and

Manual
Operation

Installation
Maintenance
8M0133624 617 eng
© 2017 Mercury Marine 250 and 300 XS OptiMax
eng
Welcome
You have selected one of the finest marine power packages available. It
incorporates numerous design features to ensure operating ease and durability.
With proper care and maintenance, you will enjoy using this product for many
boating seasons. To ensure maximum performance and carefree use, we ask
that you thoroughly read this manual.
The Operation and Maintenance Manual contains specific instructions for using
and maintaining your product. We suggest that this manual remain with the
product for ready reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely hope your boating
will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:
John Pfeifer, President,
Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your
dealer. Your dealer can also provide a demonstration of actual starting and
operating procedures.

Notice
Throughout this publication, and on your power package, warnings, cautions,

and notices, accompanied by the International Hazard Symbol ! , may be

used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict
compliance with these special instructions while performing the service, plus
common sense operation, are major accident prevention measures.

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.

eng i
 NOTICE
Indicates a situation which, if not avoided, could result in engine or major
component failure.

IMPORTANT: Identifies information essential to the successful completion of

the task.
NOTE: Indicates information that helps in the understanding of a particular step
or action.
IMPORTANT: The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard, and the safety of all occupants
aboard. We strongly recommend that the operator read this Operation and
Maintenance Manual and thoroughly understand the operational instructions for
the power package and all related accessories before the boat is used.

! WARNING
The engine exhaust from this product contains chemicals known to the state
of California to cause cancer, birth defects or other reproductive harm.

The serial numbers are the manufacturer’s keys to numerous engineering

details that apply to your Mercury Marine power package. When contacting
Mercury Marine about service, always specify model and serial numbers.
Descriptions and specifications contained herein were in effect at the time this
was approved for printing. Mercury Marine, whose policies are based on
continuous improvement, reserves the right to discontinue models at any time
or to change specifications or designs without notice and without incurring
obligation.

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 Manual included
with the product. The Warranty Manual contains a description of what is
covered, what is not covered, the duration of coverage, how to best obtain
warranty coverage, important disclaimers and limitations of damages, and
other related information. Please review this important information.

Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in
part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo,
K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves
Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury
Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft,
Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're
Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a
trademark of Brunswick Corporation. Mercury Product Protection is a registered
service mark of Brunswick Corporation.

ii eng
Identification Records
Please record the following applicable information:

Outboard
Engine Model and Horsepower
Engine Serial Number
Gear Ratio
Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

eng iii
eng iv
 General Information

Boater's Responsibilities..................................................................................... 1
Before Operating Your Outboard........................................................................ 1
Boat Horsepower Capacity................................................................................. 1
High‑Speed and High‑Performance Boat Operation.......................................... 2
Outboard Remote Control Models ..................................................................... 2
Remote Steering Notice...................................................................................... 3
Lanyard Stop Switch........................................................................................... 3
Protecting People in the Water........................................................................... 6
Passenger Safety Message ‑ Pontoon Boats and Deck Boats........................... 6
Wave and Wake Jumping................................................................................... 8
Impact with Underwater Hazards........................................................................ 9
Exhaust Emissions........................................................................................... 10
Selecting Accessories for Your Outboard......................................................... 12
Safe Boating Recommendations...................................................................... 12
Recording Serial Number................................................................................. 14
Specifications—250 XS OptiMax...................................................................... 15
Specifications—300XS OptiMax....................................................................... 16
Special Tools and Kits...................................................................................... 18
Component Identification.................................................................................. 18
Propeller Selection............................................................................................ 19

Transporting

Trailering Boat/Outboard ................................................................................. 20

Fuel and Oil

Fuel Requirements........................................................................................... 21
Oil Recommendation........................................................................................ 22
Fuel Additives................................................................................................... 22
Avoiding Fuel Flow Restrictions........................................................................ 23
Low Permeation Fuel Hose Requirement ........................................................ 23
EPA Pressurized Portable Fuel Tank Requirements........................................ 23
Fuel Demand Valve (FDV) Requirement.......................................................... 23
Mercury Marine's Pressurized Portable Fuel Tank........................................... 24
Filling Remote Oil Tank.................................................................................... 25
Filling Engine Mounted Oil Reservoir Tank...................................................... 25
Filling Fuel Tank............................................................................................... 26

eng v
 Features and Controls

Remote Control Features................................................................................. 27

Zero Effort Control Features............................................................................. 28
Warning System............................................................................................... 28
Power Trim and Tilt........................................................................................... 30
Power Trim Operation ...................................................................................... 30
Power Tilt Operation (Single‑Ram Systems).................................................... 32
Power Tilt Operation (Three‑Ram Trim Systems)............................................ 32
Auxiliary Tilt Switch........................................................................................... 33
Manual Tilt Operation....................................................................................... 33

Operation

Important Information........................................................................................ 35
Engine Break‑in................................................................................................ 35
Engine Break‑in Fuel Mixture........................................................................... 36
Prestarting Check List....................................................................................... 36
Operating in Freezing Temperatures................................................................ 36
Operating in Saltwater or Polluted Water......................................................... 37
Operating at High Elevations............................................................................ 37
Effects of Elevation and Weather on Performance........................................... 37
Setting Trim Angle While Running Engine at Idle Speed................................. 38
Operating in Shallow Water.............................................................................. 38
Oil Injection System.......................................................................................... 39
Starting the Engine........................................................................................... 41
Gear Shifting..................................................................................................... 44
Stopping the Engine......................................................................................... 44

vi eng
 Maintenance

Cleaning Care Recommendations.................................................................... 45

Power Package Care........................................................................................ 47
Replacement Parts for Your Power Package................................................... 47
EPA Emissions Regulations............................................................................. 47
Inspection and Maintenance Schedule............................................................. 48
Flushing the Cooling System (Powerhead)...................................................... 50
Flushing the Cooling System (Lower Unit)....................................................... 51
Top Cowl Removal and Installation.................................................................. 52
Fuel System...................................................................................................... 52
Steering Link Rod Fasteners............................................................................ 55
Fuses ............................................................................................................... 56
Corrosion Control Anodes................................................................................ 57
Spark Plug Inspection and Replacement.......................................................... 58
Battery Inspection ............................................................................................ 60
Charging System Fusible Link.......................................................................... 60
Replacing the Propeller.................................................................................... 61
Lubrication Points............................................................................................. 63
Single‑Ram Trim System.................................................................................. 64
Three‑Ram Trim System.................................................................................. 67
Gearcase Lubricant.......................................................................................... 70
Submerged Power Package............................................................................. 71

Storage

Storage Preparation.......................................................................................... 72
Protecting Internal Engine Components........................................................... 73
Protecting External Outboard Components...................................................... 74
Gearcase.......................................................................................................... 74
Positioning Outboard for Storage..................................................................... 74
Battery Storage................................................................................................. 74

Troubleshooting

Starter Motor Will Not Crank the Engine........................................................... 75

Engine Will Not Start......................................................................................... 75
Engine Runs Erratically.................................................................................... 75
Performance Loss............................................................................................. 76
Warning Horn Activates (With Power Loss)...................................................... 76
Warning Horn Activates (No Power Loss)........................................................ 76
Battery Will Not Hold Charge............................................................................ 77

eng vii
 Owner Service Assistance

Service Assistance........................................................................................... 78
Ordering Literature............................................................................................ 80

Outboard Installation

Mercury Marine Validated Engine Mounting Hardware.................................... 82

Accessories Mounted to the Transom Clamp Bracket...................................... 82
Boat Horsepower Capacity............................................................................... 86
Start in Gear Protection.................................................................................... 86
Fuel System...................................................................................................... 87
Installation Specifications................................................................................. 89
Lifting the Outboard.......................................................................................... 89
Steering Cable ‑ Starboard Side Routed Cable................................................ 90
Steering Link Rod Fasteners............................................................................ 91
Rear‑Mounted Steering Rams or Tie Bars....................................................... 92
Determining Outboard Mounting Height........................................................... 93
Drilling Outboard Mounting Holes..................................................................... 96
Fastening the Outboard to the Transom........................................................... 98
Electrical, Hoses, Control Cables, and Front Clamp...................................... 103
Oil Injection Set‑Up......................................................................................... 114
Engine Well Inlet Cover Installation (Models with Remote Trim Pump)......... 116
Trim In Pin...................................................................................................... 119

Maintenance Log

Maintenance Log............................................................................................ 121

viii eng
 GENERAL INFORMATION
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 person onboard is instructed in the basics
of starting and operating the outboard and boat handling in case the driver is
unable to operate the boat.

Before Operating Your Outboard

Read this manual carefully. Learn how to operate your outboard properly. If you
have any questions, contact your dealer.
This manual as well as safety labels posted on the outboard use the following
safety alerts to draw your attention to special safety instructions that should be
followed.

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.

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.

eng 1
 GENERAL INFORMATION
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
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777

High‑Speed and High‑Performance Boat Operation

If your outboard is to be used on a high‑speed or high‑performance boat with
which you are unfamiliar, we recommend that you do not operate it at its high
speed capability without first requesting an initial orientation and familiarization
demonstration ride with your dealer or an operator experienced with your boat/
outboard combination. For additional information, obtain a copy of our
Hi‑Performance Boat Operation booklet from your dealer, distributor, or
Mercury Marine.

Outboard Remote Control Models

The remote control connected to your outboard must be equipped with a start
in neutral only protection device. This prevents the engine from starting when
the shift is actuated in any position other than neutral.

! WARNING
Starting the engine with the drive in gear can cause serious injury or death.
Never operate a boat that does not have a neutral‑safety‑protection device.

63103

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

! WARNING
Improper fasteners 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 follow instructions and torque procedures.

a - Self‑locking nuts

a
a 27740

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator
moves far enough away from the operator's position (as in accidental ejection
from the operator's position) to activate the switch. Tiller handle outboards and
some remote control units are equipped with a lanyard stop switch. A lanyard
stop switch can be installed as an accessory ‑ generally on the dashboard or
side adjacent to the operator's position.
A decal near the lanyard stop switch is a visual reminder for the operator to
attach the lanyard to their personal flotation device (PFD) or wrist.

eng 3
 GENERAL INFORMATION
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 likelihood of
lanyard entanglement with nearby objects. Its stretched‑out length is made to
minimize the likelihood of accidental activation should the operator choose to
move around in an area close to the normal operator's position. If it is desired
to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg,
or tie a knot in the lanyard.
ATTACH LANYARD
RUN
b
OFF

a
c

53910

a - Lanyard cord clip

b - Lanyard decal
c - Lanyard stop switch

Read the following Safety Information before proceeding.

Important Safety Information: The purpose of a lanyard stop switch is to stop
the engine when the operator moves far enough away from the operator's
position to activate the switch. This would occur if the operator accidentally falls
overboard or moves within the boat a sufficient distance from the operator's
position. Falling overboard and accidental ejections are more likely to occur in
certain types of boats such as low sided inflatables, bass boats, high
performance boats, and light, sensitive handling fishing boats operated by a
hand tiller. Falling overboard and accidental ejections are also likely to occur as
a result of poor operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting on elevated
fishing boat decks, operating at planing speeds in shallow or obstacle infested
waters, releasing your grip on a steering wheel or tiller handle that is pulling in
one direction, drinking alcohol or consuming drugs, or daring high speed boat
maneuvers.

4 eng
 GENERAL INFORMATION
While activation of the lanyard stop switch will stop the engine immediately, a
boat will continue to coast for some distance depending upon the velocity and
degree of any turn at shut down. However, the boat will not complete a full
circle. While the boat is coasting, it can cause injury to anyone in the boat's
path as seriously as the boat would when under power.
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 injury or death from being struck by the boat. Always
properly connect the operator to the stop switch using a lanyard.

! WARNING
Avoid serious injury or death from deceleration forces resulting from
accidental or unintended stop switch activation. The boat operator should
never leave the operator's station without first disconnecting the stop switch
lanyard from the operator.

Accidental or unintended activation of the switch during normal operation is

also a possibility. This could cause any, or all, of the following potentially
hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward
motion ‑ a particular concern for passengers in the front of the boat who
could be ejected over the bow and possibly struck by the gearcase or
propeller.
• Loss of power and directional control in heavy seas, strong current, or
high winds.
• Loss of control when docking.
KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD
OPERATING CONDITION
Before each use, check to ensure the lanyard stop switch works properly. Start
the engine and stop it by pulling the lanyard cord. If the engine does not stop,
have the switch repaired before operating the boat.
Before each use, visually inspect the lanyard cord to ensure it is in good
working condition and that there are no breaks, cuts, or wear to the cord.
Check that the clips on the ends of the cord are in good condition. Replace any
damaged or worn lanyard cords.

eng 5
 GENERAL INFORMATION
Protecting People in the Water
WHILE YOU ARE CRUISING
It is very difficult for a person in the water to take quick action to avoid a boat
heading in their direction, even at slow speeds.

21604

Always slow down and exercise extreme caution any time you are boating in an
area where there might be people in the water.
Whenever a boat is moving (even coasting) and the gear shift is in neutral,
there is sufficient force by the water on the propeller to cause the propeller to
rotate. This neutral propeller rotation can cause serious injury.
WHILE BOAT IS STATIONARY

! WARNING
A spinning propeller, a moving boat, or any solid device attached to the boat
can cause serious injury or death to swimmers. Stop the engine immediately
whenever anyone in the water is near your boat.

Shift into neutral and shut off the engine before allowing people to swim or be
in the water near your boat.

Passenger Safety Message ‑ Pontoon Boats and Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not
allow any passengers to stand or use seats other than those designated for
traveling faster than idle speed. A sudden reduction in boat speed, such as
plunging into a large wave or wake, a sudden throttle reduction, or a sharp
change of boat direction, could throw them over the front of the boat. Falling
over the front of the boat between the two pontoons will position them to be run
over by the outboard.
BOATS HAVING AN OPEN FRONT DECK
No one should ever be on the deck in front of the fence while the boat is in
motion. Keep all passengers behind the front fence or enclosure.

6 eng
 GENERAL INFORMATION
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 back from the front
end of deck boats or raised platforms and remain seated while the boat is in
motion.

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS

Elevated fishing seats are not intended for use when the boat is traveling faster
than idle or trolling speed. Sit only in seats designated for traveling at faster
speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated
passenger falling over the front of the boat.

26783

eng 7
 GENERAL INFORMATION
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 the boat changing direction while in the midst of the
jump. In such case, the landing may cause the boat to veer violently in a new
direction. Such a sharp change in direction can cause occupants to be thrown
out of their seats, or out of the boat.

! WARNING
Wave or wake jumping can cause serious injury or death from occupants
being thrown within or out of the boat. Avoid wave or wake jumping whenever
possible.

There is another less common hazardous result from allowing your boat to
launch off a wave or wake. If the bow of your boat pitches down far enough
while airborne, upon water contact it may penetrate under the water surface
and submarine for an instant. This will bring the boat to a nearly instantaneous
stop and can send the occupants flying forward. The boat may also steer
sharply to one side.

