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1. omh3 Fuse Replacement IMPORTANT Always carry spare SFE 20 AMP fuses The electric starting circuit is protected from overload by an SFE 20 AMP fuse If the fuse is blown the electric starter motor will not oper ate Try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same rating ohk3 Corrosion Control Anode 2 The gear case has two corrosion control anodes a Another anode b is installed on the bottom of the transom bracket as sembly An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals Each anode requires periodic inspection especially in salt water which will accelerate the erosion To maintain this corrosion protec tion 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 74 MAINTENANCE goh208 ohl8 Propeller Replacement If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotat ing p
2. 5 Place the O ring seal c onto the sight bowl and reinstall sight bowl with cap Tighten cap securely IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter 72 MAINTENANCE goh103 ohi1 Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Number 10 14000 and self locking nylon insert locknuts b amp c Part Number 11 34863 These lock nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to dis engage Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent ac tion can cause occupants to be thrown overboard exposing them to serious injury or death Assemble steering link rod to steering cable with two flat washers d and self locking nylon insert locknut b Part Number 11 34863 Tighten locknut b until it seats then back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt a Part Number 10 14000 and self locking nylon insert locknut c Part Number 11 34863 First torque bolt a to 20 Ib ft 27 1 N m then torque locknut c to 20 Ib ft 27 1 N m 73 MAINTENANCE goh219
3. wherever practicable returned to the original intent of the de sign Maintenance replacement or repair of the emission con trol devices and systems may be performed by any marine Sl engine repair establishment or individual oti8 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 LZERCURY EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines Refer to Owner s Manual for required maintenance a IDLE SPEED FAMILY f b hp FEL g Cc TIMING IN DEGREES h d Standard spark plug Suppressor spark plug l GAP e Valve Clearance Cold mm enake a Idle Speed f Family Number b Engine Horsepower g Maximum Emission Output for c Timing Specification the Engine Family d Recommended Spark Plug amp Gap h Piston Displacement e Valve Clearance if Applicable i Date of Manufacture oti7 OWNER RESPONSIBILITY The owner operator is required to have engine maintenance per formed to maintain emission levels within prescribed certification stan dards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their
4. sion Lubricants 2 4 C Marine Lubricant or Special Lubricate 101 2 Swivel Bracket Lubricate through fitting 3 Tilt Support Lever Lubricate through fitting 4 Tilt Tube Lubricate through fitting 5 Tiller Handle Lubricate through fitting continued on next page 78 MAINTENANCE oho43 Lubrication Points Continued 6 Steering Cable Grease Fitting If Equipped Rotate steering wheel to fully retract the steering cable end a into the outboard tilt tube Lubricate through fitting b The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked An hydraulically locked steering cable will cause loss of steering control possibly resulting in serious injury or death Lubricate Points 7 With Light Weight Oil T Steering Link Rod Pivot Points Lubricate points ohp3 Checking Power Trim Fluid 8 Tilt outboard to the full up position and engage the tilt support lock 9 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Precision Lubricants Power Trim amp Steering Fluid If not avail able use automotive ATF automatic transmission fluid 79 MAINTENANCE goh86 ohq14 Gear Case Lubrication When adding or changing gear case lubricant visuall
5. MAINTENANCE Outboard Care To keep your outboard in the best operating condition it is important that your outboard receive the periodic inspections and mainte nance 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 Neglected inspection and maintenance service of your out board or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury death or product failure Record maintenance performed in Maintenance Log at the back of this book Save all maintenance work orders and receipts Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision or Quicksilver re placement parts and Genuine Lubricants Using a replacement part that is inferior to the original part could result in personal injury death or product failure 64 MAINTENANCE EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the fac tory procedure for servicing the product must be strictly followed and
6. block of wood between gear case and propeller and torque propeller nut to 55 Ib ft 75 N m 10 Secure propeller nut by bending three of the tabs into the thrust hub grooves 76 goh63 ohm15 MAINTENANCE Spark Plug Inspection and Replacement Avoid serious injury or death from fire or explosion caused by damaged spark plug boots a Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the en gine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to 1 2 remove spark plug boots Remove the spark plug boots a by twisting the rubber boots slightly and pull off Remove the spark plugs to inspect Replace spark plug if elec trode is worn or the insulator is rough cracked broken blistered or fouled Before installing spark plugs clean away dirt on the spark plug seats Install plugs finger tight and tighten 1 4 turn or torque to 20 Ib ft 27 N m T7 MAINTENANCE goh105 oho62 Lubrication Points Lubricate Point 1 with Quicksilver or Mercury Precision Lu bricants Anti Corrosion Grease or 2 4 C Marine Lubricant 1 Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft Lubricate Points 2 thru 6 with Quicksilver or Mercury Preci
7. essary so excess water continues leak ing out from around the rubber cups to ensure the engine is re ceiving an adequate supply of cooling water 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 at tachment Reinstall the propeller 68 MAINTENANCE goh227 ohe14 Flushing The Cooling System Models with Hose Flush Attachment 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 1 Thread a water hose into hose adaptor a 2 Remove dust cover b and push the hose adaptor into the flush connector c until it locks Snaps in place 3 Turn on the water and flush the cooling system for a minimum of 3 minutes NOTE Engine can be stopped or running at idle speed in neutral when flushing the cooling system Do not flush engine using a water system that exceeds 45 psi 4 Push button d in to release the hose adaptor Reinstall the dust cover NOTE The hose adaptor shuts off the water flow whenever it is dis connected from the flush connector FREEZING TEMPERATURE The water should be drained out of the engine flush hose If there is a chance of free
