200/225/250/275 Verado (4-Stroke) - Marine Motors · factory procedure for servicing the product...
Transcript of 200/225/250/275 Verado (4-Stroke) - Marine Motors · factory procedure for servicing the product...
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If the outboard motor’s serial number plate contains the CE markin the lower left-hand corner, the following statement applies:
This outboard motor manufactured by Mercury Marine, Fond duLac, WI, USA or Marine Power Europe Inc. Park Industrel, dePetit-Rechain, Belgium complies with the requirements of thefollowing directives and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665,ISO 11547
Machinery Directive: 98/37/EC,
EMC Directive: 89/336/EC; std.EN50081-1, SAE J551(CISPR Pub. 12), EN50082-1, IEC 61000 PT4-2,IEC 61000 PT4-3
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine,
Fond du Lac, WI USA©
200
4 M
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arin
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0/22
5/25
0/27
5 Ve
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EPA Emissions RegulationsOutboards manufactured by Mercury Marine in the United States arecertified to the United States Environmental Protection Agency asconforming to the requirements of the regulations for the control of airpollution from new outboard motors. This certification is contingent oncertain adjustments being set to factory standards. For this reason, thefactory 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 andsystems may be performed by any marine engine repair establishment orindividual.Engines are labeled with an Emission Control Information decal aspermanent evidence of EPA certification.
! WARNINGThe engine exhaust from this product contains chemicals known to thestate of California to cause cancer, birth defects or other reproductiveharm.
Thank Youfor your purchase of one of the finest outboards available. You have madea sound investment in boating pleasure. Your outboard has beenmanufactured by Mercury Marine, a world leader in marine technology andoutboard manufacturing since 1939. These years of experience have beencommitted to the goal of producing the finest quality products. This led toMercury Marine's reputation for strict quality control, excellence, durability,lasting performance and being the best at providing after the sale support.Please read this manual carefully before operating your outboard. Thismanual has been prepared to assist you in the operation, safe use and careof your outboard.All of us at Mercury Marine took pride in building your outboard and wishyou many years of happy and safe boating.Again, thank you for your confidence in Mercury Marine.Warranty MessageThe product you have purchased comes with a limited warranty fromMercury Marine, the terms of the warranty are set forth in the WarrantyInformation Section of this manual. The warranty statement contains adescription of what is covered, what is not covered, the duration ofcoverage, how to best obtain warranty coverage, important disclaimers andlimitations of damages, and other related information. Please review thisimportant information.
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The description and specifications contained herein were in effect at thetime this manual was approved for printing. Mercury Marine, whose policyis one of continued improvement, reserves the right to discontinue modelsat any time, to change specifications, designs, methods, or procedureswithout notice and without incurring obligation.Mercury Marine, Fond du Lac, Wisconsin U.S.A.Litho in U.S.A.© 2004, Mercury MarineMercury, Mercury Marine, MerCruiser, Mercury MerCruiser, MercuryRacing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver,#1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes,MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo,Mercury with Waves logo, and SmartCraft logo are all registeredtrademarks of Brunswick Corporation. Mercury Product Protection logo isa registered service mark of Brunswick Corporation.Mercury Premier ServiceMercury evaluates the service performance of its dealers and assigns itshighest rating of "Mercury Premier" to those demonstrating an exceptionalcommitment to service.Earning a Mercury Premier Service rating means a dealer:• Achieves a high 12 month service CSI (Customer Satisfaction Index)
score for warranty service.• Possesses all necessary service tools, test equipment, manuals and
parts books.• Employs at least one Certified or Master technician.• Provides timely service for all Mercury Marine customers.• Offers extended service hours and mobile service, when appropriate.• Uses, displays and stocks adequate inventory of genuine Mercury
Precision Parts.• Offers a clean, neat shop with well organized tools and service
literature.
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Warranty Information
Transfer Of Warranty................................................................................1Warranty Registration United States And Canada...................................1Warranty Registration Outside The United States And Canada...............2Four Stroke Outboard Limited Warranty...................................................33 Year Limited Warranty Against Corrosion.............................................6Warranty Coverage And Exclusions.........................................................9California Emissions Limited Warranty...................................................11Star Label............................................................................................... 16
General Information
Boater's Responsibilities.........................................................................18Before Operating Your Outboard............................................................18Boat Horsepower Capacity.....................................................................18High-Speed And High-Performance Boat Operation..............................19Outboard Remote Control Models .........................................................19Lanyard Stop Switch...............................................................................19Protecting People In The Water..............................................................21Passenger Safety Message - Pontoon Boats And Deck Boats.............. 22Wave And Wake Jumping...................................................................... 23Impact With Underwater Hazards...........................................................24Exhaust Emissions................................................................................. 25Selecting Accessories For Your Outboard..............................................27Safe Boating Suggestions...................................................................... 27Recording Serial Number....................................................................... 29Specifications..........................................................................................29Component Identification........................................................................31
Installation
Installing Outboard..................................................................................32Propeller Selection..................................................................................34
Transporting
Trailering Boat/Outboard ....................................................................... 35
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Fuel and Oil
Gasoline Recommendations...................................................................37Filling Fuel Tank.....................................................................................38Engine Oil Recommendations................................................................38Checking And Adding Engine Oil............................................................39
Features and Controls
Remote Control Features.......................................................................42Warning System.....................................................................................45Power Trim and Tilt.................................................................................49
Operation
Pre-Starting Check List...........................................................................54Operating In Freezing Temperatures......................................................54Operating In Salt Water Or Polluted Water.............................................54Engine Break-in Procedure.....................................................................55Starting The Engine................................................................................55Gear Shifting...........................................................................................64Dual Helm Station Transfer....................................................................65Synchronizing Dual Engines...................................................................66Stopping The Engine..............................................................................67Remote Control Adjustments..................................................................68
Maintenance
Outboard Care........................................................................................69EPA Regulations.....................................................................................69EPA Emissions.......................................................................................70Inspection And Maintenance Schedule..................................................70Flushing The Cooling System.................................................................72Cowl Removal and Installation...............................................................73Exterior Care...........................................................................................74Battery Inspection ..................................................................................74DTS Battery Specifications.....................................................................75Air Filter..................................................................................................76Fuel System............................................................................................78Corrosion Control Anode........................................................................81
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Propeller Replacement...........................................................................82Spark Plug Inspection and Replacement................................................84Fuses......................................................................................................86DTS Wiring System................................................................................ 87Accessory Drive Belt Inspection............................................................. 88Checking Power Trim Fluid.....................................................................88Checking Power Steering Fluid.............................................................. 89Changing Engine Oil ..............................................................................89Gearcase Lubrication..............................................................................92
Storage
Storage Preparation................................................................................94Protecting External Outboard Components............................................94Protecting Internal Engine Components.................................................95Gearcase................................................................................................ 95Positioning Outboard For Storage.......................................................... 95Battery Storage.......................................................................................95
Troubleshooting
Starter Motor Will Not Crank the Engine.................................................96Engine Will Not Start...............................................................................96Engine Starts But Will Not Shift Into Gear.............................................. 96Engine Runs Erratically.......................................................................... 96Performance Loss...................................................................................97Battery Will Not Hold Charge..................................................................97
Owner Service Assistance
Local Repair Service...............................................................................98Service Away From Home......................................................................98Parts And Accessories Inquiries.............................................................98Service Assistance................................................................................. 98Mercury Marine Service Offices..............................................................99
Maintenance Log
Maintenance Log..................................................................................101
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Transfer Of WarrantyThe limited warranty is transferable to a subsequent purchaser, but onlyfor the remainder of the unused portion of the limited warranty. This will notapply to products used for commercial applications.To transfer the warranty to the subsequent owner, send or fax a copy ofthe bill of sale or purchase agreement, new owner’s name, address andengine serial number to Mercury Marine’s warranty registrationdepartment.Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Upon processing the transfer of warranty, Mercury Marine will sendregistration verification to the new owner of the product by mail.There is no charge for this service.For products purchased outside the United States and Canada, contact thedistributor in your country, or the Mercury Marine Service Office closest toyou.
Warranty Registration United States And Canada1. You may change your address at any time, including at time of warranty
claim, by calling Mercury Marine or sending a letter or fax with yourname, old address, new address, and engine serial number to MercuryMarine’s warranty registration department. Your dealer can alsoprocess this change of information.Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054
NOTE: Registration lists must be maintained by Mercury Marine and anydealer on marine products sold in the United States, should a safety recallnotification under the Federal Safety Act be required.
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2. To be eligible for warranty coverage, the product must be registeredwith Mercury Marine. At the time of sale, the dealer should completethe warranty registration and immediately submit it to Mercury Marinevia MercNET, E-mail, or mail. Upon receipt of this warranty registration,Mercury Marine will record the registration.
3. Upon processing the warranty registration, Mercury Marine will sendregistration verification by mail to the purchaser of the product. If thisregistration verification is not received within 30 days, please contactyour selling dealer immediately. Warranty coverage is not effective untilyour product is registered with Mercury Marine.
Warranty Registration Outside The United StatesAnd Canada1. It is important that your selling dealer fills out the Warranty Registration
Card completely and mails it to the distributor or Marine Power ServiceCenter responsible for administering the warranty registration/claimprogram for your area.
2. The Warranty Registration Card identifies your name and address,product model and serial numbers, date of sale, type of use and theselling distributor's/dealer's code number, name and address. Thedistributor/dealer also certifies that you are the original purchaser anduser of the product.
3. A copy of the Warranty Registration Card, designated as thePurchaser's Copy, MUST be given to you immediately after the cardhas been completely filled out by the selling distributor/dealer. This cardrepresents your factory registration identification, and should beretained by you for future use when required. Should you ever requirewarranty service on this product, your dealer may ask you for theWarranty Registration Card to verify date of purchase and to use theinformation on the card to prepare the warranty claim forms.
4. In some countries, the Marine Power Service Center will issue you apermanent (plastic) Warranty Registration Card within 30 days afterreceiving the Factory Copy of the Warranty Registration Card from yourdistributor/dealer. If you receive a plastic Warranty Registration Card,you may discard the Purchaser's Copy that you received from thedistributor/dealer when you purchased the product. Ask yourdistributor/dealer if this plastic card program applies to you.
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IMPORTANT: Registration lists must be maintained by the factory anddealer in some countries by law. It is our desire to have ALL productsregistered at the factory should it ever be necessary to contact you. Makesure your dealer/distributor fills out the warranty registration cardimmediately and sends the factory copy to the Marine Power InternationalService Center for your area.5. For further information concerning the Warranty Registration Card and
its relationship to Warranty Claim processing, refer to the InternationalWarranty.
Four Stroke Outboard Limited WarrantyUNITED STATES AND CANADAOutside the United States and Canada - Check with your local distributor.California residents that have purchased a 2001 model year outboard froma California dealer receive coverage in addition to that identified below foremissions related components. Please see the California EmissionWarranty Statement provided by your dealer.WHAT IS COVERED: Mercury Marine warrants its new products to be freeof defects in material and workmanship during the period described below.DURATION OF COVERAGE: This Limited Warranty provides coverage forthree (3) years from the date the product is first sold to a recreational useretail purchaser, or the date on which the product is first put into service,whichever occurs first. Commercial users of these products receivewarranty coverage of one (1) year from the date of first retail sale, or one(1) year from the date on which the product was first put into service,whichever occurs first. Commercial use is defined as any work oremployment related use of the product, or any use of the product whichgenerates income, for any part of the warranty period, even if the productis only occasionally used for such purposes. The repair or replacement ofparts, or the performance of service under this warranty, does not extendthe life of this warranty beyond its original expiration date. Unexpiredwarranty coverage can be transferred from one recreational use customerto a subsequent recreational use customer upon proper re-registration ofthe product. Unexpired warranty coverage cannot be transferred either toor from a commercial use customer.
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CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTYCOVERAGE: Warranty coverage is available only to retail customers thatpurchase from a Dealer authorized by Mercury Marine to distribute theproduct in the country in which the sale occurred, and then only after theMercury Marine specified pre-delivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Inaccurate warrantyregistration information regarding recreational use, or subsequent changeof use from recreational to commercial (unless properly re-registered) mayvoid the warranty at the sole discretion of Mercury Marine. Routinemaintenance outlined in the Operation and Maintenance Manual must betimely performed in order to maintain warranty coverage. Mercury Marinereserves the right to make warranty coverage contingent upon proof ofproper maintenance.WHAT MERCURY WILL DO: Mercury's sole and exclusive obligationunder this warranty is limited to, at our option, repairing a defective part,replacing such part or parts with new or Mercury Marine certifiedre-manufactured parts, or refunding the purchase price of the Mercuryproduct. Mercury reserves the right to improve or modify products from timeto time without assuming an obligation to modify products previouslymanufactured.HOW TO OBTAIN WARRANTY COVERAGE: The customer must provideMercury with a reasonable opportunity to repair, and reasonable access tothe product for warranty service. Warranty claims shall be made bydelivering the product for inspection to a Mercury dealer authorized toservice the product. If purchaser cannot deliver the product to such adealer, written notice must be given to Mercury. We will then arrange forthe inspection and any covered repair. Purchaser in that case shall pay forall related transportation charges and/or travel time. If the service providedis not covered by this warranty, purchaser shall pay for all related labor andmaterial, and any other expenses associated with that service. Purchasershall not, unless requested by Mercury, ship the product or parts of theproduct directly to Mercury. Proof of registered ownership must bepresented to the dealer at the time warranty service is requested in orderto obtain coverage.U.S. EPA EMISSIONS LIMITED WARRANTY: Consistent with theobligations created by 40 CFR Part 91, Subpart M, Mercury Marineprovides a two year limited warranty to the retail purchaser, that the engineis designed, built, and equipped so as to conform at the time of sale withapplicable regulations under section 213 of the Clean Air Act, and that theengine is free from defects in materials and workmanship which cause theengine to fail to conform with applicable regulations.