8 eng
 GENERAL INFORMATION
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 striking a
floating or underwater object is to control the boat speed. Under these
conditions, boat speed should be kept to a minimum planing speed of
24 to 40 km/h (15 to 25 mph).

26785

Striking a floating or underwater object could result in an infinite number of

situations. Some of these situations could result in the following:
• Part of the outboard or the entire outboard could break loose and fly into
the boat.
• The boat could move suddenly in a new direction. Such a sharp change in
direction can cause occupants to be thrown out of their seats or out of the
boat.
• A rapid reduction in speed. This will cause occupants to be thrown
forward, or even out of the boat.
• Impact damage to the outboard and/or boat.
Keep in mind, the most important thing you can do to help reduce injury or
impact damage during an impact is control the boat speed. Boat speed should
be kept to a minimum planing speed when driving in waters known to have
underwater obstacles.
After striking a submerged object, stop the engine as soon as possible and
inspect it for any broken or loose parts. If damage is present or suspected, the
outboard should be taken to an authorized dealer for a thorough inspection and
necessary repair.
The boat should also be checked for any hull fractures, transom fractures, or
water leaks.
Operating a damaged outboard could cause additional damage to other parts
of the outboard, or could affect control of the boat. If continued running is
necessary, do so at greatly reduced speeds.

eng 9
 GENERAL INFORMATION
! 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) is a deadly gas that is present in the exhaust fumes of
all internal combustion engines, including the engines that propel boats, and
the generators that power boat accessories. By itself, CO is odorless, colorless,
and tasteless, but if you can smell or taste engine exhaust, you are inhaling
CO.
Early symptoms of carbon monoxide poisoning, which are similar to the
symptoms of seasickness and intoxication, include headache, dizziness,
drowsiness, and nausea.

! 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

co
co
co
co co
co
co co co
co co
co co
co

co co
co co
co co

41127

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of

concentrated engine exhaust gases. When engines are running, keep
swimmers away from the boat, and do not sit, lie, or stand on swim platforms or
boarding ladders. While underway, do not allow passengers to be positioned
immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust
concentration, but also subjects them to the possibility of injury from the boat
propeller.

10 eng
 GENERAL INFORMATION
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 carbon
monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and
passengers in an open area of a stationary boat that contains, or is near, a
running engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:

a
b

21626

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 b

21628

a - Operating the boat with the trim angle of the bow too high
b - Operating the boat with no forward hatches open (station wagon effect)

eng 11
 GENERAL INFORMATION
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 use of nonapproved accessories can damage
the product.
Some accessories not manufactured or sold by Mercury Marine are not
designed to be safely used with your outboard or outboard operating system.
Read the installation, operation and maintenance manuals for all your selected
accessories.
Refer to Outboard Installation ‑ Accessories Mounted to the Transom
Clamp Bracket for important information on mounting accessories to the
transom clamp bracket.

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other
governmental boating regulations and restrictions and consider the following
suggestions.
Know and obey all nautical rules and laws of the waterways.
• 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‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
• Here are some suggestions of the types of safety equipment to carry
when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench

12 eng
 GENERAL INFORMATION
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 and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading, or are
near the back (stern) of the boat. Shifting the drive unit into neutral is not
sufficient.
Use personal flotation devices.
• Federal law requires that there be a U.S. Coast Guard‑approved life
jacket (personal flotation device), correctly sized and readily accessible
for every person onboard, plus a throwable cushion or ring. We strongly
advise that everyone wear a life jacket at all times while in the boat.
Prepare other boat operators.
• 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 boat's operating and
loading limitations. Know if your boat will float if it is full of water. When in
doubt, contact your authorized Mercury Marine dealer or the boat
manufacturer.
Ensure that everyone in the boat is properly seated.
• Do not allow anyone to sit or ride on any part of the boat that was not
intended for such use. This includes the backs of seats, gunwales,
transom, bow, decks, raised fishing seats, and any rotating fishing seat.
Passengers should not sit or ride anywhere that sudden unexpected
acceleration, sudden stopping, unexpected loss of boat control, or sudden
boat movement could cause a person to be thrown overboard or into the
boat. Ensure that all passengers have a proper seat and are in it before
any boat movement.
Never operate a boat while under the influence of alcohol or drugs. It is
the law.
• Alcohol or drugs can impair your judgment and greatly reduce your ability
to react quickly.
Know your boating area and avoid hazardous locations.

eng 13
 GENERAL INFORMATION
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 out for others, the water, and your wake.
Never drive your boat directly behind a water skier.
• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is
61 m (200 ft) in front of you in five seconds.
Watch fallen skiers.
• When using your boat for waterskiing or similar activities, always keep a
fallen or down skier on the operator's side of the boat while returning to
attend to the skier. The operator should always have the down skier in
sight and never back up to the skier or anyone in the water.
Report accidents.
• 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 treatment beyond first aid, 3) there is damage to boats or other
property where the damage value exceeds $500.00, or 4) there is
complete loss of the boat. Seek further assistance from local law
enforcement.

Recording Serial Number

It is important to record this number for future reference. The serial number is
located on the outboard as shown.

a
XXXXXXXXX

XXXXXXXX b
XXXX

63756

a - Model number
b - Serial number
c - Certified Europe Insignia (as applicable)

14 eng
 GENERAL INFORMATION
Specifications—250 XS OptiMax
Attribute Specifications
Horsepower 250 HP (184 kw)
Engine displacement 3038 cc (185 cid)
20 in.
229 kg (505 lb)
Sport Master
Engine 25 in.
237 kg (522 lb)
weight Fleet Master
30 in.
242 kg (533 lb)
Fleet Master
Full throttle RPM range 5500–6000 RPM
Overspeed rev limit 6300 RPM
Idle RPM 585 RPM
Neutral rev limit 2250 RPM
Cylinder configuration 60° V6
Cylinder bore 92.075 mm (3.625 in.)
Stroke 76.2 mm (3.000 in.)
NGK IZFR6J‑11 (factory installed)
Recommended spark plug
NGK IZFR6J (service)
Spark plug gap 1.1 mm (0.042 in.)
Firing order 1‑2‑3‑4‑5‑6
Maximum timing Controlled by PCM
Idle timing Controlled by PCM
Fuel line pressure 655 ± 13.8 kPa (95 ± 2 psi)
Air pressure 758 ± 13.8 kPa (110 ± 2 psi)
1.62:1
Sport Master
Gear ratio 1.75:1
Fleet Master 1.75:1
Unleaded gasoline
Required fuel
87 R+M/2 octane (90 RON)
Recommended oil Mercury Racing 2‑Stroke Oil
Gearcase oil Mercury Racing Gear Lube
Gearcase lubricant capacity 710 ml (24 fl oz)
1000 marine cranking amps (MCA), 800
Battery rating*
cold cranking amps (CCA), 105 Ah
Charging system output 50 A maximum

eng 15
 GENERAL INFORMATION
Attribute Specifications
20 in. Three‑ram (integral) trim
Trim system
25/30 in. Single‑ram (remote pump) trim
Emission control system Electronic engine control (EC)

*Battery manufacturers may rate and test their batteries to different standards.
MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by
Mercury Marine. Manufacturers that use standards different than these, such
as equivalent MCA, do not meet Mercury Marine battery requirements.

Specifications—300XS OptiMax
Specifications
Propshaft horsepower 300 HP (221 kw)
Engine displacement 3160 cc (193 cid)
20 in.
218 kg (480 lb)
(Torque Master)
20 in.
229 kg (505 lb)
(Sport Master)
25 in.
Engine weight 239 kg (528 lb)
(Torque Master)
25 in.
237 kg (522 lb)
(Fleet Master)
30 in.
242 kg (533 lb)
(Fleet Master)
20 in.
5500–6300 RPM
(Torque Master)
20 in.
5500–6300 RPM
(Sport Master)
25 in.
Full throttle RPM range 5500–6300 RPM
(Torque Master)
25 in.
5300–5800 RPM
(Fleet Master)
30 in.
5300–5800 RPM
(Fleet Master)

16 eng
 GENERAL INFORMATION
Specifications
20 in.
6350 RPM
(Torque Master)
20 in.
6350 RPM
(Sport Master)
25 in.
Overspeed rev limit 6350 RPM
(Torque Master)
25 in.
5900 RPM
(Fleet Master)
30 in. Models
5900 RPM
(Fleet Master)
Idle RPM 585 RPM
Neutral rev limit 1900 RPM
Cylinder configuration 60° V6
Cylinder bore 92.075 mm (3.625 in.)
Stroke 78.9 mm (3.110 in.)
Spark plug NGK IZFR7M
Spark plug gap 0.81 mm (0.032 in.)
Firing order 1‑2‑3‑4‑5‑6
Maximum timing Controlled by PCM
Idle timing Controlled by PCM
Fuel pressure 655 ± 13.8 kPa (95 ± 2 psi)
Air pressure 758 ± 13.8 kPa (110 ± 2 psi)
1.62:1
Torque Master
1.75:1
Gear ratio 1.62:1
Sport Master
1.75:1
Fleet Master 1.75:1
Premium unleaded
Required fuel
91 R+M/2 octane (96 RON)
Recommended oil Premium Plus TC‑W3 2‑Cycle
Gearcase oil High‑Performance gear lube
Gearcase lubricant capacity 710 ml (24 fl oz)
1000 marine cranking amps,
Battery rating 800 cold cranking amps
105 amp hours1.
Charging system output 50 A maximum

1. Battery manufacturers may rate and test their batteries to different standards. Consult with the specific battery
manufacturer for comparison ratings.

eng 17
 GENERAL INFORMATION
Specifications
Emission control system Electronic engine control (EC)

Special Tools and Kits

Description Part Number
Stainless Steel Tilt Pin (Three‑Ram Trim Systems) 17‑49930A1
Oil Syringe 91‑803976T
Flushing Attachment (for Torque/Fleet Master gearcase) 44357T2
Flushing Attachment (for Sport Master gearcase) 848998A1
Dual Water Pick‑Up Flush Seal Kit (Fleet/Torque Master
881150K1
gearcase)

Component Identification

1- Top cowl
2- Side cowl latches (both
sides)
1 2 3- Front cowl latch
4- Auxiliary tilt switch
5- Clamp/swivel bracket
3
6- Gearcase
13
7- Cooling water intake
4 (location dependent on
12 gearcase)
8- Skeg
11 5 9- Anode plate
10 - Anti‑ventilation plate
11 - Driveshaft housing
10 12 - Water pump indicator
13 - Bottom cowl
6
9 7

8 24318

18 eng
 GENERAL INFORMATION
Propeller Selection
Propping the engine at the higher end of the RPM range may increase
acceleration, but decrease top boat speed. Conversely, propping the engine at
the lower end of the range may increase top boat speed but hinder
acceleration. Mercury Marine recommends selecting a propeller that allows the
engine to operate in the upper half of the recommended full throttle RPM range
with the boat normally loaded (refer to General Information ‑ Specifications).
This RPM range allows for better acceleration while maintaining maximum boat
speed.
All "L" models (20 in. driveshaft) are capable of operating at engine speeds of
up to 6000 RPM. This increased engine speed gives the operator a greater
range of pitch selection. However, propping at the uppermost limit of the RPM
range may not necessarily result in improved high speed performance. Boat
weight and hull design influence the effectiveness of this increased engine
speed and may decrease top boat speed.
If full throttle operation is below the recommended full throttle range, the
propeller must be changed to prevent loss of performance and possible engine
damage. On the other hand, operating an engine above the recommended
operating RPM range will cause higher than normal wear or damage.
Generally, there is a 200‑300 RPM change between propeller pitches.

22551

If changing conditions cause the RPM to drop below the recommended range
(such as warmer, more humid weather, operation at higher elevations,
increased boat load, or a dirty boat bottom/gearcase), a propeller change or
cleaning may be required to maintain performance and ensure the outboards
durability.
Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed
out to a balanced‑steering condition (steering effort equal in both directions)
without causing the propeller to break loose.

eng 19
 TRANSPORTING
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 crossings,
driveways and trailer bouncing.

2722

IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to
maintain proper ground clearance for trailering. The outboard tilt support lever
is not intended to support the outboard for trailering.
Shift the outboard to forward gear. This prevents the propeller from spinning
freely.

20 eng
 FUEL AND OIL
Fuel Requirements
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 will not be covered under the limited warranty.
FUEL RATINGS
Mercury outboard engines will operate satisfactorily with any major brand of
unleaded gasoline that meets the following specifications:
USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for
most models. Premium gasoline 91 (R+M)/2 octane is also acceptable for most
models. Do not use leaded gasoline.
Outside USA and Canada ‑ A posted pump octane rating of 91 RON,
minimum, for most models. Premium gasoline (95 RON) is also acceptable for
all models. Do not use leaded gasoline.
USING REFORMULATED (OXYGENATED) GASOLINE (USA ONLY)
Reformulated gasoline is required in certain areas of the USA and is
acceptable for use in your Mercury Marine engine. The only oxygenate
currently in use in the USA is alcohol (ethanol, methanol, or butanol).
GASOLINE CONTAINING ALCOHOL
Bu16 Butanol Fuel Blends
Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury
Marine fuel rating requirements are an acceptable substitute for unleaded
gasoline. Contact your boat manufacturer for specific recommendations on
your boat's fuel system components (fuel tanks, fuel lines, and fittings).
Methanol and Ethanol Fuel Blends
IMPORTANT: The fuel system components on your Mercury Marine engine will
withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your
boat's fuel system may not be capable of withstanding the same percentage of
alcohol. Contact your boat manufacturer for specific recommendations on your
boat's fuel system components (fuel tanks, fuel lines, and fittings).
Be aware that gasoline containing methanol or ethanol may cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through the rubber fuel lines
• Likelihood of phase separation (water and alcohol separating from the
gasoline in the fuel tank)

eng 21
 FUEL AND OIL
! 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.

IMPORTANT: If you use gasoline that contains or might contain methanol or

ethanol, you must increase the frequency of inspection for leaks and
abnormalities.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing
methanol or ethanol, do not store the gasoline in the fuel tank for long periods.
Cars normally consume these blended fuels before they can absorb enough
moisture to cause trouble; boats often sit idle long enough for phase separation
to take place. Internal corrosion may occur during storage if alcohol has
washed protective oil films from internal components.

Oil Recommendation
Recommended oil Mercury Racing 2‑Stroke Oil
OptiMax DFI engine oil
Alternate oil
Premium Plus 2‑Cycle Outboard Oil

Mercury Racing 2‑Stroke Oil is recommended for OptiMax engines that are
used in applications of extreme loads associated with commercial, work, or
extended periods of high RPM. The added lubrication and protection properties
with Mercury Racing 2‑Stroke oil, maximizes engine horsepower while
protecting against heat, reduces wear and carbon deposit build‑up.
OptiMax DFI engine oil or Premium Plus 2‑Cycle Outboard Oil can be used as
an alternate oil.
IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil.
Periodically consult with your dealer to get the latest gasoline and oil
recommendations. If Quicksilver 2‑Cycle Outboard Oil is not available,
substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3.
The use of an inferior 2‑Cycle outboard oil can reduce engine durability.
Damage from use of inferior oil may not be covered under the limited warranty.

