! WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. i 90-10261080 1008 25/30 2-Stroke EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.
Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information Section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.
Handling characteristics (A.4) ISO 8665 Outboard engine starting (A.5.1.4) ISO 11547 Fuel tanks (A.5.2.2) ISO 13591; ISO 8469 General steering system ABYC P‑17 Safety of Machinery Directive 98/37/EC Principles of safety integration (1.1.2) EN 292‑1; EN 292‑2; EN 1050 Noise (1.5.
Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment 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.
TABLE OF CONTENTS Warranty Information Transfer of Warranty....................................................................1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan............................................................................1 Warranty Registration United States And Canada......................2 Outboard Limited Warranty..........................................................3 3 Year Limited Warranty Against Corrosion................................
TABLE OF CONTENTS TRANSPORTING Trailering Boat/Outboard...........................................................49 Removing the Motor..................................................................49 Transporting Portable Fuel Tanks.............................................50 FUEL & OIL Fuel Recommendations.............................................................52 Oil Recommendation.................................................................53 Mixing Fuel and Oil............................
TABLE OF CONTENTS MAINTENANCE Outboard Care...........................................................................77 EPA Regulations........................................................................ 77 EPA Emissions..........................................................................78 Inspection and Maintenance Schedule......................................78 Flushing the Cooling System.....................................................80 Top Cowl Removal and Installation..................
TABLE OF CONTENTS ASSOCIATED PARTS Associated Parts........................................................................98 ACCESSORIES Accessories...............................................................................99 WIRING DIAGRAMS Wiring Diagrams......................................................................103 OWNER SERVICE ASSISTANCE Local Repair Service................................................................ 112 Service Away from Home........................................
WARRANTY INFORMATION Transfer of Warranty The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty registration department.
WARRANTY INFORMATION Plan coverage is not transferable from one product to another product or for non‑eligible applications. The Certified Pre‑Owned engine plans are not transferable. For help or assistance, contact Mercury Product Protection Department at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST, Monday ‑ Friday or email mpp_support@mercurymarine.com. Warranty Registration United States And Canada Outside United States and Canada ‑ Check with your local distributor. 1.
WARRANTY INFORMATION 3. Upon processing the warranty registration, Mercury Marine will send registration verification by mail to the purchaser of the product. If this registration verification is not received within 30 days, please contact your selling dealer immediately. Warranty coverage is not effective until your product is registered with Mercury Marine. Outboard Limited Warranty Outside the United States and Canada ‑ Check with your local distributor.
WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
WARRANTY INFORMATION WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident,
WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU.
WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
WARRANTY INFORMATION WHAT IS NOT COVERED: This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by customer); products used in a commercial application.
WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU.
WARRANTY INFORMATION 2. Factory installed jet drive units ‑ Specific parts excluded from the warranty are: The jet drive impeller and jet drive liner damaged by impact or wear, and water damaged drive shaft bearings as a result of improper maintenance. 3. Damage caused by neglect, lack of maintenance, accident, abnormal operation or improper installation or service. 4.
WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 13. Water entering engine through the fuel intake, air intake or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high or trimmed too far out. 15. Use of fuels and lubricants which are not suitable for use with or on the 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. Be sure at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION Boat Horsepower Capacity ! WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating. Do not overpower or overload your boat.
GENERAL INFORMATION ! WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 37991 Remote Steering Notice ! 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 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed as an accessory–generally on the dashboard or side adjacent to the operator's position.
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 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 Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat reenters the water.
GENERAL INFORMATION There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward. The boat may also steer sharply to one side.
GENERAL INFORMATION Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles. After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts.
GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
GENERAL INFORMATION WHILE BOAT IS MOVING a b 21628 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 Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. IMPORTANT: Check with your dealer before installing accessories.
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. Inquiries may 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.
GENERAL INFORMATION Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is complete loss of the boat.