8. icing any part of the fuel system stop engine and discon nect 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 ap proved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for signs of fuel leakage FUEL LINE FILTER 1 Inspect the fuel line filter If the filter appears to be contaminated remove and replace IMPORTANT Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm forcing fuel into the filter FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions is found the fuel line or primer bulb must be re placed 71 MAINTENANCE goh218 p Nant ohh17 Fuel System Continued FUEL LINE FILTER NON OIL INJECTED MODELS Inspect the sight bowl b for water accumulation The sight bowl is equipped with a float d that floats on water Also inspect the filter element e for sediment Clean filter as follows REMOVAL 1 Turn the engine off 2 Turn off cap a and remove the sight bowl 3 Remove the filter element e and wash it with cleaning solvent INSTALLATION 4 Reinstall filter element open end up
9. p adding lubricant Install the rear vent plug and sealing washer b before removing lubricant tube 6 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer f ohr1 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 81
10. predetermined factory specifications 65 ohd9 MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE 1 SA E 6 Check that lanyard stop switch stops the engine Visually inspect the fuel system for deterioration or leaks Check outboard for tightness on transom Check steering system for binding or loose components Visually check steering link rod fasteners for proper tightness page 73 Check propeller blades for damage AFTER EACH USE 1 Flush out the outboard cooling system if operating in salt or pol luted water pages 68 and 69 Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water EVERY 100 HOURS OF USE OR ONCE YEARLY WHICHEVER OCCURS FIRST 1 oa fF WON Lubricate all lubrication points Lubricate more frequently when used in salt water page 78 Inspect and clean spark plugs page 77 Check engine fuel filter for contaminants pages 71 and 72 Adjust carburetor s if required Check engine timing setup Check corrosion control anodes Check more frequently when used in salt water page 74 continued on next page These items should be serviced by an authorized dealer 66 MAINTENANCE Inspection And Maintenance Schedule Continued EVERY 100 HOURS OF USE OR ONCE YEARLY WHICHEVER OCCURS FIRST 7 Drain and replace gear case lubricant page 80 8 Lubricate splines on
11. ropeller always shift outboard to neutral position and re move spark plug leads when you are servicing the propeller Shift outboard to neutral N position Remove spark plug leads to prevent engine from starting Straighten the bent tabs on the propeller nut retainer kh O N Place a block of wood between gear case and propeller to hold propeller and remove propeller nut 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an au thorized dealer 75 MAINTENANCE goh83 ohl35 Propeller Replacement 6 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C Marine Lubrican IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propel ler shaft at the recommended maintenance intervals and also each time the propeller is removed 7 Flo Torg Drive Hub Propellers Install thrust washer a pro peller b continuity washer c thrust hub d propeller nut re tainer e and propeller nut f onto the shaft 8 Flo Torq II Drive Hub Propellers Install forward thrust hub a replaceable drive sleeve b propeller c thrust hub d propel ler nut retainer e and propeller nut f onto the shaft 9 Place a
12. the drive shaft 9 Check power trim fluid page 79 10 Inspect battery page 70 11 Check control cable adjustments 12 Remove engine deposits with Mercury Precision or Quicksilver Power Tune Engine Cleaner 13 Check tightness of bolts nuts and other fasteners EVERY 300 HOURS OF USE OR THREE YEARS 1 Replace water pump impeller more often if overheating occurs or reduced water pressure is noted BEFORE PERIODS OF STORAGE 1 Refer to Storage procedure page 82 These items should be serviced by an authorized dealer 67 MAINTENANCE ohe18 Flushing The Cooling System 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 Use a Mercury Precision or Quicksilver accessory or equivalent flushing attachment To avoid possible injury when flushing remove the propeller Refer to Propeller Replacement 1 Remove propeller refer to Propeller Replacement Install the flushing attachment so the rubber cups fit tightly over the cooling water intake holes 2 Attach a water hose to the flushing attachment Turn on the wa ter and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water 3 Start the engine and run it at idle speed in neutral shift position 4 Adjust water flow if nec
13. y check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gear case checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gear case Examine the drained gear case lubricant for metal particles A small amount of fine metal particles indicates normal gear wear An ex cessive amount of metal filings or larger particles chips may indi cate abnormal gear wear and should be checked by an authorized dealer DRAINING GEAR CASE 1 Place outboard in a vertical operating position 2 Place a drain pan below outboard 3 Remove vent plugs and fill drain plug and drain lubricant ohv8 GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is approximately 22 5 fl oz 666 ml 80 goh87 MAINTENANCE ohy2 Gear Case Lubrication Continued CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE 1 Place outboard in a vertical operating position 2 Remove the front vent plug a and rear vent plug b 3 Place lubricant tube c into the fill hole and add lubricant until it appears at the front vent hole d At this time install the front vent plug and sealing washer a 4 Continue adding lubricant until it appears at the rear vent hole e 5 Sto
14. zing temperature Drain water as follows Remove water hose from the hose adaptor Insert the adaptor only into the flush connector Tilt the outboard up until all the water as drained out of the hose 69 MAINTENANCE goh101 ohf2 Top Cowl Removal And Installation REMOVAL 1 Unlock the rear latch by pushing lever down 2 Lift rear of cowl and disengage front hook INSTALLATION Engage the front hook and push cowl back over the cowl seal Push cowl down and move the rear latch lever up to lock ohn1 Battery Inspection The battery should be inspected at periodic intervals to ensure prop er engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 Make sure the battery is secure against movement 4 Battery cable terminals should be clean tight and correctly in stalled Positive to positive and negative to negative 5 Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals 70 MAINTENANCE goh102 ohh1 Fuel System Avoid serious injury or death from gasoline fire or explosion Carefully follow all fuel system service instructions Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system Before serv

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