Fuel Additives
To minimize carbon deposit buildup in the engine, it is recommended to add
Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine's fuel at
each tank fill throughout the boating season. Use additive as directed on
container.

22 eng
 FUEL AND OIL
Avoiding Fuel Flow Restrictions
NOTICE
Adding components to the fuel supply system can damage the engine. These
additions can restrict fuel flow, stall the engine at low speeds, and create lean
fuel conditions at high speeds. Follow all regulations for fuel system
installation and do not add any additional components to the fuel system.

Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered for sale in the
United States.
• The Environmental Protection Agency (EPA) requires that any outboard
manufactured after January 1, 2009, must use low permeation fuel hose
for the primary fuel hose connecting the fuel tank to the outboard.
• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not
exceeding 15 g/m²/24 h with CE 10 fuel at 23 °C as specified in SAE J
1527 ‑ marine fuel hose.

EPA Pressurized Portable Fuel Tank Requirements

The Environmental Protection Agency (EPA) requires portable fuel systems
that are produced after January 1, 2011, for use with outboard engines to
remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may
contain the following:
• An air inlet that opens to allow air to enter as the fuel is drawn out of the
tank.
• An air outlet that opens (vents) to the atmosphere if pressure exceeds
34.4 kPa (5.0 psi).

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 primer bulb. The fuel
demand valve prevents pressurized fuel from entering the engine and causing
a fuel system overflow or possible fuel spillage.
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.

b a - Fuel demand valve ‑ installed in the

a fuel hose between the fuel tank and
primer bulb
b - Manual release
c 46273
c - Vent/water drain holes

eng 23
 FUEL AND OIL
Mercury Marine's Pressurized Portable Fuel Tank
Mercury Marine has created a new portable pressurized fuel tank that meets
the preceding EPA requirements. These fuel tanks are available as an
accessory or are provided with certain portable outboard models.
SPECIAL FEATURES OF THE PORTABLE FUEL TANK
• The fuel tank has a two‑way valve which allows air to enter the tank as
the fuel is drawn to the engine, and also opens to vent to the atmosphere
if internal pressure in the tank exceeds 34.4 kPa (5.0 psi). A hissing noise
may be heard as the tank vents to the atmosphere. This is normal.
• The fuel tank includes a fuel demand valve that prevents pressurized fuel
from entering the engine and causing a fuel system overflow or possible
fuel spillage.
• When installing the fuel tank cap, turn the cap to the right until you hear a
click. This signals that the fuel cap is fully seated. A built‑in device
prevents overtightening.
• The fuel tank has a manual vent screw which should be closed for
transportation and open for operation and cap removal.
Since sealed fuel tanks are not vented, they will expand and contract as the
fuel expands and contracts during heating and cooling cycles of the outside air.
This is normal.
REMOVING THE FUEL CAP

b a - Fuel cap
a b - Manual vent screw
c - Tab lock

c
46290
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 fuel cap 1/4 turn to relieve the
pressure.
4. Press down on the tab lock again and remove the cap.

24 eng
 FUEL AND OIL
DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK
1. When installing the fuel tank cap, turn the cap to the right until you hear a
click. This signals that the fuel cap is fully seated. A built‑in device
prevents overtightening.
2. Open the manual vent screw on top of the cap for operation and cap
removal. Close the manual vent screw for transportation.
3. For fuel hoses that have quick disconnects, disconnect the fuel line from
the engine or fuel tank when not in use.
4. Follow Filling Fuel Tank instructions for fueling.

Filling Remote Oil Tank

Remove the filler cap and fill with the specified oil. Oil tank capacity is
11.5 liters (3 gallons). Replace the filler cap and tighten securely.
IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air
leak will prevent oil flow to the engine.

2723

Filling Engine Mounted Oil Reservoir Tank

NOTE: Filling this tank is only necessary if the oil level should ever drop and
the low oil warning system is activated.
1. Remove the top cowl.
2. Loosen the fill cap on the engine oil reservoir tank. Run the engine until all
the air has been vented out of the oil reservoir tank and tank is filled with
oil to the point of overflow.
3. Tighten the fill cap. Stop the engine and replace the top cowl.

29424

eng 25
 FUEL AND OIL
Filling 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 smoke or allow
open flames or sparks in the area while filling fuel tanks.

Fill the fuel tanks outdoors away from heat, sparks, and open flames.
Remove the portable fuel tanks from the boat to refill them.
Always stop the engine before filling the tanks.
Do not completely fill the fuel tanks. Leave approximately 10% of the tank
volume unfilled. Fuel will expand in volume as its temperature rises and can
leak under pressure if the tank is completely filled.

26 eng
 FEATURES AND CONTROLS
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.

c c
c
a a
b
h
b g
f i
a i
g
d d
f f
e 26800
e

a - Control handle – forward, neutral, reverse

b - Neutral release lever
c - Trim/tilt switch (if equipped) – Refer to Features and Controls –
Power Trim and Tilt
d - Lanyard stop switch – Refer to General Information – Lanyard Stop
Switch
e - Lanyard – Refer to General Information – Lanyard Stop Switch
f - Throttle friction adjustment – Console controls require cover removal for
adjustment
g - Ignition key switch – "OFF," "ON," START"
h - Fast idle lever – Refer to Operation – Starting the Engine
i - Throttle only button – Refer to Operation – Starting the Engine

eng 27
 FEATURES AND CONTROLS
Zero Effort Control Features

a a - Throttle lever
b - Trim switch
c - Shift lever
b

4090

Warning System
WARNING HORN SIGNALS
When the key switch is turned to the ON position, the horn will turn on for a
moment as a test to indicate the horn is working.
There are two types of warning horns to alert the operator of an active problem
within the engine’s operating system.
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 engine
condition. This condition does not require immediate attention. You may
continue using your boat, however, depending on the nature of the
problem, the engine’s power may be limited by the Engine Guardian
system (see Engine Guardian System following) to protect the engine.
You should contact your servicing dealer at your earliest convenience.
It is important to note that in either of the above scenarios, the horn will only
sound one time. If you key the engine off and restart it, the horn will sound
again, one time, if the fault is still present. For visual display of the specific
engine functions and additional engine data, refer to SmartCraft Product
information, following.
A few of the noncritical conditions indicated by the intermittent short beeps for
six seconds can be corrected by the operator. These operator correctable
conditions are as follows:
• Water in the engine mounted fuel filter. Refer to Maintenance – Water
Separating Fuel Filter.

28 eng
 FEATURES AND CONTROLS
• Cooling system (water pressure or engine temperature) problem. Stop the
engine and check the water intake holes in the lower unit for obstruction.
• Low engine oil level. Refer to Fuel and Oil – Filling Engine Mounted Oil
Reservoir Tank.

ENGINE GUARDIAN SYSTEM

The Engine Guardian system monitors the critical sensors on the engine for
any early indications of problems. Engine Guardian is functional whenever your
engine is operating, so you never have to be concerned about whether or not
you are protected. The system will respond to a problem by sounding the
warning horn for six seconds and/or reducing engine power in order to provide
engine protection.
If Engine Guardian has been activated, reduce the engine speed. The problem
will need to be identified and corrected. The system must be reset before the
engine will operate at higher speeds. Moving the throttle lever back to the idle
position will reset the Engine Guardian system. If the Engine Guardian system
has determined the reset has not corrected the problem, Engine Guardian will
remain activated, limiting the throttle. The problem must be identified and
corrected before Engine Guardian will allow the engine to reach a normal
operating RPM.

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 engine’s
RPM limit.
Upon reaching the beginning of the rev limit, Engine Guardian will cut‑out the
ignition to specific cylinders. If the operator does not reduce engine speed,
Engine Guardian will cut‑out the ignition to all the cylinders. There is no audible
warning while Engine Guardian overspeed limit is active.
To reset the Engine Guardian protection:
1. Completely reduce the throttle for three seconds.
2. Engage the throttle. If the engine does not respond, repeat step one.

SMARTCRAFT PRODUCT
A Mercury SmartCraft System instrument package can be purchased for this
outboard. A few of the functions the instrument package will display are engine
RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel
consumption, and engine operating hours.
The SmartCraft instrument package will also aid in Engine Guardian
diagnostics. The SmartCraft Instrument package will display critical engine
alarm data and potential problems.

eng 29
 FEATURES AND CONTROLS
Power Trim and Tilt
NOTE: Outboard position can be adjusted by pressing trim switch. This range
is used while operating your boat on plane.

c
b
b 2726

a - Trim switch
b - Trim range
c - Tilt range

• Pressing (DN): Moves the outboard in closer to the boat transom, called
trimming in or down.
• Pressing (UP): Moves the outboard further away from the boat transom,
called trimming out or up.
• The term trim generally refers to the adjustment of the outboard within
the first 20° range of travel.
• The term tilt generally refers to adjusting the outboard further up out of
the water.
With the engine turned off, the outboard can be tilted out of the water. At low
idle speed, the outboard can also be tilted up past the trim range to permit, for
example, shallow water operation.

Power Trim Operation

With most boats, operating around the middle of the trim range will give
satisfactory results. Trimming your outboard all the way in or out may improve
performance, but cause some potential control hazards.

30 eng
 FEATURES AND CONTROLS
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a
pull on the steering wheel or tiller handle and loss of boat control. Maintain
control of the boat if trimming beyond a neutral steering condition.

Consider the following lists carefully.

Trimming in or down can:
• Lower the bow of the boat.
• Result in quicker planing off.
• Generally improve the ride in choppy water.
• Increase steering torque or pull to the right (with the normal right‑hand
rotation propeller).
• In excess, lower the bow to a point at which the boat begins to plow with
the bow in the water while on plane. This can result in an unexpected turn
in either direction called bow steering or over steering if any turn is
attempted, or if a significant wave is encountered.
LIMITING TRIM IN
In rare circumstances, the owner may decide to limit the trim in to avoid unsafe
handling or steering conditions at planing speeds.

! 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.

! WARNING
On some boats, increased trim‑in range can cause handling problems at high
speeds, resulting in personal injury or death. We recommend that only
qualified personnel adjust the trim‑in limit inserts and test the boat for
handling problems.

IMPORTANT: Some boat/engine combinations not using a trim angle

adjustment device, or trimmed to the full trim in position, may not exhibit any
undesireable or unsafe handling or steering conditions. In these cases, a trim
limiting device may not be adventageous to accelleration or planing. Always
perform a water test to determine if these characteristics apply to a particular
boat/engine combination.
To limit trim in on models with a three‑ram trim system, purchase a stainless
steel tilt pin from your dealer and insert it in whichever adjustment hole is
desired.

eng 31
 FEATURES AND CONTROLS
To limit trim in on models with a single‑ram trim system, use the cadmium
plated bolt shipped with the engine.

b
a

15923

a - Stainless steel tilt pin (Three‑Ram trim system)

b - Bolt shipped with engine (Single‑Ram trim system)

Trimming out or up can:

• Lift the bow higher out of the water.
• Generally increase top speed.
• Gain clearance over submerged objects or a shallow bottom.
• Increase steering torque or pull to the left at a normal installation height
(with the normal right hand rotation propeller).
• In excess, cause boat porpoising (bouncing) or propeller ventilation.
• Cause engine overheating if any cooling water intake holes are above the
water line.

Power Tilt Operation (Single‑Ram Systems)

To tilt the outboard, shut off the engine and press the trim/tilt switch or the
auxiliary tilt switch to the up position. The outboard tilts up until the switch is
released or it reaches the maximum tilt position.
The hydraulic system is fully capable of supporting the outboard during normal
tilting operation. However, if trailering the boat in the trim/tilt position, use an
accessory outboard support device.

Power Tilt Operation (Three‑Ram Trim Systems)

To tilt the outboard, shut off the engine and press the trim/tilt switch or the
auxiliary tilt switch (located on the cowl) to the up position. The outboard tilts up
until the switch is released or it reaches the maximum tilt position.

32 eng
 FEATURES AND CONTROLS
1. Engage the tilt support lever by pushing the metal stop and rotating the
knob to bring the support lever upward.

a
c
b 37214

a - Tilt support lever

b - Metal stop
c - Knob

2. Lower the outboard to rest on the tilt support lever.

3. Disengage the tilt support lever by raising the outboard off the support
lever and rotating the lever until it locks. Lower the outboard.

Auxiliary Tilt Switch

This switch can be used to tilt the outboard up or down using the power trim
system.

a - Auxiliary tilt switch

a

2745

Manual Tilt Operation

If the outboard cannot be tilted using the power trim/tilt switch, the outboard can
be tilted manually.

eng 33
 FEATURES AND CONTROLS
1. Turn out the manual tilt release valve three turns (counterclockwise). This
allows manual tilting of the outboard.

2728

2. Tilt the outboard to the desired position and tighten the manual tilt release
valve.
NOTE: The manual tilt release valve must be tightened before operating the
outboard to prevent the outboard from tilting up during reverse operation.

34 eng
 OPERATION
Important Information
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 bracket

BEFORE STARTING THE ENGINE

NOTICE
Lack of oil pressure in the system can cause severe internal engine damage
during start‑up. Prime the oil injection pump on new or rebuilt engines or after
performing maintenance on the oiling system.

Refer to Outboard Installation ‑ Priming the Oil Injection Pump for

instructions.

FUEL REQUIREMENTS
Do not use premixed gas and oil in this engine. The engine automatically
receives extra oil during engine break‑in. Use a fresh supply of the
recommended gasoline during engine break‑in and after engine break‑in.

Engine Break‑in
! 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.

eng 35
 OPERATION
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.

Break‑in Procedure
Always vary throttle settings during Break‑in
1st Hour
• Allow engine to warm‑up for 30–60 seconds.
• Do not idle for more than five (5) minutes
• Run the engine the majority of the time between 4000–5400 RPM
(approximately three quarter throttle).
• Change engine speed approximately every two (2) minutes.
• Avoid trimming the outboard out (up) beyond a vertical trim position
during operation.
• Avoid using hydraulic jack plate (if equipped) to raise engine during
break‑in cycle.
Next 3 Hours: Change engine speed every 10 minutes.

Engine Break‑in Fuel Mixture

The propulsion control module (PCM) controls oil and fuel mixture during
engine break‑in.

Prestarting Check List

Engine lowered to run position with all water intake holes submerged
Fuel tank vent cap open or fuel drain valve on
Fuel supply OK
Lanyard stop switch in "RUN" position and cord connected
Remote control in neutral
Top cowl latches secure
Make inspection checks listed in the Inspection and Maintenance
Schedule. Refer to Maintenance section.

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
components.

36 eng
 OPERATION
If there is a chance of ice forming on the water, the outboard should be
removed and drained completely of water. If ice should form at the water level
inside the outboard driveshaft housing, it will block water flow to the engine
causing possible damage.