GENERAL INFORMATION 25/30 Specifications Model 25M 30M 30EH 30E Overall length 884 mm (34.8 in.) 600 mm (23.6 in.) Overrall width 412 mm (16.2 in.) 355 mm (14 in.) Overrall height S: 1116 mm (44 in.) ‑ L: 1243 mm (49 in.) Transom height S: 435 mm (17.1 in.) ‑ L: 562 mm (22.1 in.) Weights Max output PS/(KW) Full‑throttle RPM 51 kg (112 lb) 55 kg (124 lb) 25 (18.4) 30 (22.1) 5,000 ‑ 6,000 5,150 ‑ 5,850 Fuel consumption 13 ltr/hr Number of cylinders 2 Piston displacement 430 cc (26.
GENERAL INFORMATION Components: 25/30M 20 11 1 12 2 13 14 3 21 22 15 4 16 5 6 7 8 17 18 9 10 24 19 25 26 27 23 28 MH models 27 37417
GENERAL INFORMATION 1 - Tilt handle 2 - Upper cowl 3 - Water pump indicator hole 4 - Water plug 5 - Reverse Lock Lever 6 - Drive shaft housing 7 - Anti‑ventilation plate 8 - Trim tab 9 - Secondary water intake 10 - Propeller 11 - Starter rope handle 12 - Shift lever 13 - Throttle grip 14 - Clamp screw 15 - Clamp bracket 16 - Trim position pin 17 - Upper oil plug 18 - Cooling water intake 19 - Lower oil plug 20 - Connector B 21 - Stop switch 22 - Choke knob 23 - Fuel tank 24 - Primer valve 25 - Fuel connecto
29
GENERAL INFORMATION 1 2 11 21 12 22 13 14 3 15 4 16 5 23 24 17 6 7 18 8 19 9 20 10 26 25 27 28 29 30 37461 EH models 30
GENERAL INFORMATION 1 - Tilt handle 2 - Upper cowl 3 - Water pump indicator hole 4 - Water plug 5 - Reverse Lock Lever 6 - Drive shaft housing 7 - Anti‑ventilation plate 8 - Trim tab 9 - Secondary water intake 10 - Propeller 11 - Starter rope handle 12 - Shift lever 13 - Throttle grip 14 - Clamp screw 15 - Clamp bracket 16 - Trim position pin 17 - Battery cable 18 - Upper oil plug 19 - Cooling water intake 20 - Lower oil plug 21 - Connector B 22 - Main switch 23 - Stop switch 24 - Choke knob 25 - Fuel tank
GENERAL INFORMATION 1 11 2 12 20 13 3 14 4 15 5 16 6 7 17 8 18 9 19 10 26 21 22 27 23 28 24 29 25 30 37463 E models 32
GENERAL INFORMATION 1 - Tilt handle 2 - Upper cowl 3 - Water pump indicator hole 4 - Water plug 5 - Reverse Lock Lever 6 - Drive shaft housing 7 - Anti‑ventilation plate 8 - Trim tab 9 - Secondary water intake 10 - Propeller 11 - Starter rope handle 12 - Shift lever 13 - Clamp screw 14 - Clamp bracket 15 - Trim position pin 16 - Battery cable 17 - Upper oil plug 18 - Cooling water intake 19 - Lower oil plug 20 - Connector B 21 - Remote control box 22 - Main switch 23 - Stop switch 24 - Cord assembly 25 - Fu
INSTALLATION Installing Outboard We strongly recommend that your dealer install your outboard and related accessories ot ensure proper installation and good performance. If you install the outboard yourself, follow instructions in the manual which is provided with the outboard.
INSTALLATION NOTE: Most boats are rated and certified in terms of their maximum horse power limit, and this is shown on the boatt's certification plate. Do not equip your boat with an outboard that exceeds this limit. If in doubt, contact your dealer. Do not operate the engine until it has been securely mounted on the boat in accordance withthe instructions below. 1. Position the outboard motor at the center of the stern. a 37508 2. Position the outboard engines about 580 mm (23 in.) apart.
INSTALLATION TRANSOM MATCHING NOTE: Be sure that the Anti‑ventilation plate of the outboard is below the water surface when running with wide‑open throttle. In case the above condition cannot be met due to a bottom shape of your boat, please consult the dealer. Installing the Remote Control Device (Right‑Hand Steering) 1. Positioning the remote-control box: Position the remote control box in a place that will not obstruct handling of the control levers and switches.
