operation maintenance and installation

OperationMaintenance

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Manual

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WelcomeYou have selected one of the finest marine power packages available. Itincorporates numerous design features to ensure operating ease and durability.With proper care and maintenance, you will enjoy using this product for manyboating seasons. To ensure maximum performance and carefree use, we askthat you thoroughly read this manual.The Operation and Maintenance Manual contains specific instructions for usingand maintaining your product. We suggest that this manual remain with theproduct for ready reference whenever you are on the water.Thank you for purchasing one of our products. We sincerely hope your boatingwill be pleasant!Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:John Pfeifer, President,Mercury Marine

Read This Manual ThoroughlyIMPORTANT: If you do not understand any portion of this manual, contact yourdealer. Your dealer can also provide a demonstration of actual starting andoperating procedures.

NoticeThroughout this publication, and on your power package, warnings, cautions,

and notices, accompanied by the International Hazard Symbol ! , may beused to alert the installer and user to special instructions concerning aparticular service or operation that may be hazardous if performed incorrectlyor carelessly. Observe them carefully.These safety alerts alone cannot eliminate the hazards that they signal. Strictcompliance with these special instructions while performing the service, pluscommon sense operation, are major accident prevention measures.

! WARNINGIndicates a hazardous situation which, if not avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, if not avoided, could result in minor ormoderate injury.

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NOTICEIndicates a situation which, if not avoided, could result in engine or majorcomponent failure.

IMPORTANT: Identifies information essential to the successful completion ofthe task.NOTE: Indicates information that helps in the understanding of a particular stepor action.IMPORTANT: The operator (driver) is responsible for the correct and safeoperation of the boat, the equipment aboard, and the safety of all occupantsaboard. We strongly recommend that the operator read this Operation andMaintenance Manual and thoroughly understand the operational instructions forthe power package and all related accessories before the boat is used.

! WARNINGThe engine exhaust from this product contains chemicals known to the stateof California to cause cancer, birth defects or other reproductive harm.

The serial numbers are the manufacturer’s keys to numerous engineeringdetails that apply to your Mercury Marine power package. When contactingMercury Marine about service, always specify model and serial numbers.Descriptions and specifications contained herein were in effect at the time thiswas approved for printing. Mercury Marine, whose policies are based oncontinuous improvement, reserves the right to discontinue models at any timeor to change specifications or designs without notice and without incurringobligation.

Warranty MessageThe product you have purchased comes with a limited warranty from MercuryMarine; the terms of the warranty are set forth in the Warranty Manual includedwith the product. The Warranty Manual contains a description of what iscovered, what is not covered, the duration of coverage, how to best obtainwarranty coverage, important disclaimers and limitations of damages, andother related information. Please review this important information.

Copyright and Trademark Information© MERCURY MARINE. All rights reserved. Reproduction in whole or inpart without permission is prohibited.Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo,K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with WavesLogo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, MercuryRacing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft,Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We'reDriven to Win are registered trademarks of Brunswick Corporation. Pro XS is atrademark of Brunswick Corporation. Mercury Product Protection is a registeredservice mark of Brunswick Corporation.

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Identification RecordsPlease record the following applicable information:

OutboardEngine Model and HorsepowerEngine Serial NumberGear RatioPropeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Boat Model Length Exhaust Gas Emissions Certification Number (Europe Only)

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General Information

Boater's Responsibilities..................................................................................... 1Before Operating Your Outboard........................................................................ 1Boat Horsepower Capacity................................................................................. 1Lanyard Stop Switch........................................................................................... 2Protecting People in the Water........................................................................... 5Exhaust Emissions............................................................................................. 5Selecting Accessories for Your Outboard........................................................... 7Safe Boating Recommendations........................................................................ 7Recording Serial Number................................................................................. 10Component Identification—4C/4.9/5BD............................................................ 114/4.9/5 Specifications........................................................................................12

Installation

Mercury Marine Validated Engine Mounting Hardware.................................... 15Installing Outboard............................................................................................15

Transporting

Removing the Motor......................................................................................... 17Carrying the Motor............................................................................................ 17Storing the Motor.............................................................................................. 17Trailering the Boat............................................................................................ 18

Fuel and Oil

Fuel Requirements........................................................................................... 20Oil Recommendation........................................................................................ 21Mixing Fuel and Oil........................................................................................... 21Engine Break‑In................................................................................................ 22Filling Fuel Tank............................................................................................... 22

Features and Controls

Remote Control Features................................................................................. 23Tilting Outboard................................................................................................ 25Shallow Water Operation.................................................................................. 26Trim Angle Adjustment..................................................................................... 27

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Operation

Prestarting Check List.......................................................................................29Operating in Freezing Temperatures................................................................ 29Operating at High Elevations............................................................................ 29Operating in Saltwater or Polluted Water......................................................... 29Engine Break‑in Procedure...............................................................................30Warming Up the Engine....................................................................................30Starting the Engine........................................................................................... 31Gear Shifting..................................................................................................... 35Stopping the Engine......................................................................................... 35