Operating in Saltwater or Polluted Water

We recommend that you flush the internal water passages of your outboard
with fresh water after each use in salt or polluted water. This will prevent a
buildup of deposits from clogging the water passages. Refer to Maintenance ‑
Flushing the Cooling System.
If you keep your boat moored in the water, always tilt the outboard so the
gearcase is completely out of water (except in freezing temperatures) when not
in use.
Wash the outboard exterior and flush out the exhaust outlet of the propeller and
gearcase with fresh water after each use. Each month, spray Mercury Precision
or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on
corrosion control anodes as this will reduce the effectiveness of the anodes.

Operating at High Elevations

Your engine automatically compensates for high elevation changes. A different
pitch propeller may help reduce some normal performance loss resulting from
reduced oxygen in the air. Consult your dealer.

Effects of Elevation and Weather on Performance

The following conditions lower engine performance and cannot be
compensated by the engine fuel or electronic management systems:
• Above sea level elevations
• High temperature
• Low barometric pressure
• High humidity
These conditions above reduce air density to the engine, which in turn lowers
the following:
• Boost pressure on supercharged engines
• Horsepower and torque throughout the RPM range
• Peak RPM
• Cranking compression
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 ratio.

eng 37
 OPERATION
Some boat performance can be improved by dropping to a lower pitch
propeller, but engine performance will still remain lower. In some cases, a gear
ratio reduction may be more beneficial. To optimize engine performance, prop
the engine to allow it to operate at or near the top end of the recommended
maximum RPM range at wide‑open throttle with a normal boat load.
Other advantages to propeller or gear ratio changes:
• Reduces the possibility of detonation
• Enhances overall reliability and durability of the engine

Setting Trim Angle While Running Engine at Idle Speed

Submerging the exhaust relief hole on the outboard can happen on some boats
if you trim full in while running at idle speed, resulting in, exhaust restriction,
rough idle, excessive smoke, and fouled spark plugs. If this condition exists,
trim outboard up until exhaust relief hole is out of the water.

a - Relief hole submerged

a (wrong)
b
b - Relief hole above waterline
(correct)

2729

Operating in Shallow Water

When operating your boat in shallow water, you can tilt the outboard beyond
the maximum trim range to prevent hitting bottom.

NOTICE
Operating the engine with the outboard in the tilt range can damage the
engine or the transom. If operating the engine in the tilt range, such as in
shallow water, do not exceed 2000 RPM.

1. Reduce the engine speed below 2000 RPM.

2. Tilt the outboard up. Make sure all the cooling water intake holes stay
submerged at all times.
3. Operate the engine at slow speed only.
Models with a three‑ram trim system: If engine speed exceeds 2000 RPM, the
outboard will automatically return down to the maximum trim range.
Models with a single‑ram trim system: The outboard will remain at the selected
tilt position, regardless of engine RPM.

38 eng
 OPERATION
Oil Injection System
FILLING THE OIL TANKS
1. Remove the fill cap from the remote oil tank and fill the tank with the
recommended oil. Install the fill cap and tighten securely.

a
a - Fill cap

2683

IMPORTANT: Do not remove the vent cap from the engine‑mounted oil
reservoir tank when filling the tank. Removal of the vent cap may damage the
threads in the oil reservoir tank. Damaged threads may result in future oil
leakage.
2. Check the oil level in the engine‑mounted oil reservoir tank. The tank
must contain at least 118 ml (4 oz) of oil prior to starting the engine.
3. If the oil level is less than 118 ml (4 oz), loosen the vent cap. Use a squirt
can and fill the tank with at least 118 ml (4 oz) of the recommended oil.
Tighten the vent cap.

b a - Engine‑mounted oil reservoir tank

b - Vent cap

7745

eng 39
 OPERATION
PRIMING THE OIL INJECTION PUMP
Before starting the engine for the first time, prime the oil injection pump.
Priming will remove any air that may be in the pump, oil supply hose, or internal
passages.

7747

a - Oil injection pump

b - Oil supply hose

IMPORTANT: Fill the engine fuel system with fuel before priming the oil
injection pump. Otherwise, the fuel pump will run without fuel during the priming
process and may be damaged.
Prime the oil injection pump as follows:
1. Fill the engine fuel tank with fuel.
2. Position the fuel primer bulb so the arrow on the side of the bulb is
pointing up. Squeeze the fuel hose primer bulb until it feels firm.

27348

40 eng
 OPERATION
3. Turn the ignition key switch to the "ON" position.

26846

4. Within the first 10 seconds after the key switch has been turned on, move
the remote control handle from neutral into forward gear 3 to 5 times. This
will automatically start the priming process.
NOTE: It may take a few minutes for the pump to complete the priming
process.
PURGING AIR FROM THE ENGINE MOUNTED OIL RESERVOIR TANK
1. Loosen the vent cap on the engine mounted oil reservoir tank.
2. Start the engine.
3. Operate the engine until all the air has vented out and oil starts to flow out
of the tank.
4. Tighten the vent cap.

Starting the Engine

NOTICE
Without sufficient cooling water, the engine, the water pump, and other
components will overheat and suffer damage. Provide a sufficient supply of
water to the water inlets during operation.

INITIAL STARTING PROCEDURE

NOTE: For initial start up of a new engine, or for an engine that ran out of fuel
or was drained of fuel, the fuel system should be filled according to the
following procedure.
1. Squeeze the fuel line primer bulb until it feels firm.
2. Turn the ignition key switch to the ON position for three seconds. This
operates the electric fuel pump.
3. Turn the ignition key switch back to the OFF position, and squeeze the
primer bulb again until it feels firm. Turn the ignition key switch to the ON
position again for three seconds. Continue this procedure until the fuel
line primer bulb stays firm.
Before starting, read the Prestarting Check List, special operating instructions
in the Operation section.

eng 41
 OPERATION
STARTING PROCEDURE
1. Lower the outboard to the RUN position. Make sure all the cooling water
intake holes are submerged.

26837

2. Open fuel tank filler cap vent screw (manual venting fuel tanks).

19748

3. Squeeze the fuel line primer bulb several times until it feels firm.

19779

4. Set the lanyard stop switch to the RUN position. Read the Lanyard Stop
Switch safety explanation and warning in the General Information
section.

19791

42 eng
 OPERATION
5. Shift the outboard to the neutral position.

26838

6. Do not advance the neutral fast idle speed feature on the remote control
for starting (if equipped).

27242

7. Turn the ignition key to the START position. Release the key when the
engine starts. If the engine fails to start in ten seconds, return the key to
the OFF position, wait one second, and try again.

19804

8. Check for water coming out of the water pump indicator hole.

2746

NOTE: The electronic starting system will automatically prime (choke) the
engine and increase idle speed for starting.

eng 43
 OPERATION
NOTICE
Operating the engine while overheated can cause engine damage. If no
water exits the water pump indicator hole, stop the engine and check the
cooling water intake holes for obstruction. No obstruction may indicate a
water pump failure or blockage in the cooling system, which can overheat the
engine. Have an authorized Mercury Marine dealer check the system.

Gear Shifting
IMPORTANT: Observe the following:
• Never shift the outboard into or out of gear unless the engine speed
is at idle. Shifting at higher than engine idle speed could cause
damage to the gearcase.
• Do not shift the outboard into reverse when the forward motion of
the boat is greater than a no wake speed. Shifting into reverse at
higher boat speeds could cause the engine to stall, and in some
situations, this could cause water to be drawn into the cylinders,
resulting in severe engine damage.
• Do not shift the outboard into reverse when the engine is not
running. Damage to the shift linkage could occur.
• The outboard has three gear shift positions: forward (F), neutral (N), and
reverse (R).
• When shifting, always stop at the neutral position and allow the engine
idle speed to stabilize before shifting into another gear.
• Always shift the outboard into gear with a quick motion.
• After shifting the outboard into gear, advance the lever further to increase
speed.

Stopping the Engine

Reduce the engine speed and shift the outboard to neutral position. Turn the
ignition key to "OFF" position.
OFF
ON
START

26843

44 eng
 MAINTENANCE
Cleaning Care Recommendations
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.
Record maintenance performed in the Maintenance Log at the back of this
book. Save all maintenance work orders and receipts.
Selecting Replacement Parts For Your Outboard
We recommend using original Mercury Precision or Quicksilver replacement
parts and Genuine Lubricants.

DO NOT USE CAUSTIC CLEANING CHEMICALS

IMPORTANT: Do not use caustic cleaning chemicals on the outboard power
package. Some cleaning products contain strong caustic agents such as hull
cleaners with hydrochloric acid. These cleaners can degrade some of the
components they come in contact with including critical steering fasteners.
Damage to steering fasteners may not be obvious during visual inspection and
this damage may lead to catastrophic failure. Some caustic cleaning chemicals
may cause or accelerate corrosion. Exercise caution when using cleaning
chemicals around the engine and follow the recommendations on the
packaging of the cleaning product.

CLEANING GAUGES
IMPORTANT: Never use high‑pressure water to clean gauges.
Routine cleaning of the gauges is recommended to prevent a buildup of salt
and other environmental debris. Crystalized salt can scratch the gauge display
lens when using a dry or damp cloth. Ensure that the cloth has a sufficient
amount of fresh water to dissolve and remove salt or mineral deposits. Do not
apply aggressive pressure on the display lens while cleaning.
When water marks cannot be removed with a damp cloth, mix a 50/50 solution
of warm water and isopropyl alcohol to clean the display lens. Do not use
acetone, mineral spirits, turpentine type solvents, or ammonia based cleaning
products. The use of strong solvents or detergents may damage the coating,
the plastics, or the rubber keys on the gauges. If the gauge has a sun cover
available, it is recommended that the cover be installed when the unit is not in
use to prevent UV damage to the plastic bezels and rubber keys.

CLEANING REMOTE CONTROLS

IMPORTANT: Never use high‑pressure water to clean remote controls.

eng 45
 MAINTENANCE
Routine cleaning of the remote control external surfaces is recommended to
prevent a buildup of salt and other environmental debris. Use a cloth towel
which has a sufficient amount of fresh water to dissolve and remove salt or
mineral deposits.
When water marks cannot be removed with a damp cloth, mix a 50/50 solution
of warm water and isopropyl alcohol to clean the remote control. Do not use
acetone, mineral spirits, turpentine type solvents, or ammonia based cleaning
products. The use of strong solvents or detergents may damage the coating,
the plastics, or the rubber components on the remote control.

CLEANING CARE FOR TOP AND BOTTOM COWLS

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in
minor surface scratches. Always wet the surface before cleaning. Do not use
detergents containing hydrochloric acid. Follow the cleaning and waxing
procedure.
Cleaning and Waxing Procedure
1. Before washing, rinse the cowls with clean water to remove dirt and dust
that may scratch the surface.
2. Wash the cowls with clean water and a mild nonabrasive soap. Use a soft
clean cloth when washing.
3. Dry thoroughly with a soft clean cloth.
4. Wax the surface using a nonabrasive automotive polish (polish designed
for clear coat finishes). Remove the applied wax by hand using a clean
soft cloth.
5. To remove minor scratches, use Mercury Marine Cowl Finishing
Compound (92‑859026K 1).

CLEANING CARE FOR THE POWERHEAD (SALTWATER USE)

If the outboard is operated in 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 and alternator.
After washing, allow the powerhead and components to dry. Apply Quicksilver
or Mercury Precision Lubricants Corrosion Guard spray on the external metal
surfaces of the powerhead and powerhead components. Do not allow the
Corrosion Guard spray to come in contact with the alternator drive belt or belt
pulleys.
IMPORTANT: Do not allow lubricant or Corrosion Guard spray to come in
contact with the alternator drive belt or the belt pulleys. The alternator drive belt
could slip and be damaged if it becomes coated with any lubricant or Corrosion
Guard spray.

46 eng
 MAINTENANCE

Tube Ref
Description Where Used Part No.
No.
External metal surfaces of the powerhead
120 Corrosion Guard 92-802878 55
and powerhead components.

Power Package Care

! WARNING
Neglect or improper maintenance, repairs, or inspections of the power
package can result in product damage or serious injury or death. Perform all
procedures as described in this manual. If you are not familiar with proper
maintenance or service procedures, consign the work to an authorized
Mercury Marine dealer.

To ensure safety and retain dependability, keep your power package in the
best operating condition by performing the periodic inspections and
maintenance listed in the Inspection and Maintenance Schedule. Record
maintenance performed in the Maintenance Log at the back of this book. Save
all maintenance work orders and receipts.

Replacement Parts for Your Power Package

Mercury recommends using original Mercury Precision replacement parts and
lubricants.

EPA Emissions Regulations

All new outboards manufactured by Mercury Marine are certified to the United
States Environmental Protection Agency, as conforming to the requirements of
the regulations for the control of air pollution from new outboard motors. This
certification is contingent on certain adjustments set to factory standards. For
this reason, the factory procedure for servicing the product must be strictly
followed and, wherever practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission control devices and
systems may be performed by any marine spark ignition (SI) engine
repair establishment or individual.

eng 47
 MAINTENANCE
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.

EMISSION CONTROL
a INFORMATION
f
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA

b
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, g
SPECIFICATIONS, AND ADJUSTMENTS

c IDLE SPEED (in gear): FAMILY:

h
hp L HC+NOx:FEL: g/kWh

d kw
SPARK PLUG:
CO FEL: g/kWh
i
GAP:
e LOW PERM/HIGH PERM: j
43210

a- Idle speed
b- Engine horsepower
c- Piston displacement
d- Engine power ‑ kilowatts
e- Date of manufacture
f- US EPA engine family name
g- Regulated emission limit for the engine family
h- Regulated emission limit for the engine family
i- Recommended spark plug and gap
j- Percent of fuel line permeation

OWNER RESPONSIBILITY
The owner/operator is required to have routine engine maintenance performed
to maintain emission levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter
the horsepower or allow emission levels to exceed their predetermined factory
specifications.

Inspection and Maintenance Schedule

DAILY CHECKS
• Check the engine oil level
• Check the lanyard stop switch
• Inspect the fuel system for leaks
• Inspect the engine tightness on the transom
• Check the steering system for binding
• Check the propeller for damage
• Inspect the hydraulic steering fittings and hoses for leaks or signs of
damage, if equipped

48 eng
 MAINTENANCE
• Check the hydraulic steering fluid level, if equipped
AFTER EACH USE
• Wash the power package exterior with fresh water
• Flush the outboard cooling system, saltwater or brackish water only
ANNUALLY OR 100 HOURS
• Grease the engine, if applicable
• Change the engine oil and filter, if equipped
• Inspect the thermostat, saltwater or brackish water only
• Add Quickleen to the fuel tank, once per year, per engine
• Apply anti‑seize to the spark plug threads
• Replace the gear lubricant
• Inspect the corrosion control anodes
• Lubricate the propeller shaft splines
• Replace all filters on the suction side of the fuel system—dealer item
• Lubricate the driveshaft splines—dealer item
• Check the tightness on all the fasteners—dealer item
• Check the torque of the outboard mounting hardware—dealer item
• Check the battery condition and tightness of the battery cable connection
—dealer item
THREE YEARS OR 300 HOURS
• Replace the spark plugs
• Replace the water pump impeller—dealer item
• Inspect the carbon fiber reeds—dealer item
• Inspect the wire harness connectors—dealer item
• Check the remote control cable adjustment, if applicable—dealer item
• Replace the high‑pressure fuel filter—dealer item
• Replace the accessory drive belt—dealer item
• Check the power trim fluid level—dealer item
• Inspect the engine motor mounts—dealer item

eng 49
 MAINTENANCE
Flushing the Cooling System (Powerhead)
Flush the internal water passages of the engine 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.

a
b 2730

a - Plug located on fitting

b - Water hose

1. Remove the plug from fitting in the bottom cowl.

2. Attach a water hose to the fitting. Turn on the water and flush for three to
five minutes.
NOTE: The engine can be stopped or operated at idle speed when flushing the
cooling system. Do not flush engine using a water system that exceeds
310 kPa (45 psi).

