Mercury 20 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.................................................................................... 38 Low Permeation Fuel Hose Requirement ........................................................ 39 EPA Pressurized Portable Fuel Tank Requirements........................................ 39 Fuel Demand Valve (FDV) Requiremen[...]

eng vii Maintenance Outboard Care.................................................................................................. 75 EPA Emission Regulations............................................................................... 75 Inspection and Maintenance Schedule............................................................. 76 Flushing[...]

viii eng Owner Service Assistance Local Repair Service....................................................................................... 103 Service Away from Home............................................................................... 103 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 any time you are boating in an area where there might be peopl[...]

GENERAL INFORMATION 26 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 27 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 28 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 29 ! 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occu[...]

GENERAL INFORMATION 30 eng ! WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41 127 [...]

GENERAL INFORMATION eng 31 1. Examples of poor ventilation while the boat is stationary: a - Operating the engine when the boat is moored in a confined space b - Mooring close to another boat that has its engine operating 2. Examples of poor ventilation while the boat is moving: a - Operating the boat with the trim angle of the bow too high b - Ope[...]

GENERAL INFORMATION 32 eng • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOA[...]

GENERAL INFORMATION eng 33 • Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. Do not overload your boat. • Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your [...]

GENERAL INFORMATION 34 eng • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatmen[...]

GENERAL INFORMATION eng 35 Models 15/15 ProKicker 20 Exhaust valve 0.18–0.22 mm (0.007–0.008 in.) Recommended spark plug NGK DCPR6E Spark plug gap 0.8–0.9 mm (0.031–0.035 in.) Gear ratio 2.15:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity 370 ml (12.5 fl oz) Engine oil capacity[...]

TRANSPORTING 36 eng Carrying, Storing, and Transporting Your Outboard when Removed from Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run the engine until it stops. This will [...]

TRANSPORTING eng 37 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 crossings, driveways, and trailer bouncing. 32176 IMPORTANT: Do not rely on the power tilt system or the tilt s[...]

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 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 eng 41 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 42 eng 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 eng 43 IMPORTANT: Do not try to fill the oil level to the top of the operating range (upper hole). Oil level is correct as long as it appears in the operating range between the upper and lower hole. a - Oil level operating range b - Dipstick c - Oil fill cap 5. If the oil level is below the operating range (lower hole), remove the oil [...]

FEATURES AND CONTROLS 44 eng Tiller Handle Features • Tiller handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage. 28535 • Tiller lock release lever ‑ Push lever to move tiller handle from one position to another. a - Tiller lock release lever a 3274[...]

FEATURES AND CONTROLS eng 45 • Tiller handle lock cap ‑ Remove and retain the lock cap on the 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. Install the lock cap to prevent the tiller handle from locking in the up position. a - Lock cap b - Locking mecha[...]

FEATURES AND CONTROLS 46 eng • Power tilt switch ‑ Push to tilt the engine up/down. 4639 • Throttle grip friction knob ‑ Turn the friction knob to set and maintain the throttle at desired speed. Turn the knob clockwise to tighten friction or turn the knob counterclockwise to loosen friction. a - Loosen friction (counterclockwise) b - Tighte[...]

FEATURES AND CONTROLS eng 47 • Throttle grip ‑ Controls engine speed and shifting. The outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). N R F 31971 • Choke/fast idle ‑ Pull out when starting a cold engine. • Fuel primer ‑ Press in when starting a cold engine. Refer to Operation ‑[...]

FEATURES AND CONTROLS 48 eng Remote Control Features a - Control handle ‑ forward, neutral, reverse b - Neutral release lever c - Power tilt switch (if equipped) ‑ Refer to Features and Controls ‑ Power Tilt Features and Operation d - Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch e - Lanyard ‑ Refer to General[...]

FEATURES AND CONTROLS eng 49 ! 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 b 31965 Tiller handle models R[...]

FEATURES AND CONTROLS 50 eng • Fuel connector protector cap ‑ Place over the fuel connector when the fuel hose is disconnected. a - Fuel connector protector cap • Cooling water intakes ‑ The outboard has two water intakes for cooling the engine, the primary water intake and the secondary water intake. a - Secondary water intake b - Primary [...]

FEATURES AND CONTROLS eng 51 • Tilt pin ‑ Set the vertical operating angle on the outboard. Refer to Setting the Operation Angle of the Outboard. a - Tilt lever b - Tilt pin BASIC TILTING OPERATION The tilt feature allows the operator to tilt the outboard to a higher tilt angle for operation in shallow water, or tilt the outboard to the full up[...]

FEATURES AND CONTROLS 52 eng 4. Take hold of the top cowl grip and tilt the outboard all the way up until it locks in place. 32150 LOWERING OUTBOARD DOWN TO RUN POSITION Position the tilt lever to the release position. Raise the outboard slightly to release it from its locked position and gently lower it. SHALLOW WATER OPERATION The shallow water d[...]