Maintenance

Outboard Care.................................................................................................. 36EPA Regulations...............................................................................................36EPA Emissions................................................................................................. 37Inspection and Maintenance Schedule............................................................. 37Flushing the Cooling System............................................................................ 38Top Cowl Removal And Installation.................................................................. 39Corrosion Control Anode.................................................................................. 40Exterior Care.....................................................................................................40Fuel System...................................................................................................... 40Propeller Replacement..................................................................................... 42Propeller Selection............................................................................................43Spark Plug Inspection And Replacement......................................................... 44Lubrication Points............................................................................................. 45Gearcase Lubrication........................................................................................47Submerged Outboard....................................................................................... 48

Storage

Storage Preparation..........................................................................................49Protecting External Outboard Components...................................................... 49Protecting Internal Engine Components........................................................... 49Gearcase.......................................................................................................... 50Positioning Outboard for Storage..................................................................... 50

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Owner Service Assistance

Local Repair Service.........................................................................................51Service Away from Home................................................................................. 51Parts and Accessories Inquiries....................................................................... 51Service Assistance........................................................................................... 51Mercury Marine Service Offices........................................................................51

Maintenance Log

Maintenance Log.............................................................................................. 53

Accessories

Propeller Recommendation.............................................................................. 54Tool Kit and Spare Parts...................................................................................54Optional Accessories........................................................................................ 55Wiring Diagram................................................................................................. 58Wire Color Code Abbreviations........................................................................ 59

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Boater's ResponsibilitiesThe operator (driver) is responsible for the correct and safe operation of theboat and the safety of its occupants and general public. It is stronglyrecommended that each operator read and understand this entire manualbefore operating the outboard.Be sure that at least one additional person onboard is instructed in the basicsof starting and operating the outboard and boat handling in case the driver isunable to operate the boat.

Before Operating Your OutboardRead this manual carefully. Learn how to operate your outboard properly. If youhave any questions, contact your dealer.Safety and operating information that is practiced, along with using goodcommon sense, can help prevent personal injury and product damage.This manual as well as safety labels posted on the outboard use the followingsafety alerts to draw your attention to special safety instructions that should befollowed.

! WARNINGIndicates a hazardous situation which, if not avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, if not avoided, could result in minor ormoderate injury.

NOTICEIndicates a situation which, if not avoided, could result in engine or majorcomponent failure.

Boat Horsepower Capacity

! WARNINGExceeding the boat's maximum horsepower rating can cause serious injuryor death. Overpowering the boat can affect boat control and flotationcharacteristics or break the transom. Do not install an engine that exceedsthe boat's maximum power rating.

GENERAL INFORMATION

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Do not overpower or overload your boat. Most boats will carry a requiredcapacity plate indicating the maximum acceptable power and load asdetermined by the manufacturer following certain federal guidelines. If in doubt,contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSON CAPACITY (POUNDS) XXXMAXIMUM WEIGHT CAPACITY XXX

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Lanyard Stop SwitchThe purpose of a lanyard stop switch is to turn off the engine when the operatormoves far enough away from the operator's position (as in accidental ejectionfrom the operator's position) to activate the switch. Tiller handle outboards andsome remote control units are equipped with a lanyard stop switch. A lanyardstop switch can be installed as an accessory ‑ generally on the dashboard orside adjacent to the operator's position.A decal near the lanyard stop switch is a visual reminder for the operator toattach the lanyard to their personal flotation device (PFD) or wrist.

GENERAL INFORMATION

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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 onthe other end for attaching to the operator's PFD or wrist. The lanyard is coiledto make its at‑rest condition as short as possible to minimize the likelihood oflanyard entanglement with nearby objects. Its stretched‑out length is made tominimize the likelihood of accidental activation should the operator choose tomove around in an area close to the normal operator's position. If it is desiredto have a shorter lanyard, wrap the lanyard around the operator's wrist or leg,or tie a knot in the lanyard.

a - Lanyard cord clipb - Lanyard decalc - Lanyard stop switch

Read the following Safety Information before proceeding.Important Safety Information: The purpose of a lanyard stop switch is to stopthe engine when the operator moves far enough away from the operator'sposition to activate the switch. This would occur if the operator accidentally fallsoverboard or moves within the boat a sufficient distance from the operator'sposition. Falling overboard and accidental ejections are more likely to occur incertain types of boats such as low sided inflatables, bass boats, highperformance boats, and light, sensitive handling fishing boats operated by ahand tiller. Falling overboard and accidental ejections are also likely to occur asa result of poor operating practices such as sitting on the back of the seat orgunwale at planing speeds, standing at planing speeds, sitting on elevatedfishing boat decks, operating at planing speeds in shallow or obstacle infestedwaters, releasing your grip on a steering wheel or tiller handle that is pulling inone direction, drinking alcohol or consuming drugs, or daring high speed boatmaneuvers.

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GENERAL INFORMATION

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While activation of the lanyard stop switch will stop the engine immediately, aboat will continue to coast for some distance depending upon the velocity anddegree of any turn at shut down. However, the boat will not complete a fullcircle. While the boat is coasting, it can cause injury to anyone in the boat'spath as seriously as the boat would when under power.We strongly recommend that other occupants be instructed on proper startingand operating procedures should they be required to operate the engine in anemergency (if the operator is accidentally ejected).

! WARNINGIf the operator falls out of the boat, stop the engine immediately to reduce thepossibility of serious injury or death from being struck by the boat. Alwaysproperly connect the operator to the stop switch using a lanyard.

! WARNINGAvoid serious injury or death from deceleration forces resulting fromaccidental or unintended stop switch activation. The boat operator shouldnever leave the operator's station without first disconnecting the stop switchlanyard from the operator.