50 eng
 MAINTENANCE
Flushing the Cooling System (Lower Unit)
! 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 the
propeller blade and the anti‑ventilation plate.

a- Fleet Master gearcase

b- Sport Master gearcase
c- Water hose
d- Flushing attachments

1. Remove the propeller. Refer to Replacing the Propeller.

2. Fleet Master gearcases – Install the appropriate flushing attachment so
the rubber cups fit tightly over the strut intake holes. Attach the Dual
Water Flush Seal over the nose inlets.
3. Sport Master gearcases – Install the appropriate flushing attachment so
the nose cone cup fits tightly over the intake holes.
4. Attach a water hose to the flushing attachment. Turn on the water and
adjust the flow so water is leaking around the rubber cups or nose cone
cup to ensure the engine receives an adequate supply of cooling water.
5. Start the engine and run it at idle speed in neutral shift position.
6. Adjust water flow so excess water continues leaking out from around the
rubber cups or nose cone cup to ensure the engine is receiving an
adequate supply of cooling water.
7. Check for water coming out of the water pump indicator hole. Continue
flushing for three to five minutes, carefully monitoring water supply at all
times.
8. Stop the engine, turn off the water, and remove the flushing attachment.
Install the propeller.

eng 51
 MAINTENANCE
Top Cowl Removal and Installation
REMOVAL
Release the front and side cowl latches. Lift the top cowl from the outboard.

2732

INSTALLATION
Position the top cowl over the engine. Make sure the bottom rubber seal fits
properly and lock the front and side latches.

Fuel System
FUEL SYSTEM SERVICE INFORMATION

! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the
lanyard is positioned so that the engine cannot start. Do not smoke or allow
sources of spark or open flame in the area while servicing. Keep the work
area well ventilated and avoid prolonged exposure to vapors. Always check
for leaks before attempting to start the engine, and wipe up any spilled fuel
immediately.

IMPORTANT: 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.
Before servicing any part of the fuel system:
• Stop engine and disconnect the battery.
• Drain the fuel system completely.
• Perform fuel system service in a well‑ventilated area.
• Inspect any completed service work for sign of fuel leakage.

FUEL LINE INSPECTION

Visually inspect the fuel line and primer bulb for cracks, swelling, leaks,
hardness, or other signs of deterioration or damage. If any of these conditions
are found, the fuel line or primer bulb must be replaced.

52 eng
 MAINTENANCE
WATER SEPARATING FUEL FILTER
This filter removes moisture and debris from the fuel. If the filter becomes filled
with water, the water can be removed. If the filter becomes plugged with debris,
replace the filter. The warning system engages when water in the fuel filter
reaches the full level. Refer to Warning System in Features and Controls.
Refer to the Inspection and Maintenance Schedule for the proper
maintenance interval.
Removal

a - O‑ring seals
b - Filter
c - Raised bosses

2733

1. Disconnect the link rod.

2. Use the shaft of a screwdriver between the filter cap bosses and unscrew
the filter.
Installation
1. Lubricate the O‑ring seals with oil.
2. Install the fuel filter and tighten securely.
3. Connect the link rod.

eng 53
 MAINTENANCE
IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing
the primer bulb until firm, forcing fuel into the filter.

DRAINING WATER FROM THE FUEL FILTER CHAMBER

NOTE: If a sufficient amount of water accumulates in the fuel filter chamber, the
engine's warning system alerts the operator with the warning horn. Some
SmartCraft gauges are capable of alerting the operator of this and other
operating conditions/faults. Refer to Warning System in the Features and
Controls section of this manual for more information. If the warning system
alerts you to this condition, drain the water from the fuel filter chamber.

b
a
c

29600

a - Drain hose
b - Aft hose fitting
c - Filter drain screw

1. Remove the drain hose from the aft hose fitting (right side of the
chamber). Hold the unattached end of the hose over a suitable container.
2. Loosen the filter drain screw (left side of the chamber) and allow the
contents to drain.
NOTE: If little or no liquid drains from the hose, loosen the red filter to vent the
chamber.
3. Tighten the drain screw and attach the hose.
IMPORTANT: Visually inspect for fuel leakage from the drain screw by
squeezing the primer bulb until firm, forcing fuel into the chamber.
If you experience multiple issues with water in the fuel system over a short
period of time, see your authorized Mercury dealer.

54 eng
 MAINTENANCE
Steering Link Rod Fasteners
IMPORTANT: The steering link rod that connects the steering cable to the
engine must be fastened using a special washer head bolt (P/N 10‑849838)
and self‑locking nylon insert locknuts (P/N 11‑826709113). Never replace
locknuts with common nuts (nonlocking) as they will work loose and vibrate off,
freeing the link rod to disengage.

! 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 follow instructions and torque procedures.

! WARNING
Worn, loose, or seized steering components can lead to loss of boat control.
Inspect all steering attachment components for wear, lubricate all attachment
hardware, and check all fasteners for proper tightness in accordance with the
inspection and maintenance schedule.

d
b
2767

a- Special washer head bolt (P/N 10‑849838)

b- Nylon insert locknut (P/N 11‑826709113) ‑ used on head bolt
c- Flat washer (2)
d- Nylon insert locknut (P/N 11‑826709113) ‑ used on cable coupler

1. Assemble steering link rod to steering cable coupler with two flat washers
"c" and a self‑locking nylon insert locknut "d." Tighten the locknut until it
seats, then loosen ¼ turn.
2. Assemble the steering link rod to the engine with the special washer head
bolt "a" and self‑locking nylon insert locknut "b."
3. Torque the head bolt, then the locknut to specifications.

eng 55
 MAINTENANCE
Description Nm lb‑in. lb‑ft
Cable coupler nylon insert locknut Tighten locknut until it seats, then
"d" loosen ¼ turn.
Head bolt nylon insert locknut "b" 27 – 20
Special washer head bolt 27 – 20

Fuses
IMPORTANT: Always carry spare 2‑, 15‑, and 20‑amp fuses.
The electrical wiring circuits on the engine are protected from overload by fuses
in the wiring. If a fuse is blown, try to locate and correct the cause of the
overload before replacing the fuse. If the cause is not found, the fuse may blow
again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If
the band is broken, replace the fuse.
2. Replace the fuse with a new fuse with the same rating.

56 eng
 MAINTENANCE
The fuses and circuits are identified as follows:

a b

g
c
2 15

20 20

f d 51464

Fuse location and identification

a - Good fuse
b - Blown fuse
c - Power‑on circuit – 15‑amp fuse
d - Ignition coil circuit – 20‑amp fuse
e - Spare fuse slot
f - Fuel injector/direct injector/PCM and electric fuel pump circuits –
20‑amp fuse
g - Diagnostic circuit – 2‑amp fuse

Corrosion Control Anodes

NOTICE
Anodes made of insufficiently pure aluminum alloys may not adequately
protect critical drive components from corrosion. We recommend using
anodes sold through Mercury Precision Parts only.

Anodes help protect the power package against galvanic corrosion by

sacrificing their metal to be slowly eroded instead of other metals.

eng 57
 MAINTENANCE
This model has three corrosion control anodes on the gearcase—two above
and one below the anti‑ventilation plate. A fourth anode is located on the
bottom of the clamp/swivel bracket assembly.

a - Corrosion control
anodes (three on
gearcase)
b - Corrosion control anode
(one on clamp/swivel
bracket)

All anodes require periodic inspection, especially in saltwater (refer to the

Inspection and Maintenance Schedule). Replace any anodes before they are
50% corroded. Never paint or apply protective coating on an anode, as
effectiveness of the anode will be reduced.

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 spark plug leads by twisting the rubber boots while pulling
them off the spark plugs.

26899

2. Remove the spark plugs. 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.

58 eng
 MAINTENANCE
IMPORTANT: The color of the plug may not accurately reflect its condition. To
accurately diagnose a faulty plug, inspect the precious metal on the plug's
electrode. If no precious metal is visible, replace the plug.

9381

a - Precious metal

3. Set the spark plug gap. Refer to Specifications.

27848

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 critical with any type of spark plug that has a
wear surface, such as platinum or iridium added to either the ground
electrode or the center electrode.
d. When it is necessary to widen the gap, use a tool that only pulls back
on the ground electrode without touching the center electrode, the
porcelain, or the wear portion of the ground electrode.
e. When it is necessary to close the gap, gently tap the plug ground
electrode on a hard surface.
4. Before installing spark plugs, clean off any dirt on the spark plug seats.
Install the plugs finger‑tight and then tighten an additional 1/4 turn or
tighten to the specified torque.

eng 59
 MAINTENANCE
Description Nm lb‑in. lb‑ft
Spark plug 27 – 20

Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine
starting capability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Ensure the battery is secure against movement.
3. Battery cable terminals should be clean, tight, and correctly installed.
Positive to positive and negative to negative.
4. Ensure the battery is equipped with a nonconductive shield to prevent
accidental shorting of battery terminals.

Charging System Fusible Link

This model has a 100 amp fusible link between the alternator and the +12 volt
stud. This fusible link protects the alternator from damage due to accidental
reverse battery connection. If the battery cables are reversed, the fusible link
creates an open circuit, protecting the alternator. With the fusible link open, the
engine can be started; however, the run time is limited, because the alternator
is not charging the boat battery. If the fusible link circuit becomes open, contact
your authorized Mercury Marine dealer.

3797

60 eng
 MAINTENANCE
Replacing the Propeller
! 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 the
propeller blade and the anti‑ventilation plate.

REMOVING THE PROPELLER

NOTE: If propeller is seized to the shaft and cannot be removed, consult your
authorized Mercury dealer.
1. Shift the outboard to neutral.
2. Remove the keys from the ignition and engage the safety stop switch.
3. Straighten the bent tabs on the propeller nut retainer (if applicable).
4. Place a block of wood between the gearcase and the propeller to hold the
propeller and remove the propeller nut.

26901

5. Remove the propeller and associated hardware from the propeller shaft.
INSTALLING THE PROPELLER

NOTICE
Operating the engine with the wrong propeller installed can limit power,
increase fuel consumption, overheat the engine, or cause internal powerhead
damage. Choose a propeller that allows the engine to operate at the
specified wide open throttle RPM.

Mercury Racing applications use 19‑spline propeller shafts and require

installation of the Heavy‑Duty Propeller Hub kit, included with most Mercury
Racing propellers.

eng 61
 MAINTENANCE
IMPORTANT: To prevent the propeller hub from corroding and seizing to the
propeller shaft, especially in salt water, always apply a coat of Extreme Grease
to the entire propeller shaft at the recommended maintenance intervals and
also each time the propeller is removed.
1. Lubricate the propeller shaft splines with Extreme Grease.
2. Install the propeller hub assembly, propeller, washer, Belleville washer,
washer, and propeller nut onto the propeller shaft.

a - Propeller hub
d e assembly
b - Propeller
c - Washer
d - Belleville washer
e - Washer
f - Propeller nut

a c f

b 2693

Tube Ref
Description Where Used Part No.
No.

Extreme Grease Propeller shaft splines 8M0071842

3. Place a block of wood between the gearcase and propeller and torque the
propeller nut.

2691

Description Nm lb‑in. lb‑ft

Propeller nut 75 – 55
4. Disengage the safety stop switch by placing it in the RUN position and
return the keys to the ignition switch.

62 eng
 MAINTENANCE
Lubrication Points
Lubricate the following with Extreme Grease and 2‑4‑C with PTFE.

94

95 95

95

5517

Tube Ref
Description Where Used Part No.
No.

Extreme Grease Trim rod ball ends, propeller shaft 8M0071842

95 2-4-C with PTFE Swivel bracket, tilt support lever, tilt tube 92-802859A 1

NOTE: Turn the ball ends to work the lubricant into the ball sockets. Lubricate
through fittings.

eng 63
 MAINTENANCE
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury
or death from loss of boat control. Completely retract the end of the steering
cable before applying lubricant.

Lubricate the steering link with lightweight oil.

Lubricate the belt tensioner pulley and steering cable with 2‑4‑C with PTFE.

95 95
95

4833

Tube Ref
Description Where Used Part No.
No.
Steering cable, grease fitting on belt
95 2-4-C with PTFE 92-802859A 1
tensioner pulley

Single‑Ram Trim System

GENERAL INFORMATION
The single‑ram (heavy‑duty) trim pump is installed in a remote location, usually
inside the engine motor well. It is available on all offshore models. The
heavy‑duty trim system:
• Is intended for offshore applications.
• Is not integrated into the engine (like the three‑ram system).
• Requires the heavy‑duty (offshore) transom bracket and midsection.
• Includes a trim stop pin to limit the degree of which the outboard is tucked
under.
IMPORTANT: The trim system has no trim out limits. Exercise care that engine
is not trimmed out beyond safe operation limits.
To install the single‑ram trim system, order the the Heavy‑Duty Trim Pump
assembly and refer to the instructions included with the pump for installation.

64 eng
 MAINTENANCE
Optional Accessories
Assembly Part Number
Floor Mount Kit 842109A01
Bracket Assembly 87762A2

POWER TRIM OPERATION (SINGLE-RAM SYSTEM)

The trim system has no trim out limits. Exercise care that engine is not trimmed
out beyond safe operation limits.

! WARNING
Trimming the outboard beyond a neutral steering condition may result in a
pull on the steering wheel or tiller handle and loss of boat control. Maintain
control of the boat if trimming beyond a neutral steering condition.

The outboard can be operated beyond the 20° trim limit if operating outboard in
shallow water as long as the engine RPM is kept below 1200 RPM.

! WARNING
Operating a boat in a trim up position can cause severe equipment damage
or loss of boat control. This product may not have a trim out limiting device or
trim indicator. Never trim up beyond the unit's side support flanges while the
boat is underway or at engine speeds above 1200 RPM.

TRIM IN PIN (SINGLE-RAM)

a - Trim in pin

a
15280
Install the trim stop pin to the desired adjustment hole in the heavy duty swivel
bracket. This pin is included with heavy‑duty models.

eng 65
 MAINTENANCE
CHECKING POWER TRIM FLUID (SINGLE-RAM TRIM SYSTEMS)
1. Place outboard in the full down/in position.

or52

2. Check the fluid level in the trim pump reservoir. The level should be
between the "MIN" and "MAX" level marks on the reservoir.
3. If necessary, remove the yellow fill cap and add Power Trim and Steering
Fluid until the level in the reservoir reaches the "MIN" level mark. It is
acceptable to fill the reservoir beyond the "MIN" level mark, but do not
overfill past the "MAX" level mark.

