© 2016 Mercury Marine 8/9.9 and 9.
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Welcome You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation and Maintenance Manual contains specific instructions for using and maintaining your product.
NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard.
Identification Records Please record the following applicable information: Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Length Boat Model Exhaust Gas Emissions Certification Number (Europe Only) eng iii
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General Information Boater's Responsibilities..................................................................................... 1 Before Operating Your Outboard........................................................................ 1 Boat Horsepower Capacity................................................................................. 1 High‑Speed and High‑Performance Boat Operation.......................................... 2 Outboard Remote Control Models ............................................
Features and Controls Tiller Handle Features...................................................................................... 30 Remote Control Features................................................................................. 36 Warning System............................................................................................... 37 Power Tilt (if equipped)..................................................................................... 38 Setting The Transom Angle Of Your Outboard .
Maintenance Outboard Care.................................................................................................. 57 EPA Emission Regulations............................................................................... 57 Inspection and Maintenance Schedule............................................................. 58 Flushing the Cooling System............................................................................ 59 Top Cowl Removal And Installation......................................
Owner Service Assistance Service Assistance........................................................................................... 82 Ordering Literature............................................................................................ 84 Installation Boat Horsepower Capacity............................................................................... 86 Start in Gear Protection....................................................................................
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard. Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S.
GENERAL INFORMATION Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage. ! WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.
GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.
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 Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 ! WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water. 26784 The primary concern is the boat changing direction while in the midst of the jump. In such case, the landing may cause the boat to veer violently in a new direction.
GENERAL INFORMATION Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.
GENERAL INFORMATION ! WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.
GENERAL INFORMATION ! WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases.
GENERAL INFORMATION 1. Examples of poor ventilation while the boat is stationary: a b 21626 a - Operating the engine when the boat is moored in a confined space b - Mooring close to another boat that has its engine operating 2.
GENERAL INFORMATION • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628). Perform safety checks and required maintenance. • Follow a regular schedule and ensure that all repairs are properly made. Check safety equipment onboard.
GENERAL INFORMATION • Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. Do not overload your boat. • Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water.
GENERAL INFORMATION • 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 Models 8 9.9 9.9 Command Thrust/ ProKicker Recommended oil Refer to Fuel and Oil Engine oil capacity 800 ml (27.0 fl oz) Gearcase lubricant capacity 320 ml (10.8 fl oz) Battery rating (electric start models) 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA) Emission control system 370 ml (12.5 fl oz) Engine modification (EM) Sound at drivers ear (ICOMIA 39‑94) dBA Tiller handle vibration (ICOMIA 38‑94) m/s² 78.7 79.6 Standard Models 9.
GENERAL INFORMATION FRONT VIEW a b c d f e 57671 abcdef- eng Choke/fast idle knob Oil pressure light Fuel line connector Start switch (electric tiller handle) Lanyard safety switch Copilot tension adjustment 17
GENERAL INFORMATION PORT VIEW b a c d 60884 abcd- Tiller lock release lever Start switch (electric tiller handle model) Steering friction adjustment lever (tiller model only) Tilt lock knob 18 eng
GENERAL INFORMATION Component Identification ‑ Command Thrust/ProKicker Models p j o a h c d e abcdefghijklmn- m k b eng n i g l f 60798 Transom bracket Tilt support lever Gear lubricant level plug Primary water inlet Gear lubricant fill/drain plug Secondary water inlet Anti‑ventilation plate Engine flush plug Water pump indicator hole Cowl latch Oil drain screw Power tilt Kicker strap Throttle only button 19
GENERAL INFORMATION o - Throttle grip friction knob p - Power tilt button 20 eng
TRANSPORTING Carrying, Storing, and Transporting Your Outboard when Removed from Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run engine until it stops. This will drain fuel from the carburetor. Install the protector cap over the fuel connector. a - Protector cap a 28530 2.
TRANSPORTING 4. Never carry, store, or transport the outboard in the two positions shown. Engine damage could result from oil draining out of the crankcase. a a - Tiller handle up b - Front side up b 39058 Trailering Boat/Outboard ‑ Models with Power Tilt 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.
TRANSPORTING Shift the outboard to forward gear. This prevents the propeller from spinning freely.
FUEL AND OIL Fuel Requirements IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine and will not be covered under the limited warranty. FUEL RATINGS Mercury outboard engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following specifications: USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for most models.
FUEL AND OIL ! WARNING Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation. IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of inspection for leaks and abnormalities.