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WHAT IS NOT COVERED: This limited warranty does not cover routinemaintenance items, tune ups, adjustments, normal wear and tear, damagecaused by abuse, abnormal use, use of a propeller or gear ratio that doesnot allow the engine to run in its recommended wide open throttle RPMrange (see the Operation and Maintenance Manual), operation of theproduct in a manner inconsistent with the recommended operation/dutycycle section of the Operation and Maintenance Manual, neglect, accident,submersion, improper installation (proper installation specifications andtechniques are set forth in the installation instructions for the product),improper service, use of an accessory or part not manufactured or sold byus, jet pump impellers and liners, operation with fuels, oils or lubricantswhich are not suitable for use with the product (see the Operation andMaintenance Manual), alteration or removal of parts, water entering theengine through the fuel intake, air intake or exhaust system, or damage tothe product from insufficient cooling water caused by blockage of thecooling system by a foreign body, running the engine out of water, mountingthe engine too high on the transom, or running the boat with the enginetrimmed out too far. Use of the product for racing or other competitiveactivity, or operating with a racing type lower unit, at any point, even by aprior owner of the product, voids the warranty.Expenses related to haul out, launch, towing, storage, telephone, rental,inconvenience, slip fees, insurance coverage, loan payments, loss of time,loss of income, or any other type of incidental or consequential damagesare not covered by this warranty. Also, expenses associated with theremoval and/or replacement of boat partitions or material caused by boatdesign for access to the product are not covered by this warranty.No individual or entity, including Mercury Marine authorized dealers, hasbeen given authority by Mercury Marine to make any affirmation,representation or warranty regarding the product, other than thosecontained in this limited warranty, and if made, shall not be enforceableagainst Mercury Marine.For additional information regarding events and circumstances covered bythis warranty, and those that are not, see the Warranty Coverage sectionof the Operation and Maintenance Manual, incorporated by reference intothis warranty.
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DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TOTHE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIALDAMAGES ARE EXCLUDED FROM COVERAGE UNDER THISWARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THEDISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIEDABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THISWARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAYALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TOSTATE AND COUNTRY TO COUNTRY.
3 Year Limited Warranty Against CorrosionWHAT IS COVERED: Mercury Marine warrants that each new Mercury,Mariner, Mercury Racing, Sport Jet, M2 Jet Drive, Tracker by MercuryMarine Outboard, MerCruiser Inboard or sterndrive engine (Product) willnot be rendered inoperative as a direct result of corrosion for the period oftime described below.DURATION OF COVERAGE: This limited corrosion warranty providescoverage for three (3) years from either the date the product is first sold,or the date on which the product is first put into service, whichever occursfirst. The repair or replacement of parts, or the performance of serviceunder this warranty does not extend the life of this warranty beyond itsoriginal expiration date. Unexpired warranty coverage can be transferredto subsequent (non-commercial use) purchaser upon proper re-registrationof the product.
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CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTYCOVERAGE: Warranty coverage is available only to retail customers thatpurchase from a Dealer authorized by Mercury Marine to distribute theproduct in the country in which the sale occurred, and then only after theMercury Marine specified pre-delivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Corrosion preventiondevices specified in the Operation and Maintenance Manual must be in useon the boat, and routine maintenance outlined in the Operation andMaintenance Manual must be timely performed (including without limitationthe replacement of sacrificial anodes, use of specified lubricants, andtouch-up of nicks and scratches) in order to maintain warranty coverage.Mercury Marine reserves the right to make warranty coverage contingentupon proof of proper maintenance.WHAT MERCURY WILL DO: Mercury's sole and exclusive obligationunder this warranty is limited to, at our option, repairing a corroded part,replacing such part or parts with new or Mercury Marine certifiedre-manufactured parts, or refunding the purchase price of the Mercuryproduct. Mercury reserves the right to improve or modify products from timeto time without assuming an obligation to modify products previouslymanufactured.HOW TO OBTAIN WARRANTY COVERAGE: The customer must provideMercury with a reasonable opportunity to repair, and reasonable access tothe product for warranty service. Warranty claims shall be made bydelivering the product for inspection to a Mercury dealer authorized toservice the product. If purchaser cannot deliver the product to such adealer, written notice must be given to Mercury. We will then arrange forthe inspection and any covered repair. Purchaser in that case shall pay forall related transportation charges and/or travel time. If the service providedis not covered by this warranty, purchaser shall pay for all related labor andmaterial, and any other expenses associated with that service. Purchasershall not, unless requested by Mercury, ship the product or parts of theproduct directly to Mercury. Proof of registered ownership must bepresented to the dealer at the time warranty service is requested in orderto obtain coverage.
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WHAT IS NOT COVERED: This limited warranty does not cover electricalsystem corrosion; corrosion resulting from damage, corrosion whichcauses purely cosmetic damage, abuse or improper service; corrosion toaccessories, instruments, steering systems; corrosion to factory installedjet drive unit; damage due to marine growth; product sold with less than aone year limited Product warranty; replacement parts (parts purchased bycustomer); products used in a commercial application. Commercial use isdefined as any work or employment related use of the product, or any useof the product which generates income, for any part of the warranty period,even if the product is only occasionally used for such purposes.Corrosion damage caused by stray electrical currents (on-shore powerconnections, nearby boats, submerged metal) is not covered by thiscorrosion warranty and should be protected against by the use of acorrosion protection system, such as the Mercury Precision Parts orQuicksilver MerCathode system and/or Galvanic Isolator. Corrosiondamage caused by improper application of copper base anti-fouling paintsis also not covered by this limited warranty. If anti-fouling protection isrequired, Tri-Butyl-Tin-Adipate (TBTA) base anti-fouling paints arerecommended on Outboard and MerCruiser boating applications. In areaswhere TBTA base paints are prohibited by law, copper base paints can beused on the hull and transom. Do not apply paint to the outboard orMerCruiser product. In addition, care must be taken to avoid an electricalinterconnection between the warranted product and the paint. ForMerCruiser product, an unpainted gap of at least 38 mm (1.5 in.) should beleft around the transom assembly. Refer to the Operation and MaintenanceManual for additional details.For additional information regarding events and circumstances covered bythis warranty, and those that are not, see the Warranty Coverage sectionof the Operation and Maintenance Manual, incorporated by reference intothis warranty.
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DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TOTHE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIALDAMAGES ARE EXCLUDED FROM COVERAGE UNDER THISWARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THEDISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIEDABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THISWARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAYALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TOSTATE AND COUNTRY TO COUNTRY.
Warranty Coverage And ExclusionsThe purpose of this section is to help eliminate some of the more commonmisunderstandings regarding warranty coverage. The followinginformation explains some of the types of services that are not covered bywarranty. The provisions set forth following have been incorporated byreference into the Three Year Limited Warranty Against Corrosion Failure,the International Limited Outboard Warranty, and the United States andCanada Limited Outboard Warranty.Keep in mind that warranty covers repairs that are needed within thewarranty period because of defects in material and workmanship.Installation errors, accidents, normal wear, and a variety of other causesthat affect the product are not covered.Warranty is limited to defects in material or workmanship, but only whenthe consumer sale is made in the country to which distribution is authorizedby us.Should you have any questions concerning warranty coverage, contactyour authorized dealer. They will be pleased to answer any questions thatyou may have.GENERAL EXCLUSIONS FROM WARRANTY1. Minor adjustments and tune-ups, including checking, cleaning or
adjusting spark plugs, ignition components, carburetor settings, filters,belts, controls, and checking lubrication made in connection withnormal services.
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2. Factory installed jet drive units - Specific parts excluded from thewarranty are: The jet drive impeller and jet drive liner damaged byimpact or wear, and water damaged drive shaft bearings as a result ofimproper maintenance.
3. Damage caused by neglect, lack of maintenance, accident, abnormaloperation or improper installation or service.
4. Haul out, launch, towing charges, removal and/or replacement of boatpartitions or material because of boat design for necessary access tothe product, all related transportation charges and/or travel time, etc.Reasonable access must be provided to the product for warrantyservice. Customer must deliver product to an authorized dealer.
5. Additional service work requested by customer other than thatnecessary to satisfy the warranty obligation.
6. Labor performed by other than an authorized dealer may be coveredonly under following circumstances: When performed on emergencybasis (providing there are no authorized dealers in the area who canperform the work required or have no facilities to haul out, etc., andprior factory approval has been given to have the work performed atthis facility).
7. All incidental and/or consequential damages (storage charges,telephone or rental charges of any type, inconvenience or loss of timeor income) are the owner's responsibility.
8. Use of other than Mercury Precision or Quicksilver parts when makingwarranty repairs.
9. Oils, lubricants or fluids changed as a matter of normal maintenance iscustomer's responsibility unless loss or contamination of same iscaused by product failure that would be eligible for warrantyconsideration.
10. Participating in or preparing for racing or other competitive activity oroperating with a racing type lower unit.
11. Engine noise does not necessarily indicate a serious engine problem.If diagnosis indicates a serious internal engine condition which couldresult in a failure, condition responsible for noise should be correctedunder the warranty.
12. Lower unit and/or propeller damage caused by striking a submergedobject is considered a marine hazard.
13. Water entering engine through the fuel intake, air intake or exhaustsystem or submersion.
14. Failure of any parts caused by lack of cooling water, which results fromstarting motor out of water, foreign material blocking inlet holes, motorbeing mounted too high or trimmed too far out.
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15. Use of fuels and lubricants which are not suitable for use with or on theproduct. Refer to the Maintenance section.
16. Our limited warranty does not apply to any damage to our productscaused by the installation or use of parts and accessories which arenot manufactured or sold by us. Failures which are not related to theuse of those parts or accessories are covered under warranty if theyotherwise meet the terms of the limited warranty for that product.
California Emissions Limited WarrantyThe California Air Resources Board has promulgated air emissionsregulations for outboard engines. The regulations apply to all outboardengines sold to retail consumers in California, and which weremanufactured for the 2001 model year, and later. Mercury Marine, incompliance with those regulations, provides this limited warranty for theemission control systems (see the components of the emission controlsystem listed following), and further warrants that the outboard engine wasdesigned, built and equipped to conform with all applicable regulationsadopted by the California Air Resources Board pursuant to its authority inChapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. Forinformation regarding the limited warranty for the non emissions relatedcomponents of the outboard, please see the limited warranty statement foryour outboard.WHAT IS COVERED: Mercury Marine warrants the components of theemissions control systems (see the components of the emission controlsystem listed following) of its new, 2001 model year (and later) outboards,sold by a California dealer to retail customers residing in California, to befree from defects in material or workmanship, that cause the failure of awarranted part to be identical in all material respects to that part asdescribed in the application of Mercury Marine for certification from theCalifornia Air Resources Board, for the period of time, and under theconditions, identified below. The cost to diagnose a warranty failure iscovered under the warranty (if the warranty claim is approved). Damage toother engine components caused by the failure of a warranted part will alsobe repaired under warranty.
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DURATION OF COVERAGE: This limited warranty provides coverage forthe components of the emissions control systems of new, 2001 model year(and later) outboards, sold to retail customers in California for 4 years fromeither the date the product is first sold, or first put into service, whicheveroccurs first, or the accumulation of 250 hours of engine operation (asdetermined by the engines hour meter, if any). Emission related normalmaintenance items such as spark plugs and filters, that are on thewarranted parts list (see following) are warranted up to their first requiredreplacement interval only. (See Maintenance - Inspection andMaintenance Schedule). The repair or replacement of parts, or theperformance of service under this warranty, does not extend the life of thiswarranty beyond its original expiration date. Unexpired warranty coveragecan be transferred to a subsequent purchaser. (See instructions on transferof warranty).HOW TO OBTAIN WARRANTY COVERAGE: The customer must provideMercury with a reasonable opportunity to repair, and reasonable access tothe product for warranty service. Warranty claims shall be made bydelivering the product for inspection to a Mercury dealer authorized toservice the product. If purchaser cannot deliver the product to such adealer, please notify Mercury Marine and Mercury will then arrange for theinspection and any covered repair. Purchaser in that case shall pay for allrelated transportation charges and/or travel time. If the service provided isnot covered by this warranty, purchaser shall pay for all related labor andmaterial, and any other expenses associated with that service. Purchasershall not, unless requested by Mercury, ship the product or parts of theproduct directly to Mercury.WHAT MERCURY WILL DO: Mercury Marine's sole and exclusiveobligation under this warranty is limited to, at our expense and at our option,repairing or replacing defective parts with new or Mercury Marine certifiedre-manufactured parts, or refunding the purchase price of the Mercuryproduct. Mercury reserves the right to improve or modify products from timeto time without assuming an obligation to modify products previouslymanufactured.
