1. Mercury 115 Elpto Parts

Boatinfo requires FlashPlayer 9 or newer to display this document! SERVICE MANUAL MODELS 75. 75 MARATHON. 75 SEA PRO 90. 100. 115. 125.

65/80 JET With Serial Numbers United States. 0D283222 and Above Belgium. 09793577 and Above Printed in U.S.A. W1997, Mercury Marine 90-830234R3 DECEMBER 1997 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.

OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength.

American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch./mm. When any product component is serviced, care and cleanliness are important.

Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. 90-830234R3 DECEMBER 1997 i Whenever components are removed for service, they should be retained in order. At the time of instal- lation, they should be installed in the same locations and with the same mating surfaces as when re- moved. Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crank- shaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns.

Connect a hoist of suitable strength to the lifting eye. In addition, personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible.

We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent in- formation concerning the products described in this manual. Propeller Information For in-depth information on marine propellers and boat performance – see your Authorized Dealer for the illustrated “What You Should Know About Quick- silver Propellers. And Boat Performance Informa- tion” (90-86144).

How To Use This Manual The manual is divided into SECTIONS (shown, right) which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A “Table of Contents” for the particular PART is printed on the back page of the title page. SECTIONS and PARTS are listed on the “Service Manual Outline” sheet which immediately follows the cover of this book. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory.

EXAMPLE: 90-830234 R3 NOVEMBER 1997 LOWER UNIT - 6A-7 Revision No. 3 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number Whenever components are removed for service, they should be retained in order. At the time of instal- lation, they should be installed in the same locations and with the same mating surfaces as when re- moved. Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crank- shaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. Connect a hoist of suitable strength to the lifting eye. In addition, personnel should not work on or under an outboard which is suspended.

Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent in- formation concerning the products described in this manual.

Propeller Information For in-depth information on marine propellers and boat performance – see your Authorized Dealer for the illustrated “What You Should Know About Quick- silver Propellers. And Boat Performance Informa- tion” (90-86144). How To Use This Manual The manual is divided into SECTIONS (shown, right) which represents major components and systems. Some SECTIONS are further divided into PARTS.

Each PART has a title page. A “Table of Contents” for the particular PART is printed on the back page of the title page. SECTIONS and PARTS are listed on the “Service Manual Outline” sheet which immediately follows the cover of this book. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory.

EXAMPLE: 90-830234 R3 NOVEMBER 1997 LOWER UNIT - 6A-7 Revision No.

. This manual has been prepared to assist you in the operation, safe use, and care of your outboard. All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating. Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information section of this manual.

Mercury 115 Elpto Parts

The warranty statement contains a description of what is covered, what is not. 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. Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle ☒ Outboard engine ☒ Petrol ☒ 2 stroke Identification of Engines Covered by This Declaration of Conformity Unique engine EC Module H Name of engine family identification number: certificate starting serial number number. Name / function: Mark D.

Schwabero, President, Mercury Outboard Date and place of issue:July 24, 2008 Fond du Lac, Wisconsin, USA. Warranty Information Transfer of Warranty.1 Warranty Registration United States and Canada. 1 Warranty Registration Outside the United States and Canada.

2 Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle‑East and Africa. 3 3 Year Limited Warranty Against Corrosion. 6 Warranty Coverage and Exclusions. Fuel and Oil Fuel Recommendations. 36 Fuel Requirements.38 Fuel Additives.38 Avoiding Fuel Flow Restriction.38 Low Permeation Fuel Hose Requirement.

38 Oil Recommendation.38 Filling Oil Injection System.39 Filling Fuel Tank. 41 Features and Controls Remote Control Features.43 Warning System. Maintenance Outboard Care.60 EPA Emissions.61 Inspection and Maintenance Schedule.62 Flushing the Cooling System. 64 Top Cowl Removal and Installation. 65 Cleaning Care for Top Cowl.66 Flywheel Cover Removal and Installation.66 Side Panel Removal and Installation.