INSTALLATION 2. Remote control features f e d d g c b c b a h a 37531 abcd- Fully opened position Fully closed position Throttle Shift efgh- Neutral (N) Forward (F) Reverse (R) Throttle only lever 3. Determining remote control cable length: A guideline for determining the proper length for a remote control cable is dimensions A plus B plus 300 mm (1 foot). A a B 37530 a - Center of stern NOTE: The minimum bend radius for a remote control cable is typically 203 mm (8 in.).
INSTALLATION 4. Connecting remote control cable to the remote control box: Remove the back panel by loosening two screws. a 37528 a - Back panel 5. Thread the remote control cables through the terminal eyes at a distance of more than 11 mm (0.43 in.). Securely lock the terminal eyes with the nut lock.
INSTALLATION 6. Press the neck of the shift remote control cable down into the clamp on the housing of the remote control box. Connect the terminal eye to the shift arm with the pin and E‑ring. Insert a grommet, supplied with the remote control box, into the clamp. a c b d 37527 a - Grommet b - Shift arm pin c - E‑ring d - Shift arm 7. Connect the throttle remote control cable to the throttle arm in a manner similar to the shift remote control cable.
INSTALLATION 8. Install the back panel. a 37528 a - Back panel 9. Install the remote control box with three screws, spacers and nuts.
INSTALLATION 10. Connect the remote control cable to the engine and attach the cord assembly as shown below.
INSTALLATION 12. Throttle side: Slide a grommet onto an end of the cable, put a holder cap on it, and lock it with a nut, as shown. b a c 37502 a - Throttle cable b - Nut c - Holder cap 13. Shift side: Attach the sleeve guide B to the shift remote control cable, and lock it with a nut. d a c b 37503 a - Neck of remote control cable b - Shift remote control cable c - Nut d - Sleeve guide B 14. Connect the remote control cable to the engine. 15.
INSTALLATION NOTE: Confirm the motion of the control lever: Turn the control lever to Forward (F) or Reverse (R) at 32° where the lever is latched. The shift lever will be moved to the shift‑in position, and the throttle is fully opened when shifted further. Confirm the throttle lever is Fully Closed when the control lever is shifted to Neutral (N). If the throttle is completely closed, position the holder cap on the engine, and attach it.
INSTALLATION 17. Attach the cord assembly: Connect the cord assembly from the remote control box to respective terminals through the lower motor cover as illustrated. Fasten the cord assembly with clamps.
INSTALLATION BLK GRN BLK GRN RED RED BLU WHT WHT BLU YEL g h BRN c d e f BRN b RED a YEL 18. Connect the cables to their respective terminals at the cable terminal holder.
INSTALLATION The steering link rod parts are available and assembled as illustrated below. Spacers may or may not be required depending on cable brands. c d e g d b a f h d a abcdef- i j k d i Grease Spacer (option) Bolt Washer B Cushion rubber Spring ghijkl- l 37507 Spacer Collar Nut lock Rod Washer A Seal ring Battery Installation MOUNTING BATTERY Follow the battery manufacturer's instructions carefully. Mount battery securely to the hull in a place free from splashing water.
INSTALLATION Required battery rating: 12V battery with a recommended capacity of 70 AH or over. • Battery cables must be long enough to allow free steering. • Battery cables must be arranged and protected from damage during steering. • With poor cable connections, the starter will fail to start. • Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. • Battery must be fully charged before running the motor.
INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information-Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed. The propeller supplied with your outboard provides the best overall performance under average operating conditions.
TRANSPORTING Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. IMPORTANT: The tilt lock and shallow water drive feature (tiller handle models) on the outboard are not intended to support the outboard in the tilted position when trailering. 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.
TRANSPORTING 4. Rest the motor on the ground with the clamp screw handles facing upward. 37884 Transporting Portable Fuel Tanks ! WARNING Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank. Transport the fuel tank in a well ventilated area away from open flame or sparks. MANUAL VENTING TYPE FUEL TANK Close fuel tank air vent when transporting tank. This will prevent escape of fuel or vapors from tank.
TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidently pushed‑in, thus, allowing fuel or vapor to escape.
FUEL & OIL Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a 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 & 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 & OIL IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. Severe engine damage may result from use of an inferior oil.
FUEL & 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. FILLING PERMANENTLY INSTALLED TANKS Slowly pour the correct amount of oil along with gasoline as the tank is being filled. FILLING PORTABLE FUEL TANKS Remove the portable fuel tanks from the boat to refill them. Pour the full amount of oil, along with one gallon of gasoline into the fuel tank.
FEATURES & CONTROLS Remote Control Features Your boat may be equipped with the Mercury Precision or Quicksilver remote control shown. If not, consult your dealer for a description of the functions and operations of the remote control.
FEATURES & CONTROLS TILT DOWN Turn the reverse lock lever to lock side, lift up the engine slightly, and put it down. Reverse lock is done automatically. a 37537 a - Reverse lock lever Shallow Water Operation The outboard is equipped with a shallow water tilt feature that allows you to tilt the outboard to a higher tilt angle to prevent hitting bottom. SHALLOW WATER RUNNING POSITION Turn the reverse lock lever to release side, and tilt up the engine to set the engine to shallow water running position.
FEATURES & CONTROLS TILT DOWN FROM SHALLOW WATER RUNNING POSITION Turn the reverse lock lever to lock side, lift up the engine slightly, and put it down. Reverse lock is done automatically. a 37537 a - Reverse lock lever IMPORTANT: While in shallow water drive position, do not operate the outboard in reverse. Operate the outboard at slow speed and keep the cooling water intake submerged. Trim Adjustment Trim of the motor can be adjusted to suit the transom angle and loading conditions of your boat.
FEATURES & CONTROLS • Trim up: If the bow falls into the water level when cruising, trim the trim position pin up. a b d c e f 37883 a - Correct trim b - Trim down c - Trim up d - Trim position pin e - Up f - Down Steering Friction Adjustment Steering friction can be adjusted according to your preference with the steering co‑pilot.
FEATURES & CONTROLS • Turn counterclockwise: Less friction a 37516 a - Steering co‑pilot 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.
FEATURES & CONTROLS • If the boat steers toward the left, set the trim tab in the direction of (b). d e a b c 37494 a - Trim tab b - Steers toward the left, set the trim tab in the direction of B c - Steers toward the right, set the trim tab in the direction of C d - Turning left e - Turning right NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti‑ventilation plate approximately 50 mm (2 in.) or more above the boat bottom.
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. Know your boats' maximum load capacity. Look at the boat capacity plate. Fuel supply OK.
OPERATION If you keep your boat moored in the water, always tilt the outboard so the gearcase is completely out of water (except in freezing temperatures) when not in use. Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.
OPERATION The use of poor quality fuel will shorten the life of a motor and cause trouble, including starting failure. It is recommended to use a high quality gasoline and genuine or recommended engine oil. (Refer to Oil and Fuel section.) Starting the Engine PREPARATIONS 1. Install the fuel connector to the engine side connector. 37522 2. Loosen the air vent screw on the tank cap. For tanks with a fuel tank auto air vent (optional): There is no need to loosen the air vent screw.
OPERATION 3. Feed fuel to the carburetor by squeezing the primer valve until firm. b a c 37714 a - To fuel tank b - To outboard c - Fuel flow direction NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. NOTE: Be sure that the shift is at Neutral (N) when starting the engine. This model is provided with start in gear protection. 4.
OPERATION 6. Pull out the choke knob fully. (No choke operation is necessary on warmed engine.) N 37521 7. Remote control models: Insert the key. 8. Turn the key to the ON position, and push it for choke operation. (No need to push the key when the engine is warm.