FUEL AND OIL The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve. b a c 46273 a - Fuel demand valve ‑ installed in the fuel hose between the fuel tank and primer bulb b - Manual release c - Vent/water drain holes Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements.
FUEL AND OIL 1. Open the manual vent screw on top of the fuel cap. 2. Turn the fuel cap until it contacts the tab lock. 3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure. 4. Press down on the tab lock again and remove the cap. DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening. 2.
FUEL AND OIL IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
FUEL AND OIL 4. Install the oil filler cap and tighten securely.
FEATURES AND CONTROLS Tiller Handle Features IMPORTANT: Avoid engine flooding ‑ Do not rotate the throttle grip while engine is not running. Doing so will inject fuel into the engine and cause a possible hard starting flooded condition. • A decal on the tiller handle is a quick reference guide for starting a cold or hot engine. 57622 • Tiller handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage.
FEATURES AND CONTROLS • Tiller lock release lever ‑ Push the lever to move tiller handle from one position to another. a - Tiller lock release lever a 3274 • Tiller handle lock cap ‑ Remove the lock cap on top of the tiller handle to lock in the up position. Push the tiller lock release lever to release the handle from the locked up position. a b 57672 a - Lock cap b - Locking mechanism • Starter rope ‑ Pulling the starter rope cranks the engine over for starting.
FEATURES AND CONTROLS • Lanyard stop switch ‑ Refer to General Information ‑ Lanyard Stop Switch. 19791 • Engine stop switch ‑ Push in to stop the engine. 57673 • Power tilt switch ‑ Push to tilt engine up/down. 4639 • Throttle grip friction knob ‑ Turn the friction knob to set and maintain the throttle at desired speed. Turn the knob clockwise to tighten friction or turn the knob counterclockwise to loosen friction.
FEATURES AND CONTROLS • Throttle only button ‑ Pressing the button in while the outboard is in neutral disables the gear shift control of the tiller handle. 28550 • Throttle grip ‑ Controls the engine speed and shifting. a b 57674 a - Reverse gear throttle b - Forward gear throttle • Choke ‑ Pull out when starting a cold engine.
FEATURES AND CONTROLS • Low oil pressure warning light ‑ Warns the operator the engine has low oil pressure. When the low oil pressure light is on or is blinking, the engine will run rough and will not exceed 3000 RPM. 57676 • Electric start button (electric start models) ‑ Press the button to start the engine. 28532 ! WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control.
FEATURES AND CONTROLS • Tilt lock knob ‑ Locks the engine in the full tilt position. 28564 • Trim position knob ‑ Presets the trim position. 28551 • Kicker strap (power tilt models) ‑ Prevents the engine from turning while tilted up.
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.
FEATURES AND CONTROLS GEAR SHIFTING IMPORTANT: Observe the following: • Never shift the drive into gear unless the engine speed is at idle. • Do not shift the drive into reverse when the engine is not running. • Your power package has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). • When shifting, always stop at the neutral position and allow the engine speed to return to idle. • Always shift into gear with a quick motion.
FEATURES AND CONTROLS Power Tilt (if equipped) This outboard has a tilt control called power tilt. This enables the operator to easily adjust the position of the outboard by pressing the tilt switch. With the engine turned off, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up to permit shallow water operation.
FEATURES AND CONTROLS TILTING OPERATION To tilt the outboard, shut off the engine and press the tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. Tiller handle models have a kicker strap located on each side of the outboard, preventing the outboard from turning when tilted up. 4676 60801 1. Engage the tilt support lever by rotating lever down. 2. Lower the outboard to rest on the tilt support lever.
FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and lifting the knob. Lower the outboard. a - Tilt support lever b - Knob a b 4650 Setting The Transom Angle Of Your Outboard The vertical transom angle of your outboard is adjusted by changing the position of the preset tilt knob in one of the three adjustment holes provided. Proper adjustment allows the boat to achieve optimum performance, stability, and minimize steering effort.
FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. a b c 28533 a - Too much angle (stern down ‑ bow up) b - Not enough angle (stern up ‑ bow down) c - Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom can: • Lower the bow. • Result in quicker planing off, especially with a heavy load or a stern heavy boat.
FEATURES AND CONTROLS • In excess can cause boat porpoising (bouncing) or propeller ventilation. Adjusting Transom Angle 1. Stop the engine. Shift the outboard into forward. Raise the engine to one of the tilt release positions. Change the preset knob position and lower the outboard to the preset transom angle position. 2. Repeat step number one if the transom angle needs further adjustment.