Accidental or unintended activation of the switch during normal operation isalso a possibility. This could cause any, or all, of the following potentiallyhazardous situations:• Occupants could be thrown forward due to unexpected loss of forward

motion ‑ a particular concern for passengers in the front of the boat whocould be ejected over the bow and possibly struck by the gearcase orpropeller.

• Loss of power and directional control in heavy seas, strong current, orhigh winds.

• Loss of control when docking.

KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOODOPERATING CONDITIONBefore each use, check to ensure the lanyard stop switch works properly. Startthe engine and stop it by pulling the lanyard cord. If the engine does not stop,have the switch repaired before operating the boat.Before each use, visually inspect the lanyard cord to ensure it is in goodworking condition and that there are no breaks, cuts, or wear to the cord.Check that the clips on the ends of the cord are in good condition. Replace anydamaged or worn lanyard cords.

GENERAL INFORMATION

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Protecting People in the WaterWHILE YOU ARE CRUISINGIt is very difficult for a person standing or floating in the water to take quickaction to avoid a boat heading in his/her direction, even at slow speed.

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Always slow down and exercise extreme caution any time you are boating in anarea where there might be people in the water.Whenever a boat is moving (coasting) and the outboard gear shift is in neutralposition, there is sufficient force by the water on the propeller to cause thepropeller to rotate. This neutral propeller rotation can cause serious injury.

WHILE THE BOAT IS STATIONARY

! WARNINGA spinning propeller, a moving boat, or any solid device attached to the boatcan cause serious injury or death to swimmers. Stop the engine immediatelywhenever anyone in the water is near your boat.

Shift the outboard into neutral and shut off the engine before allowing people toswim or be in the water near your boat.

Exhaust EmissionsBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide (CO) is a deadly gas that is present in the exhaust fumes ofall internal combustion engines, including the engines that propel boats, andthe generators that power boat accessories. By itself, CO is odorless, colorless,and tasteless, but if you can smell or taste engine exhaust, you are inhalingCO.Early symptoms of carbon monoxide poisoning, which are similar to thesymptoms of seasickness and intoxication, include headache, dizziness,drowsiness, and nausea.

GENERAL INFORMATION

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! WARNINGInhaling engine exhaust gases can result in carbon monoxide poisoning,which can lead to unconsciousness, brain damage, or death. Avoid exposureto carbon monoxide.Stay clear from exhaust areas when engine is running. Keep the boatwell‑ventilated while at rest or underway.

STAY CLEAR OF EXHAUST AREAS

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Engine exhaust gases contain harmful carbon monoxide. Avoid areas ofconcentrated engine exhaust gases. When engines are running, keepswimmers away from the boat, and do not sit, lie, or stand on swim platforms orboarding ladders. While underway, do not allow passengers to be positionedimmediately behind the boat (platform dragging, teak/body surfing). Thisdangerous practice not only places a person in an area of high engine exhaustconcentration, but also subjects them to the possibility of injury from the boatpropeller.

GOOD VENTILATIONVentilate the passenger area, open side curtains or forward hatches to removefumes.Example of desired air flow through the boat:

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POOR VENTILATIONUnder certain running and/or wind conditions, permanently enclosed or canvasenclosed cabins or cockpits with insufficient ventilation may draw in carbonmonoxide. Install one or more carbon monoxide detectors in your boat.Although the occurrence is rare, on a very calm day, swimmers andpassengers in an open area of a stationary boat that contains, or is near, arunning engine may be exposed to a hazardous level of carbon monoxide.

GENERAL INFORMATION

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1. Examples of poor ventilation while the boat is stationary:

a - Operating the engine when the boat is moored in a confined spaceb - Mooring close to another boat that has its engine operating

2. Examples of poor ventilation while the boat is moving:

a - Operating the boat with the trim angle of the bow too highb - Operating the boat with no forward hatches open (station wagon effect)

Selecting Accessories for Your OutboardGenuine Mercury Precision or Quicksilver Accessories have been specificallydesigned and tested for your outboard. These accessories are available fromMercury Marine dealers.IMPORTANT: Check with your dealer before installing accessories. The misuseof approved accessories or the use of nonapproved accessories can damagethe product.Some accessories not manufactured or sold by Mercury Marine are notdesigned to be safely used with your outboard or outboard operating system.Acquire and read the installation, operation and maintenance manuals for allyour selected accessories.

Safe Boating RecommendationsTo safely enjoy the waterways, familiarize yourself with local and all othergovernmental boating regulations and restrictions and consider the followingsuggestions.Know and obey all nautical rules and laws of the waterways.

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GENERAL INFORMATION

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• We recommend that all powerboat operators complete a boating safetycourse. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron,the Red Cross, and your state or provincial boating law enforcementagency provide courses. For more information in the U.S., call the BoatU.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.• Here are some suggestions of the types of safety equipment to carry

when boating:Approved fire extinguishers

Signal devices: flashlight, rockets or flares, flag, and whistle or horn

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

Watch for signs of weather change and avoid foul weather and rough‑seaboating.Tell someone where you are going and when you expect to return.Passenger boarding.• Stop the engine whenever passengers are boarding, unloading, or are

near the back (stern) of the boat. Shifting the drive unit into neutral is notsufficient.