OPERATION 9. Place the control lever at Neutral (N), and move the Throttle only lever to the open position. N a b c d e 37715 a - Fully opened position b - Fully closed position c - Throttle only lever d - Ignition key switch e - Lanyard stop switch SET THE LANYARD STOP SWITCH TO RUN POSITION Be sure to connect the lanyard stop switch to your body. The engine will shut down if the stop lanyard is disconnected.
OPERATION Remote control models c b d a e 37716 a - Hook b - OFF c - ON d - Stop switch lock e - Lanyard stop switch NOTE: The engine will not start unless this switch has been properly connected and locked beforehand. Refer to General Information - Lanyard Stop Switch. STARTING THE ENGINE 1. Pull the rewind starter slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow the rope to return slowly.
OPERATION IMPORTANT: Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in Procedures in the Operation Section. 2. Tiller handle models: Push the starter button. 3. After the engine starts, release the button. 37524 4. Remote control models: Insert, push, and turn the key to the START position. NOTE: When restarting a warm engine, do not push the key; merely turn it to the start position.
OPERATION 5. When the engine starts, release the key, and it will return automatically to the original position. 6. If the engine fails to start in 10 seconds, wait 30 seconds and try again. If the engine begins to stall, reprime (push key in) until the engine is running. IMPORTANT: RAPID ACCELERATION HAZARD: Before shifting your outboard from neutral into gear, decrease engine speed to slow.
OPERATION IMPORTANT: If cooling water is not discharged, and operation continues, it may cause overheating, resulting in engine damage. a b 37514 a - Water pomp indicator b - Cooling water discharge port Gear Shifting FORWARD IMPORTANT: It may be dangerous to attempt shifting at high RPM. Be sure to slow down to trolling or idling RPM before shifting.
OPERATION Remote control models: Move the throttle‑only lever to the lower position, then shift the control lever to Forward (F) position. NOTE: CONFIRM reverse lock lever is in Release (R) position. NOTE: Forward running is not possible unless the throttle‑only lever is at the lower position.
OPERATION NOTE: Confirm that the reverse lock lever is at the lock position. a 37538 a - Reverse lock lever: R = Release, L = Lock Remote control models: Operate the clutch only when the engine operates at idle speed. To change Forward (F) to Reverse (R), first idle the engine and shift into Neutral (N). With the engine still running, slowly engage and gradually increase the reverse speed. NOTE: Confirm that the reverse lock lever is at the LOCK position.
OPERATION 3. Press the stop switch until the engine stops completely, or pull the stop switch lock. 1. Remote control models: Place the remote control lever at Neutral (N) and idle the engine.
OPERATION 2. Turn the key to OFF position, or pull the stop switch lock. b c d a e 37716 a - Hook b - OFF c - ON d - Stop switch lock e - Lanyard stop switch IMPORTANT: Follow the instruction below. • After the engine stops, tighten the air vent screw on the tank cap. • Disconnect the fuel connector from the engine. • For the EH and E types, disconnect the cables from the battery when not in use for extended periods.
OPERATION 3. Use a 10 mm socket wrench as a pull grip, as shown below. 37880 NOTE: Confirm that the shift lever is in Neutral (N). ! WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine. Do not attempt to reinstall the rewind starter assembly or top cowl when engine is running.
MAINTENANCE Outboard Care To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.
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. a b c EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines. Refer to Owner's Manual for required maintenance.
MAINTENANCE • • Remote control models ‑ Visually check steering link rod fasteners for proper tightness. See Steering Link Rod Fasteners. 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 saltwater.
MAINTENANCE EVERY 300 HOURS OF USE OR THREE YEARS • Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).1. BEFORE PERIODS OF STORAGE • Refer to Storage procedure. See Storage section. Flushing the Cooling System FLUSHING Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.
MAINTENANCE 2. Connect a hose to the flushing plug to flush out the inside of the motor with water. Be sure to seal the cooling water intake and secondary water intake, located at the gearcase with tape. a 37515 a - Flushing plug 3. With the shift lever in Neutral (N), run the engine at a low speed so that water flushes out the cooling system to remove seawater and mud. Top Cowl Removal and Installation REMOVAL 1. Unlock the rear latch by pushing lever down.