FEATURES AND CONTROLS eng 53 5. To release the outboard out of shallow water drive, position the tilt lever to the release position, slightly lift up the outboard, and gently lower it down. 32151 SETTING THE OPERATION ANGLE OF THE OUTBOARD The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the six [...]

FEATURES AND CONTROLS 54 eng Arrange passengers and load in the boat so the weight is distributed evenly. a - Too much angle (stern down ‑ bow up) b - Not enough angle (stern up ‑ bow down) c - Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outb[...]

FEATURES AND CONTROLS eng 55 • In excess, can cause boat porpoising (bouncing) or propeller ventilation Power Tilt Features and Operation POWER TILT Models equipped with power tilt allows the operator to use the tilt switch to adjust the tilt position of the outboard from full down to full up. This tilt system is designed to be adjusted when the [...]

FEATURES AND CONTROLS 56 eng 3. Disengage the tilt support lever by slightly tilting up the outboard and releasing the tilt support bracket. Lower the outboard. a - Tilt support lever PROKICKER CENTERING STRAPS FEATURE ProKicker centering straps (if equipped) will center the outboard and prevent the outboard from turning while the outboard is tilte[...]

FEATURES AND CONTROLS eng 57 SHALLOW WATER OPERATION When operating your boat in shallow water, the outboard can be tilted up to a higher tilt angle. Reduce engine speed to idle for tilting. Operate the outboard at slow speed while tilted up for shallow water operation. Keep the cooling water intake holes submerged in the water and continue to chec[...]

FEATURES AND CONTROLS 58 eng The adjustment of the tilt‑in stop pins will set the vertical operating angle of your outboard. Proper adjustment allows the boat to run stable, achieve optimum performance, and minimize steering effort. a - Tilt‑in stop pins NOTE: Refer to the following lists when adjusting the operating angle of your outboard. The[...]

FEATURES AND CONTROLS eng 59 Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom 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 to[...]

FEATURES AND CONTROLS 60 eng ENGINE OVERHEAT Check for a steady stream flowing out of the water pump indicator hole. If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check cooling water intake holes for obstruction. If no obstruction is found, this may indicate a blockage in the cooling system or a[...]

FEATURES AND CONTROLS eng 61 If adjustment is necessary, loosen the trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right, move the trailing edge of trim tab to the right. Tighten the bolt and retest. 31970[...]

OPERATION 62 eng Prestarting 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&apos[...]

OPERATION eng 63 Operating Outboard as an Auxiliary Engine If the outboard is used as an auxiliary engine, stop the engine and tilt the outboard out of the water when using the main power source. IMPORTANT: The outboard must be restrained from bouncing while operating the boat using the main power source. Bouncing can damage the outboard and boat t[...]

OPERATION 64 eng 3. Make sure the cooling water intake is submerged. 26837 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. Use this quick reference for cold or hot starting. 2 3 3 4 4 5 5 6 7 1 52379 Tiller handle starting sequence decal Engine[...]

OPERATION eng 65 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after the engine has warmed up. 27348 3. Set the lanyard stop switch to the "RUN" position. R[...]

OPERATION 66 eng NOTE: For initial start of a new engine or first start after a prolonged storage, the primer lines may have air in them. In this case, depress the fuel primer ten times rapidly. a - Choke/fast idle knob b - Fuel primer IMPORTANT: Avoid engine flooding ‑ Do not press in the fuel primer if engine is warm. This will inject fuel into[...]

OPERATION eng 67 7. Electric starting models ‑ Push the starter button and crank the engine. Release button when the engine starts. Do not operate the starter motor continuously for longer than ten seconds at a time. If the engine fails to start, wait 30 seconds and try again. 31979 8. Flooded engine ‑ If the engine will not start, push in the [...]

OPERATION 68 eng 10. Check for a steady stream of water flowing out of the water pump indicator hole. 31982 IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions wi[...]

OPERATION eng 69 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after the engine has warmed up. 27348 3. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch . 19791 4. Set the remote control handle to the neutral position. IMPORTANT: Avoid engine flooding ‑ Do no[...]

OPERATION 70 eng 5. Temperatures above 0 °C (32 °F) ‑ Do not use the throttle only feature on the remote control for initial starting. After starting the engine, you can slowly advance the throttle only feature, to increase idle speed until the engine is warmed up. Keep engine speed below 2000 RPM. 27242 6. Temperatures below 0 °C (32 °F) ‑[...]

OPERATION eng 71 8. Check for the low oil pressure warning light to turn off. The low oil pressure warning light will turn on for ten seconds after the outboard starts as a normal system test. If the light should stay on, refer to Features and Controls ‑ Warning System . 32210 9. Check for a steady stream of water flowing out of the water pump in[...]

