Mercury 3.5 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.................................................................................... 35 Special Features of the Fuel Tank.................................................................... 36 Filling the Fuel Tank......................................................................................... 37 Eng[...]

eng vii Storage Storage Preparation.......................................................................................... 62 Protecting External Outboard Components...................................................... 62 Protecting Internal Engine Components........................................................... 62 Gearcase................[...]

eng viii[...]

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 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 eng 23 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 24 eng 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 eng 25 ! 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 26 eng 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 eng 27 • 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 28 eng • 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 eng 29 • 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 30 eng Models 2.5 3.5 Exhaust valve 0.11–0.19 mm (0.0043–0.0075 in.) Engine oil capacity 300 ml (10 fl oz) Recommended spark plug NGK DCPR6E Spark plug gap 0.9 mm (0.035 in.) Gearcase lubricant capacity 180 ml (6.0 fl oz) Gear ratio 2.15:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Emiss[...]

INSTALLATION eng 31 Installing the Outboard BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of the boat. The anti‑ventilation plate should be 25–50 mm (1–2 in.) below the bottom of the boat. a - Anti‑ventilation plate INSTALLING THE OUTBOARD ON THE TRANSOM 1. Place the outboard on the centerline of the transom. 27005 2. Tighten t[...]

TRANSPORTING 32 eng Carrying, Storing, and Transporting the Outboard When Removed from Boat With the outboard still in the water, close the fuel valve and run the engine until it stops. This will empty the fuel from the carburetor. a - Transport mode b - Vent position c - Fuel valve position d - Vent screw e - Fuel valve Close the manual vent screw[...]

TRANSPORTING eng 33 Carry, transport, or store the outboard only in the upright position, or with the tiller handle (port) side facing up. These positions will prevent oil from draining out of the crankcase. A decal on the port side of the engine indicates which side should be up. a - Upright position b - Tiller handle up position Never carry, stor[...]

TRANSPORTING 34 eng Set the gear shift into forward gear. This prevents the propeller from spinning freely. 19049[...]

FUEL AND OIL eng 35 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 36 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 37 2. Open the manual vent screw on top of the cap for operation and cap removal. Close the manual vent screw for transportation. a - Fuel cap b - Manual vent screw Filling the Fuel Tank ! WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not [...]

FUEL AND OIL 38 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 39 NOTE: If oil level is at the lower mark, add 100 ml (3 oz.) of oil. a - Oil level inspection window b - Upper oil level c - Lower oil level 3. Install the oil fill cap, and tighten securely. a - Oil fill cap c b a 52334 a 19139[...]

FEATURES AND CONTROLS 40 eng Features and Controls Fuel shut off valve ‑ Turn the valve to the closed (OFF) position to prevent fuel flow to the engine. Turn the valve to the open (ON) position when starting the engine. 52331 Choke knob ‑ Pull completely out when starting a cold engine. Push halfway in as the engine is warming up. Push in compl[...]

FEATURES AND CONTROLS eng 41 ! 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. Steering friction adjustment ‑[...]

FEATURES AND CONTROLS 42 eng Engine stop switch/lanyard stop switch ‑ Push in or pull lanyard to stop the engine. The engine will not start unless the lanyard is engaged with the stop switch. a - Engine stop switch/lanyard stop switch b - Lanyard Starter rope ‑ Pulling the starter rope cranks the engine over for starting. 19105 Tilting Outboard[...]

FEATURES AND CONTROLS eng 43 3. Push in the tilt support pin. Lower the outboard to rest on the tilt support pin. a - Tilt support pin LOWERING TO RUN POSITION Lift the outboard and pull out the tilt support pin. Lower the outboard. Setting the Operating Angle of the Outboard The vertical operating angle of the outboard is adjusted by changing the [...]

OPERATION 44 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 45 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 procedures. 1. For the first hour of operation, run the engine at varied throttle settings up to 2000 RPM or at approximatel[...]

OPERATION 46 eng 2. Shift the outboard to the neutral (N) position. N 19170 3. Make sure the cooling water intake is submerged. 19056 4. Open the manual vent screw on the fuel tank. 47370 5. Move the fuel shut off valve to the open (ON) position. 52331[...]

OPERATION eng 47 6. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch . NOTE: The engine will not start unless the lanyard is engaged with the stop switch. a - Stop switch b - Lanyard 7. If the engine is cold, set the throttle grip to the "START" position. If the engine is warm, set the throttle g[...]

OPERATION 48 eng 9. Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow the rope to return slowly. Repeat until the engine starts. 19172 10. Check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, [...]

OPERATION eng 49 Always shift the outboard into gear with a quick motion. N F 19103 Reversing Boat 1. Move the throttle grip to the slow position. 2. To reverse direction, turn the outboard 180°. The tiller handle can be swung back for ease of operation. 3. Return the throttle grip to the slow position when turning the outboard back to forward dir[...]

MAINTENANCE 50 eng 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 eng 51 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 52 eng EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST • Lubricate all lubrication points. Lubricate more frequently when used in saltwater. See Lubrication Points . • Change the engine oil. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. See Changing[...]

MAINTENANCE eng 53 4. Turn the water off. Remove the hose coupling and install the plug and gasket. a - Plug and gasket b - Hose coupling Top Cowl Removal and Installation REMOVAL 1. Release the rear cowl latch. 47360 b a 52350[...]

MAINTENANCE 54 eng 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 19043 INSTALLATION 1. Engage the front hook and position the cowl over the engine. 2. Lock the rear cowl latch. Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase. An anode helps protect [...]

MAINTENANCE eng 55 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 56 eng 4. Pull the propeller straight off the shaft. Retain the drive pin. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. a - Drive pin 5. Insert the drive pin into the propeller shaft. a - Drive pin 6. Slide the propeller onto the shaft, making sure the slot in the pro[...]

MAINTENANCE eng 57 Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots. 1. Remove the [...]

MAINTENANCE 58 eng Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Extreme Grease. Tube Ref No. Description Where Used Part No. Extreme Grease Steering friction knob threads, swivel bracket bushing, tilt support pin, transom clamp screws 8M0071842 • Steering friction knob ‑ lubr[...]

MAINTENANCE eng 59 • Swivel bracket ‑ remove four bolts and rear cover and lubricate the inner nylon bushing. a - Rear cover Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 300 ml (10 fl. oz.). OIL CHANGING PROCEDURE 1. Place the outboard in an upright (not tilted) position. 2. Turn the outboard to gain access to th[...]

MAINTENANCE 60 eng Idle engine for five minutes and check for leaks. Stop engine and check oil level. Add oil if necessary. 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 i[...]

MAINTENANCE eng 61 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. a - Vent plug and new sealing washer b - Vent hole c - Fill/drain plug and new sealing washer Tube Ref No. Description Where Used Part No. 82 Premium Gear Lubricant Gearcase 92-858058K01 4. Stop adding lubricant[...]

STORAGE 62 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 63 Gearcase • Drain and refill the gearcase lubricant (refer to Gearcase Lubrication ). Positioning Outboard for Storage NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard [...]

OWNER SERVICE ASSISTANCE 64 eng Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Servic[...]

OWNER SERVICE ASSISTANCE eng 65 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 66 eng CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence. United States, Canada Telephone English +1 920 929 5040 Français +1 905 636 4751 Mercury Marine W6250 Pione[...]

OWNER SERVICE ASSISTANCE eng 67 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 68 eng Quantity Item Stock Number Price Total . . Total Due .[...]

MAINTENANCE LOG eng 69 Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours[...]