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WHAT IS NOT COVERED: This limited warranty does not cover routinemaintenance items, tune ups, adjustments, normal wear and tear, damagecaused by abuse, abnormal use, use of a propeller or gear ratio that doesnot allow the engine to run in its recommended wide open throttle RPMrange (see General Information - Specifications), operation of the productin a manner inconsistent with the recommended operation procedures,neglect, accident, submersion, improper installation (proper installationspecifications and techniques are set forth in the installation instructionsfor the product), improper service, use of an accessory or part notmanufactured or sold by us, jet pump impellers and liners, operation withfuels, oils or lubricants which are not suitable for use with the product (seeFuel and Oil), alteration or removal of parts, or water entering the enginethrough the fuel intake, air intake or exhaust system. Use of the product forracing or other competitive activity, or operating with a racing type lowerunit, at any point, even by a prior owner of the product, voids the warranty.Expenses related to haul out, launch, towing, storage, telephone, rental,inconvenience, slip fees, insurance coverage, loan payments, loss of time,loss of income, or any other type of incidental or consequential damagesare not covered by this warranty. Also, expenses associated with theremoval and/or replacement of boat partitions or material caused by boatdesign for access to the product are not covered by this warranty.Non-warranty maintenance, replacement, or repair of emission controldevices and systems may be performed by any marine engine repairestablishment or individual. The use of non-Mercury parts for non-warrantymaintenance or repairs will not be grounds for disallowing other warrantywork. The use of add-on (as defined at section 1900 (b)(1) and (b)(10) ofTitle 13 of the California Code of Regulations) or modified parts notexempted by the California Air Resources Board may be grounds fordisallowing a warranty claim, at the discretion of Mercury Marine. Failuresof warranted parts caused by the use of a non-exempted add-on ormodified part will not be covered.COMPONENTS OF THE EMISSIONS CONTROL SYSTEM:1. Fuel Metering System
a. Carburetor and internal parts (and/or pressure regulator or fuelinjection system)
b. Cold start enrichment systemc. Intake valves
2. Air Induction Systema. Intake manifoldb. Turbocharger or supercharger systems (where applicable)
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3. Ignition Systema. Spark plugsb. Magneto or electronic ignition systemc. Spark advance/retard systemd. Ignition coil and/or control modulee. Ignition wires
4. Lubrication System (4-Stroke engines excluded)a. Oil pump and internal partsb. Oil injectorsc. Oil meter
5. Exhaust systema. Exhaust manifoldb. Exhaust valves
6. Miscellaneous Items Used in Above Systemsa. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and
mounting hardware.b. Pulleys, belts and idlers.c. Vacuum, temperature, check and time sensitive valves and
switchesd. Electronic controls.
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TOTHE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIALDAMAGES ARE EXCLUDED FROM COVERAGE UNDER THISWARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THEDISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIEDABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THISWARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAYALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TOSTATE AND COUNTRY TO COUNTRY.
If you have any questions regarding your warranty rights andresponsibilities, you should contact Mercury Marine at 1-920-929-5040.
WARRANTY INFORMATION
15
CALIFORNIA AIR RESOURCES BOARD EXPLANATION OFYOUR CALIFORNIA EMISSION CONTROL WARRANTYSTATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS: The California AirResources Board is pleased to explain the emission control systemwarranty on your 2001 model year and later outboard engine. In California,new outboard engines must be designed, built and equipped to meet theState's stringent anti-smog standards. Mercury Marine must warrant theemission control system on your outboard engine for the periods of timelisted below provided there has been no abuse, neglect or impropermaintenance of your outboard engine.Your emission control system may include parts such as the carburetor orfuel injection system, the ignition system, and catalytic converter. Alsoincluded may be hoses, belts, connectors and other emission-relatedassemblies.Where a warrantable condition exists, Mercury Marine will repair youroutboard engine at no cost to you, including diagnosis, parts and labor.MANUFACTURER'S WARRANTY COVERAGE: Select emission controlparts from model year 2001 and later outboard engines are warranted for4 years, or for 250 hours of use, whichever occurs first. However, warrantycoverage based on the hourly period is only permitted for outboard enginesand personal watercraft equipped with appropriate hour meters or theirequivalent. If any emission related part on your engine is defective underwarranty, the part will be repaired or replaced by Mercury Marine.OWNER'S WARRANTY RESPONSIBILITIES: As the outboard engineowner, you are responsible for the performance of the requiredmaintenance listed in the Maintenance section. Mercury Marinerecommends that you retain all receipts covering maintenance on youroutboard engine, but Mercury Marine cannot deny warranty solely for thelack of receipts or your failure to ensure the performance of all scheduledmaintenance.As the outboard engine owner, you should however be aware that MercuryMarine may deny you warranty coverage if your outboard engine or a parthas failed due to abuse, neglect, improper maintenance or unapprovedmodifications.You are responsible for presenting your outboard to a Mercury dealerauthorized to service the product as soon as a problem exists. The warrantyrepairs will be completed in a reasonable amount of time, not to exceed 30days.If you have any questions regarding your warranty rights andresponsibilities, you should contact Mercury Marine at 1-920-929-5040.
WARRANTY INFORMATION
16
Star LabelOutboards are labeled on the cowl with one of the following star labels.The Symbol for Cleaner Marine Engines Means:Cleaner Air and Water - for a healthier lifestyle and environment.Better Fuel Economy - burns up to 30-40 percent less gas and oil thanconventional carbureted two-stroke engines, saving money and resources.Longer Emission Warranty - Protects consumer for worry free operation.
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One Star - Low Emission
The one Star Label identifies engines that meetthe Air Resources Board's 2001 exhaustemissions standards. Engines meeting thesestandards have 75% lower emissions thanconventional carbureted two-stroke engines.These engines are equivalent to the U.S.EPA's 2006 standards for marine engines.
FO IDA
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Two Stars - Very Low Emission
The two Star Label identifies engines that meetthe Air Resources Board's Personal Watercraftand Outboard marine engine 2004 exhaustemissions standards. Engines meeting thesestandards have 20% lower emissions thanOne Star - Low Emission engines.
ASS
D
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Three Stars - Ultra Low Emission
The three Star Label identifies engines thatmeet the Air Resources Board's personalWatercraft and Outboard marine engine 2008exhaust emissions standards or the Sterndriveand Inboard marine engine 2003-2008exhaust emission standards. Engines meetingthese standards have 65% lower emissionsthan One Star - Low Emission engines.
WARRANTY INFORMATION
17
RNF T
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Four Stars - Super Ultra Low Emission
The four Star label identifies engines that meetthe Air Resources Board's Sterndrive andInboard marine engine 2009 exhaust emissionstandards. Personal Watercraft and Outboardmarine engines may also comply with thesestandards. Engines meeting these standardshave 90% lower emissions than One Star -Low Emission engines.
GENERAL INFORMATION
18
Boater's ResponsibilitiesThe operator (driver) is responsible for the correct and safe operation ofthe boat and safety of its occupants and general public. It is stronglyrecommended that each operator (driver) read and understand this entiremanual before operating the outboard.Be sure at least one additional person on board is instructed in the basicsof starting and operating the outboard and boat handling in case the driveris unable to operate the boat.
Before Operating Your OutboardRead this manual carefully. Learn how to operate your outboard properly.If you have any questions, contact your dealer.Safety and operating information that is practiced, along with using goodcommon sense, can help prevent personal injury and product damage.This manual as well as safety labels posted on the outboard use thefollowing safety alerts to draw your attention to special safety instructionsthat should be followed.
! DANGERDANGER - indicates an imminently hazardous situation that, if notavoided, will result in death or serious injury.
! WARNINGWARNING - indicates a potentially hazardous situation that, if notavoided, could result in death or serious injury.
! CAUTIONCAUTION - indicates a potentially hazardous situation that, if notavoided, may result in minor or moderate injury or property damage. Itmay also be used to alert against unsafe practices.
Boat Horsepower Capacity
! WARNINGUsing an outboard that exceeds the maximum horsepower limit of a boatcan: 1) cause loss of boat control 2) place too much weight at the transomaltering the designed flotation characteristics of the boat or 3) cause theboat to break apart particularly around the transom area. Overpoweringa boat can result in serious injury, death or boat damage.
GENERAL INFORMATION
19
Do not overpower or overload your boat. Most boats will carry a requiredcapacity plate indicating the maximum acceptable power and load asdetermined by the manufacturer following certain federal guidelines. If indoubt, contact your dealer or the boat manufacturer.
U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSON CAPACITY (POUNDS) XXXMAXIMUM WEIGHT CAPACITY XXX
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High-Speed And High-Performance Boat OperationIf your outboard is to be used on a high speed or high performance boatwith which you are unfamiliar, we recommend that you never operate it atits high speed capability without first requesting an initial orientation andfamiliarization demonstration ride with your dealer or an operatorexperienced with your boat/outboard combination. For additionalinformation, obtain a copy of our Hi-Performance Boat Operation booklet(part number 90-849250--1) from your dealer, distributor, or MercuryMarine.
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Outboard Remote Control ModelsThe outboard must be equipped with a Mercury remote control designedfor digital throttle and shift. Start-in-gear protection is provided by theremote control system.
Lanyard Stop SwitchThe purpose of a lanyard stop switch is to turn off the engine when theoperator moves far enough away from the operator's position (as inaccidental ejection from the operator's position) to activate the switch. Tillerhandle outboards and some remote control units are equipped with alanyard stop switch. A lanyard stop switch can be installed as an accessory- generally on the dashboard or side adjacent to the operator's position.
GENERAL INFORMATION
20
The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) inlength when stretched out, with an element on one end made to be insertedinto the switch and a snap on the other end for attaching to the operator.The lanyard is coiled to make its at-rest condition as short as possible tominimize the likelihood of lanyard entanglement with nearby objects. Itsstretched-out length is made to minimize the likelihood of accidentalactivation should the operator choose to move around in an area close tothe 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 thelanyard.
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a b
a - Lanyard cord b - Lanyard stop switch
Read the following Safety Information before proceeding.Important Safety Information: The purpose of a lanyard stop switch is tostop the engine when the operator moves far enough away from theoperator's position to activate the switch. This would occur if the operatoraccidentally falls overboard or moves within the boat a sufficient distancefrom the operator's position. Falling overboard and accidental ejections aremore likely to occur in certain types of boats such as low sided inflatables,bass boats, high performance boats, and light, sensitive handling fishingboats operated by a hand tiller. Falling overboard and accidental ejectionsare also likely to occur as a result of poor operating practices such as sittingon the back of the seat or gunwale at planing speeds, standing at planingspeeds, sitting on elevated fishing boat decks, operating at planing speedsin shallow or obstacle infested waters, releasing your grip on a steeringwheel or tiller handle that is pulling in one direction, drinking alcohol orconsuming drugs, or daring high speed boat maneuvers.While activation of the lanyard stop switch will stop the engine immediately,a boat will continue to coast for some distance depending upon the velocityand degree of any turn at shut down. However, the boat will not completea full circle. While the boat is coasting, it can cause injury to anyone in theboat's path as seriously as the boat would when under power.We strongly recommend that other occupants be instructed on properstarting and operating procedures should they be required to operate theengine in an emergency (e.g. if the operator is accidentally ejected).
GENERAL INFORMATION
21
! WARNINGShould the operator fall out of the boat, the possibility of serious injury ordeath from being run over by the boat can be greatly reduced by stoppingthe engine immediately. Always properly connect both ends of the stopswitch lanyard to the stop switch and the operator.
! WARNINGAvoid serious injury or death from deceleration forces resulting fromaccidental or unintended stop switch activation. The boat operator shouldnever leave the operator's station without first disconnecting the stopswitch lanyard from the operator.
Accidental or unintended activation of the switch during normal operationis also a possibility. This could cause any, or all, of the following potentiallyhazardous situations:• Occupants could be thrown forward due to unexpected loss of forward
motion - a particular concern for passengers in the front of the boat whocould be ejected over the bow and possibly struck by the gearcase orpropeller.
• Loss of power and directional control in heavy seas, strong current orhigh winds.
• Loss of control when docking.
Protecting People In The WaterWHILE YOU ARE CRUISINGIt is very difficult for a person standing or floating in the water to take quickaction to avoid a boat heading in his/her direction, even at slow speed.
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Always slow down and exercise extreme caution any time you are boatingin an area where there might be people in the water.Whenever a boat is moving (coasting) and the outboard gear shift is inneutral position, there is sufficient force by the water on the propeller tocause the propeller to rotate. This neutral propeller rotation can causeserious injury.
GENERAL INFORMATION
22
WHILE BOAT IS STATIONARY
! WARNINGStop your engine immediately whenever anyone in the water is near yourboat. Serious injury to the person in the water is likely if contacted by arotating propeller, a moving boat, a moving gearcase, or any solid devicerigidly attached to a moving boat or gearcase.
Shift outboard into neutral and shut off the engine before allowing peopleto swim or be in the water near your boat.
Passenger Safety Message - Pontoon Boats AndDeck BoatsWhenever the boat is in motion, observe the location of all passengers. Donot allow any passengers to stand or use seats other than those designatedfor traveling faster than idle speed. A sudden reduction in boat speed, suchas plunging into a large wave or wake, a sudden throttle reduction, or asharp change of boat direction, could throw them over the front of boat.Falling over the front of the boat between the two pontoons will positionthem to be run over by the outboard.BOATS HAVING AN OPEN FRONT DECKNo one should ever be on the deck in front of the fence while the boat is inmotion. Keep all passengers behind the front fence or enclosure.Persons on the front deck could easily be thrown overboard or personsdangling their feet over the front edge could get their legs caught by a waveand pulled into the water.
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! WARNINGAvoid serious injury or death from falling over the front end of a pontoonor deck boat and being run over by the outboard. Stay back from the frontend of the deck and remain seated while the boat is in motion.
GENERAL INFORMATION
23
BOATS WITH FRONT MOUNTED, RAISED PEDESTALFISHING SEATSElevated fishing seats are not intended for use when the boat is travelingfaster than idle or trolling speed. Sit only in seats designated for travelingat faster speeds.Any unexpected, sudden reduction in boat speed could result in theelevated passenger falling over the front of the boat.
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Wave And Wake JumpingOperating recreational boats over waves and wake is a natural part ofboating. However, when this activity is done with sufficient speed to forcethe boat hull partially or completely out of the water, certain hazards arise,particularly when the boat re-enters the water.
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The primary concern is the boat changing direction while in the midst of thejump. In such case the landing may cause the boat to veer violently in anew direction. Such a sharp change in direction can cause occupants tobe thrown out of their seats, or out of the boat.
! WARNINGAvoid serious injury or death from being thrown within or out of a boatwhen it lands after jumping a wave or wake. Avoid wave or wake jumpingwhenever possible. Instruct all occupants that if a wake or wave jumpoccurs, get low and hang on to a boat hand hold.