11
4

15033

Tube Ref
Description Where Used Part No.
No.
Power Trim and
114 Trim pump reservoir 92-858074K01
Steering Fluid

4. Trim the outboard down to bleed air out of the system. The fluid level may
drop. Add more Power Trim and Steering Fluid if necessary, but do not
overfill past the "MAX" level mark.

66 eng
 MAINTENANCE
5. Replace the fill cap.

Three‑Ram Trim System

GENERAL INFORMATION
The power trim system was filled prior to shipment and is ready for use.
The outboard can be raised or lowered manually by loosening the manual
release valve four turns.

a - Manual release valve

2687

The trim out angle of this outboard is not adjustable. The trim system has an
internal valve, which will automatically stop the outward trim travel at 20° when
engine RPM is approximately 2000 RPM or higher; outboard also has to be in
water and in gear.
The outboard can be operated beyond the 20° trim limit for operating outboard
in shallow water if engine RPM is kept below approximately 2000 RPM.

POWER TRIM OPERATION (THREE-RAM SYSTEM)

! WARNING
Trimming the outboard beyond a neutral steering condition may result in a
pull on the steering wheel or tiller handle and loss of boat control. Maintain
control of the boat if trimming beyond a neutral steering condition.

eng 67
 MAINTENANCE
With most boats, operating around the middle of the trim range will give
satisfactory results. However, to take full advantage of the trimming capability,
there may be times when you choose to trim your outboard all the way in or
out. Along with an improvement in some performance aspects comes a greater
responsibility for the operator, and this is being aware of some potential control
hazards. The most significant of which is a pull or torque, which can be felt on
the steering wheel. This steering torque results from the outboard being
trimmed so that the propeller shaft is not in a horizontal position.

TRIM IN PIN (THREE-RAM)

! 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, particularly some bass boats, are built with a greater than normal
transom angle, which will allow the outboard to be trimmed further in or under.
This greater trim under capability is desirable to improve acceleration, reduce
the angle and time spent in a bow high boat during planing off, and in some
cases, may be necessary to plane off a boat with aft live wells, given the variety
of available propellers and height range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate
position to avoid a bow‑down planing condition called plowing. Plowing can
cause bow steering or oversteering and inefficiently consumes horsepower.

a - Tilt pin (not included with engine)

2688

Stainless Steel Tilt Pin 17‑ 49930A 1

Limits the down trim angle of the power

trim equipped engines, or aids in
determining the trim out angle on
non‑power trim engines.
2749

The owner may decide to limit the trim in. For standard models, purchase a
stainless steel tilt pin from your dealer and insert it in whatever adjustment hole
in the transom brackets is desired.

68 eng
 MAINTENANCE
CHECKING POWER TRIM FLUID (THREE-RAM TRIM SYSTEMS)
1. Tilt outboard to the full up position and engage the tilt support lock.

11
4

or47-1

a - Tilt support lock

Tube Ref. No. Description Where Used Part Number

114 Power Trim and Steering
Fill hole 92‑802880A1
Fluid
2. Remove fill cap and check fluid level. The fluid level should be even with
the bottom of the fill hole. Add fluid if required.

eng 69
 MAINTENANCE
Gearcase Lubricant
CHECKING/REFILLING GEARCASE LUBRICANT

c
c d d
a b

f
e
2743

a- Sport Master gearcase (vertical operating position)

b- Fleet Master gearcase (vertical operating position)
c- Vent hole
d- Vent plug and sealing washer
e- Fill/drain hole
f- Fill/drain plug

Tube Ref
Description Where Used Part No.
No.
SAE 85W90 Mercury
Gearcase 8M0078015
Racing Gear Oil

1. Place the outboard in a vertical operating position.

2. Remove the vent plug (upper plug) and sealing washer.
3. Remove the fill/drain plug (lower plug).
4. Quickly place lubricant tube into the fill hole.
5. Slowly add lubricant until it flows from the (upper) vent hole.
6. Stop adding lubricant. Install the (upper) vent plug and sealing washer
before removing the lubricant tube.
IMPORTANT: Replace sealing washers if damaged.
NOTE: Examine the magnetic fill/drain plug for metal particles. A small amount
of metal filings or fine metal particles indicates normal gear wear. An
excessive amount of metal filings or larger particles (chips) should be checked
by an authorized dealer.
7. Remove lubricant tube and reinstall cleaned (lower) fill/drain plug and
sealing washer.

70 eng
 MAINTENANCE
Water in gear lubricant may:
• Settle to bottom and drain out with the lubricant
• Be mixed with lubricant giving a milky color to the lubricant
Water in gear lubricant will:
• Result in premature bearing failure
• In freezing temperatures, turn to ice and damage gearcase
DRAINING THE GEARCASE

c c
a b

or50-1

a- Sport Master gearcase (vertical operating position)

b- Fleet Master gearcase (vertical operating position)
c- Vent plug and sealing ring
d- Fill/drain plug and sealing ring
e- Drain pan

1. Place the outboard in a vertical operating position.

2. Place a drain pan below the outboard gearcase.
3. Remove the vent plug (upper plug) and sealing ring.
4. Remove the fill/drain plug (lower plug) and sealing ring and drain the
lubricant.
GEARCASE LUBRICANT CAPACITY
Gearcase lubricant capacity is approximately 710 ml (24 oz).

Submerged Power Package

A submerged power package requires prompt service by an authorized dealer
after recovery. This immediate attention is necessary once the engine is
exposed to the atmosphere to minimize internal corrosion damage to the
engine.

eng 71
 STORAGE
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. Follow
these storage procedures to prepare your outboard for out‑of‑season or
prolonged storage (two months or longer).

NOTICE
Without sufficient cooling water, the engine, the water pump, and other
components will overheat and suffer damage. Provide a sufficient supply of
water to the water inlets during operation.

FUEL SYSTEM
IMPORTANT: Fuel containing alcohol (ethanol or methanol) can cause a
formation of acid during storage that can damage the fuel system. If the fuel
being used contains alcohol, Mercury Marine recommends draining as much of
the remaining fuel as possible from the fuel tank, remote fuel line, and engine
fuel system.
The most effective method for storage preparation is to add the recommended
amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen
products, as described on their respective containers, to the fuel tank before
the final operation of the boat prior to storage. Fuel Stabilizer helps prevent the
formation of varnish and gum in the fuel. Quickleen helps clean and lubricate
the fuel injectors.
1. Pour additives into the fuel:
a. Portable Fuel Tank ‑ Pour the required amount of fuel stabilizer into
fuel tank. Close the tank and tip back and forth to mix.
b. Permanently Installed Fuel Tank ‑ Pour the required amount of fuel
stabilizer into a separate container. Add approximately one quart of
fuel to the container. Mix and pour into the fuel tank.
2. Remove the drain hose from the aft hose fitting (right side of the
chamber). Hold the unattached end of the hose over a suitable container.

a - Filter drain screw

b - Drain hose
c - Aft hose fitting

c
a

b
28956

72 eng
 STORAGE
3. Loosen the filter drain screw (left side of the chamber) and allow the
contents to drain.
NOTE: If little or no liquid drains from the hose, loosen the red filter to vent the
chamber.
4. Tighten drain screw and reattach the hose.
5. Remove the drain hose from the forward hose fitting (left side of the
chamber). Hold the unattached end of the hose over a suitable container.

a - Forward hose fitting

b - Float chamber drain screw
c - Drain hose

a
b
c

29451
6. Loosen the float chamber drain screw (right side of the chamber) and
allow the contents to drain.
7. Tighten drain screw and reattach the hose.
8. Premix the following in a container:
• 8 cc (0.3 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant.
• 8 cc (0.3 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer.
9. Remove the fuel filter. Refer to Fuel System in the Maintenance section
of this manual.
10. Pour the mixture into the fuel filter opening.
11. Install the fuel filter.
12. Prime the fuel system as described in the Starting the Engine in the
Operation section of this manual.
13. Place the outboard in water or use the flushing attachment for circulating
cooling water. Start the engine and run at idle speed for 5 minutes to
allow the treated fuel to fill the fuel system.

Protecting Internal Engine Components

NOTE: Make sure the fuel system has been prepared for storage. Refer to Fuel
System, preceding.
IMPORTANT: Refer to Spark Plug Inspection and Replacement for correct
procedure for removing spark plug leads.

eng 73
 STORAGE
1. Remove the spark plugs and add approximately 30 ml (1 oz) of engine oil
into each spark plug hole.
2. Rotate the flywheel manually several times to distribute the oil in the
cylinders.
3. Install the spark plugs.

Protecting External Outboard Components

• Lubricate all outboard components listed in Maintenance ‑ Inspection
and Maintenance Schedule.
• 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
Description Where Used Part No.
No.

120 Corrosion Guard External metal surfaces 92-802878 55

Gearcase
• Drain and refill the gearcase lubricant (refer to Gearcase Lubricant).

Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of the
outboard.

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 in the full down
position.

Battery Storage
• Follow the battery manufacturer's instructions for storage and charging.
• Remove the battery from the boat and check water level. Charge if
necessary.
• Store the battery in a cool, dry place.
• Periodically check the water level and charge the battery during storage.

74 eng
 TROUBLESHOOTING
Starter Motor Will Not Crank the Engine
POSSIBLE CAUSES
• Blown 20‑amp fuse in the starting circuit. Refer to Maintenance.
• Outboard is not shifted to neutral position.
• Weak battery or battery connections are loose or corroded.
• Ignition key switch failure.
• Wiring or electrical connection faulty.
• Starter motor solenoid or slave solenoid failure.

Engine Will Not Start

POSSIBLE CAUSES
• Lanyard stop switch not in "RUN" position.
• Battery not fully charged.
• Incorrect starting procedure. Refer to Operation section.
• Old or contaminated fuel.
• Fuel is not reaching the engine.
• Fuel tank is empty.
• Fuel tank vent not open or restricted.
• Fuel line is disconnected or kinked.
• Primer bulb not squeezed.
• Primer bulb check valve is faulty.
• Fuel filter is obstructed. Refer to Maintenance section.
• Fuel pump failure.
• Fuel tank filter obstructed.
• Open 20‑amp fuse. Check fuses, refer to Maintenance section.
• Threaded connection of an air hose is loose.
• Ignition system component failure.
• Spark plugs fouled or defective. Refer to Maintenance section.

Engine Runs Erratically

POSSIBLE CAUSES
• Spark plugs fouled or defective. Refer to Maintenance section.
• Incorrect setup and adjustments.
• Fuel is being restricted to the engine.
a. Engine fuel filter is obstructed. Refer to Maintenance section.
b. Fuel tank filter obstructed.
c. Stuck antisiphon valve on built‑in fuel tank.

eng 75
 TROUBLESHOOTING
d. Fuel line is kinked or pinched.
e. Injector plugged.
• Threaded connection of an air hose is loose.
• Fuel pump failure.
• Ignition system component failure.

Performance Loss
POSSIBLE CAUSES
• Throttle not fully open.
• Damaged propeller or improper propeller size.
• Boat overloaded or load improperly distributed.
• Excessive water in bilge.
• Boat bottom is dirty or damaged.

Warning Horn Activates (With Power Loss)

POSSIBLE CAUSES
• Intermittent horn sound:
• The oil level in the engine‑mounted oil reservoir tank is low. Refill the
reservoir tank and the remote oil tank. Refer to Fuel and Oil for
details.
• Battery voltage is out of limits.
• Throttle position sensor failure.
• Continuous horn sound:
• The oil level in the engine‑mounted oil reservoir tank is critically low.
Refill the reservoir tank and the remote oil tank. Refer to Fuel and Oil
for details.
• The oil pump has failed, halting the oil supply to the engine.
• High engine temperature or low block water pressure.
• Cooling system clogged.
• Incorrect transom height (water pickups not getting adequate water
supply).

Warning Horn Activates (No Power Loss)

POSSIBLE CAUSES
• Warning horn activates on start up. This is normal operation.
• Water is detected in the water‑separating fuel filter. Refer to Maintenance
for procedures on removing water from the filter.

76 eng
 TROUBLESHOOTING
Battery Will Not Hold Charge
POSSIBLE CAUSES
• Battery connections are loose or corroded.
• Low electrolyte level in battery.
• Worn out or inefficient battery.
• Excessive use of electrical accessories.
• Defective rectifier, alternator, or voltage regulator.
• Open circuit in the alternator output wire (fused link).

eng 77
 OWNER SERVICE ASSISTANCE
Service Assistance
LOCAL REPAIR SERVICE
If you need service for your Mercury‑outboard‑powered boat, take it to your
authorized dealer. Only authorized dealers specialize in Mercury products and
have factory‑trained mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your engine.
NOTE: Quicksilver parts and accessories are engineered and built by Mercury
Marine specifically for your power package.
SERVICE AWAY FROM HOME
If you are away from your local dealer and the need arises for service, contact
the nearest authorized dealer. If, for any reason, you cannot obtain service,
contact the nearest Regional Service Center. Outside the United States and
Canada, contact the nearest Marine Power International Service Center.
STOLEN POWER PACKAGE
If your power package is stolen, immediately advise the local authorities and
Mercury Marine of the model and serial numbers and to whom the recovery is
to be reported. This information is maintained in a database at Mercury Marine
to aid authorities and dealers in the recovery of stolen power packages.
ATTENTION REQUIRED AFTER SUBMERSION
1. Before recovery, contact an authorized Mercury dealer.
2. After recovery, immediate service by an authorized Mercury dealer is
required to reduce the possibility of serious engine damage.
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
these standards. When servicing the electrical and fuel systems, properly
install and tighten all components.

Marine engines are expected to operate at or near full throttle for most of their
lives. They are also expected to operate in both fresh and saltwater
environments. These conditions require numerous special parts.
PARTS AND ACCESSORIES INQUIRIES
Direct any inquiries concerning genuine Mercury Precision Parts® or
Quicksilver Marine Parts and Accessories® to a local authorized dealer.
Dealers have the proper systems to order parts and accessories, if they are not
in stock. Engine model and serial number are required to order correct parts.

78 eng
 OWNER SERVICE ASSISTANCE
RESOLVING A PROBLEM
Satisfaction with your Mercury product is important to your dealer and to us. If
you ever have a problem, question or concern about your power package,
contact your dealer or any authorized Mercury dealership. If you need
additional assistance:
1. Talk with the dealership's sales manager or service manager.
2. If your question, concern, or problem cannot be resolved by your
dealership, please contact the Mercury Marine Service Office for
assistance. Mercury Marine will work with you and your dealership to
resolve all problems.
The following information will be needed by the Customer Service:
• Your name and address
• Your daytime telephone number
• The model and serial numbers of your power package
• The name and address of your dealership
• The nature of the problem
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

English +1 920 929 5040 Mercury Marine
Telephone
Français +1 905 636 4751 W6250 Pioneer Road
English +1 920 929 5893 P.O. Box 1939
Fax Fond du Lac, WI 54936-1939
Français +1 905 636 1704
Website www.mercurymarine.com

Australia, Pacific
Telephone +61 3 9791 5822 Brunswick Asia Pacific Group
41–71 Bessemer Drive
Fax +61 3 9706 7228 Dandenong South, Victoria 3175
Australia

Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe
Parc Industriel de Petit-Rechain
Fax +32 87 31 19 65 B-4800 Verviers,
Belgium

eng 79
 OWNER SERVICE ASSISTANCE
Mexico, Central America, South America, Caribbean
Telephone +1 954 744 3500 Mercury Marine
11650 Interchange Circle North
Fax +1 954 744 3535 Miramar, FL 33025
U.S.A.