Use personal flotation devices.• Federal law requires that there be a U.S. Coast Guard‑approved life

jacket (personal flotation device), correctly sized and readily accessiblefor every person onboard, plus a throwable cushion or ring. We stronglyadvise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

GENERAL INFORMATION

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• Instruct at least one person onboard in the basics of starting andoperating the engine and boat handling in case the driver becomesdisabled 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 andloading limitations. Know if your boat will float if it is full of water. When indoubt, contact your authorized Mercury Marine dealer or the boatmanufacturer.

Ensure that everyone in the boat is properly seated.• Do not allow anyone to sit or ride on any part of the boat that was not

intended for such use. This includes the backs of seats, gunwales,transom, bow, decks, raised fishing seats, and any rotating fishing seat.Passengers should not sit or ride anywhere that sudden unexpectedacceleration, sudden stopping, unexpected loss of boat control, or suddenboat movement could cause a person to be thrown overboard or into theboat. Ensure that all passengers have a proper seat and are in it beforeany boat movement.

Never operate a boat while under the influence of alcohol or drugs. It isthe law.• Alcohol or drugs can impair your judgment and greatly reduce your ability

to react quickly.Know your boating area and avoid hazardous locations.Be alert.• The operator of the boat is responsible by law to maintain a proper

lookout by sight and hearing. The operator must have an unobstructedview particularly to the front. No passengers, load, or fishing seats shouldblock the operator's view when the boat is above idle or planing transitionspeed. Watch out for others, the water, and your wake.

Never drive your boat directly behind a water skier.• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is

61 m (200 ft) in front of you in five seconds.Watch fallen skiers.• When using your boat for waterskiing or similar activities, always keep a

fallen or down skier on the operator's side of the boat while returning toattend to the skier. The operator should always have the down skier insight and never back up to the skier or anyone in the water.

Report accidents.

GENERAL INFORMATION

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• Boat operators are required by law to file a boating accident report withtheir state boating law enforcement agency when their boat is involved incertain boating accidents. A boating accident must be reported if 1) thereis loss of life or probable loss of life, 2) there is personal injury requiringmedical treatment beyond first aid, 3) there is damage to boats or otherproperty where the damage value exceeds $500.00, or 4) there iscomplete loss of the boat. Seek further assistance from local lawenforcement.

Recording Serial NumberIt is important to record the serial number and other important information forfuture reference.Please record the serial number of the engine as indicated (on the lower enginecover and the cylinder block) in the space below. This number will come inhandy in the event of theft and it can help you to quickly identify the producttype.

Serial number:Model year:Model designation:Year manufactured:Certified Europe Insignia (as applicable):

GENERAL INFORMATION

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Component Identification—4C/4.9/5BD

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GENERAL INFORMATION

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1 - Air vent screw2 - Fuel tank cap3 - Tilt handle4 - Upper motor cover5 - Lower motor cover6 - Water pump indicator port7 - Tilt lever8 - Steering friction adjustment screw9 - Anode10 - Anti‑ventilation plate11 - Water inlet12 - Propeller13 - Starter handle14 - Shift lever15 - Throttle grip16 - Choke knob17 - Stop switch18 - Fuel connector19 - Clamp screw20 - Clamp bracket21 - Trim position pin22 - Oil plug (upper)23 - Oil plug (lower)24 - Fuel tank25 - Fuel pickup elbow26 - Primer bulb27 - Fuel tank cap28 - Air vent screw29 - Fuel connector30 - Air vent screw31 - Fuel valve32 - Choke knob33 - Stop switch34 - Fuel connector

4/4.9/5 Specifications

Models 4C 4.9 5B‑DOverall length 700 mm (27.6 in.)Overall width 310 mm (12.2 in.)

GENERAL INFORMATION

12 eng

Models 4C 4.9 5B‑D

Overall heightS=1007 mm (39.6 in.), L=1134 mm (44.6 in.)– – UL=1261 mm (49.6 in.)

Transomheight

S=435 mm (17.1 in.), L=562 mm (22.1 in.),UL=689 mm (27.1 in.)

WeightS=20.0 kg (44 lb), L=20.5 kg (45 lb)

– – UL=21.0 kg (46 lb)

Output 2.9 kW (4 HP) 3.6 kW(4.9 HP) 3.7 kW (5 HP)

Max operatingrange 4500–5500 RPM

Idle speed inforward gear 850 RPM

Idle speed inneutral gear 1000 RPM

Engine type Two‑StrokeNumber ofcylinders 1

Bore x stroke 55 x 43 mm (2.17 x 1.69 in.)Displacement 102 mL (6.22 in.³)Exhaustsystem Through hub exhaust

Coolingsystem Thermostat controlled

Lubricationsystem Engine oil mixed gasoline

Fuel Unleaded regular gasoline pump posted 87 Octane(research octane rating of 92)

Engine oil Mercury/Quicksilver or recommended Two‑Stroke engine oilEngine oilmixing ratio 1:50 (Engine oil:fuel)

Startingsystem Manual starter

Ignitionsystem Flywheel magneto CDI

Spark plug NGK BPR7HS‑10Trim position 6

Gear oil Mercury/Quicksilver gear oil or API GLS, SAE #80 to #90,approximately 195 mL (6.6 fl oz)

GENERAL INFORMATION

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Models 4C 4.9 5B‑DFuel tankcapacity 2.5 L (0.66 US gal) 2.5 L

(0.66 US gal)2.5 L (0.66 US gal),12 L (3.17 US gal)*

Gearreduction ratio 2.15 (13:28)

* In case of dual fuel tank system, use together with 12 L separate tank.