GENERAL INFORMATION
24
There is another less common hazardous result from allowing your boat tolaunch off a wave or wake. If the bow of your boat pitches down far enoughwhile airborne, upon water contact it may penetrate under the water surfaceand submarine for an instant. This will bring the boat to a nearlyinstantaneous stop and can send the occupants flying forward. The boatmay also steer sharply to one side.
Impact With Underwater HazardsReduce speed and proceed with caution whenever you drive a boat inshallow water areas, or in areas where you suspect underwater obstaclesmay exist which could be struck by the outboard or the boat bottom. Themost important thing you can do to help reduce injury or impact damagefrom striking a floating or underwater object is to control the boat speed.Under these conditions, boat speed should be kept to a minimum planingspeed 24 to 40 km/h (15 to 25 MPH) .
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! WARNINGTo avoid serious injury or death from all or part of an outboard cominginto the boat after striking a floating or underwater obstacle maintain atop speed no greater than minimum planing speed.
Striking a floating or underwater object could result in an infinite number ofsituations. 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 outof the boat.
• A rapid reduction in speed. This will cause occupants to be thrownforward, or even out of the boat.
• Impact damage to the outboard and/or boat.
GENERAL INFORMATION
25
Keep in mind, the most important thing you can do to help reduce injury orimpact damage during an impact is control the boat speed. Boat speedshould be kept to a minimum planing speed when driving in waters knownto have underwater obstacles.After striking a submerged object, stop the engine as soon as possible andinspect it for any broken or loose parts. If damage is present or suspected,the outboard should be taken to an authorized dealer for a thoroughinspection 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 otherparts of the outboard, or could affect control of the boat. If continued runningis necessary, do so at greatly reduced speeds.
! WARNINGAvoid serious injury or death from loss of boat control. Continued boatingwith major impact damage can result in sudden outboard componentfailure with or without subsequent impacts. Have the outboard thoroughlyinspected and any necessary repairs made.
Exhaust EmissionsBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide is present in the exhaust fumes of all internal combustionengines. This includes the outboards, sterndrives and inboard engines thatpropel boats, as well as the generators that power various boataccessories. Carbon monoxide is a deadly gas that is odorless, colorlessand tasteless.Early symptoms of carbon monoxide poisoning which should not beconfused with seasickness or intoxication, include headache, dizziness,drowsiness, and nausea.
! WARNINGAvoid the combination of a running engine and poor ventilation.Prolonged exposure to carbon monoxide in sufficient concentration canlead to unconsciousness, brain damage, or death.
GENERAL INFORMATION
26
GOOD VENTILATIONVentilate passenger area, open side curtains, or forward hatches to removefumes.
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Example of desired air flow through the boat.POOR VENTILATIONUnder certain running and/or wind conditions, permanently enclosed orcanvas enclosed cabins or cockpits with insufficient ventilation may drawin carbon monoxide. Install one or more carbon monoxide detectors in yourboat.Although the occurrence is rare, on a very calm day, swimmers andpassengers in an enclosed area of a stationary boat that contains or is neara running engine may be exposed to a hazardous level of carbonmonoxide.WHILE BOAT IS STATIONARY
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ab
a - Running the engine when the boat is moored in a confined space.b - Mooring close to another boat that has its engine running.
GENERAL INFORMATION
27
WHILE BOAT IS MOVING
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a b
a - Running the boat with the trim angle of the bow too high.b - Running the boat with no forward hatches open.
Selecting Accessories For Your OutboardGenuine Mercury Precision or Quicksilver Accessories have beenspecifically designed and tested for your outboard. These accessories areavailable from Mercury Marine dealers.
! WARNINGCheck with your dealer before installation of accessories. The misuse ofacceptable accessories or the use of unacceptable accessories canresult in serious injury, death, or product failure.
Some accessories not manufactured or sold by Mercury Marine are notdesigned to be safely used with your outboard or outboard operatingsystem. Acquire and read the installation, operation, and maintenancemanuals for all your selected accessories.
Safe Boating SuggestionsIn order to safely enjoy the waterways, familiarize yourself with local andother governmental boating regulations and restrictions, and consider thefollowing suggestions.Use flotation devices. Have an approved personal flotation device ofsuitable size for each person aboard (it is the law) and have it readilyaccessible.Do not overload your boat. Most boats are rated and certified for maximumload (weight) capacities (refer to your boat capacity plate). If in doubt,contact your dealer or the boats manufacturer.Perform safety checks and required maintenance. Follow a regularschedule and ensure that all repairs are properly made.
GENERAL INFORMATION
28
Know and obey all nautical rules and laws of the waterways. Boat operatorsshould complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) TheRed Cross and 4) your state boating law enforcement agency. Inquiriesmay be made to the Boating Hotline, 1-800-368-5647 or the Boat U.S.Foundation information number 1-800-336-BOAT.Make sure everyone in the boat is properly seated. Do not allow anyone tosit or ride on any part of the boat that was not intended for such use. Thisincludes the back of seats, gunwales, transom, bow, decks, raised fishingseats, any rotating fishing seat; or anywhere that an unexpectedacceleration, sudden stopping, unexpected loss of boat control, or suddenboat movement could cause a person to be thrown overboard or into theboat.Never be under the influence of alcohol or drugs while boating (it is thelaw). Alcohol or drug use impairs your judgment and greatly reduces yourability to react quickly.Prepare other boat operators. Instruct at least one other person on boardin the basics of starting and operating the outboard, and boat handling, incase the driver becomes disabled or falls overboard.Passenger boarding. Stop the engine whenever passengers are boarding,unloading, or are near the back (stern) of the boat. Just shifting theoutboard into neutral is not sufficient.Be alert. The operator of the boat is responsible by law to maintain a properlookout by sight and hearing. The operator must have an unobstructed viewparticularly to the front. No passengers, load, or fishing seats should blockthe operators view when operating the boat above idle speed.Never drive your boat directly behind a water skier in case the skier falls.As an example, your boat traveling at 40 km/h (25 MPH) will overtake afallen skier 61 m (200 ft.) in front of you in 5 seconds.Watch fallen skiers. When using your boat for water skiing or similaractivities, always keep a fallen or down skier on the operator's side of theboat while returning to assist the skier. The operator should always havethe down skier in sight and never back up to the skier or anyone in thewater.
GENERAL INFORMATION
29
Report accidents. Boat operators are required by law to file a BoatingAccident Report with their state boating law enforcement agency whentheir boat is involved in certain boating accidents. A boating accident mustbe reported if 1) there is loss of life or probable loss of life, 2) there ispersonal injury requiring medical treatment beyond first aid, 3) there isdamage to boats or other property where the damage value exceeds$500.00 or 4) there is complete loss of the boat. Seek further assistancefrom local law enforcement.
Recording Serial NumberIt is important to record this number for future reference. The serial numberis located on the outboard as shown.
S ee rrial Numb
MAXRPM
HPLB
KWKG
20XX
XX
OTXXXXXX
XXXX
a
b
c
ed
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a - Serial numberb - Model yearc - Model designation
d - Year manufacturede - Certified Europe Insignia (as
applicable)
SpecificationsModels 200/225/250/275
Horsepower 200/225/250/275
Kilowatts 149/168/186/205
Full Throttle RPM Range 5800-6400
Idle Speed in Neutral Gear1. 550 RPM
Number of Cylinders 6
1. With engine fully warmed up.
GENERAL INFORMATION
30
Models 200/225/250/275
Piston Displacement 2,598 cc (158.5 cid)
Cylinder Bore 82 mm (3.23 in.)
Stroke 82 mm (3.23 in.)
Recommended Spark Plug NGK ILFR6G
Spark Plug Gap 0.8 mm (0.0315 in.)
Spark Plug Hex Size 16 mm
Gear Ratio 1.85:1
Recommended Gasoline Refer to Fuel & Oil
Recommended Oil Refer to Fuel & Oil
Right Hand RotationGearcase Lubricant Capacity 970 ml (32.8 fl. oz.)
Left Hand Rotation GearcaseLubricant Capacity 900 ml (30.4 fl. oz.)
Engine Oil Capacity With OilFilter Replacement 7.0 liters (7.4 qt)
Battery Rating1000 Marine Cranking Amps (MCA), 800
Cold Cranking AMPS (CCA) or 180Ampere Hour (Ah)
GENERAL INFORMATION
31
Component Identification
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j
a
b
c
d
e
g
h
i
f
a - Rear cowlb - Lower cowl chapsc - Anti-ventilation plated - Gearcasee - Cooling water intake holes
f - Spray plateg - Pedestalh - Engine flushi - Auxiliary tilt switchj - Top cowl
INSTALLATION
32
Installing Outboard
! WARNINGBefore operation, the outboard must be correctly installed with therequired mounting hardware as shown. Failure to correctly fastenoutboard could result in outboard ejecting off boat transom causingserious injury, death, or property damage.
IMPORTANT: For optimum boat performance and detailed engineinstallation instructions, refer to the outboard installation manual, suppliedwith the outboard.We strongly recommend that your dealer install your outboard and relatedaccessories to ensure proper installation and good performance. If youinstall the outboard yourself, follow instructions in the Outboard InstallationManual which is provided with the outboard.The outboard must be secured to the boat transom with the four 12.7 mm(1/2 in.) diameter mounting bolts, locknuts and washers provided. Installtwo bolts through the upper set of mounting holes and two bolts throughthe lower set of mounting slots.
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INSTALLATION
33
MAXIMUM OUTBOARD MOUNTING HEIGHTThe mounting height of the outboard must not exceed 63.5 cm (25 in.) forL models, 76.2 cm (30 in.) for XL models and 88.9 cm (35 in.) for XXLmodels. Mounting the outboard higher may cause damage to the gearcasecomponents.
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Maximum Static WaterlineThe static waterline, with boat at rest, must be below the "MAX STATICWATERLINE" mark on the idle relief grommet (located at the rear of theoutboard) when the outboard is fully tilted in/down. If waterline is above"MAX STATIC WATERLINE" mark, adjust boat load forward or increase(raise) outboard mounting height to correctly place mark above waterline.
MAX STATICWATERLINE
4224
INSTALLATION
34
Propeller SelectionFor best all around performance from your outboard/boat combination,select a propeller that allows the engine to operate in the upper half of therecommended full throttle RPM range with the boat normally loaded (referto General Information - Specifications). This RPM range allows for betteracceleration while maintaining maximum boat speed.
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If changing conditions cause the RPM to drop below the recommendedrange, such as warmer, more humid weather, operation at higherelevations, increased boat load, or a dirty boat bottom/gearcase, apropeller change or cleaning may be required to maintain performance andensure the outboards durability.Check full-throttle RPM, using an accurate tachometer, with the enginetrimmed out to a balanced-steering condition (steering effort equal in bothdirections) without causing the propeller to break loose.
TRANSPORTING
35
Trailering Boat/OutboardWhen transporting the boat on a trailer, the outboard should be positionedand/or supported in one of the following ways:1. If the boat trailer provides sufficient ground clearance, the outboard
may be tilted down to the vertical operating position with no additionalsupport required.
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2. If additional ground clearance is required, the outboard should be tiltedup and supported using the outboard's tilt support bracket (traileringposition) and/or an accessory transom support device. Refer toFeatures and Controls - Tilting Operation.
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TRANSPORTING
36
3. For maximum ground clearance, the outboard can be tilted to the fulltilt position and supported using the outboards tilt support bracket and/or an accessory transom support device.
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Additional clearance may be required for railroad crossings, driveways andtrailer bouncing. Refer to your local dealer for recommendations.IMPORTANT: Do not rely on the power trim/tilt system to maintain properground clearance for trailering. The power trim/tilt system is not intendedto support the outboard for trailering.Shift the outboard to forward gear. This prevents the propeller fromspinning freely when boat is trailered.
FUEL AND OIL
37
Gasoline RecommendationsUNITED STATES AND CANADAModel 275 The use of a major brand of automotive unleaded gasoline witha minimum posted octane rating of 91 is required for best performance.Use of a major brand of automotive unleaded gasoline with a minimumpump posted octane rating of 87 is acceptable, however performancelosses may occur. Automotive gasolines that contain fuel injector cleanersare preferred for added internal engine cleanliness. Leaded gasoline is notrecommended.Models 200/225/250 Use a major brand of automotive unleaded gasolinewith a minimum pump posted octane rating of 87. Automotive gasolinesthat contain fuel injector cleaners are preferred for added internal enginecleanliness. Leaded gasoline is not recommended.USING REFORMULATED (OXYGENATED) FUELS - UNITEDSTATES ONLYThis type of fuel is required in certain areas of the United States. The twotypes of reformulated ingredients in these fuels are alcohol (Ethanol) orEther (MTBE or ETBE). If Ethanol is the oxygenate that is used in thegasoline, refer to Alcohol in Gasoline.These reformulated fuels are acceptable for use in the Mercury engine.INTERNATIONALModel 275 The use of a major brand of automotive unleaded gasoline witha minimum posted octane rating of 96 RON is required for bestperformance. Use of a major brand of automotive unleaded gasoline witha minimum pump posted octane rating of 90 RON is acceptable, howeverperformance losses may occur. Automotive gasolines that contain fuelinjector cleaners are preferred for added internal engine cleanliness.Leaded gasoline is acceptable in areas where unleaded gasoline is notavailable.Models 200/225/250 Use a major brand of automotive unleaded gasolinewith a minimum pump posted octane rating of 90 RON. Automotivegasolines that contain fuel injector cleaners are preferred for added internalengine cleanliness. Leaded gasoline is acceptable in areas whereunleaded gasoline is not available.ALCOHOL IN GASOLINEWe do not recommend the use of gasoline which contains alcohol becauseof the possible adverse effect the alcohol may have on the fuel system. Ingeneral, if only gasoline containing alcohol is available, it must not containmore than 10% ethanol or 5% methanol, and the addition of an accessorywater separating fuel filter is recommended.