67 Fuel System. Owner Service Assistance Local Repair Service.93 Service Away from Home.93 Parts and Accessories Inquiries.93 Service Assistance.93 Mercury Marine Service Offices.94 Outboard Installation Important Information.96 Boat Horsepower Capacity.96 Start in Gear Protection. 97 Selecting Accessories for Your Outboard.97 Fuel Tanks. 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 your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

Federal Safety Act be required. To be eligible for warranty coverage, the product must be registered with Mercury Marine.

At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail. Outside the United States, Canada, Europe, Confederation of Independent States, Middle‑East and Africa ‑ check with your local distributor. WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below. WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre–delivery inspection process is completed and documented. Mercury dealer authorized to service the product.

If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Mercury dealer authorized to service the product.

If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time. Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty. WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty.

The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants, or fluids changed as a matter of normal. WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us.

Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product. GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public.

It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine.

To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your. GENERAL INFORMATION Propellers are designated by the diameter, pitch, number of blades, and material.

The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. The first number represents the diameter of the propeller and the second number represents the pitch.

RPM range when under normal full throttle operation. PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats.

GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death. GENERAL INFORMATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. GENERAL INFORMATION The lanyard is a cord usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.

The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position. GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.

GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. GENERAL INFORMATION WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.

WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes.

Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system.

Acquire and read the installation, operation and maintenance manuals for all your selected accessories. GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should 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) the Red Cross, and 4) your state boating law enforcement agency. GENERAL INFORMATION Watch fallen skiers. When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to assist the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. GENERAL INFORMATION Specifications 115/115 Pro Models Horsepower Kilowatts 55.2 66.2 84.6 91.3 Full throttle 5000–5750 RPM RPM range Idle speed in 625–675 RPM forward gear Number of cylinders Piston 1523.5 cc (92.9 in³) displacement Cylinder bore 92.11 mm (3.63 in.) Piston stroke 76.2 mm (3.0 in.) Recommended.

GENERAL INFORMATION 115/115 Pro Models Sound at drivers ear 82.0 (ICOMIA 39‑94) Component Identification Top cowl Auxiliary tilt switch Transom brackets Gearcase Cooling water intake holes Trim tab Anti‑ventilation plate Driveshaft housing Water pump indicator hole Bottom cowl 29461. TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device.

Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing. FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum. FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand.

Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Fuel Additives To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickleen Engine Treatment additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container. FUEL AND OIL Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended for your engine.

If Mercury OptiMax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium Plus 2‑Cycle Oil. Severe engine damage may result from use of an inferior oil. FUEL AND OIL 4. Oil filler caps with a dipstick ‑ Check the oil level on the dipstick. The first set of holes indicates 0.94 liters (1 US qt) low.

The second set of holes indicates 1.89 liters (2 US qt) low. FUEL AND OIL Capacity Fluid Type Oil tank 4.72 liters (5 US qt) OptiMax/DFI 2‑Cycle Engine Oil 29465 7. Install the oil filler cap and tighten securely.

Install the cowl cover. 29466 Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. FUEL AND OIL Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled.

FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle ‑. FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch.

27755 Horn inside remote control Horn connected to ignition key switch WARNING HORN SIGNALS When the key switch is turned to the 'ON'. FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling Continuous Engine Guardian System is activated. System Power limit will vary with level of overheat. Problem Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. The horn will turn off when throttle speed is within the allowable limit. Consult your dealer for assistance.

SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption, and engine operating hours. FEATURES AND CONTROLS Power Trim and Tilt Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle.

This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and. FEATURES AND CONTROLS 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. Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller). FEATURES AND CONTROLS NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction.

This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort. OPERATION 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. Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes. OPERATION Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full‑in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs.

OPERATION The engine automatically receives extra oil during the first hours of operation. For most boaters this extra oil mode will be complete in about ten hours. BREAK-IN PROCEDURE 1. For the first hour of operation, allow the engine to warm up for 30–60 seconds. OPERATION 1. Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged.