FEATURES AND CONTROLS 2. To release the shallow water drive, stop the engine and tilt the outboard up to one of the tilt release position. Gently lower the outboard to the preset transom angle. a b 28592 c a - Shallow water drive positions b - Tilt release positions c - Water Intake Tilting Outboard 1. Stop the engine. Shift the outboard into the forward gear position. 2. Take hold of the top cowl grip and raise the outboard to the full up position. 3.
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 Prestarting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water. • Know your boats' maximum load capacity. Look at the boat capacity plate. • Fuel supply OK.
OPERATION Operating Outboard as an Auxiliary Engine If the outboard is used as an auxiliary engine, stop the engine and tilt the outboard out of the water when using the main power source. IMPORTANT: The outboard must be restrained from bouncing while operating the boat using the main power source. Bouncing can damage the outboard and boat transom. Prestarting Instructions 1. Connect the remote fuel line to the outboard. Make sure connector is snapped into place. 27231 2. Check the engine oil level.
OPERATION Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 1. For the first hour of operation, run the engine at varied throttle settings up to 2000 RPM or at approximately half throttle. 2.
OPERATION 3. Set the lanyard stop switch to RUN position. Refer to General Information—Lanyard Stop Switch. 19791 4. Set the tiller handle gear shift to the neutral start position. 57677 5. Cold engine ‑ • Pull the choke knob out two detent positions for starting a cold engine. The choke is closed in this position. • After the engine is running, push the choke knob in one detent. The choke is partially open in this position. • After the engine starts to warm up, push the choke knob in.
OPERATION 6. Manual starting models ‑ Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until the engine starts. After the engine has started, push in the choke knob. 28586 7. Electric start tiller handle models ‑ Push the starter button and crank the engine. Release the button when the engine starts. Do not operate the starter motor continuously for longer than ten seconds at a time.
OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat. Have the outboard checked by your dealer. Operating the engine while overheated will cause serious engine damage. WARMING UP ENGINE Before beginning operation, allow the engine to warm up at idling speed for three minutes.
OPERATION 3. Set the lanyard stop switch to RUN position. Refer to General Information—Lanyard Stop Switch. 19791 4. Ensure the remote control handle is in the neutral position. IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle when the engine is not running. This will inject fuel into the engine and may cause a hard starting flooded condition. N 26838 IMPORTANT: Outboards with battery charging capabilities must not be operated with the battery cables disconnected from the battery.
OPERATION 6. Turn the ignition key to the START position. If the engine is cold, push the key in to choke the engine while cranking. If the engine fails to start in ten seconds, wait 30 seconds and try again. If the engine begins to stall, push the key in (choke) until the engine is running smoothly. 19804 7. Check for a steady stream of water flowing out of the water pump indicator hole.
OPERATION • Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R). • Tiller handle models ‑ Reduce the engine speed to idle before shifting. a b c 57740 a - (R) reverse b - (N) neutral c - (F) forward • Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle. F N R 27237 • Always shift the outboard into gear with a quick motion.
OPERATION 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to neutral position. Push in the engine stop button or turn the ignition key to "OFF" position. 26776 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow this procedure. ! WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope.
OPERATION 4. Remove the three screws holding the flywheel cover on. b a a c 28614 a a - Flywheel cover screws (3) b - Recoil neutral interlock c - Fuse holder 5. Remove the flywheel cover. 6. Remote Control models ‑ Ensure the key switch is in the "ON" position. ! WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests.
OPERATION 8. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 28616 9. Pull the starter rope quickly.
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 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. 2008 a JAN b MAR FEB APR c MAY d JUN EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2010 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES. REFER TO OWNER’S MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
MAINTENANCE • Check the hydraulic steering fluid level, if equipped AFTER EACH USE • Wash the power package exterior with fresh water • Flush the outboard cooling system, saltwater or brackish water only ANNUALLY OR 100 HOURS • Grease the engine, if applicable • Change the engine oil and filter, if equipped • Inspect the thermostat, saltwater or brackish water only • Add Quickleen to the fuel tank, once per year, per engine • Apply anti‑seize to the spark plug threads • Replace the gear lub
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. Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Remove the propeller. Refer to Propeller Replacement.
MAINTENANCE 4. Adjust the water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 27260 5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times. 6. Stop the engine, turn off the water, and remove the flushing attachment. Install the propeller.
MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 4.