FUEL AND OIL
38
If gasoline containing alcohol is used or if you suspect the presence ofalcohol in your gasoline, increase your inspection of the fuel system,visually checking for fuel leaks or abnormalities.Gasoline containing alcohol may cause the following problems to youroutboard and fuel system:• Corrosion of metal parts• Deterioration of elastomers and plastic parts• Wear and damage of internal engine parts• Starting and operating difficulties• Vapor lock or fuel starvationSome of these adverse effects are due to the tendency of gasolinecontaining alcohol to absorb moisture from the air, resulting in a phase ofwater and alcohol which separates from the gasoline in the fuel tank.The adverse effects of alcohol are more severe with methanol and areworse with increasing content of alcohol.
Filling Fuel Tank
! WARNINGAvoid serious injury or death from a gasoline fire or explosion. Alwaysstop the engine and do not smoke or allow open flames or sparks in thearea while filling fuel tanks.
Fill fuel tanks outdoors away from heat, sparks, and open flames.Remove portable fuel tanks from boat to refill them.Always stop engine before refilling tanks.Do not completely fill the fuel tanks. Leave approximately 10% of the tankvolume unfilled. Fuel will expand in volume as its temperature rises andcan leak under pressure if the tank is completely filled.PORTABLE FUEL TANK PLACEMENT IN THE BOATPlace the fuel tank in the boat so the vent is higher than the fuel level undernormal boat operating conditions.
Engine Oil RecommendationsMercury or Quicksilver NMMA FC-W certified synthetic blend 25W-40multi-viscosity 4-Stroke Outboard Oil is recommended for general,all-temperature use. If the recommended Mercury or Quicksilver NMMAFC-W certified oil is not available, a major brand of NMMA FC-W certified4-Stroke Outboard Oil of similar viscosity may be used.
FUEL AND OIL
39
IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other thanMercury or Quicksilver NMMA FC-W certified oil or a major brand NMMAFC-W certified oil), synthetic oils, low quality oils or oils that contain solidadditives are not recommended.
4-STROKE ENGINE OIL
SAE 25W-40OIL CAPACITY: 7.0L (7.4 U.S. qt.)
C
+100+80+60+40+20
0
+38+120 +49
+27+16+4-7-18
F
7.0L
37-89
5315
-001
3435
Checking And Adding Engine OilIMPORTANT: Do not overfill. Tilt outboard out/up past vertical forapproximately one minute to allow trapped oil to drain back to the oil sump.Tilt outboard to vertical (not tilted) position when checking engine oil. Foraccurate readings, check oil only when engine is cold or after engine hasnot run for at least an hour.1. Beofre starting (cold engine) tilt outboard out/up past vertical to allow
trapped oil to drain back to the oil sump. Allow outboard to remain tiltedfor approximately one minute.
2. Tilt outboard to vertical operating position.3. Remove the top cowl. Refer to Maintenance - Cowl Removal And
Installation.4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and
push it back in all the way.5. Pull the dipstick back out again and observe the oil level. Oil should be
in the operating range (cross hatched region).
FUEL AND OIL
40
IMPORTANT: Do not try to fill the oil level to the top of the operating range(cross hatched region). Oil level is correct as long as it appears in theoperating range (cross hatched region).
ob01255
6. If the oil level is below the operating range (cross hatched region),remove the oil filler cap and add approximately 500 ml (16 oz.) ofspecified outboard motor oil. Allow a few minutes for the added oil todrain to the oil sump and recheck the dipstick. Repeat the process untiloil level is on the operating range (cross hatched region). Do not try tofill to the upper end of the operation range (cross hatched region).
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FUEL AND OIL
41
IMPORTANT: Inspect oil for signs of contamination. Oil contaminated withwater will have a milky color to it; oil contaminated with fuel will have astrong fuel smell. If contaminated oil is noticed, have the engine checkedby your dealer.7. Push the dipstick back in all the way.8. Reinstall the oil fill cap hand tight.9. Reinstall top cowl.
FEATURES AND CONTROLS
42
Remote Control FeaturesPANEL MOUNT FEATURES
3409
+-
a
b
cd
h
e
f
g
a - Lanyard/lanyard stop switch - Refer to General Information -Lanyard Stop Switch.
b - Control handle – Forward (F), Neutral (N), Reverse (R).c - Shift lock - Refer to Operation - Gear Shifting.d - Trim/tilt switch - Refer to Power Trim and Tilt.e - Throttle only button - Allows the boat operator to increase engine
RPM for warm-up, without shifting the engine into gear.f - Stop/start button - Allows the boat operator to start or stop the
engine without using the ignition key.g - Detent tension adjustment - Refer to Operation - Remote Control
Adjustments.h - Control handle friction adjustment screw - Refer to Operation -
Remote Control Adjustments.
FEATURES AND CONTROLS
43
CONSOLE MOUNT FEATURES - SINGLE ENGINE
+-
3410
a
b
c
de
fg
i
h
a - Control handle - Forward (F), Neutral (N), Reverse (R).b - Trim/tilt switch - Refer to Power Trim and Tilt.c - Active light - Illuminated when remote control is active and ready.d - Neutral light - Illuminated when engine is in neutral gear position.
Blinks when engine is in throttle only mode.e - Select key - Used to select System View on-screen options, if
equipped. Refer to System View Operation Manual for screenoptions.
f - Arrow trackpad - Used to scroll through System View displays, ifequipped. Refer to System View Operation Manual for screenoptions.
g - Throttle only/station select key - Allows the boat operator toincrease engine RPM for warm-up, without shifting the engineinto gear. Allows the boat operator to select which station will beused for dual helm applications. Refer to Operation - Starting TheEngine.
h - Detent tension adjustment - Refer to Operation - Remote ControlAdjustments.
i - Control handle friction adjustment screw - Refer to Operation -Remote Control Adjustments.
FEATURES AND CONTROLS
44
CONSOLE MOUNT FEATURES - DUAL ENGINE
3411
a
c
d
e
fg
ij
+-
ACTIVE SYNC
b
THROTTLEONLY
STATION SELECT
ha - Trim/tilt switch - Refer to Power Trim and Tilt.b - Control handles - Forward (F), Neutral (N), Reverse (R).c - Active light - Illuminated when remote control is active and ready
to use.d - Neutral light - Illuminated when engine is in neutral gear position.
Blinks when engine is in throttle only mode.e - Select key - Used to select System View on-screen options, if
equipped. Refer to System View Operation Manual for screenoptions.
f - Arrow trackpad - Used to scroll through System View displays, ifequipped. Refer to System View Operation Manual for screenoptions.
g - Sync light - Illuminated when the auto synchronizing feature isengaged. Refer to Operation - Starting The Engine.
h - Throttle only/station select key - Allows the boat operator toincrease engine RPM for warm-up, without shifting the engineinto gear. Allows the boat operator to select which station will beused for dual helm applications. Refer to Operation - Starting TheEngine.
i - Detent tension adjustment - Refer to Operation - Remote ControlAdjustments.
j - Control handle friction adjustment screw - Refer to Operation -Remote Control Adjustments.
FEATURES AND CONTROLS
45
Warning SystemWARNING HORN SIGNALSWhen the key switch is turned to the "ON" position, the horn (located onthe command module harness) will turn on for a moment as a test toindicate the horn is working.The warning horn will emit either a continuous beep or intermittent shortbeeps. This will alert the operator and help identify the following listedsituations. For visual display of the specific engine functions and foradditional engine data, refer to SmartCraft Product information, following.
Warning Horn
Function Sound Description
Start up Single beep Normal system test
Water in Fuel Four beeps every 2minutes
Water in enginemounted fuel filter.Refer to Maintenance- Water SeparatingFuel Filter.
Low battery Four beeps every 2minutes
Battery chargingunable to keep up withdemand. Raiseengine speed, toincrease charge, orshut downaccessories, toreduce demand.
FEATURES AND CONTROLS
46
Warning Horn
Function Sound Description
Cooling system problem Continuous Engine GuardianSystem is activated.Power limit will varywith level of overheat.Shift outboard intoneutral and check fora steady stream ofwater coming out ofthe water pumpindicator hole. If nowater is coming out ofthe water pumpindicator hole or flowis intermittent, stopengine and checkwater intake holes forobstruction.
Oil pressure low Continuous Engine GuardianSystem is activated.Power limit will varydepending onavailable oil pressure.Stop engine andcheck oil dipstick. Addoil if necessary. Referto Fuel and Oil -Checking and AddingEngine Oil.
FEATURES AND CONTROLS
47
Warning Horn
Function Sound Description
Engine Overspeed Continuous The warning horn isactivated any time theengine speedexceeds themaximum allowableRPM. The system willlimit the engine speedto within the allowablerange. Engineoverspeed indicates acondition that shouldbe corrected. Overspeed could becaused by incorrectpropeller pitch, engineheight, trim angle, tiltangle (shallow wateroperation) etc.
Engine Communication/Remote control failure
Intermittent beep Engine GuardianSystem is activated.Power limit will restrictengine speed to idle.
Sensor/Actuator out ofrange
Single beep (enginerunning)
May be a problem withone of the enginefunctions. Have yourdealer check theengine soon.
Continuous Engine GuardianSystem is activated.Power limit will restrictengine speed to eitheridle or 75%,depending on fault.
FEATURES AND CONTROLS
48
ENGINE GUARDIAN SYSTEMThe Engine Guardian System monitors the critical sensors on the enginefor any early indications of problems. The system will respond to a problemby emitting a continuous beep and/or reducing engine power in order toprovide engine protection.If Guardian System has been activated, reduce throttle speed. The problemwill need to be identified and corrected, if possible. The system must bereset before the engine will operate at higher speeds. Moving the throttlelever back to the idle position will reset the system.
SMARTCRAFT PRODUCTA Mercury SmartCraft System instrument package can be purchased forthis outboard. A few of the functions the instrument package will displayare engine RPM, coolant temperature, oil pressure, water pressure, batteryvoltage, fuel consumption and engine operating hours.The SmartCraft Instrument package will also aid in Engine Guardiandiagnostics. The SmartCraft Instrument package will display critical enginealarm data and potential problems.
FEATURES AND CONTROLS
49
Power Trim and TiltThe outboard has a trim/tilt control called power trim. This enables theoperator to easily adjust the position of the outboard by pressing the trimswitch. Moving the outboard in closer to the boat transom is called trimmingin or trimming down. Moving the outboard further away from the boattransom is called trimming out or trimming up. The term trim generallyrefers to the adjustment of the outboard within the first 20° range of travel.This is the range used while operating the boat on plane. The term tilt isgenerally used when referring to adjusting the outboard further up out ofthe water. With the engine not running and the key switch in the "ON"position, the outboard can be tilted out of the water. At low idle speed (2000RPM and below), the outboard can also be tilted up past the trim range topermit shallow water operation.
ob01303c
b
a
a - Trim switchb - Tilt range of travel
c - Trim range of travel
POWER TRIM OPERATIONWith most boats, operating around the middle of the trim range will givesatisfactory results. However, to take full advantage of the trimmingcapability there may be times when you choose to trim the outboard all theway in or out. Along with an improvement in some performance aspectscomes a greater responsibility for the operator, this being an awareness ofsome potential control hazards.Consider the following lists carefully:1. Trimming In or Down Can:
• Lower the bow.
FEATURES AND CONTROLS
50
• Result in quicker planing off, especially with a heavy load or a sternheavy boat.
• Generally improve the ride in choppy water.• In excess can lower the bow of some boats to a point where they
begin to plow with their bow in the water while on plane. This canresult in an unexpected turn in either direction (called bow steeringor over-steering) if any turn is attempted, or if a significant wave isencountered.
! WARNINGAvoid possible serious injury or death. Adjust outboard to an intermediatetrim position as soon as boat is on plane to avoid possible ejection dueto boat spin out. Do not attempt to turn boat when on plane if outboardis trimmed extremely in or down and there is a pull on the steering wheel.
2. Trimming Out or Up can:• Lift the bow higher out of the water.• Generally increase top speed.• Increase clearance over submerged objects or a shallow bottom.• In excess can cause boat porpoising (bouncing) or propeller
ventilation.• Cause engine overheating if any cooling water intake holes are
above the water line.
TILTING TO FULL UP POSITIONTilt At HelmIMPORTANT: Turning key to the "START" position while the engine isrunning will result in engine shut down, while leaving the DTS systemactive. This will allow the use of the power trim/tilt from the remote controlhandle.1. Shut off engine by:
a. Turning the key to the "START" position, then releasing it to the"ON" position.
b. Turning the key to "OFF" position and returning it to the "ON"position.
FEATURES AND CONTROLS
51
2. Press the trim/tilt switch to the up position. The outboard will tilt up untilthe switch is released or it reaches its maximum tilt position.
4221
Tilt At EngineThe cowl mounted auxiliary tilt switch can be used to tilt the outboard withthe key switch in the "OFF" position.
ob01309
1. Rotate the tilt support lever down.2. Lower outboard until tilt support bracket rests on the pedestal.3. Disengage the tilt support bracket, by raising the outboard up and
rotating the tilt support lever up. Lower the outboard.
ob01305
a b
a - Tilt support lever b - Tilt support bracket
FEATURES AND CONTROLS
52
MANUAL TILTINGIf the outboard cannot be tilted using the power trim/tilt switch, the outboardcan be manually tilted.
ob01143
NOTE: The manual tilt release valve must be tightened before operatingthe outboard to prevent the outboard from tilting up during reverseoperation.1. Turn out the manual tilt release valve 3 turns counterclockwise. This
allows manual tilting of the outboard. Tilt the outboard to the desiredposition and tighten the manual tilt release valve.
AUXILIARY TILT SWITCHThe auxiliary tilt switch can be used to tilt the outboard up or down usingthe power trim system.
ob01309
SHALLOW WATER OPERATIONWhen operating your boat in shallow water, you can tilt the outboardbeyond the maximum trim range to prevent hitting bottom.1. Reduce engine speed below 2000 RPM.