Open the fuel tank vent screw, located in the filler cap, on manual venting type fuel tanks. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up.

OPERATION 5. Shift outboard to neutral ('N') position. For the initial start of a new engine, or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: a. OPERATION NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting. Check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for obstruction.

OPERATION. After shifting outboard into gear, advance the lever further to increase speed. 27237 Stopping the Engine Reduce engine speed and shift outboard to neutral position.

Turn ignition key to 'OFF' position. Record maintenance performed in the Maintenance Log at the back of this book.

Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.

MAINTENANCE EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines. Refer to Owner's Manual for required maintenance. MAINTENANCE Inspection and Maintenance Schedule BEFORE EACH USE. Check that the lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks.

Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retorque the outboard mounting fasteners to the specified torque. MAINTENANCE. Replace spark plugs at first 100 hours or first year. After that, inspect spark plugs every 100 hours or once yearly. Replace spark plugs as needed. See Spark Plug Inspection and Replacement.

Replace fuel filter. See Fuel System.

MAINTENANCE EVERY 300 HOURS OF USE OR THREE YEARS. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Replace the in‑line oil filter that is located in the oil hose between the oil tank and the oil injection pump. BEFORE PERIODS OF STORAGE. MAINTENANCE 4.

Turn off the water and remove the water hose from the hose adapter. Reinstall the cover into the hose adapter. 22703 Hose adapter Sealing washer Cover Top Cowl Removal and Installation REMOVAL 1. Unlock the rear latch by pushing lever up. MAINTENANCE Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning.

Follow the cleaning and waxing procedure. CLEANING AND WAXING PROCEDURE 1. Before washing, rinse the top cowl with clean water to remove the dirt and dust that may scratch the surface. MAINTENANCE INSTALLATION Position the cover onto the three mounting pins. Insert the tabs into the slots in the side panel and push the cover down onto the mounting pins.

23754 Flywheel cover Mounting pins Tabs Side Panel Removal and Installation REMOVAL Pull the side panel off the three mounting pins. MAINTENANCE INSTALLATION Position the side panel onto the three mounting pins. Insert the tabs on the flywheel cover into the upper slots and push the side panel onto the mounting pins.

23765 Side panel Upper slots Mounting pins Fuel System WARNING Fuel is flammable and explosive. MAINTENANCE Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle.

MAINTENANCE DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on. Draining the water from the fuel filter chamber is required. Pull the drain hose off the right side fitting.

Hold the open end of the hose over a container. MAINTENANCE Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt ('a' ‑ Part Number 10‑849838) and self‑locking nylon insert locknuts ('c' and 'd' ‑ Part Number 13). These locknuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage. MAINTENANCE Description lb‑in.

Lb‑ft Tighten until it seats, then back off 1/4 Nylon insert locknut 'c' turn Assemble steering link rod to steering cable with two flat washers and self‑locking nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with special washer head bolt and self‑locking nylon insert locknut. MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 23793 Good fuse Blown fuse 14 pin remote control harness/cowl trim switch/main power relay ‑.

MAINTENANCE Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode.

The gearcase has two corrosion control anodes, one on each side. 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. 3486 Propellers REMOVAL IMPORTANT: Propellers used on this product require the Mercury Marine Flo‑Torq III type hub or equivalent. MAINTENANCE WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.

Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.

MAINTENANCE Tube Description Where Used Part No. 2-4-C with Propeller shaft 92-802859A 1 PTFE NOTE: The Flo‑Torq lll propeller drive hubs are designed to have a small amount of free play when installed. This free play allows the propeller to slide back and forth on the rear thrust hub (up to 3.17 mm 1/8 in.) and rotate up to 10 degrees. MAINTENANCE 4. Secure the propeller nut by bending three of the tabs into the thrust hub grooves.

26945 Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. MAINTENANCE 3. Set the spark plug gap to specifications.