MAINTENANCE FUEL LINE FILTER Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. 58658 IMPORTANT: Inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine.
MAINTENANCE ! WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.
MAINTENANCE Corrosion Control Anode Your outboard has a corrosion control anode installed to the gearcase. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. 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.
MAINTENANCE 2. Move the gear shift lever into neutral (N). N 26838 57677 3. Straighten and remove the cotter pin. 4. Place a block of wood between the gearcase and propeller to hold the propeller and remove the propeller nut. 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.
MAINTENANCE Tube Ref No. 95 Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 7. Install the front thrust washer, propeller, rear thrust washer, and propeller nut onto the shaft. 8. Place a block of wood between the gearcase and propeller to prevent rotation and tighten the propeller nut. Secure the propeller nut to the shaft with the cotter pin.
MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace the fuse with a new fuse with the same rating. a b Identifying a blown fuse a - Good fuse b - Blown fuse 28619 Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion.
MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 4. 0.9 mm (0.035 in.) Before installing spark plug, clean off any dirt on the spark plug seat. Install plug finger‑tight, and then tighten 1/4 turn or torque to specifications. Description Nm Spark plug 27 lb‑in. lb‑ft 20 Timing Belt Inspection 1. Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found. a.
MAINTENANCE OIL CHANGING PROCEDURE 1. Lock the outboard in the full tilt up position. 2. Position the outboard so the drain hole is facing downward. 3. Remove the drain plug and drain the engine oil into an appropriate container. IMPORTANT: Do not use a crankcase oil pump when changing the oil or engine damage may occur. 4. After the initial oil has been drained, temporarily install the drain plug. Disengage the tilt lock and lower the outboard.
MAINTENANCE Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref No. 95 Description Where Used Part No. Extreme Grease Swivel bracket, transom clamp screws, tilt tube, throttle and shift cables, steering cable grease fitting 8M0071842 2-4-C with PTFE Swivel bracket, transom clamp screws, tilt tube, throttle and shift cables, steering cable grease fitting 92-802859A 1 • Swivel bracket ‑ Lubricate fitting. • Transom clamp screws ‑ Lubricate threads.
MAINTENANCE • Lubricate the throttle and shift cable moving components, pivot locations, and shift detent. 57719 • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. b a a - Steering cable grease fitting b - Steering cable end 27351 ! WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.
MAINTENANCE 3. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref No. 95 Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Apply lubricant to the entire propeller shaft to prevent the propeller hub from corroding to the shaft.
MAINTENANCE 3. Remove the fill/drain plug and vent plug and drain lubricant. a a - Vent plug b - Fill/drain plug b 28652 GEARCASE LUBRICANT CAPACITY Standard model gearcase: Approximately 320 ml (10.8 fl oz). Command Thrust model gearcase: Approximately 370 ml (12.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position. 2.
MAINTENANCE 5. Remove lubricant tube and install cleaned fill/drain plug and sealing washer. 28662 Checking Power Tilt Fluid 1. Tilt the outboard to the full up position and engage the tilt lock lever. 4530 2. Remove the fill cap and check the 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 automatic transmission fluid (ATF).
MAINTENANCE Tube Ref No. 114 Description Where Used Part No. Power tilt 92-858074K01 Power Trim and Steering Fluid Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.
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 • 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. 120 Description Corrosion Guard Where Used Part No. External metal surfaces 92-802878 55 Protecting Internal Engine Components • Remove the spark plugs and add approximately 30 ml (1 oz.) of engine oil or inject a five second spray of storage seal inside of each cylinder.
STORAGE • Never carry, store, or transport the outboard in the two positions shown. Engine damage could result from oil draining out of the crankcase. a a - Tiller handle up b - Front side up b 39058 Battery Storage • Follow the battery manufacturer's instructions for storage and charging. • Remove the battery from the boat and check water level. Charge if necessary. • Store the battery in a cool, dry place. • Periodically check the water level and charge the battery during storage.
TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • 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/start button 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 c. Stuck anti‑siphon valve located on permanently built in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Low oil pressure. Check the oil level. • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged.
OWNER SERVICE ASSISTANCE Service Assistance LOCAL REPAIR SERVICE If you need service for your Mercury‑outboard‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package.
OWNER SERVICE ASSISTANCE PARTS AND ACCESSORIES INQUIRIES Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has the necessary information to order parts and accessories for you if they are not in stock. Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers.