MAINTENANCE 2. Lift rear of cowl and disengage front hook. 26851 INSTALLATION 1. Engage the front hook and push cowl back over the cowl seal. 2. Push cowl down and move the rear latch lever up to lock. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2.
MAINTENANCE Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well‑ventilated area. Inspect any completed service work for sign of fuel leakage.
MAINTENANCE 2. Remove the cap, then clean the fuel filter at the engine. c b a 37710 a - Fuel filter b - Carburetor c - Fuel pipe Fuse Replacement ‑ Electric Start Remote Control Models IMPORTANT: Always carry spare SFE 20 apm fuses. The electric starting circuit is protected from overload by an SFE 20 apm fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again.
MAINTENANCE The anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. a 37879 a - Anode (trim tab) Important: • Before replacing the anode, remove the spark plug cap to make sure the engine will not start, then check and replace the anode.
MAINTENANCE REMOVING PROPELLER 1. Remote control model: Shift outboard to Neutral (N) position. N 37882 2. Tiller handle model: Move shift lever to Neutral (N) position. 38030 3. Remove the spark plug leads to prevent the engine from starting.
MAINTENANCE 4. Place a block of wood between the gearcase and propeller to hold the propeller. 27296 5. Remove the cotter pin, propeller nut, and washer. a c b d e f 37520 d - Propeller e - Propeller thrust holder f - Propeller shaft a - cotter pin b - Nut c - Washer 6. Pull propeller straight off the propeller shaft. If the propeller is seized to the propeller shaft and cannot be removed, have the propeller removed by an authorized dealer. 7.
MAINTENANCE Tube Ref No. 95 Description 2-4-C with Teflon Where Used Part No. Propeller shaft 92-802859A 1 27344 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed. INSTALLING PROPELLER 1.
MAINTENANCE Description Nm Propeller nut 75 lb. in. lb. ft. 55 3. Install the spark plug leads. 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. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots. 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2.
MAINTENANCE Spark Plug Spark plug gap 1.0 mm (0.035 in.) 4. 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 to specifications. Description Nm Spark plug 27 lb. in. lb. ft. 20 Lubrication Points It is important to inspect and maintain your outboard motor regularly. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first.
MAINTENANCE CHANGING GEAR OIL 1. Place the outboard in a vertical operating position. 2. Place a drain pan below the outboard. 3. Remove the oil plugs (upper and lower) and drain the gear oil completely. 37849 4. Place the lubricant tube into the fill/drain hole and add the lubricant until it appears at the upper oil plug hole. a 37848 a - Upper oil plug hole 5. Install the upper oil plug before removing the lubricant tube.
MAINTENANCE 6. Remove the lubricant tube and install the lower oil plug. 37849 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 280 cc (9.5 fl. oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.
STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
STORAGE Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Protecting External Outboard Components • • • Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. Touch up any paint nicks. See your dealer for touch‑up paint. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No.
STORAGE • Rotate the flywheel manually several times to distribute the storage seal in the cylinder. Reinstall spark plug. Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance ‑ Gearcase Lubrication). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. NOTICE Storing the outboard in a tilted position can damage the outboard.
TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models ‑ Blown 20 Amp fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure. • Wiring or electrical connection faulty. • Starter motor or starter solenoid failure. Engine Will Not Start POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position.
TROUBLESHOOTING • • • • Incorrect setup and adjustments. Fuel is being restricted to the engine. • Engine fuel filter is obstructed. Refer to Maintenance section. • Fuel tank filter obstructed. • Stuck anti‑siphon valve on built in fuel tank. • Fuel line is kinked or pinched. Fuel pump failure. Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup.
ASSOCIATED PARTS Associated Parts Name Service tools Spare parts Other* Quantity Dimensions Tool bag 1 Pliers 1 Socket wrench 1 10 x 13 mm Socket wrench 1 21 mm Socket wrench handle 1 Screwdriver 1 Starter rope 1 1000 mm Spark plug 1 NGK B7HS‑10 or Campion L82C (Gap: 1.0 mm ‑ 0.