GENERAL INFORMATION

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Mercury Marine Validated Engine Mounting HardwareIMPORTANT: Mercury Marine provides validated fasteners and installationinstructions, including torque specifications, with all of our outboards so theycan be properly secured to boat transoms. Improper installation of the outboardcan cause performance and reliability issues that can lead to safety concerns.Follow all of the instructions relating to the outboard installation. DO NOTmount any other accessory onto the boat with the fasteners provided with theoutboard. For example, do not mount tow sport bars or boarding ladders ontothe boat using the mounting hardware included with the outboard. Installingother products onto the boat that utilize the outboard mounting hardware willcompromise the ability of that hardware to properly and safely secure theoutboard to the transom.Outboards that require validated mounting hardware will have the followingdecal on the transom clamp.

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Installing OutboardINSTALLING OUTBOARD ON TRANSOMIMPORTANT: Most boats are rated and certified in terms of their maximumhorsepower, and this is shown on the boat's certification plate. Do not equipyour boat with an outboard that exceeds this limit. If in doubt, contact yourdealer. Do not operate the engine unit until it has been securely mounted onthe boat in accordance with the instructions below.

INSTALLATION

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1. Position the outboard at the center of the transom. Mount it using acushioning pad or plate.

a - Boat transom

BOAT TRANSOM HEIGHT REQUIREMENT1. Measure the transom height of your boat. The anti‑ventilation plate should

be 30 ‑ 50 mm (1.2 ‑ 2 in.) below the bottom of the boat.

a - Bottom of hullb - Anti‑ventilation plate

ATTACH THE ENGINE TO THE BOAT1. Tighten the clamp screws by turning their handles. Secure with a cable to

prevent accidental loss overboard.

a - Clamp screw

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INSTALLATION

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Removing the MotorIMPORTANT: Ensure the proper procedures are followed for transportation andstorage of the outboard to avoid the possibility of oil leaks.1. Stop the engine and close the air vent screw.2. Close the fuel valve knob. Disconnect the fuel connector.3. Remove the motor from the hull and completely drain the water from the

gearcase.

Carrying the MotorBe sure to keep the engine vertical posture whenever you carry the motor.

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NOTE: If you carry the motor horizontal posture, keep the power head higherthan the propeller.IMPORTANT: Beware of explosion danger. Spilled and vapored gasoline mayeasily catch fire and explode. Be sure to fully discharge gasoline from thecarburetors when transporting the engine. Wipe off spilled gasoline with a rag.

Storing the Motor1. With the outboard still in the water, close the fuel shut‑off valve or

disconnect the remote fuel line (if equipped) and run engine until it stops.This will drain fuel from the carburetor. Remove outboard from the boatand hold upright until all cooling water is drained out.

TRANSPORTING

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2. Lay the outboard down on its back side so the tiller handle is facing up asshown. Place a protective pad under the outboard.

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3. Close the fuel tank vent.

Trailering the BoatIMPORTANT: The tilt lock mechanism is not intended to support the outboardin the tilted up position when trailering. Use of the tilt lock mechanism couldallow the outboard to bounce and drop down causing damage to the outboard.The boat should be trailered with the outboard tilted down (normal operatingposition). If trailering with the engine fully down is not possible (the gearcaseskeg is too close to the road in a vertical position), tilt the motor securely usinga device (like a transom saver bar) in the tilted up position.If additional ground clearance is required, remove the outboard from the boatand store securely. Additional clearance may be needed for railroad crossings,driveways, and trailer bouncing.Set the gear shift into forward (F) gear. This prevents the propeller fromspinning freely.

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TRANSPORTING

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NOTE: The tilt support device supplied on your outboard is not intended fortowing. It is intended to support the engine while the boat is docked, beached,etc.

TRANSPORTING

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Fuel RequirementsIMPORTANT: Use of improper gasoline can damage your engine. Enginedamage resulting from the use of improper gasoline is considered misuseof the engine and will not be covered under the limited warranty.

FUEL RATINGSMercury outboard engines will operate satisfactorily with any major brand ofunleaded gasoline that meets the following specifications:USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, formost models. Premium gasoline 91 (R+M)/2 octane is also acceptable for mostmodels. Do not use leaded gasoline.Outside USA and Canada ‑ A posted pump octane rating of 91 RON,minimum, for most models. Premium gasoline (95 RON) is also acceptable forall models. Do not use leaded gasoline.

USING REFORMULATED (OXYGENATED) GASOLINE (USA ONLY)Reformulated gasoline is required in certain areas of the USA and isacceptable for use in your Mercury Marine engine. The only oxygenatecurrently in use in the USA is alcohol (ethanol, methanol, or butanol).

GASOLINE CONTAINING ALCOHOL

Bu16 Butanol Fuel BlendsFuel blends of up to 16.1% butanol (Bu16) that meet the published MercuryMarine fuel rating requirements are an acceptable substitute for unleadedgasoline. Contact your boat manufacturer for specific recommendations onyour boat's fuel system components (fuel tanks, fuel lines, and fittings).