FEATURES AND CONTROLS
53
2. Tilt outboard up. Make sure all the water intake holes stay submergedat all times.
3. Operate the engine at slow speed only. With the outboard tilted past20° trim limit, the warning horn will sound and engine speed will beautomatically limited to approximately 2000 RPM. The outboard mustbe tilted (trimmed) down below the maximum trim range to allowoperation above 2000 RPM.
OPERATION
54
Pre-Starting Check List• Operator knows safe navigation, boating, and operating procedures.• An approved personal flotation device of suitable size for each person
aboard and readily accessible (it is the law).• A ring type life buoy or buoyant cushion designed to be thrown to a
person in the water.• Know your boats maximum load capacity. Look at the boat capacity
plate.• Fuel supply OK.• Arrange passengers and load in the boat so the weight is distributed
evenly and everyone is seated in a proper seat.• Tell someone where you are going and when you expect to return.• It is illegal to operate a boat while under the influence of alcohol or
drugs.• Know the waters and area you will be boating; tides, currents, sand
bars, rocks, and other hazards.• Make inspection checks listed in Maintenance - Inspection and
Maintenance Schedule.
Operating In Freezing TemperaturesWhen using your outboard or having your outboard moored in freezing ornear freezing temperatures, keep the outboard tilted down at all times sothe gearcase is submerged. This prevents trapped water in gearcase fromfreezing and causing possible damage to the water pump and othercomponents.If there is a chance of ice forming on the water, the outboard should beremoved and drained completely of water. If ice should form at the waterlevel inside the outboard driveshaft housing, it will block water flow to theengine causing possible damage.
Operating In Salt Water Or Polluted WaterWe recommend that you flush the internal water passages of your outboardwith fresh water after each use in salt or polluted water. This will prevent abuildup of deposits from clogging the water passages. Refer toMaintenance - Flushing The Cooling System.If you keep your boat moored in the water, always tilt the outboard so thegearcase is completely out of water (except in freezing temperatures) whennot in use.
OPERATION
55
Wash the outboard exterior and flush out the exhaust outlet of the propellerand gearcase with fresh water after each use. Each month, spray MercuryPrecision or Quicksilver Corrosion Guard on external metal surfaces. Donot spray on corrosion control anodes as this will reduce the effectivenessof the anodes.
Engine Break-in Procedure
! CAUTIONSevere damage to the engine can result by not complying with the EngineBreak-in Procedure.
1. For the first two hours of operation, run the engine at varied throttlesettings up to 4500 RPM or at three-quarter throttle, and at full throttlefor approximately one minute every ten minutes.
2. For the next eight hours of operation, avoid continuous operation at fullthrottle for more than five minutes at a time.
Starting The EnginePANEL MOUNT - SINGLE ENGINE STARTING PROCEDUREBefore starting, read the Pre-Starting Check List, Special OperatingInstructions, and Engine Break-in Procedure in the Operation Section.
! CAUTIONNever start or operate your outboard (even momentarily) without watercirculating through all the cooling water intake holes in the gearcase toprevent damage to the water pump (running dry) or overheating of theengine.
1. Make sure the cooling water intake is submerged.
ob01310
OPERATION
56
2. Check the engine oil level.
ob00667
3. Open fuel tank vent on manual venting type tanks.
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN"position.4. Set the lanyard stop switch to the "RUN" position. Refer to General
Information - Lanyard Stop Switch.
ob00350
5. Shift outboard to neutral (N) position.
F
N
R
3413
NOTE: The engine can be started by using the ignition key or the start/stopbutton located on the remote control handle.
OPERATION
57
6. Ignition key starting - Turn the ignition key to "START" position andrelease the key. The electronic starting system will automatically crankthe engine for starting. If the engine fails to start, the engine will stopcranking. Turn the key to "START" position again until engine starts.
START
OFF ACC ON
START
OFFACC ON
3485
7. Start/stop button - Turn the ignition key to "ON" position and press start/stop button and release. The electronic starting system willautomatically crank the engine for starting. If the engine fails to start,the engine will stop cranking. Press start/stop button and release againuntil engine starts.
3414
Warming up engineThrottle Only Button - This feature allows the boat operator to increaseengine RPM for warm-up, without shifting the engine into gear.
3416
1. Move the control handle into neutral position.2. Depress shift lock button, press and hold the throttle only button while
moving the control handle ahead to the forward detent. The horn soundindicates that throttle only is engaged.
OPERATION
58
3. Advance the control handle to increase engine RPM. Engine RPM islimited to prevent engine damage.
4. To disengage, return the control handle back to neutral position.
CONSOLE MOUNT - SINGLE ENGINE STARTINGPROCEDUREBefore starting, read the Pre-Starting Check List, Special OperatingInstructions, and Engine Break-in Procedure in the Operation Section.
! CAUTIONNever start or operate your outboard (even momentarily) without watercirculating through all the cooling water intake holes in the gearcase toprevent damage to the water pump (running dry) or overheating of theengine.
1. Make sure the cooling water intake is submerged.
ob01310
2. Check the engine oil level.
ob00667
3. Open fuel tank vent on manual venting type tanks.
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN"position.
OPERATION
59
4. Set the lanyard stop switch to the "RUN" position. Refer to GeneralInformation - Lanyard Stop Switch.
ob00350
5. Shift outboard to neutral (N) position.
FN
R
3417
6. Turn the ignition key to "START" position and release the key. Theelectronic starting system will automatically crank the engine forstarting. If the engine fails to start, the engine will stop cranking. Returnthe key to "START" position and try again.
START
OFF ACC ON
START
OFFACC ON
3485
OPERATION
60
7. The "ACTIVE" light located on the console remote control key pad willbecome illuminated once the engine is started and communicating withthe remote control.
ACTIVE
3418
THROTTLEONLY
STATION SELECT
Warming up engineThrottle Only/Station Select Button - This feature allows the boat operatorto increase engine RPM for warm-up, without shifting the engine into gear.
ACTIVE
3419
THROTTLEONLY
STATION SELECT
1. Move the control handle into neutral position.2. Press and hold the throttle only/station select button while moving the
control handle ahead to the forward detent.3. Hold in the button until the horn sounds twice and the neutral light starts
flashing. The flashing light indicates that the throttle only is engaged.4. Advance the control handle to increase engine RPM. Engine RPM is
limited to prevent engine damage.5. To disengage, return the control handle back to neutral position.
CONSOLE MOUNT - DUAL ENGINE/DUAL HELM STARTINGPROCEDUREBefore starting, read the Pre-Starting Check List, Special OperatingInstructions, and Engine Break-in Procedure in the Operation Section.
OPERATION
61
! CAUTIONNever start or operate your outboard (even momentarily) without watercirculating through all the cooling water intake holes in the gearcase toprevent damage to the water pump (running dry) or overheating of theengine.
1. Make sure the cooling water intake is submerged.
ob01310
2. Check the engine oil level.
ob00667
3. Open fuel tank vent on manual venting type tanks.
ob00348
NOTE: The engine will not start unless the lanyard is set to the "RUN"position.4. Set the lanyard stop switch to the "RUN" position. Refer to General
Information - Lanyard Stop Switch.
ob00350
OPERATION
62
5. Shift outboard to neutral (N) position.
FN
R
3417
6. Turn the ignition key to "START" position and release the key. Theelectronic starting system will automatically crank the engine forstarting. If the engine fails to start, the engine will stop cranking. Returnthe key to "START" position and try again. Repeat the procedure forthe second engine.
START
OFF ACC ON
START
OFFACC ON
3485
7. The "ACTIVE" light located on the console remote control key pad willbecome illuminated once the engine is started and communicating withthe remote control.
3424
ACTIVE SYNCTHROTTLE
ONLYSTATION SELECT
OPERATION
63
Warming up engineThrottle Only/Station Select Button - This feature allows the boat operatorto increase engine RPM for warm-up, without shifting the engines into gear.
3425
ACTIVE SYNC
STATION SELECT
THROTTLEONLY
1. Move the control handles into neutral position.2. Press and hold the throttle only/station select button while moving the
control handles ahead to the forward detent.3. Hold in the button until the horn sounds twice and the neutral lights
starts flashing. The flashing lights indicates that the throttle only isengaged.
4. Advance the control handles to increase engine RPM. Engine RPM islimited to prevent engine damage.
5. To disengage, return the control handles back to neutral position.6. The warm up mode can be re-activated by turning off and re-starting
the engine.
OPERATION
64
Gear ShiftingDTS PANEL MOUNT REMOTE CONTROLIMPORTANT: Never shift outboard into gear unless engine speed is at idle.Do not shift outboard into forward or reverse when the engine is notrunning.• The outboard has three gear shift positions to provide operation.
Forward (F), Neutral (N) and Reverse (R).
3427
F
NR
• When shifting, always stop at neutral position and allow the enginespeed to return to idle.
• Panel mount remote control requires the operator to always press shiftlock while moving the control handle out of the neutral position.
3428
• Advance the control lever to further increase speed.
OPERATION
65
DTS CONSOLE MOUNT REMOTE CONTROLIMPORTANT: Never shift outboard into gear unless engine speed is at idle.Do not shift outboard into forward or reverse when the engine is notrunning.• The outboard has three gear shift positions to provide operation.
Forward (F), Neutral (N) and Reverse (R).
FN
R
3417
• When shifting, always stop at neutral position and allow the enginespeed to return to idle.
• Advance the control lever to further increase speed.
Dual Helm Station TransferThe throttle only/station select button allows the boat operator to selectwhich remote control is in control of the engine operation.The active light is illuminated at the remote control station that is in controlof the engine.
! WARNINGAvoid serious injury or death from loss of boat control. The boat operatorshould never leave the active station while engine is in gear. Helmtransfer should only be attempted while both stations are manned. Oneperson helm transfer should only be performed while engine is in neutral.
NOTE: Idle position is preferred when doing a station transfer. If conditionsdo not allow the remote control to be placed at idle position, a stationtransfer can be done while in gear.NOTE: Pressing and releasing station select button at new station allowsthe engine control to be transferred to the new station. The control willautomatically start adjusting engine RPM and gear position to match thecontrol handle setting at the new station. Adjust control handles to thedesired throttle and gear position.1. Place active remote control lever to idle position.
OPERATION
66
2. Proceed to the inactive helm station and position remote control leverto the idle position.
3. Press throttle only/station select button once. The "ACTIVE" light willilluminate to indicate the remote control station is in control of theengine.
ACTIVE
STATION SELECT
3433
ACTIVE SYNC
STATION SELECT
a a
bTHROTTLE
ONLY
THROTTLEONLY
b
a - Active light b - Throttle only/station selectbutton
4. The active light will switch off at the original remote control station.SYNCHRONIZING DUAL HELMS PRIOR TO STATIONTRANSFERPressing the station select button and holding it in allows the boat operatorten seconds to match up the control handle settings at the new station withthe handle settings that are at the old (to be inactive) station. If the handlesare not matched, the neutral light will flash. The light blinks faster as thehandles are nearing match position. Once light stays on solid, the handlesare matched and the button can be released. Transfer process is completeand the new station is now in control. If the button is held for over 10seconds, the station transfer is cancelled.
Synchronizing Dual EnginesThe auto synchronizing feature, when engaged, will automatically adjustthe port engine speed to match the speed of the starboard engine.Synchronizing of engines will automatically engage when the speed of bothengines are over 900 RPM for two seconds and remote control handlesare positioned are within 5° of each other.
OPERATION
67
Auto Synchronizing will stay engaged up to 95% throttle opening. The Synclight will turn on when the engines are synchronized.
3434
ACTIVE SYNC
STATION SELECT
THROTTLEONLY
To disengage, move one or both control handles until they are more than5° apart, reduce engine speed below 900 RPM, or increase engine speedbeyond 95%.
Stopping The EngineIMPORTANT: Turning key to the "START" position while the engine isrunning will result in engine shut down, while leaving the DTS systemactive. This will allow the use of the power trim/tilt from the remote controlhandle.Reduce engine speed and shift outboard to neutral position. Turn ignitionkey to "OFF" position.
START
OFF ACC ON
START
OFFACC ON
3482
OPERATION
68
Remote Control Adjustments
5176
+-a
ba
b
ob01170
+-
a - Detent tension adjustmentb - Control handle friction adjustment screw
1. Remove cover to gain access to screws.2. Detent tension adjustment - The detent screw can be adjusted to
increase or decrease the effort needed to move the control handle intoor out of detent position.
3. Control handle friction adjustment - The friction adjustment screw canbe adjusted to increase or decrease the overall effort to move thecontrol handle. This will help prevent unwanted motion of the handle inrough water.
4. Turn screw towards "+" to increase friction or towards "–" to decreasefriction.
5. Reinstall cover.
MAINTENANCE
69
Outboard CareTo keep your outboard in the best operating condition, it is important thatyour outboard receive the periodic inspections and maintenance listed inthe Inspection and Maintenance Schedule. We urge you to keep itmaintained properly to ensure the safety of you and your passengers, andretain its dependability.
! WARNINGNeglected inspection and maintenance service of your outboard orattempting to perform maintenance or repair on your outboard if you arenot familiar with the correct service and safety procedures could causepersonal injury, death, or product failure.
Record maintenance performed in Maintenance Log at the back of thisbook. Save all maintenance work orders and receipts.SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARDWe recommend using original Mercury Precision or Quicksilverreplacement parts and Genuine Lubricants.
! WARNINGUsing a replacement part that is inferior to the original part could resultin personal injury, death, or product failure.
EPA RegulationsAll new outboards manufactured by Mercury Marine are certified to theUnited States Environmental Protection Agency, as conforming to therequirements of the regulations for the control of air pollution from newoutboard motors. This certification is contingent on certain adjustmentsbeing set to factory standards. For this reason, the factory procedure forservicing the product must be strictly followed and, wherever practicable,returned to the original intent of the design. Maintenance, replacement, orrepair of the emission control devices and systems may be performed byany marine spark ignition (SI) engine repair establishment or individual.