ACCESSORIES Accessories OPTIONAL ACCESSORIES a c b e d f g h j i k l 37846 abcdef- Speedometer (50 MPH) Speedometer (75 MPH) Fuel meter Tachometer Hour meter Genuine engine oil 99 g - Genuine grease (50 g, 250 g) h - Genuine gear oil (260 cc, 500 cc) i - Touch‑up spray paint (300 ml) j - Stop switch k - Extension cord, light l - Meter lamp switch
ACCESSORIES a b 37540 a - Turnbuckle plate b - Twin remote control turnbuckle assembly b a 37506 a - Steering spacer b - Steering link assembly(standard: EP type) 100
ACCESSORIES a e f b g c d 37493 a - Twin remote control box kit b - 3 screws (included in kit) c - 3 spacers (included in kit) d - 6 spacers 101 e - Hull f - 6 washers g - 3 nuts
ACCESSORIES a 37504 a - Clutch lever reverse lock kit 102
WIRING DIAGRAMS Wiring Diagrams 1 20 17 18 3 2 4 19 5 6 16 13 12 11 14 7 15 8 10 9 37842 103
WIRING DIAGRAMS 1 - Remote control box 2 - Battery 3 - 12 V, 800 W (DC) 4 - Extension cord (optional) 5 - Fuse (15 A) 6 - Rectifier (optional) 7 - Extension cord, light (optional) 8 - Receptacle plug (optional) 9 - Lamp (12 V, 80 W) (AC) 10 - Tachometer (optional) 11 - Separate cord (yellow) (optional) 12 - Separate cord (white) (optional) 13 - Flywheel magneto 14 - Ignition coil 15 - Spark plug 16 - CD unit 17 - Stop switch (optional) 18 - Stop switch 19 - Remote control stop cord (optional) 20 - Remote co
105
WIRING DIAGRAMS 1 17 13 2 16 14 3 15 4 12 9 8 10 7 5 11 6 37843 106
WIRING DIAGRAMS 1 - Starter motor 2 - Starter solenoid 3 - Fuse (15 A) 4 - Rectifier 5 - Tachometer lead wire (optional) 6 - Tachometer (optional) 7 - Separate cord (yellow) (optional) 8 - Separate cord (white) (optional) 9 - Flywheel magneto 10 - Ignition coil 11 - Spark plug 12 - CD unit 13 - Stop switch (optional) 14 - Stop switch 15 - Battery: 12 V, 70 AH (optional) 16 - Neutral switch 17 - Main switch 107
WIRING DIAGRAMS 27 28 26 25 29 21 1 30 20 22 31 19 23 24 18 2 4 14 17 16 15 13 5 9 8 6 12 11 10 7 108 3 37844
WIRING DIAGRAMS 1 - Assist cord (black) (optional) 2 - Tachometer lead wire (optional) 3 - Rectifier 4 - Fuse wire (15 A) 5 - Starter solenoid 6 - Separate cord (white) (optional) 7 - Separate cord (yellow) (optional) 8 - Starter cord 9 - Starter motor 10 - Alternator 11 - Trigger coil 12 - Flywheel magneto 13 - Exciter coil 14 - Choke solenoid 15 - CD unit 16 - Ignition coil 17 - Spark plug 18 - Stop switch (optional) 19 - Meter lead wire (optional) 20 - Cord assembly 21 - Remote control box (see next page
WIRING DIAGRAMS REMOTE CONTROL BOX 1 2 5 4 3 37845 110
WIRING DIAGRAMS 12345- Neutral switch Main switch Stop switch Cord assembly Meter lead wire (optional) 111
OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Service Away from Home If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer.
OWNER SERVICE ASSISTANCE • • • Model and serial number of your outboard 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 Telephone (920) 929‑5040 Fax (920) 929‑5893 Website www.mercurymarine.com Mercury Marine W6250 W. Pioneer Road P.O.
OWNER SERVICE ASSISTANCE Japan Telephone 81‑053‑423‑2500 Fax 81‑053‑423‑2510 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Fax 5467789 Mercury Marine Singapore 72 Loyang Way Singapore, 508762 114
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