Methanol and Ethanol Fuel BlendsIMPORTANT: The fuel system components on your Mercury Marine engine willwithstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Yourboat's fuel system may not be capable of withstanding the same percentage ofalcohol. Contact your boat manufacturer for specific recommendations on yourboat's fuel system components (fuel tanks, fuel lines, and fittings).Be aware that gasoline containing methanol or ethanol may cause increased:• Corrosion of metal parts• Deterioration of rubber or plastic parts• Fuel permeation through the rubber fuel lines• Likelihood of phase separation (water and alcohol separating from the

gasoline in the fuel tank)

FUEL AND OIL

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! WARNINGFuel leakage is a fire or explosion hazard, which can cause serious injury ordeath. Periodically inspect all fuel system components for leaks, softening,hardening, swelling, or corrosion, particularly after storage. Any sign ofleakage or deterioration requires replacement before further engineoperation.

IMPORTANT: If you use gasoline that contains or might contain methanol orethanol, you must increase the frequency of inspection for leaks andabnormalities.IMPORTANT: When operating a Mercury Marine engine on gasoline containingmethanol or ethanol, do not store the gasoline in the fuel tank for long periods.Cars normally consume these blended fuels before they can absorb enoughmoisture to cause trouble; boats often sit idle long enough for phase separationto take place. Internal corrosion may occur during storage if alcohol haswashed protective oil films from internal components.

Oil Recommendation

Recommended Oil Mercury or Quicksilver Premium 2‑Cycle TC‑W3Outboard Oil

IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil.Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for thisengine. For added protection and lubrication, Mercury or Quicksilver PremiumPlus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oilis not available, substitute another brand of 2‑cycle outboard oil that is NMMACertified TC‑W3. Severe engine damage may result from use of an inferior oil.

Mixing Fuel and OilUse a 1:25 oil/gasoline mixture in the first tank of fuel.After the break‑in fuel mixture is used up, use a 1:50 oil/gasoline mixture. Referto the table (following) for mixing ratios.

GASOLINE/OIL MIXING RATIO CHART

OIL/GASOLINE MIXING RATIO CHARTOil/Gas Ratio 3.8 liters (1 gal) gas 11.5 liters (3 gal) gas 23 liters (6 gal) gas

1:25 148 ml (5 fl oz) oil 473 ml (16 fl oz) oil 946 ml (32 fl oz) oil1:50 89 ml (3 fl oz) oil 237 ml (8 fl oz) oil 473 ml (16 fl oz) oil

MIXING PROCEDUREPour the full amount of oil along with approximately one gallon of gasoline intoan approved container. Shake the two together until they are thoroughly mixed.Add the remainder of gasoline and shake container to ensure mixing.

FUEL AND OIL

eng 21

Engine Break‑InEngine Break‑In Fuel MixtureUse a 1:25 oil/gasoline mixture in the first tank of fuel.Engine Break‑In ProcedureRefer to Operation ‑ Engine Break‑In Procedure for correct break‑inprocedure.

Filling Fuel Tank

! WARNINGAvoid serious injury or death from a gasoline fire or explosion. Use cautionwhen filling fuel tanks. Always stop the engine and do not smoke or allowopen flames or sparks in the area while filling fuel tanks.

Fill fuel tanks outdoors away from heat, sparks, and open flames.Always stop engine before refilling tanks.Do not overfill the fuel tank. Fuel will expand in volume as its temperature risesand can leak under pressure if the tank is completely filled.The oil and fuel mixture should always be thoroughly mixed in an approvedcontainer before pouring into motor fuel tank. Do not pour separately into fueltank.Pour fuel into tank through a fine mesh strainer to remove dirt which may bepresent.

PORTABLE FUEL TANKFill fuel tanks outdoors away from heat, sparks, and open flames.Remove portable fuel tanks from boat to refill them.Always stop engine before refilling tanks.Do not completely fill the fuel tank. Leave approximately 10% of tank volumeunfilled. Fuel will expand in volume as its temperature rises and can leak underpressure if tank is completely filled.

FUEL AND OIL

22 eng

Remote Control Features

Your boat may be equipped with the remote control shown. If not, consult yourdealer for a description of the functions and operations of the remote control.

a - Remote control handleb - Throttle only leverc - Ignition key switchd - Lanyard stop switch

Throttle grip friction knob: The throttle friction can be adjusted in accordancewith your preference by turning the adjustment screw.

a - Direction to heavier frictionb - Direction to lighter frictionc - Throttle adjustment screw

37982

a

b

c

d

41034

cb

a

FEATURES AND CONTROLS

eng 23

Choke knob: Pull completely out when starting a cold engine. Push halfway inas engine is warming up. Push in completely after engine is warmed up.

38349

Steering friction adjustment: The steering friction can be adjusted inaccordance with your preference by turning the adjustment screw.

a - Steering adjustment screwb - Turn counterclockwise to lighter steeringc - Turn clockwise to heavier steering

! WARNINGInsufficient friction adjustment can cause serious injury or death due to lossof boat control. When setting the friction adjustment, maintain sufficientsteering friction to prevent the outboard from steering into a full turn if thetiller handle or steering wheel is released.

Starter rope: Pull the starter handle slowly until you feel engagement. Thenpull it quickly. Repeat if necessary until engine is started.