Japan
Telephone +072 233 8888 Kisaka Co., Ltd.
4‑130 Kannabecho, Sakai‑ku
Fax +072 233 8833 Sakai‑shi, Osaka 590‑0984, Japan

Asia, Singapore
Telephone +65 65466160 Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
Fax +65 65467789 29 Loyang Drive
Singapore, 508944

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
Telephone Fax Mail
Mercury Marine
(920) 929‑5110 (920) 929‑4894 Attn: Publications Department
(USA only) (USA only) P.O. Box 1939
Fond du Lac, WI 54936-1939

OUTSIDE THE UNITED STATES AND CANADA

Contact your nearest Mercury Marine authorized service center to order
additional literature that is available for your particular power package.

80 eng
 OWNER SERVICE ASSISTANCE
Mercury Marine
Submit the following Attn: Publications Department
order form with payment W6250 Pioneer Road
to: P.O. Box 1939
Fond du Lac, WI 54936-1939
Ship To: (Copy this form and print or type–This is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country

Quantity Item Stock Number Price Total

. .
. .
. .
. .
. .
Total Due .

eng 81
 OUTBOARD INSTALLATION
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 issues that can lead to safety concerns.
Follow all of the instructions relating to the outboard installation. DO NOT
mount any other accessory onto the boat with the fasteners provided with the
outboard. For example, do not mount tow sport bars or boarding ladders onto
the boat using the mounting hardware included with the outboard. Installing
other products onto the boat that utilize the outboard mounting hardware will
compromise the ability of that hardware to properly and safely secure the
outboard to the transom.
Outboards that require validated mounting hardware will have the following
decal on the transom clamp.

51965

Accessories Mounted to the Transom Clamp Bracket

Mercury Marine has been made aware that certain aftermarket marine
accessories, such as emergency boarding ladders, shallow water anchors,
transom wedge kits, and tow sport attaching devices, have been mounted to
the boat by use of the same fasteners that secure the outboard to the transom
or jack plate. Using the same fastener to secure both an accessory and the
engine to the boat compromises the ability of the fasteners to maintain the
proper clamp load. A boat with loose engine mounting fasteners creates the
possibility of performance, durability, and safety issues.

82 eng
 OUTBOARD INSTALLATION
! 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 TO THE TRANSOM CLAMP

BRACKET
After the engine is mounted to the transom or jack plate in accordance with the
engine installation instructions, it is acceptable to attach an accessory to the
boat by use of the unused bolt holes in the transom clamp bracket as shown in
Figure 1.
The following list provides additional guidelines for mounting accessories to the
transom clamp bracket.
• The accessory fasteners must pass through the boat transom or jack
plate.

eng 83
 OUTBOARD INSTALLATION
• 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.

a
f

b d 54624

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 fasteners
f - Fasteners supplied by the accessory manufacturer installed through
unused engine mounting bracket holes

84 eng
 OUTBOARD INSTALLATION
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 2

2. Do not attach an accessory to the boat by use of the engine mounting

hardware. Refer to Figure 3.

Figure 3
b c a - Engine supplied mounting
fasteners
b - Transom clamp bracket
c - Accessory

53523

eng 85
 OUTBOARD INSTALLATION
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 a - Boat transom or jack plate
b - Transom clamp bracket
b c - Wedge/plate

c
54058

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 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
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777

Start in Gear Protection

! WARNING
Starting the engine with the drive in gear can cause serious injury or death.
Never operate a boat that does not have a neutral‑safety‑protection device.

86 eng
 OUTBOARD INSTALLATION
The remote control connected to the outboard must be equipped with a start in
neutral only protection device. This prevents the engine from starting in gear.

Fuel System
AVOIDING FUEL FLOW RESTRICTION
IMPORTANT: Adding components to the fuel supply system (filters, valves,
fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low
speed, and/or a lean fuel condition at high RPM that could cause engine
damage.

ELECTRIC FUEL PUMP

The fuel pressure must not exceed 28 kPa (4 psi). If necessary, install a
pressure regulator.

LOW PERMEATION FUEL HOSE REQUIREMENT

Required for outboards manufactured for sale, sold, or offered for sale in the
United States.
• The Environmental Protection Agency (EPA) requires that any outboard
manufactured after January 1, 2009, must use low permeation fuel hose
for the primary fuel hose connecting the fuel tank to the outboard.
• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not
exceeding 15 g/m²/24 h with CE 10 fuel at 23 °C as specified in SAE J
1527 ‑ marine fuel hose.

EPA PRESSURIZED PORTABLE FUEL TANK REQUIREMENTS

The Environmental Protection Agency (EPA) requires portable fuel systems
that are produced after January 1, 2011, for use with outboard engines to
remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may
contain the following:
• An air inlet that opens to allow air to enter as the fuel is drawn out of the
tank.
• An air outlet that opens (vents) to the atmosphere if pressure exceeds
34.4 kPa (5.0 psi).

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 primer bulb. The fuel
demand valve prevents pressurized fuel from entering the engine and causing
a fuel system overflow or possible fuel spillage.

eng 87
 OUTBOARD INSTALLATION
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.

b a - Fuel demand valve ‑ installed in the

a fuel hose between the fuel tank and
primer bulb
b - Manual release
c 46273
c - Vent/water drain holes

FUEL TANKS
Portable Fuel Tank
Select a suitable location in the boat within the engine fuel line length
limitations and secure the tank in place.
Permanent Fuel Tank
Permanent fuel tanks should be installed in accordance with industry and
federal safety standards, which include recommendations applicable to
grounding, antisiphon protection, ventilation, etc.

FILLING THE FUEL SYSTEM

For the initial start of a new engine, or for an engine that ran out of fuel or was
drained of fuel, the fuel system should be filled as follows:
1. Squeeze the fuel line primer bulb until it feels firm.
2. Turn the ignition key switch to the "ON" position for three seconds. This
operates the electric fuel pump.
3. Turn the ignition key switch back to the "OFF" position, and squeeze the
primer bulb again until it feels firm. Turn the ignition key switch to the
"ON" position again for three seconds. Continue this procedure until the
fuel line primer bulb stays firm.

88 eng
 OUTBOARD INSTALLATION
Installation Specifications
a
a b

18552

a - Minimum transom opening

b - Engine centerline for dual engine ‑ 66.0 cm (26 in.)

Minimum Transom Opening

Single engine 84.8 cm (33‑3/8 in.)
Dual engine 151.8 cm (59‑3/4 in.)

Lifting the Outboard

! WARNING
Improperly supporting an engine during lifting can result in the engine falling,
causing serious injury or death. Before lifting the engine, verify that the lifting
ring is threaded into the flywheel for a minimum of five turns and that the
hoist has the correct lifting capacity for the engine weight.

To lift the outboard:

1. Remove the cowl from the outboard.
2. Thread the lifting eye into the flywheel hub for a minimum of five turns.

a a - Lifting eye

28495

eng 89
 OUTBOARD INSTALLATION
3. Connect a hoist to the lifting eye.
4. Lift the outboard and place it on the boat transom.
Lifting Eye 91‑90455‑‑1

Threads into the flywheel to remove the

powerhead assembly from the driveshaft
housing, or to lift entire engine for
2756 removal/installation.

Steering Cable ‑ Starboard Side Routed Cable

1. Lubricate the O‑ring seal and the entire cable end.

95

3724

Tube Ref
Description Where Used Part No.
No.

95 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1

2. Insert the steering cable into the tilt tube.

3725

90 eng
 OUTBOARD INSTALLATION
3. Tighten the nut to the specified torque.

3727

Description Nm lb‑in. lb‑ft

Nut 47.5 – 35

Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the
engine must be fastened using a special washer head bolt (P/N 10‑849838)
and self‑locking nylon insert locknuts (P/N 11‑826709113). Never replace
locknuts with common nuts (nonlocking) as they will work loose and vibrate off,
freeing the link rod to disengage.

! 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 follow instructions and torque procedures.

eng 91
 OUTBOARD INSTALLATION
! WARNING
Worn, loose, or seized steering components can lead to loss of boat control.
Inspect all steering attachment components for wear, lubricate all attachment
hardware, and check all fasteners for proper tightness in accordance with the
inspection and maintenance schedule.

d
b
2767

a- Special washer head bolt (P/N 10‑849838)

b- Nylon insert locknut (P/N 11‑826709113) ‑ used on head bolt
c- Flat washer (2)
d- Nylon insert locknut (P/N 11‑826709113) ‑ used on cable coupler

1. Assemble steering link rod to steering cable coupler with two flat washers
"c" and a self‑locking nylon insert locknut "d." Tighten the locknut until it
seats, then loosen ¼ turn.
2. Assemble the steering link rod to the engine with the special washer head
bolt "a" and self‑locking nylon insert locknut "b."
3. Torque the head bolt, then the locknut to specifications.

Description Nm lb‑in. lb‑ft

Cable coupler nylon insert locknut Tighten locknut until it seats, then
"d" loosen ¼ turn.
Head bolt nylon insert locknut "b" 27 – 20
Special washer head bolt 27 – 20

Rear‑Mounted Steering Rams or Tie Bars

Offshore Models Only
To install rear‑mounted steering rams or tie bars, follow the instructions
included with the steering kit and observe the following guidelines:
• Install the steering brackets to the driveshaft housing mounting studs
(lower studs).

92 eng
 OUTBOARD INSTALLATION
• Do not install the steering brackets to the powerhead studs (upper studs).
• Trim the port and starboard bottom cowls as needed.

NOTICE
Attaching rear‑mounted steering rams or tie bars to the powerhead studs
may cause cylinder distortion and premature engine failure. Attach steering
brackets to the correct installation locations.

a b a - Exhaust adapter plate

b - Powerhead studs
c - Steering bracket
mounting locations
(driveshaft housing
mounting studs)

c
a 4087

Determining Outboard Mounting Height

INCREASING OUTBOARD MOUNTING HEIGHT
Increasing the height of the outboard generally provides more steering torque,
more top speed, and more propeller cavitation, particularly noticeable when
planing off or when operating with a heavy load.
Observe the following:
• Monitor water pressure and engine temperature at all times. Improper
mounting height may result in reduced available power due to low water
pressure and high temperature.
• Prevent exhaust restriction, which could result in poor idle performance,
by mounting the outboard high enough on the transom to keep the
exhaust relief hole at least 25 mm (1 in.) above the waterline when the
engine is operating at idle speed.
• All gearcase models except Sport Master: Be sure that the outboard
mounting height does not exceed 71.1 cm (28 in.). Mounting outboards
with these gearcases too high exposes the upper water inlets, causing
possible damage to the powerhead from loss of water pressure.

eng 93
 OUTBOARD INSTALLATION
MOUNTING HEIGHT - FLEET MASTER GEARCASE

! WARNING
Improper installation of an outboard can result in serious injury or death. Do
not allow the upper outboard mounting bolts to be closer than 25 mm (1 in.)
from the top of the boat transom, not including any shims used to increase
transom mounting height. Never install the upper mounting bolts through
these shims.

Install the outboard to a height so that the distance between the underside of
transom bracket hooks and the bottom of the boat (measurement "c" in the
diagram below) falls between the recommended mounting height range.
Ensure that this measurement is to the actual bottom of the boat, not to any
steps or notches in the hull.
IMPORTANT: The recommended mounting height is based on performance
testing with single‑engine applications on hulls with no stepped or notched
transoms. Your results may vary, depending on hull design.

c
722.6 mm
(28.45 in.)

b
d

14220

a- Underside of transom bracket hooks

b- Bottom of the boat
c- Distance between "a" and "b"
d- Propeller shaft centerline

94 eng
 OUTBOARD INSTALLATION
Item Model Recommended Mounting Height Range
c 25 in. driveshaft models 533–609 mm (21–24 in.)
c 30 in. driveshaft models 660–736 mm (26–29 in.)

MOUNTING HEIGHT - SPORT MASTER GEARCASE

! WARNING
Improper installation of an outboard can result in serious injury or death. Do
not allow the upper outboard mounting bolts to be closer than 25 mm (1 in.)
from the top of the boat transom, not including any shims used to increase
transom mounting height. Never install the upper mounting bolts through
these shims.

Install the outboard to a height so that the distance between the underside of
transom bracket hooks and the bottom of the boat (measurement "c" in the
diagram below) falls between the recommended mounting height range.
Ensure that this measurement is to the actual bottom of the boat, not to any
steps or notches in the hull.

eng 95
 OUTBOARD INSTALLATION
IMPORTANT: The recommended mounting height is based on performance
testing with a single‑engine application on a hull with no stepped or notched
transoms. Your performance results may vary, depending on hull design.
For best overall performance on boats with Sport Master gearcases, try to
mount the outboard so the propeller shaft centerline is even with the bottom of
the boat, as this gearcase is designed for surfacing applications.

722.6 mm c
(28.45 in.)

b 14313

a- Underside of transom bracket hooks

b- Bottom of the boat
c- Distance between "a" and "b"
d- Propeller shaft centerline

Item Model1. Recommended Mounting Height Range

c 20 in. driveshaft models 685–732 mm (27–30 in.)

Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read Determining
Outboard Mounting Height and install outboard to the nearest recommended
mounting height.

1. Some models may not be available with this outboard.

96 eng
 OUTBOARD INSTALLATION
1. Mark four mounting holes on the transom using the transom drilling
fixture.

b a - Drill guide holes

b - Transom drilling fixture
c - Transom centerline

c 2757

Transom Drilling Fixture 91‑98234A2

Aids in engine installation by acting as a

template for engine mounting holes.

5489

2. Drill four 13.5 mm (17/32 in.) mounting holes.

3973

eng 97
 OUTBOARD INSTALLATION
Fastening the Outboard to the Transom
MOUNTING BOLTS

Outboard Transom Mounting Hardware ‑ Supplied with Outboard

Part Number Part Name Description
8M0071543 Outboard mounting bolt ½‑20 x 5.00 in. long (3.25 in. thread)
826711‑17 Nylon insert locknut ½‑20
28421 Flat washer 1.50 in. diameter
54012 Flat washer 0.875 in. diameter

Available Outboard Mounting Bolts

Part Number Description
67755005 ½‑20 x 2.50 in. long (1.25 in. thread)
67755006 ½‑20 x 3.50 in. long (1.25 in. thread)
814259 ½‑20 x 4.00 in. long (2.25 in. thread)
67755‑1 ½‑20 x 4.50 in. long (2.25 in. thread)
8M0071543 ½‑20 x 5.00 in. long (3.25 in. thread)
8M0038370 ½‑20 x 5.50 in. long (3.25 in. thread)
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)

98 eng
 OUTBOARD INSTALLATION
CHECKING BOAT TRANSOM CONSTRUCTION
IMPORTANT: Determine the strength of the boat transom. The outboard
mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque
without the boat transom yielding or cracking. If the boat transom yields or
cracks under this torque, the construction of the transom may not be adequate.
The boat transom must be strengthened or the load carrying area increased.

b 18961

a - Transom yielding under bolt torque

b - Transom cracking under bolt torque

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.