26947 Spark Plug Spark plug gap 0.80 mm (0.030 in.) 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten to the specified value.

Belt surfaces rough or uneven. Signs of wear on edges or outer surfaces of belt. 29477 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Description Where Used Part No. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.

Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Special Lubricant 101. Tube Description Where Used Part No. MAINTENANCE. Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

Completely retract the end of the steering cable before applying lubricant. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

26977 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml (22.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place outboard in a vertical operating position.

MAINTENANCE 3. Remove fill/drain plug. Place lubricant tube into the fill/drain plug hole and add lubricant until it appears at the front vent hole.

At this time install the front vent plug and sealing washer. 27001 Front vent plug Front vent hole Rear vent hole Rear vent plug Fill/drain plug. Adding fuel stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will help clean and lubricate the fuel injectors. Retighten the drain screw and reattach the hose.

Premix the following in a container: a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant.

8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer. STORAGE 10. Remove the fuel filter. See Maintenance ‑ Fuel System for procedure. Pour this mixture into the fuel filter opening. Reinstall the fuel filter.

Prime the fuel system. See Operation ‑ Starting The Engine. Place the outboard in water or use the flush hose or flushing device or for circulating cooling water. STORAGE.

Touch up any paint nicks. See your dealer for touch‑up paint. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Description Where Used Part No. Corrosion External metal surfaces.

TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES. Blown 20 amp fuse in the starting circuit. Refer to Maintenance. Outboard is not shifted to neutral position.

Weak battery or battery connections are loose or corroded. TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES. Spark plugs fouled or defective. Refer to Maintenance section. Incorrect setup and adjustments. Fuel is being restricted to the engine.

Engine fuel filter is obstructed. Refer to Maintenance section. Fuel tank filter obstructed. If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

The name and address of your dealership. Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.

United States, Canada English ‑ (920) 929‑5040. OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944.

Rigging boats, which includes proper engine installation, has become more complex over the years. As a result, we recommend our engines be installed only by Mercury authorized dealers. If you intend to disregard this recommendation and install the engine yourself, please make sure to read and comply with these instructions. Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.

Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories. OUTBOARD INSTALLATION. Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑ marine fuel hose. Installation Specifications 18552 Minimum transom opening Engine centerline for dual engine ‑.

OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. 15363 Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine 2756 for removal/installation. OUTBOARD INSTALLATION Tube Description Where Used Part No. 2-4-C with O-ring seal and entire cable 92-802859A 1 PTFE 2.

Insert steering cable into tilt tube. Torque nut to specification. 3727 Description lb‑in. OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 18562 The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions. OUTBOARD INSTALLATION NOTICE 1.

The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions. OUTBOARD INSTALLATION Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes.

Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description. OUTBOARD INSTALLATION Available Outboard Mounting Bolts Part Number Description 10‑8M0033366 ½‑20 x 5.00 in. Long (3.25 in. Thread) 10‑67755‑003 ½‑20 x 5.50 in. Long (3.25 in. Thread) 10‑67755‑2 ½‑20 x 6.50 in.

Long (2.75 in. Thread) 10‑8M0028080 ½‑20 x 7.50 in. Long (2.75 in. Thread) 10‑8M0032860 ½‑20 x 8.00 in.

OUTBOARD INSTALLATION Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding.

The load area can be increased by using a larger washer or a transom reinforcement plate. OUTBOARD INSTALLATION NOTE: For more accurate torque, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 1/2 in. Diameter outboard mounting bolt (4) 7/8 in.

Flat washer (4) Nylon insert locknut (4) 1‑1/2 in. Flat washer (4) Marine sealer ‑ apply to the shank of the bolts, not the threads Description lb‑in. OUTBOARD INSTALLATION Electrical, Fuel Hose, Flush Hose and Control Cables FRONT COWL GROMMET NOTE: Sufficient slack must exist in wiring, battery cables, and hoses that are routed between the grommet and engine attachment points to relieve stress and prevent hoses from being kinked or pinched. OUTBOARD INSTALLATION 4. Install the flush hose after removing the knockouts. Refer to Flush Hose Routing. 23638 Flush hose Grommet Remote boat harness Shift cable Throttle cable Fuel hose Upper alignment pin SmartCraft harness or additional harness opening Water pressure tube Battery cables Lower alignment pin 5.