28851

After the engine has started, push the choke knob back then return the grip toSLOW position and run the engine to warm up for several minutes.

41067

a

b c


24 eng

Tilting OutboardTILTING TO FULL UP POSITION1. Stop the engine. Shift the outboard into Forward (F) gear.2. Take hold of the top cowl grip and raise outboard to the full up position.

27023

3. Then slightly lower the motor for locking at tilt‑up position.

a - Tilt up positionb - Tilt stopperc - Tilt lever

4. The spring loaded tilt lock lever will engage automatically and lock theoutboard in full up position.

LOWERING TO RUN POSITION1. Raise the outboard and pull up on the tilt release lever. Gently lower

outboard down.

a - Tilt leverb - Tilt stopper

41065

a

bc

41066

ab


eng 25

Shallow Water OperationThis outboard has a shallow water drive position. This will allow you to tilt theoutboard to a higher position to prevent hitting bottom.

ENGAGING SHALLOW WATER DRIVE1. Reduce engine speed to idle in forward gear. Take hold of the top cowl

grip and raise outboard to the higher tilt position. The spring loaded tiltlock lever will engage automatically and lock the outboard in the shallowwater drive position.

27025

2. Ensure the cooling water intake is submerged.

27029

IMPORTANT: Operate outboard at slow speed for shallow water operationand keep the cooling water intake submerged.


26 eng

3. To release outboard back down to run position, tilt outboard up slightly(approximately 15°), then pull up on the tilt release lever. Gently loweroutboard down to the normal running position.

a - Tilt leverb - Tilt stopper

Please follow the instructions below.• Be sure that the water intake is submerged at all times and that water is

continuously flowing from the cooling water pump indicator hole.• Be sure to run the engine slowly when using the shallow water drive.

Running at higher speeds will result in lack of control and may damagethe mounting bracket.

• Care must be taken while running in this tilt position not come in contactwith the bottom, or submerged objects, especially in reverse. This maycause damage to the motor and/or boat.

Trim Angle AdjustmentThe vertical operating angle of your outboard is adjusted by changing theposition of the tilt pin in the adjustment holes provided. Proper adjustmentallows the boat to achieve optimum performance, stability, and minimizesteering effort.The following instructions explain how to set the best angle of the boat.The tilt pin should be adjusted so the outboard is positioned to runperpendicular to the water when the boat is running at full speed. This allowsthe boat to be driven parallel to the water.Arrange passengers and load in the boat so the weight is distributed evenly.The trim angle is adjusted by setting the trim position pin in the correct trimposition.

TRIM POSITION ADJUSTMENTS• Correct trim: The trim angle is optimum when the boat is parallel to the

water surface while running.• Trim down: If the trim angle is excessive, the bow will rise out of the

water and the speed will decrease. Furthermore, the bow may sway or thebottom may slam the water while cruising. In this case, decrease the trimangle by setting the trim position pin in a lower position.

41066

ab


eng 27

• Trim up: If the trim angle is too small, the bow will enter the water, thespeed will decrease, and water may enter the boat. In this case, the trimangle should be increased by setting the trim position pin in a higherposition.

a - Correct trimb - Trim downc - Trim upd - Move pin to raise bow upe - Move pin to lower bow downf - Trim position pin

41064

f

b

c

a

d e


28 eng

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.• Arrange passengers and load in the boat so the weight is distributed

evenly and everyone is seated in a proper seat.• Tell someone where you are going and when you expect to return.• It is illegal to operate a boat while under the influence of alcohol or drugs.• Know the waters and area you will be boating; tides, currents, sand bars,

rocks, and other hazards.• Make inspection checks listed in Maintenance ‑ Inspection and

Maintenance Schedule.

Operating in Freezing TemperaturesWhen using your outboard or having your outboard moored in freezing or nearfreezing temperatures, keep the outboard tilted down at all times so thegearcase is submerged. This prevents the trapped water in the gearcase fromfreezing and causing possible damage to the water pump and othercomponents.If there is a chance of ice forming on the water, the outboard should beremoved and drained completely of water. If ice should form at the water levelinside the outboard driveshaft housing, it will block water flow to the enginecausing possible damage.

Operating at High ElevationsIMPORTANT: To prevent serious damage to the engine caused by a lean fuelmixture, do not operate the outboard (if the jets were changed for highelevation) at a lower elevation unless the jets are changed again to correspondto the new elevation.Operating the outboard at an elevation higher than 762 m (2500 ft.) above sealevel may require a carburetor jet change. Consult your dealer. This will reducethe normal performance loss experienced as a result of reduced oxygen in theair causing an overly rich fuel mixture.

Operating in Saltwater or Polluted WaterWe recommend that you flush the internal water passages of your outboardwith fresh water after each use in salt or polluted water. This will prevent abuildup of deposits from clogging the water passages. Refer to Maintenance ‑Flushing the Cooling System.

OPERATION

eng 29

If you keep your boat moored in the water, always tilt the outboard so thegearcase is completely out of water (except in freezing temperatures) when notin use.Wash the outboard exterior and flush out the exhaust outlet of the propeller andgearcase with fresh water after each use. Each month, spray Mercury Precisionor Quicksilver Corrosion Guard on external metal surfaces. Do not spray oncorrosion control anodes as this will reduce the effectiveness of the anodes.