MAINTENANCE
70
EPA EmissionsEMISSION CERTIFICATION LABELAn emission certification label, showing emission levels and enginespecifications directly related to emissions, is placed on the engine at timeof manufacture.
ob00366
c hde
ba f
i
g
a - Idle speedb - Engine horsepowerc - Piston displacementd - Date of manufacturee - Valve clearance (if
applicable)
f - Family numberg - Maximum emission output for
the engine familyh - Timing specificationi - Recommended spark plug
and gap
OWNER RESPONSIBILITYThe owner/operator is required to have routine engine maintenanceperformed to maintain emission levels within prescribed certificationstandards.The owner/operator is not to modify the engine in any manner that wouldalter the horsepower or allow emissions levels to exceed theirpredetermined factory specifications.
Inspection And Maintenance ScheduleBEFORE EACH USE• Check engine oil level. See Fuel & Oil - Checking and Adding Engine
Oil.• Check that lanyard stop switch stops the engine.• Visually inspect the fuel system for deterioration or leaks.• Check outboard for tightness on transom.
MAINTENANCE
71
• Check steering system for binding or loose components.• Visually check power steering fittings and hoses for leaks or signs of
damage. Check tie bar fasteners (multiple outboard rigs) for propertightness.
• Check propeller blades for damage.AFTER EACH USE• Flush out the outboard cooling system if operating in salt or polluted
water. See Flushing the Cooling System.• Wash off all salt deposits and flush out the exhaust outlet of the
propeller and gearcase with fresh water if operating in salt water.EVERY 100 HOURS OF USE OR ONCE YEARLY,WHICHEVER OCCURS FIRST• Change engine oil and replace the oil filter. The oil should be changed
more often when the engine is operated under adverse conditions suchas extended trolling. See Changing Engine Oil.
• Inspect thermostat visually for corrosion and broken spring. Make surethermostat closes completely at room temperature.1.
• Check engine fuel filter for contaminants. See Fuel System.• Check corrosion control anodes. Check more frequently when used in
salt water. See Corrosion Control Anodes.• Drain and replace gearcase lubricant. See Gearcase Lubrication.• Check power steering fluid. See Checking Power Steering Fluid.• Inspect battery. See Battery Inspection.• Saltwater usage. Remove and inspect spark plugs for corrosion and
replace spark plugs as necessary. Apply a thin coating of Anti-SeizeCompound only on threads of spark plug prior to installation. SeeMaintenance - Spark Plug Inspection and Replacement.
• Check wiring and connectors• Check tightness of bolts, nuts, and other fasteners.EVERY 300 HOURS OF USE OR THREE YEARSIMPORTANT: Engine oil must be drained before removing gearcase toavoid oil spillage. Perform scheduled water pump replacement incombination with an engine oil change.• Replace water pump impeller (more often if overheating occurs or
reduced water pressure is noted).1.
• Check power trim fluid. See Checking Power Trim Fluid.
1. These items should be serviced by an authorized dealer.
MAINTENANCE
72
• Replace spark plugs at first 300 hours or three years. After that, inspectspark plugs every 300 hours or three years. Replace spark plugs asneeded. See Spark Plug Inspection and Replacement.
• Replace accessory drive belt. See Accessory Drive Belt Inspection.1.
BEFORE PERIODS OF STORAGE• Refer to Storage procedure. See Storage section.
Flushing The Cooling SystemFlush the internal water passages of the outboard with fresh water aftereach use in salt, polluted, or muddy water. This will help prevent a buildupof deposits from clogging the internal water passages.NOTE: The outboard can be tilted or in the vertical operating positionduring flushing.1. With the engine turned off, place the outboard in either the operating
position (vertical) or in a tilted position.2. Disconnect the flush connector from fitting on the bottom cowl.
ob01236
3. Thread a water hose into the flush fitting.
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4. Turn on the water tap (1/2 maximum) and let the water flush throughthe cooling system for about 15 minutes.
5. When flushing is complete, turn off water and disconnect the waterhose.
MAINTENANCE
73
6. Reinstall the flushing connector to the fitting on the bottom cowl.Tighten the connector securely.
Cowl Removal and InstallationCOWL REMOVALIMPORTANT: Most maintenance points are accessible by removing thetop cowl only.1. Pull up on the top cowl lock latch.
ob01324
2. Pull top cowl forward and lift off.3. Pull lower cowl release latch up.4. Remove rear cowl towards aft of outboard.
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COWL INSTALLATION1. Position lower cowl from aft side of outboard. Make sure it fits properly
in the rubber seal.
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2. Lock cowl in place by pulling lower cowl latch down.
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3. Place top cowl into position over engine, front first. Ensure cowl fitsproperly into the rubber seal.
4. The top cowl will lock into place when downward pressure is applied tothe back side of cowl. Ensure cowl is securely fastened by pulling upon back of cowl.
Exterior CareThe outboard is protected with a durable baked enamel finish. Clean andwax often using marine cleaners and waxes. Do not wax textured areas ofcowl.
Battery InspectionThe battery should be inspected at periodic intervals to ensure properengine starting capability.IMPORTANT: Read the safety and maintenance instructions whichaccompany your battery.1. Turn off the engine before servicing the battery.2. Add water as necessary to keep the battery full.3. Make sure the battery is secure against movement.4. Battery cable terminals should be clean, tight, and correctly installed.
Positive to positive and negative to negative.5. Make sure the battery is equipped with a nonconductive shield to
prevent accidental shorting of battery terminals.
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DTS Battery SpecificationsIMPORTANT: Do not use deep cycle batteries for the main engine startingbattery.IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federalstandards and Coast Guard regulations must be adhered to when installingthe battery. Ensure that battery cable installation meets the pull testrequirements and that positive battery terminal is properly insulated inaccordance with regulations.IMPORTANT: It is recommended (required in some states) that the batterybe installed in an enclosed case. Refer to regulations for your area.
Minimum SAE Starting Battery Requirements - BCI GRP 24
MCA 1000
CCA 800
Ah 180 (International Rating)
NOTE: Due to the wide variety of battery manufactures throughout theworld, ratings and physical battery sizes will vary. Check with themanufacturer for a starting battery with a MCA, CCA, or Ah specificationthat will be equal to or greater than the SAE Standard J537 specified above.IMPORTANT: For DTS products, each engine must be equipped with itsown starting battery. If your boat application requires additional batteryloads for boat accessories or marine electronics, it is recommended thatan auxiliary battery or batteries be installed.
! CAUTIONHex nuts must be used to secure battery leads to battery posts to avoidloss of electrical power.
When connecting engine battery, hex nuts must be used to secure batteryleads to battery posts. Torque nuts to specifications.
Description Nm lb. in. lb. ft.
Hex nuts 13.5 120
IMPORTANT: Battery cable size and length is critical. Refer to BatteryCable Size tables or engine installation manual for size requirements.
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Decal needs to be placed on or near battery box for future servicereference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery forwing nut replacement. Metric hex nuts are not supplied.
Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.
NOTICE - DTS & Optimax Engines
37-895387
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
DO NOT USE WING NUTS.
DO NOT USE DEEP CYCLE BATTERIES!
13.5Nm (120 lbs. in.)
DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.rating.
3486
Air FilterThe air filter assembly is a serviceable item and can be cleaned with warmsoap water if required.AIR FILTER REMOVAL AND CLEANING1. Loosen air filter clamp screw.2. Remove crankcase ventilation hose.
3664
a
b
c
da - Crankcase ventilation hoseb - Fuel System Module (FSM)
purge valve hose
c - Filter assemblyd - Clamp screw
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3. Remove air filter assembly and disconnect Fuel System Module (FSM)purge valve hose by rotating the air filter assembly and pulling on hose.
3665
4. Wash air filter assembly in warm soap water.5. Dry filter assembly with compressed air.6. Apply 4-Cycle Outboard Oil on rag or towel and lightly pad air filter
element. Wipe off excess oil. Air filter element should be moist to thetouch.
AIR FILTER INSTALLATION1. Install Fuel System Module (FSM) purge valve hose to air filter
assembly.
3665
2. Install crancase ventilation hose.
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3. Install air filter assembly and tighten clamp screw securely.
3664
a
b
c
da - Crankcase ventilation hoseb - Fuel System Module (FSM)
purge valve hose
c - Filter assemblyd - Clamp screw
Fuel System
! WARNINGAvoid serious injury or death from gasoline fire or explosion. Carefullyfollow all fuel system service instructions. Always stop the engine and donot smoke or allow open flames or sparks in the area while servicing anypart of the fuel system.
IMPORTANT: Use an approved container to collect and store fuel. Wipeup spilled fuel immediately. Material used to contain spilled fuel must bedisposed of in an approved receptacle.Before servicing any part of the fuel system:1. Stop engine and disconnect the battery.2. Perform fuel system service in a well ventilated area.3. Inspect any completed service work for sign of fuel leakage.
FUEL LINE INSPECTIONVisually inspect the fuel line for cracks, swelling, leaks, hardness, or othersigns of deterioration or damage. If any of these conditions are found, thefuel line must be replaced.
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WATER SEPARATING FUEL FILTERNOTE: The warning system will turn on when water in the fuel filter reachesthe full level. Refer to Features and Controls - Warning System.This filter removes moisture and debris from the fuel. If the filter holderbecomes filled with water, the water can be removed. If the filter becomesplugged with debris, replace the filter.Refer to the Inspection and Maintenance Schedule for the propermaintenance interval.Filter Removal1. Turn ignition key switch to "OFF" position.2. Remove fuel vapor purge relief valve cap (green cap located aft of
starter motor).
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! CAUTIONFuel vapor vent system is under pressure. Cover valve assembly with arag or towel to prevent fuel or fuel vapor spray. Relieve pressure slowly.
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3. Place rag or towel around valve, release pressure by pushing core ofvalve end in.
3472
4. Unscrew the filter in a counterclockwise direction to remove.
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Filter Draining1. Slide filter holder up to release from bracket. Hoses and wire harness
can remain attached to filter holder.
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2. Tip the filter holder to drain any fluid into an approved container.
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Filter Installation1. Position filter holder onto bracket and secure filter holder in place.2. Lubricate the sealing ring on the filter with oil.3. Install the filter and tighten securely by hand.IMPORTANT: Visually inspect for fuel leakage from the filter while turningthe ignition key to the run position, forcing fuel into the filter.
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Corrosion Control AnodeThe outboard has corrosion control anodes at different locations. An anodehelps protect the outboard against galvanic corrosion by sacrificing itsmetal to be slowly eroded instead of the outboard metals.
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Each anode requires periodic inspection, especially in salt water which willaccelerate the erosion. To maintain this corrosion protection, alwaysreplace the anode before it is completely eroded. Never paint or apply aprotective coating on the anode as this will reduce effectiveness of theanode.Two anodes are located on each side of the gearcase. Another anode isinstalled on the bottom of the pedestal. Two more anodes are located onthe bottom of each power trim ram.
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Propeller Replacement1. Shift outboard to neutral position.2. Straighten the bent tabs on the propeller nut retainer.
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3. Place a block of wood between gearcase and propeller to hold propellerand remove propeller nut.
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4. Pull propeller straight off shaft. If propeller is seized to the shaft andcannot be removed, have the propeller removed by an authorizeddealer.
5. To aid in future removal of the propeller, liberally coat the propeller shaftsplines with one of the following Mercury/Quicksilver products:
Tube Ref No. Description Where Used Part No.
94Anti-CorrosionGrease
Propeller shaftsplines
92-802867A1
952-4-C MarineLubricant with Teflon
Propeller shaftsplines
92-802859A1
6. Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceabledrive sleeve, propeller, thrust hub, propeller nut retainer and propellernut onto the shaft.
b ca
d
fe
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a - Propeller nutb - Propeller nut retainerc - Thrust hub
d - Propellere - Replaceable drive sleevef - Forward thrust hub
7. Place a block of wood between gearcase and propeller and torque tospecifications.
Description Nm lb. in. lb. ft.
Propeller nut 75 55
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8. Secure propeller nut by bending three of the tabs into the thrust hubgrooves.
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Spark Plug Inspection and Replacement1. Remove top and rear cowlings. Refer to Cowl Removal and Installation.2. Disconnect the six wiring harness connectors from pencil coil
connections.3. Remove mounting bolts, using a twisting motion, and pull pencil coils
from spark plugs.
a b
c
3658
a - Wiring harness connectorb - Pencil coil
c - Bolt
4. Remove the spark plugs to inspect. Replace spark plug if electrode isworn, threads of seal area are corroded, or the insulator is rough,cracked, broken, blistered or fouled.
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5. Set the spark plug gap to specifications.
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Spark Plug
Spark Plug Gap 0.8 mm (0.0315 in.)
6. Saltwater use - Apply a thin coating of Anti-Seize Compound only onthreads of spark plugs.
7. Clean area of spark plug seat.8. Before installing spark plugs, clean off any dirt on the spark plug seats.
Install plugs finger tight, and then tighten 1/4 turn or torque tospecifications.
Description Nm lb. in. lb. ft.
Spark plug 27 20
9. Push pencil coils into place over the spark plugs using a twistingmotion.
10. Secure coils with retained bolts. Torque to specifications.
Description Nm lb. in. lb. ft.
Bolts 8 71
11. Connect the six wiring harness connectors to pencil coil connections.
a b
c
3658
a - Wiring harness connectorb - Pencil coil
c - Bolt
12. Reinstall rear and top cowls.
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FusesThe electrical wiring circuits on the outboard are protected from overloadby fuses in the wiring. If a fuse is blown, try to locate and correct the causeof the overload. If the cause is not found, the fuse may blow again.1. Remove top cowl. Locate fuse holder on starboard side of engine.
