINTENANCE 72 eng 2. Remove the spark plugs to inspect. 47662 3. 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[...]

MAINTENANCE eng 73 a. All of the spark plugs should have the gap checked and corrected as necessary before installation. b. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap. c. If an adjustment is necessary, do not pry or apply any force on the center electrode. This is cri[...]

MAINTENANCE 74 eng Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. a - Cover b - Spare fuse holders c - Fuse holder d - Fuse 4 ‑ IGN. 20 amp ‑ ignition system e - Fuse 2 ‑ FUEL 20 amp ‑ fuel delivery f - Fuse 1 ‑ DIAG. 2 a[...]

MAINTENANCE eng 75 Alternator Drive Belt Inspection 1. Remove the three screws that fastens the flywheel cover to the engine. Lift the flywheel cover off the engine. a - Flywheel cover b - Screws (3) 2. Inspect the alternator drive belt. a - Alternator drive belt 3. Have the belt replaced by an authorized dealer if any of the following conditions a[...]

MAINTENANCE 76 eng 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 Propeller shaft 8M0071842 95 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Coat [...]

MAINTENANCE eng 77 • Steering cable grease fitting (if equipped) ‑ Rotate 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 hydraulic lock, leading to serious injury or death from loss of boat control. [...]

MAINTENANCE 78 eng Checking Power Trim Fluid 1. Tilt the outboard to the full up position and engage the tilt support lever. 47646 2. Remove the fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automot[...]

MAINTENANCE eng 79 3. Use a 16 mm (5/8 in.) wrench and loosen the oil drain valve so that it can be turned by hand. Be careful not to open the valve too far allowing oil to drain. 4. Attach a 12 mm (7/16 in.) I.D. drain hose to the oil drain valve. Position the opposite end of the hose into an appropriate container. 5. Loosen the oil drain valve 2?[...]

MAINTENANCE 80 eng 5. Clean the oil filter mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. a - Loosen b - Oil filter c - Oil trough d - Drain hose OIL FILLING 1. Remove the oil fill cap and add approximately 6 liters (6.3 US qt) of the reco[...]

MAINTENANCE eng 81 Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the ge[...]

MAINTENANCE 82 eng 3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole. a - Vent hole b - Fill hole IMPORTANT: Replace the sealing washers if damaged. 4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove the[...]

STORAGE eng 83 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 84 eng Protecting Internal Engine Components IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacement for correct procedure for removing spark plugs. • Change the engine oil and filter. • Remove the spark plugs. • Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole. Tube Ref No[...]

TROUBLESHOOTING eng 85 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 86 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 87 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 88 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 89 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 90 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 91 Quantity Item Stock Number Price Total . . Total Due .[...]

OUTBOARD INSTALLATION 92 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 93 ! 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 94 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 95 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 96 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 97 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 98 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[...]

OUTBOARD INSTALLATION eng 99 Installation Specifications a - Minimum transom opening b - Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.2 cm (33 in.) Dual engine 149.9 cm (59 in.) Lifting Outboard 1. Remove the top cowl. 2. Install the lifting base to the flywheel using three bolts. Tighten the bolts[...]

OUTBOARD INSTALLATION 100 eng Flywheel Puller/Lifting Ring 91‑895343T02 14869 Removes flywheel from engine. Used for lifting powerhead/engine. Shipping Bracket Removal 1. Remove the two top screws and loosen the two bottom screws. 2. Slide the shipping bracket off the bottom screws. 3. Tighten the bottom screws to the specified torque. a - Shippi[...]

OUTBOARD INSTALLATION eng 101 Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate O‑ring seal and entire cable end. 3724 95 Tube Ref No. Description Where Used Part No. 95 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1 2. Insert steering cable into tilt tube. 3. Tighten the nut to the specified torque. 47708 Description Nm [...]

OUTBOARD INSTALLATION 102 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 103 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 104 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 105 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 106 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 107 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 108 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 109 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 110 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 RIGGING GROMMET Installation IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, t[...]

OUTBOARD INSTALLATION eng 111 1. Route the hoses, wiring, and cables through the rigging adapter and correct opening in the rigging grommet as shown. a - Screw (2) b - Rigging adapter c - Rigging grommet d - Speedometer tube opening e - Remote 14 pin boat harness opening f - Battery cable opening g - Accessory harness opening h - Shift cable openin[...]

OUTBOARD INSTALLATION 112 eng NOTICE Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring harnesses. a - Cable tie Description Nm lb‑in. lb‑ft Screws for attaching the rigging adapter 6 53 REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the rigging gr[...]

OUTBOARD INSTALLATION eng 113 SMARTCRAFT HARNESS AND VESSEL HARNESS CONNECTION If the boat is equipped with a SmartCraft and/or vessel (accessory) harness, route the wiring harness through the rigging grommet and connect it to the connector on the engine. a - Vessel (accessory) harness connector b - SmartCraft harness connector BATTERY CABLE CONNEC[...]

OUTBOARD INSTALLATION 114 eng 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 HOSE CONNECTION Fasten the remote fuel hose to fitting with a hose[...]

OUTBOARD INSTALLATION eng 115 Fuel Hose Size Minimum fuel hose inside diameter (ID) is 9.5 mm (3/8 in.) with separate fuel hose/fuel tank pickup for each engine. a - Hose clamp b - Remote fuel hose SHIFT CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cab[...]

OUTBOARD INSTALLATION 116 eng 3. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to the neutral position. Place a mark "a" on the cable against the cable en[...]

OUTBOARD INSTALLATION eng 117 8. Secure the shift cable to the anchor pin with the bow tie clip retainer. a - Shift cable end guide b - Bow tie clip retainer c - Center mark d - Cable barrel e - Barrel cup c d e b a 47743[...]

OUTBOARD INSTALLATION 118 eng 9. Lock the barrel in place with the cable latch. a - Cable latch 10. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b. Shift remote control into neutral. The propeller shaft should turn fre[...]

OUTBOARD INSTALLATION eng 119 1. Shift remote control into the neutral (N) position. N 26838 2. Fit the throttle cable through the rigging grommet. 47739 3. Install the throttle cable to the throttle arm with the bow tie clip retainer. 4. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.[...]

OUTBOARD INSTALLATION 120 eng 5. Place the barrel cup onto the barrel. Place the cable barrel and barrel cup into the barrel retainer. a - Bow tie retainer b - Throttle cable end guide c - Cable barrel d - Barrel cup 6. Lock the cable in place with the cable latch. a - Cable latch b c d 47747 a 47748 a[...]

OUTBOARD INSTALLATION eng 121 Trim In Pin ! WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner. Some boats, particularl[...]