33962

a - Large transom washer

b - Transom reinforcement plate

eng 99
 OUTBOARD INSTALLATION
FASTENING THE OUTBOARD TO THE TRANSOM
IMPORTANT: The transom mounting surface must be flat within 3.17 mm
(0.125 in.). No step in the transom mounting surface is allowed. The inside
transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.).

51817

a - Step (not allowed)

b - Gap between transom clamp and boat transom (not allowed)

100 eng
 OUTBOARD INSTALLATION
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 proper clearance of the transom bracket relief radius
area.

51867

Installation
1. Apply marine sealer to the shanks of the bolts, not to the threads.
2. Fasten the outboard with the correct mounting hardware. Tighten the
locknuts to the specified torque.
IMPORTANT: Ensure that a minimum of two full threads of the mounting bolts
extend beyond the locknut after tightening. The locknut must be drawn tight
while still engaging the bolt threads and not contacting the shank of the bolt.

eng 101
 OUTBOARD INSTALLATION
NOTE: For a more accurate torque reading, tighten the mounting locknuts
rather than the outboard mounting bolts.

d
c
a

e
b
c

d a

40952

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 threads

Description Nm lb‑in. lb‑ft

Outboard mounting locknuts and
75 – 55
bolts – standard boat transom
Outboard mounting locknuts and
bolts – metal lift plates and setback 122 – 90
brackets

102 eng
 OUTBOARD INSTALLATION
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, Hoses, Control Cables, and Front Clamp

REMOTE WIRING HARNESS
Route the remote 14 pin boat harness through the front clamp opening in the
bottom cowl. Connect remote harness to the 14 pin connector on the engine
harness.

28742

a - 14 pin connector

eng 103
 OUTBOARD INSTALLATION
BATTERY INFORMATION (ALL BATTERIES INCLUDING DTS)

! WARNING
Failure to properly secure the battery leads can result in a loss of power to
the Digital Throttle and Shift (DTS) system, leading to serious injury or death
due to loss of boat control. Secure the battery leads to the battery posts with
hex nuts to avoid loose connections.

• Do not use deep cycle batteries. The engine must use a marine starting
battery with 1000 MCA, 800 CCA, or 180 Ah rating.
• When connecting the engine battery, use hex nuts to secure the battery
leads to the battery posts. Tighten the nuts to the specified torque.

Description Nm lb‑in. lb‑ft

Hex nuts 13.5 120 –

A decal advising against using deep cycle batteries and wing nuts should be
placed on or near the battery box for future service reference. One 5/16 in. and
one 3/8 in. hex nut is supplied per battery for wing nut replacement. Metric hex
nuts are not supplied.

NOTICE
DO NOT USE DEEP CYCLE BATTERIES!
13.5Nm (120 lb-in.)

DO NOT
USE
WINGNUTS
IMPORTANT:
Refer to the outboard owner’s manual for
battery requirements.
Battery cable size and length is critical.
Refer to engine installation manual for
size requirements.
8M0085862

Place decal on or near battery box for future

service reference. Included with the engine
rigging components are 5/16" and 3/8” hex
nuts to be used for battery terminal wing nut
replacement. Metric hex nuts must be obtained
locally.

54395

104 eng
 OUTBOARD INSTALLATION
BATTERY CABLE CONNECTIONS
Single Outboard

a a - Red sleeve ‑ positive

(+)
b - Black sleeve ‑
(+) negative (–)
c - Cranking battery

b c

(-) 15496

Dual Outboards
Connect a common ground cable (wire size same as engine battery cables)
between negative (–) terminals on starting batteries.

b
a (-)
d

b
c (-)
d

15497

a- Red sleeve ‑ positive (+)

b- Black sleeve ‑ negative (–)
c- Ground cable
d- Cranking battery

eng 105
 OUTBOARD INSTALLATION
HOSE AND TUBING CONNECTIONS
Fuel Hose
The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate
fuel line/fuel tank pickup for each engine.
Fasten the remote fuel hose to the fitting with a hose clamp.
Oil Hoses
Connect the remote oil hoses to the engine hose connections. Fasten hose
connections with cable ties.
Water Pressure and Speedometer Hose or Tubing
NOTE: This applies to models without SmartCraft gauges.
This outboard has a speedometer water pickup located in the leading edge of
the gearcase. If you want to use this water pickup for the speedometer,
disconnect the water pickup tubing from the speedometer sensor and route
tubing out of the cowl. Install the coupler provided with the outboard on the end
of the tubing.

106 eng
 OUTBOARD INSTALLATION
Make the water pressure gauge hose connection to the tubing as shown.

a b j k
l
c

i
e d g f h j k 29069

a- Water pressure tube

b- Speedometer water pickup tube (if required)
c- Coupler
d- Plug
e- Barb hose fitting
f- Speedometer hose or tubing
g- Water pressure tube
h- Remote fuel hose
i- Hose clamp
j- Oil hose with blue stripe
k- Oil hose without blue stripe
l- Cable tie

INSTALLING THE SHIFT CABLE

IMPORTANT: The shift cable is the first cable to move when the remote control
handle is moved out of neutral, so install/connect it to the engine first.
Locating the Center Point of the Shift Cable
IMPORTANT: Locate the center point of the slack or lost motion that exists in
the shift cable for proper adjustment of the shift cable.
1. Mark the forward position as follows:

eng 107
 OUTBOARD INSTALLATION
a. Move the remote control handle from neutral into forward and advance
the handle to the full speed position. Ensure the throttle control lever is
touching the throttle control lever stop screw.
b. Slowly return the handle back to the neutral detent position.
c. Place a mark on the shift cable against the cable end guide.

29076

a - Forward position mark

2. Mark the reverse position as follows:

a. Move the remote control handle into reverse and advance the handle
to the full speed position. Ensure the throttle control lever is touching
the throttle control lever stop screw.
b. Slowly return the handle back to the neutral detent position.
c. Place a mark on the shift cable against the cable end guide.

29077

a - Reverse position mark

3. Mark the center on the shift cable midway between the forward and
reverse marks.

4361

a - Center mark

108 eng
 OUTBOARD INSTALLATION
4. Align the cable end guide against this center mark when installing the
cable to the engine.
5. Position the remote control and outboard into neutral position.
6. Slide the anchor pin forward until resistance is felt, then slide the anchor
pin toward the rear until resistance is felt.
7. Center the anchor pin between these resistance points.

a - Anchor pin
a

28746

Adjusting the Shift Cable

1. Align the shift cable end guide with the center mark as instructed in
Locating the Center Point of the Shift Cable.

a
4362

a - Center mark

2. Place the shift cable end guide on the anchor pin and adjust the cable
barrel so that it slips freely into the barrel holder.

eng 109
 OUTBOARD INSTALLATION
3. Secure the shift cable to the anchor pin with the retainer clip.

a
c

b 28749

a - Cable barrel
b - Shift cable retainer
c - Retainer clip

4. Check the shift cable adjustments as follows:

a. Shift the remote control to forward while turning the propeller shaft. If
the propeller shaft does not lock in gear, adjust the cable barrel closer
to the cable end guide.
b. Shift the remote control into neutral. If the propeller shaft does not turn
freely without drag, adjust the barrel away from the cable end guide.
Repeat steps a and b.
c. Shift the remote control into reverse while turning the propeller shaft. If
the propeller shaft does not lock solidly in gear, adjust the barrel away
from the cable end guide. Repeat steps a through c.
d. Return the remote control handle to neutral. If the propeller shaft does
not turn freely without drag, adjust the barrel closer to the cable end
guide. Repeat steps a through d.

INSTALLING THE THROTTLE CABLE

IMPORTANT: Attach the shift cable to the engine prior to attaching the throttle
cable.
1. Shift the remote control into the neutral position.
2. Attach the throttle cable to the throttle lever. Secure with a washer and
locknut. Tighten the locknut to the specified value.

a - Nylon washer
a b - Locknut

b
2678

110 eng
 OUTBOARD INSTALLATION
Description Nm lb‑in. lb‑ft
Throttle cable locknut "b" Tighten, then loosen 1/4 turn
3. Adjust the cable barrel so the installed throttle cable will hold the idle stop
screw against the stop.

c
a

28751

a - Barrel sleeve
b - Cable barrel
c - Idle stop screw

4. Check the throttle cable adjustment as follows:

a. Shift the outboard into gear a few times to activate the throttle linkage.
Rotate the propeller shaft while shifting into reverse.
b. Return the remote control to neutral.
c. Place a thin piece of paper between the idle adjustment screw and the
idle stop. The adjustment is correct when the paper can be removed
without tearing, but has some drag on it.
IMPORTANT: The idle stop screw must be touching the stop.

b a - Idle stop screw

b - Idle stop
a

2680

d. Adjust the cable barrel if necessary.

eng 111
 OUTBOARD INSTALLATION
5. Lock the barrel holder in place with the cable latch.

2682

FRONT CLAMP ASSEMBLY INSTALLATION

IMPORTANT: There must be sufficient slack in the engine wiring harness,
battery cables, fuel hose, and oil hoses, between clamp and engine attachment
point, to relieve stress and prevent hoses from being kinked or pinched.
1. Place the lower half of the front clamp into the bottom cowl opening.
2. Place the neoprene wrap around the wiring, hoses, and control cables,
and place into the lower half of the front clamp.

b
29073

a - Neoprene wrap
b - Lower half of the front clamp

112 eng
 OUTBOARD INSTALLATION
3. Join the top half of the front clamp with the bottom half. Secure both
halves together with cables ties.

29074
b

a - Top half of the front clamp

b - Cable ties

4. Secure the front clamp into the bottom cowl with the retainer and two
screws.
5. Install the cowl seal.

a - Retainer

29075

eng 113
 OUTBOARD INSTALLATION
Oil Injection Set‑Up
FILLING OIL SYSTEM
1. Fill the remote oil tank with the recommended oil listed in the Operation
and Maintenance Manual. Tighten the fill cap.

a
a - Fill cap

2683

2. Remove the cap and fill the engine oil tank with oil. Install the fill cap.

b a - Engine oil tank

b - Fill cap

7745

114 eng
 OUTBOARD INSTALLATION
PRIMING THE OIL INJECTION PUMP
Before starting the engine for the first time, prime the oil injection pump.
Priming will remove any air that may be in the pump, oil supply hose, or internal
passages.

a b

3768

a - Oil supply hose

b - Oil injection pump

IMPORTANT: Fill the engine fuel system with fuel before priming the oil
injection pump. Otherwise, the fuel pump will run without fuel during the priming
process and may be damaged.
1. Fill the fuel system.
a. Connect fuel hose.
b. Fill the fuel system by squeezing the primer bulb.
c. Position the fuel line primer bulb so the arrow on the side of the bulb is
pointing up. Squeeze the fuel line primer bulb until it feels firm.

27348

eng 115
 OUTBOARD INSTALLATION
d. Turn the ignition key switch to the "ON" position for three seconds.
This operates the electric fuel pump.

26846

e. Turn the ignition key switch back to the "OFF" position, and squeeze
the primer bulb again until it feels firm.
f. Turn the ignition key switch to the "ON" position again for three
seconds.
g. Continue this procedure until the fuel primer bulb stays firm.
2. Turn the ignition key switch to the "ON" position.
3. Within the first 10 seconds after the key switch has been turned on, move
the remote control handle from neutral into forward. This will automatically
start the priming process.

PURGING AIR FROM THE ENGINE OIL TANK

1. Loosen the fill cap on the engine oil tank.
2. Start the engine.
3. Operate the engine until all the air has vented out and oil starts to flow out
of the tank.
4. Tighten the fill cap.

Engine Well Inlet Cover Installation (Models with Remote Trim

Pump)
1. Select a location for the remote pump, so it is:
• Mounted vertically on a flat surface.
• In a dry location.
• Within the limits of the hydraulic lines (without sharp bends or kinks).
• In an area that does not interfere with the outboard when tilted to its
maximum position.
• In an area where battery cables and harnesses reach the pump easily.

116 eng
 OUTBOARD INSTALLATION
• Within easy access to the filler cap.

c
a
b
b

15870

a- Transom
b- Trim lines
c- Engine centerline
d- Engine well cover

IMPORTANT: The power trim hoses must be able to extend to the rear edge
of the transom to connect to the engine.
2. Make hydraulic connections to the remote pump assembly according to
the instructions included with the pump.
3. Using the inlet cover gasket as a template, mark and drill four 3/16 in.
mounting holes.

eng 117
 OUTBOARD INSTALLATION
4. Install the gasket and cover using four 10‑32 screws, lockwashers, and
hex nuts. Cut off excess screw lengths.

b
a
d

15871

a- Screw (4)
b- Nut (4)
c- Lockwasher (4)
d- Cover
e- Gasket

5. Route the trim pump harness end through the cover and cowl and attach
the harness to the pump and the main engine harness.
6. Install the grommet to protect the harness.
7. Route the trim hoses through the two holes provided in the cover and
install the two grommets.

a - Grommet (2)
b - Cover
a

15886

118 eng
 OUTBOARD INSTALLATION
8. Connect the trim hoses to the fittings on the transom bracket as shown
below.

a b

14628

a - Power trim down circuit

b - Power trim up circuit

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, particularly some bass boats, are built with a greater than normal
transom angle, which will allow the outboard to be trimmed further in or under.
This greater trim under capability is desirable to improve acceleration, reduce
the angle and time spent in a bow high boat during planing off, and in some
cases, may be necessary to plane off a boat with aft livewells, given the variety
of available propellers and height range of engine installations.

eng 119
 OUTBOARD INSTALLATION
However, once on plane, the engine should be trimmed to a more intermediate
position to avoid a bow‑down planing condition called plowing. Plowing can
cause bow steering or oversteering and inefficiently consumes horsepower.

a - Tilt pin (not included with engine)

2688

Stainless Steel Tilt Pin 17‑49930A 1

Limits the down trim angle of the power

trim equipped engines, or aids in
determining the trim out angle on
non‑power trim engines.
2749

The owner may decide to limit the trim in. This can be accomplished by
purchasing a stainless steel tilt pin from your dealer and insert it in whatever
adjustment hole in the transom brackets is desired. A nonstainless steel
shipping bolt should not be used in this application other than on a temporary
basis.

120 eng
 MAINTENANCE LOG
Maintenance Log
Record all maintenance performed on your outboard here. Be sure to save all
work orders and receipts.

Date Maintenance Performed Engine Hours

eng 121