OUTBOARD INSTALLATION 6. Attach two cable ties around the grommet tube. 23639 Cable tie FLUSH HOSE ROUTING If desired, the flush hose can be routed outside the cowling as follows: 1. Using a needle‑nose pliers, break out the semi‑circular knockouts in the access cover and lower cover. Smooth the edges of the knockout with sandpaper or a small knife.

OUTBOARD INSTALLATION REMOTE BOAT HARNESS Route the remote boat harness through the grommet. Connect the remote harness to the 14 pin connector on the engine harness.

23699 Remote 14 pin boat harness BATTERY INFORMATION WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. OUTBOARD INSTALLATION Description lb‑in. Lb‑ft Hex nuts 13.5 IMPORTANT: Battery cable size and length is critical.

Refer to engine installation manual for size requirements. The decal needs to be placed on or near the battery box for future service reference. And one 3/8 in. Hex nut is supplied per battery for wing nut replacement. OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Black sleeve ‑ Negative (–) Ground cable Cranking battery.

OUTBOARD INSTALLATION SMARTCRAFT HARNESS CONNECTION If SmartCraft gauges are being used with the outboard, route the SmartCraft wiring harness through the grommet and connect it to the SmartCraft harness connector on the engine. 23700 SmartCraft harness connector WATER PRESSURE TUBE CONNECTION If a water connection to the engine is required for a water pressure gauge, make the connection as follows. OUTBOARD INSTALLATION 1. The water pressure tube is coiled and attached on the side of the engine.

Cut the cable tie and route the water pressure tube out through the grommet. 23702 Water pressure tube. OUTBOARD INSTALLATION 2. Remove the plug from the coupler and make the connection. A barb fitting (22‑859731) can be installed for larger diameter hose connection. 23708 Plug Coupler Barb fitting (22‑859731) FUEL HOSE CONNECTION Remote Fuel Hose Size Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with separate fuel hose/fuel tank pickup for each engine. OUTBOARD INSTALLATION Fuel Hose Connection Fasten the remote fuel hose to the fitting with a hose clamp.

23709 Hose clamp Remote fuel hose SHIFT CABLE INSTALLATION NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. OUTBOARD INSTALLATION 3.

Measure the distance between pin and center of barrel pocket. 23720 Distance between pin and center of lower hole Barrel pocket. OUTBOARD INSTALLATION 4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain distance measured in Step 3. 23721 Shift cable end Cable barrel 5.

Place the cable barrel into the pocket. Fasten the cable with locknut and flat washer. OUTBOARD INSTALLATION b. Shift the remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b.

Shift the remote control into reverse while turning propeller. OUTBOARD INSTALLATION 5.

Lock the retainer and cables in place with the cable latch. 15317 Flat washer Locknut Barrel retainer Cable barrel Cable latch Oil Injection Set‑Up FILLING OIL INJECTION SYSTEM 1. Fill the oil tank with the specified oil. Refer to Filling Oil Injection System. OUTBOARD INSTALLATION All Models Capacity Fluid Type Oil tank 4.72 liters (5 qt.) Optimax/DFI 2‑Cycle Engine Oil PRIMING THE OIL INJECTION PUMP Before starting engine for the first time, prime the oil injection pump.

Priming will remove any air that may be in the pump, oil supply hose, or internal passages. OUTBOARD INSTALLATION 3. Turn the ignition key switch to the 'ON' position. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times. This will automatically start the priming process.

OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow‑down planing condition called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower. Tilt pin (not included with engine) 2688 Stainless Steel Tilt Pin 17‑49930A 1.