OPERATION 72 eng • Remote control models ‑ Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). When shifting, always stop at neutral position and allow the engine speed to return to idle. N R F 31971 N R F 27237 • Always shift the outboard into gear with a quick motion. • After shift[...]

OPERATION eng 73 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to the neutral position. Push in the engine stop button. 26776 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow this procedure. ! WARNING The neutral‑speed‑protection device is inoperative when starting the[...]

OPERATION 74 eng ! WARNING High voltage is present when starting or operating the engine. Do not touch any ignition component, wiring, or spark plug lead when starting or operating the engine. ! WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or r[...]

MAINTENANCE eng 75 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 76 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 77 AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System . • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST [...]

MAINTENANCE 78 eng BEFORE PERIODS OF STORAGE • Refer to Storage procedure. See Storage section. 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 buildup of deposits from clogging the internal water passages. Use a Mercury Preci[...]

MAINTENANCE eng 79 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 27259 3. Start the engine and run it at idle speed in neutral shift position. IMPORTANT: Do not run engine above idle when flushing.[...]

MAINTENANCE 80 eng 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 31925 INSTALLATION 1. Engage the front hook and position the cowl over the engine. 2. Lock the rear latch. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPOR[...]

MAINTENANCE eng 81 Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be perform[...]

MAINTENANCE 82 eng Assemble the steering link rod to the engine with bolt, locknut, spacer, and flat washers. Torque the locknut to specifications. a - Bolt (12‑71970) b - Flat washer c - Spacer d - Nylon insert locknut (11‑16147‑‑3) e - Steering bracket f - Nylon insert locknut (11‑16147‑‑3) (tighten until it seats, then back off 1/4[...]

MAINTENANCE eng 83 The anode requires periodic inspection especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. POWER TILT MODELS One anode is the[...]

MAINTENANCE 84 eng 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, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between[...]

MAINTENANCE eng 85 5. Pull the propeller straight off of the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. a - Cotter pin b - Nut c - Rear thrust washer d - Front thrust hub IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especiall[...]

MAINTENANCE 86 eng 9. Place a block of wood between the gearcase and the propeller to prevent rotation and tighten the propeller nut to the specified torque. NOTE: If the propeller nut doesn't align with the propeller shaft hole after tightening, tighten the nut further to align with the hole. 10. Align the propeller nut with the propeller sha[...]

MAINTENANCE eng 87 The voltage regulator circuit and the electric starting circuit are protected from overload by a 20 amp fuse. If the fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. a - Voltage regulator circuit ‑ 20 amp fuse b - Spare fuse c - Electric starting circuit ‑[...]

MAINTENANCE 88 eng 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs to inspect. Replace the spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.9 mm (0.035 in.[...]

MAINTENANCE eng 89 • Signs of wear on edges or outer surfaces of belt 31931 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 1.0 liter (1.1 U.S. quart). OIL CHANGING PROCEDURE 1. Lock the outboard in the full tilt up position. 2. Position the outboard so the drain hole is facing downward. 3. Remove the drain plug and d[...]

MAINTENANCE 90 eng 5. Lubricate the seal on the drain plug with oil and install. Tighten to the specified torque. 31922 4537 Description Nm lb. in. lb. ft. Drain plug 23.7 210 17 CHANGING OIL FILTER 1. Position the outboard in a level operating position. 2. Electric start models ‑ To gain clearance to the oil filter, remove the starter solenoid a[...]

MAINTENANCE eng 91 4. Unscrew the old filter by turning the filter to the left. 5. Clean the mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw the new filter on until the gasket contacts the base, then tighten 3/4 to 1 turn. 6. If the starter solenoid was removed, install the starter solenoid and rubber isolati[...]

MAINTENANCE 92 eng 3. Idle engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref No. Description Where Used Part No. Extreme Grease Swivel bracket, transom clamp screws, tilt tube, [...]

MAINTENANCE eng 93 • Steering cable lubrication fitting (if equipped) ‑ Steer the outboard to fully retract the steering cable end into the outboard tilt tube. Lubricate the steering cable through the fitting. a - Steering cable lubrication fitting b - Steering cable end ! WARNING Incorrect cable lubrication can cause hydraulic lock, leading to[...]

MAINTENANCE 94 eng Tube Ref No. Description Where Used Part No. 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 the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft. 31927 Gearcase Lubrication When[...]

MAINTENANCE eng 95 3. Remove the fill/drain plug, vent plug, and drain the lubricant. a - Vent plug b - Fill/drain plug GEARCASE LUBRICANT CAPACITY Approximately 370 ml (12.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the out[...]

MAINTENANCE 96 eng 5. Remove the lubricant tube and install the cleaned fill/drain plug and new sealing washer. a - Vent plug and new sealing washer b - Vent hole c - Fill/drain plug and new sealing washer Checking Power Tilt Fluid 1. Tilt the outboard to the full up position and engage the tilt support lever. a - Tilt support lever c a b 31933 a 3[...]