OWNER SERVICE ASSISTANCE Australia, Pacific Telephone +61 3 9791 5822 Fax +61 3 9706 7228 Brunswick Asia Pacific Group 41–71 Bessemer Drive Dandenong South, Victoria 3175 Australia Europe, Middle East, Africa Telephone +32 87 32 32 11 Fax +32 87 31 19 65 Brunswick Marine Europe Parc Industriel de Petit-Rechain B-4800 Verviers, Belgium Mexico, Central America, South America, Caribbean Telephone +1 954 744 3500 Fax +1 954 744 3535 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 U
OWNER SERVICE ASSISTANCE Mercury Marine Telephone (920) 929‑5110 (USA only) Fax Mail (920) 929‑4894 (USA only) Mercury Marine Attn: Publications Department P.O. Box 1939 Fond du Lac, WI 54936-1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package. Submit the following order form with payment to: Mercury Marine Attn: Publications Department W6250 Pioneer Road P.O.
INSTALLATION Boat Horsepower Capacity ! WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating. Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines.
INSTALLATION Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.
INSTALLATION Installing Outboard ! WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat. The boat bottom should be aligned or be within 25 mm (1 in.) above the anti‑ventilation plate of the outboard.
INSTALLATION 1. Place the outboard on the centerline of the transom. 27005 2. Tighten the transom bracket clamp screws. 28501 3. Nonpower tilt models ‑ To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts. Drill two 7.9 mm (5/16 in.) holes through‑the‑transom bracket mounting holes. Fasten with two bolts, flat washers, and locknuts.
INSTALLATION 4. Power tilt models ‑ To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and four mounting bolts. Drill two 7.9 mm (5/16 in.) holes through the upper set of transom bracket mounting holes and drill two holes through the lower set of mounting holes or mounting slots. Fasten with four bolts, flat washers, and locknuts. Use a marine waterproofing sealer in the holes and around the bolts to make the installation watertight.
INSTALLATION 2. Insert the steering cable into the tilt tube. 28723 3. Tighten the steering cable nut to the specified torque. a - Steering cable nut a 28724 Description Nm lb‑in. lb‑ft Steering cable nut 47.5 – 35 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine.
INSTALLATION ! WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.
INSTALLATION Remote Wire Harness Connection 1. Remove the cover and cable receptacle bracket from the bottom cowl. a 28003 a - Cover a - Cable receptacle bracket a 28107 2. eng Route the remote wiring harness through the rubber grommet.
INSTALLATION 3. Open up the clamp in the bottom cowl and position the remote wiring harness below the clamp. Connect the 8 pin connector to the engine harness. Push the clamp down and secure the remote wiring harness into the bottom cowl. a c b b d 28798 abcd4. Clamp Remote wiring harness 8 pin connector Rubber grommet Install the cable receptacle bracket with two bolts and hex nuts. Tighten the bolts to the specified torque.
INSTALLATION Description Cable receptacle bracket Nm lb‑in. 6 53 lb‑ft Control Cable Installation THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control. 1. Position the remote control handle into full forward throttle position. NOTE: The throttle cable is the second cable to move when moving the control box out of neutral. 2. Attach the throttle cable end guide to the throttle lever with a washer and cotter pin retainer. 3.
INSTALLATION IMPORTANT: Make sure that the throttle cable end guide does not contact the remote wiring harness when the throttle cable is at full throttle position. If necessary, position and clamp the remote wiring harness.
INSTALLATION b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark ("b") on the cable next to the end guide. c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the end guide with this center mark when installing cable to the engine. a b c 6098 2. Manually shift the outboard into neutral (propeller will rotate freely). 3. Position the remote control handle into neutral.
INSTALLATION 6. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle.
INSTALLATION 7. Install the access cover with two bolts. Tighten the bolts to the specified torque. a 28097 a - Access cover Description Access cover bolt 8. Nm lb‑in. 6 53 lb‑ft Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable guide. b. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear.
INSTALLATION Battery Connections CONNECTING OUTBOARD BATTERY CABLES First, connect the red battery cable to the (+) positive battery terminal and then connect the black battery cable to the (–) negative battery terminal. DISCONNECTING OUTBOARD BATTERY CABLES First, disconnect the black battery cable from the (–) negative terminal and then disconnect the red battery cable from the (+) positive terminal. 27158 Propeller Installation ! WARNING Rotating propellers can cause serious injury or death.
INSTALLATION 3. Place a block of wood between gearcase and propeller to prevent rotation and tighten propeller nut. Secure propeller nut to the shaft with the cotter pin.
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