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2. Remove the plastic cover from the fuse holder.3. Remove fuse puller from fuse holder.4. Remove suspected blown fuse to determine if the silver colored band
is broken.
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5. Replace fuse with a new fuse of the same amperage rating.
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20 20 20
20 20 20
20
ab
c
d
ea - Electronic Control Module -
20 amp fuseb - Ignition coils - 20 amp fusec - Fuel delivery - 20 amp fuse
d - Spare fuses - 20 amp fusee - Injector power - 20 amp fuse
DTS Wiring System
! WARNINGTo avoid the possibility of serious injury or death from loss of boat control,do not splice or probe into any wire insulation of the DTS system. Splicingor probing will damage the wire insulation allowing water to enter thewiring. Water intrusion may lead to wiring failure and loss of throttle andshift control.
• Verify the harnesses are not routed near sharp edges, hot surfaces ormoving parts.
• Verify that all unused connectors and receptacles are covered with aweather cap.
• Verify that the harnesses are fastened along the routing path.
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Accessory Drive Belt InspectionInspect the accessory drive belt and have it replaced by an authorizeddealer if any of the following conditions are found.• Cracks in the back of the belt or in the base of V grooves.• Excessive wear at the roots of the groves.• Rubber portion swollen by oil.• Belt surfaces roughened.• Signs of wear on edges or outer surfaces of belt.
Checking Power Trim Fluid1. Tilt outboard to the full up position.2. Rotate the tilt support bracket down.3. Lower outboard until tilt support bracket rests on pedestal.4. Remove the power trim fill cap. The fill cap only requires 1/4 turn to
remove.
ob01526
a
d
b
c
a - Tilt support leverb - Power trim fill cap
c - Tilt support bracketd - Pedestal
5. The fluid level should be approximately 25 mm (1 in.) from the top ofthe fill neck. Add Quicksilver or Mercury Precision Lubricants PowerTrim & Steering Fluid. If not available, use automotive automatictransmission fluid (ATF).
6. Reinstall the power trim fill cap. Tighten fill cap 1/4 turn. Cap will snapin place. Do not tighten beyond this point.
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Checking Power Steering FluidRemove power steering cover and fill cap to check fluid level. The fluid levelshould be slightly below the bottom of the fill hole. Use SAE 0W-30synthetic power steering fluid, if needed.
ob01527
ab
c
a - Power steering coverb - Fill cap
c - Fill/full level
Changing Engine OilENGINE OIL CAPACITYEngine oil capacity is approximately 7.0 liters (7.4 quarts)PUMP METHODIMPORTANT: Tilt outboard out/up past vertical for approximately oneminute to allow trapped oil to drain back to the oil sump.IMPORTANT: To reduce or prevent oil spillage when removing the oil filter,make sure that the outboard is upright (not tilted) and the engine is cold orhas not run for at least one hour.IMPORTANT: The pump method is preferred to remove engine oil fromXXL models. If the drain method is used, an oil drain deflector tool must beused to divert oil from the lower splash plate and into the container.1. Tilt outboard out/up past vertical for approximately one minute to allow
trapped oil to drain back to the oil sump.2. Place the outboard in a vertical position.3. Remove dipstick and slide adaptor tube of crankcase oil pump through
oil dipstick hole, to bottom of engine oil sump.
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4. Pump out the engine oil into an appropriate container.DRAIN METHOD1. Tilt outboard out/up past vertical for approximately one minute to allow
trapped oil to drain back to the oil sump.2. Place the outboard in a vertical position.3. Place appropriate container under engine oil sump plug. Drain plug/
seal washer is located beneath the splash plate (port side of outboard).4. Loosen drain plug/seal washer and install optional oil drain funnel over
drain plug/seal washer and slide tool onto splash plate.
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a
b
a - Drain plug/seal washer b - Oil drain funnel
5. Remove drain plug/seal washer and drain engine oil into container.6. Reinstall drain plug/seal washer.CHANGING OIL FILTERIMPORTANT: To reduce or prevent oil spillage when removing the oil filterensure that the outboard is upright (not tilted) and the engine is cold or hasnot run for at least one hour.1. Remove the top cowl.2. Place a rag or towel below the oil filter to absorb any spilled oil.
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3. Unscrew old filter by using oil filter wrench tool and turning the filtercounterclockwise.
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4. Clean the oil filter mounting base.5. Apply film of clean oil to filter gasket. Do not use grease.6. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.OIL FILLING1. Remove the oil fill cap and add recommended oil to the mid point of the
operating range (mid point of cross hatched region). Addingapproximately 7 liters (7.4 quarts) will bring oil level to mid point of crosshatched region.
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2. Reinstall oil fill cap.3. With outboard in water or cooling water flush hose connected, idle
engine for five minutes to check for leaks at the oil filter.4. Stop engine and check oil level. Refer to Checking and Adding Engine
Oil.
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Gearcase LubricationWhen adding or changing gearcase lubricant, visually check for thepresence of water in the lubricant. If water is present, it may have settledto the bottom and will drain out prior to the lubricant, or it may be mixedwith the lubricant, giving it a milky colored appearance. If water is noticed,have the gearcase checked by your dealer. Water in the lubricant mayresult in premature bearing failure or, in freezing temperatures, will turn toice and damage the gearcase.Examine the drained gearcase lubricant for metal particles. A small amountof metal particles indicates normal gear wear. An excessive amount ofmetal filings or larger particles (chips) may indicate abnormal gear wearand should be checked by an authorized dealer.
DRAINING GEARCASE1. Place outboard in a vertical operating position.2. Remove propeller. Refer to Propeller Replacement.3. Place drain pan below outboard.4. Remove vent plug and fill/drain plug and drain lubricant.
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a
b
a - Vent plug b - Fill/drain plug
GEARCASE LUBRICANT CAPACITYGearcase lubricant capacity is approximately 970 ml (32.8 fl. oz.).
GEARCASE LUBRICANT RECOMMENDATIONMercury or Quicksilver Premium or High Performance Gear Lubricant.
CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE1. Place outboard in a vertical operating position.2. Remove vent plug/sealing washer.
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3. Remove fill/drain plug. Place lubricant tube into the fill hole and addlubricant until it appears at the vent hole.
aob01530
a
b
a - Vent hole b - Fill hole
IMPORTANT: Replace sealing washers if damaged.4. Stop adding lubricant. Install the vent plug and sealing washer before
removing the lubricant tube.5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing
washer.
STORAGE
94
Storage PreparationThe major consideration in preparing your outboard for storage is to protectit from rust, corrosion, and damage caused by freezing of trapped water.The following storage procedures should be followed to prepare youroutboard for out of season storage or prolonged storage (two months orlonger).
! CAUTIONNever start or operate your outboard (even momentarily) without watercirculating through all the cooling water intake holes in the gearcase toprevent damage to the water pump (running dry) or overheating of theengine.
FUEL SYSTEMIMPORTANT: Gasoline containing alcohol (ethanol or methanol) cancause a formation of acid during storage and can damage the fuel system.If the gasoline being used contains alcohol, it is advisable to drain as muchof the remaining gasoline as possible from the fuel tank, remote fuel line,and engine fuel system.IMPORTANT: This outboard is equipped with a closed fuel system whenthe engine is not running. With this closed system, fuel within the engine'sfuel system, other than the fuel tank, will remain stable during normalstorage periods without the addition of fuel treatment stabilizers.Fill the fuel tank and engine fuel system with treated (stabilized) fuel to helpprevent formation of varnish and gum. Proceed with following instructions.• Portable Fuel Tank - Pour the required amount of gasoline stabilizer
(follow instructions on container) into fuel tank. Tip fuel tank back andforth to mix stabilizer with the fuel.
• Permanently Installed Fuel Tank - Pour the required amount of gasolinestabilizer (follow instructions on container) into a separate containerand mix with approximately one quart (one liter) of gasoline. Pour thismixture into fuel tank.
Protecting External Outboard Components• 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).
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95
Protecting Internal Engine ComponentsIMPORTANT: Refer to Maintenance - Spark Plug Inspection andReplacement for correct procedure for removing spark plugs.• Remove pencil coils and spark plugs.• Spray approximately 30 ml (1 fl. oz.) of Storage Seal Rust Inhibitor into
each spark plug hole.• Actuate key/push button start switch to crank the engine through one
start cycle, which will distribute the storage seal throughout thecylinders.
• Reinstall spark plugs and pencil coils.
Gearcase• Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase
Lubrication).
Positioning Outboard For StorageStore outboard in an upright (vertical) position to allow water to drain outof outboard.
! CAUTIONIf outboard is stored tilted up in freezing temperature, trapped coolingwater or rain water that may have entered the propeller exhaust outlet inthe gearcase could freeze and cause damage to the outboard.
Battery Storage• Follow the battery manufacturer's instructions for storage and
recharging.• Remove the battery from the boat and check water level. Recharge if
necessary.• Store the battery in a cool, dry place.• Periodically check the water level and recharge the battery during
storage.
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96
Starter Motor Will Not Crank the EnginePOSSIBLE CAUSES• Lanyard stop switch not in "RUN" position.• Blown 5 Amp fuse. Check DTS power harness circuit fuse. Refer to
Maintenance section.• Outboard is not shifted to neutral position.• Shift actuator failure. "Gear Shift Diff" error message shown on System
View. Refer to Maintenance section.• 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 StartPOSSIBLE CAUSES• Incorrect starting procedure. Refer to Operation section.• Old or contaminated gasoline.• Fuel is not reaching the engine.
• Fuel tank is empty.• Fuel tank vent not open or restricted.• Fuel line is disconnected or kinked.• Fuel filter is obstructed. Refer to Maintenance section.• Fuel pump failure.• Fuel tank filter obstructed.
• Ignition system component failure.• Spark plugs fouled or defective. Refer to Maintenance section.
Engine Starts But Will Not Shift Into Gear• Shift actuator failure. "Gear Shift Diff" error message shown on System
View. Refer to Maintenance section.
Engine Runs ErraticallyPOSSIBLE CAUSES• Overheating - Warning horn not working.• Low oil pressure. Check oil level.• Spark plugs fouled or defective. Refer to Maintenance section.• Incorrect setup and adjustments.
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97
• Fuel is being restricted to the engine.a. Engine fuel filter is obstructed. Refer to Maintenance section.b. Fuel tank filter obstructed.c. Stuck anti-siphon valve located on permanently built-in type fuel
tanks.d. Fuel line is kinked or pinched.
• Fuel pump failure.• Ignition system component failure.
Performance LossPOSSIBLE CAUSES• Overheating - Warning horn not working.• Low oil pressure. Check oil level.• Throttle not opening fully.• Damaged propeller or improper propeller size.• Incorrect engine timing, adjustment, or setup.• Boat overloaded or load improperly distributed.• Excessive water in bilge.• Boat bottom is dirty or damaged.
Battery Will Not Hold ChargePOSSIBLE 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).
OWNER SERVICE ASSISTANCE
98
Local Repair ServiceAlways return your outboard to your local authorized dealer should theneed for service arise. Only he has the factory trained mechanics,knowledge, special tools, equipment, and genuine parts and accessoriesto properly service your engine should the need occur. He knows yourengine best.
Service Away From HomeIf you are away from your local dealer and the need arises for service,contact the nearest authorized dealer. Refer to the Yellow Pages of thetelephone directory. If, for any reason, you cannot obtain service, contactthe nearest Mercury Marine Service Office.
Parts And Accessories InquiriesAll inquiries concerning genuine replacement parts and accessories shouldbe directed to your local authorized dealer. The dealer has the necessaryinformation to order parts and accessories for you. When inquiring on partsand accessories, the dealer requires the model and serial number to orderthe correct parts.
Service AssistanceYour satisfaction with your outboard product is very important to yourdealer and to us. If you ever have a problem, question or concern aboutyour outboard product, contact your dealer or any authorized MercuryMarine dealership. If additional assistance is required, take these steps.1. Talk with the dealership's sales manager or service manager. If this
has already been done, then contact the owner of the dealership.2. Should you have a question, concern, or problem that cannot be
resolved by your dealership, please contact Mercury Marine ServiceOffice for assistance. Mercury Marine will work with you and yourdealership to resolve all problems.
The following information will be needed by the service office:• Your name and address• Daytime telephone number• Model and serial number of your outboard• The name and address of your dealership• Nature of problem
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Mercury Marine Service OfficesFor assistance, call, fax, or write. Please include your daytime telephonenumber with mail and fax correspondence.
United States
Telephone (920) 929-5040 Mercury MarineW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939
Fax (920) 929-5893
Website www.mercurymarine.com
Canada
Telephone (905) 567-6372 Mercury Marine Ltd.2395 Meadowpine Blvd.Mississauga, Ontario L5N 7W6Canada
Fax (905) 567-8515
Australia, Pacific
Telephone (61) (3) 9791-5822 Mercury Marine Australia132-140 Frankston RoadDandenong, Victoria 3164Australia
Fax (61) (3) 9793-5880
Europe, Middle East, Africa
Telephone (32) (87) 32 • 32 • 11 Marine Power - Europe, Inc.Parc Industriel de Petit-RechainB-4800 Verviers,Belgium
Fax (32) (87) 31 • 19 • 65
Mexico, Central America, South America, Caribbean
Telephone (954) 744-3513 Mercury Marine11650 Interchange Circle NorthMiramar, FL 33025U.S.A.
Fax (954) 744-3535
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Japan
Telephone 81-053-423-2500 Mercury Marine - JapanAnshin-cho 283-1HamamatsuShizuoka-ken, Japan 435-0005Japan
Fax 81-053-423-2510
Asia, Singapore
Telephone 5466160 Mercury Marine Singapore72 Loyang WaySingapore, 508762Fax 5467789
MAINTENANCE LOG
101
Maintenance LogRecord all maintenance performed on your outboard here. Be sure to saveall work orders and receipts.
Date Maintenance Performed Engine Hours