MAINTENANCE eng 97 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Mercury or Quicksilver Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF). a - Fill cap Submerged Outboard A submerged outboard will require service within a few ho[...]

STORAGE 98 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 99 • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No. 120 Corrosion Guard External metal surfaces 92-802878 55 Protecting Internal Engine Compon[...]

STORAGE 100 eng • Never carry, store, or transport the outboard in the two positions shown. Engine damage could result from oil draining out of the crankcase. a - Tiller handle up b - Front side up Battery Storage • Follow the battery manufacturer's instructions for storage and charging. • Remove the battery from the boat and check water[...]

TROUBLESHOOTING eng 101 Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Blown 20 amp 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/start button failure. • Wiring [...]

TROUBLESHOOTING 102 eng • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Low oil pressure. Check the oil level. • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive w[...]

OWNER SERVICE ASSISTANCE eng 103 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. Servi[...]

OWNER SERVICE ASSISTANCE 104 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 th[...]

OWNER SERVICE ASSISTANCE eng 105 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 Pion[...]

OWNER SERVICE ASSISTANCE 106 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 Teleph[...]

OWNER SERVICE ASSISTANCE eng 107 Quantity Item Stock Number Price Total . . Total Due .[...]

ENGINE INSTALLATION 108 eng 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 overpower or overlo[...]

ENGINE INSTALLATION eng 109 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 ta[...]

ENGINE INSTALLATION 110 eng INSTALLING OUTBOARD ON TRANSOM ! 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. This product must be secure[...]

ENGINE INSTALLATION eng 111 3. To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts. Drill two 7.9 mm (5/16 in.) holes through the transom bracket mounting holes. Fasten with two bolts, flat washers, and locknuts. Use a marine waterproofing sealer in the holes and aro[...]

ENGINE INSTALLATION 112 eng 2. Insert the steering cable into the tilt tube. 32081 3. Tighten the steering cable nut to the specified torque. 4. Thread the steering cable seal onto the end of the tilt tube. a - Steering cable nut b - Steering cable seal Description Nm lb‑in. lb‑ft Steering cable nut 47.5 35 Steering Link Rod Fasteners IMPORTANT[...]

ENGINE INSTALLATION eng 113 ! 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 fol[...]

ENGINE INSTALLATION 114 eng Description Nm lb‑in. lb‑ft Nylon insert locknut "f" Tighten until it seats, then back off 1/4 turn Remote Wiring Harness and Control Cable Installation REMOTE WIRE HARNESS CONNECTION 1. Remove the two bolts and remove the access cover. a - Access cover 2. Connect the remote harness to the engine harness co[...]

ENGINE INSTALLATION eng 115 4. Connect the 8 pin connector to the engine harness. If the outboard is equipped with power tilt, connect the power tilt wire connections. a - 8 pin connector b - Remote wiring harness c - Rubber grommet d - Power tilt wire connections 5. Route the remote wiring harness through the rubber grommet. 6. Open up the clamp i[...]

ENGINE INSTALLATION 116 eng a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to neutral. Place a mark ("a") on the cable next to the end guide. b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. S[...]

ENGINE INSTALLATION eng 117 4. Attach the shift cable to the shift lever with a washer and cotter pin retainer. a - Cotter pin retainer b - Flat washer c - Shift cable d - Shift lever 5. Manually shift the outboard into neutral (propeller will rotate freely). 6. Adjust the cable barrel so the center mark on the cable is aligned with the end guide w[...]

ENGINE INSTALLATION 118 eng 7. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. a - End guide b - Center mark c - Cable barrel d - Rubber grommet 8. Check shift cable adjustments as follows: a. Shift the remote control into forward. The propeller shaft should be locked in gear. If not, adjust t[...]

ENGINE INSTALLATION eng 119 4. Position the throttle cable into the rubber grommet and place the cable barrel into the barrel receptacle. a - Carburetor lever b - Full throttle stop c - Cotter pin retainer d - Flat washer e - Cable barrel f - Rubber grommet g - Throttle lever c d e f g a b 32069[...]

ENGINE INSTALLATION 120 eng 5. Install the access cover with two bolts. Tighten the bolts to the specified torque. a - Access cover Description Nm lb. in. lb. ft. Access cover bolt 6 53 Battery Installation ‑ Electric Start Models MOUNTING BATTERY Follow the battery manufacturer's instructions carefully. Mount battery in the boat so it is se[...]

ENGINE INSTALLATION eng 121 DISCONNECTING OUTBOARD BATTERY CABLES First, disconnect the black battery cable from the (–) negative terminal and then disconnect the red battery cable from the (+) positive terminal. 27158[...]

MAINTENANCE LOG 122 eng Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours[...]