Engine Break‑in ProcedureIMPORTANT: Failure to follow the engine break‑in procedures can result inpoor performance throughout the life of the engine and can cause enginedamage. Always follow break‑in procedures.

ENGINE BREAK-IN FUEL MIXTUREUse a 1:25 oil/gasoline mixture in the first tank of fuel.

BREAK-IN PROCEDUREVary the throttle setting during the first hour of operation. During the first hour ofoperation, avoid remaining at a constant speed for more than two minutes andavoid sustained wide open throttle.

Warming Up the EngineIt's important to warm‑up the engine for three minutes. This allows thelubrication system to circulate and deliver oil to all the moving parts of anengine.Operating the engine without warm‑up will reduce engine performance andshorten the life of the engine. Be sure to check that cooling water is coming outof the water pump indicator hole during warm‑up.

a - Water pump indicator hole

NOTICEWithout sufficient cooling water, the engine, the water pump, and othercomponents will overheat and suffer damage. Provide a sufficient supply ofwater to the water inlets during operation.

41060

a

OPERATION

30 eng

Engine speed: Idling speed after warming up.

In Gear In Neutral850 RPM 1000 RPM

Starting the EngineBefore starting, read the Prestarting Check List, special operatinginstructions, and Engine Break‑In Procedure in this section.

IMPORTANT: Be sure to connect the emergency lanyard to your waist orclothing. The engine will shut down if the lanyard becomes disconnected fromthe engine.NOTE: The engine will not start unless the lanyard has been properlyconnected to the emergency stop switch.1. Lower the outboard to the run position. Make sure the cooling water

intake is submerged.


27029

2. Loosen the air vent screw on the tank cap.

a - Air vent screw

41046

a

OPERATION

eng 31

19748

3. Attach the fuel connector to the engine connector.

42043

4. The arrow mark on the primer bulb should be facing the engine (separatefuel tank).

5. Open the fuel valve (internal fuel tank).

a - Air vent screwb - Fuel valve

6. Feed fuel to the carburetor by squeezing the primer bulb until it is firm(separate fuel tank).

a - To fuel tankb - To enginec - Fuel flow direction

41834

a

b

37714

a

c

b

OPERATION

32 eng

7. Move gear shift lever to neutral (N) position. Be sure that the shift lever isin neutral (N) when starting the engine. This model is provided with afunction that prevents starting in gear.

RF

N

27020

NOTE: If the motor somehow does start in gear, do not operate it. Contactyour authorized dealer.8. Move the throttle grip to the start position.

28847

9. If the engine is cold, completely pull the choke knob out. Push in thechoke halfway as the engine is warming up. Push in completely afterengine is warmed up.

38349

OPERATION

eng 33

10. Pull the starter rope slowly until you feel the starter engage, then pullrapidly to crank the engine. Allow the rope to return slowly. Repeat untilthe engine starts.

28840

NOTE: Starting flooded engine ‑ push in the choke knob. Wait 30 seconds,then continue to crank engine for starting.11. Check for a steady stream of water flowing out of the water pump

indicator hole.IMPORTANT: If no water is coming out of the water pump indicator hole, stopthe engine and check the cooling water intake for obstruction. No obstructionmay indicate a water pump failure or blockage in the cooling system. Theseconditions will cause the engine to overheat. Have the outboard checked by adealer. Operating the engine while overheated may cause serious enginedamage.

IF THE RECOIL STARTER FAILS TO OPERATE• Remove the upper motor cover and the recoil starter. Wrap a rope around

the starter pulley then pull quickly to start.• Use a 10 mm socket wrench as a rope handle.

28851

! WARNINGThe exposed moving flywheel can cause serious injury. Keep your hands,hair, clothing, tools, and other objects away from engine when starting orrunning the engine. Do not attempt to reinstall the rewind starter assembly ortop cowl when engine is running.

OPERATION

34 eng

Gear ShiftingYour outboard has three gear shift positions to provide operation: Forward (F),Neutral (N), and Reverse (R).Reduce throttle speed to idle speed.NOTE: Personal injury and/or equipment damage may occur if shifting at highspeed. Engine must be in the slow running position before shifting is attempted.NOTE: Do not increase engine speed more than necessary in reverse.

a - Reverseb - Neutralc - Forwardd - Shift lever

Always shift outboard into gear with a quick motion.• Forward: Turn the throttle grip to reduce engine speed. When the engine

reaches trolling (or idling) speed, quickly pull the shift lever to the Forward(F) position.

• Reverse: Reduce engine speed, when the engine reaches trolling (oridling) speed, quickly push the shift lever to the Reverse (R) position.

Stopping the Engine1. Turn the throttle grip to the slow position.2. Put the shift lever in Neutral (N) position. Run the engine for 2–3 minutes

at idling speed if it has been running at full speed.3. Push the stop switch to stop the engine.

a - Lanyard hookb - Stop switch lockc - Stop switch

41061

a b cd

41063

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b

c

OPERATION

eng 35

Outboard CareTo keep your outboard in the best operating condition, it is important that youroutboard receive the periodic inspections and maintenance listed in theInspection and Maintenance Schedule. We urge you to keep it maintainedproperly to ensure the safety of you and your passengers, and retain itsdependability.Record maintenance performed in the Maintenance Log at the back of thisbook. Save all maintenance work orders and receipts.

SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARDWe recommend using original Mercury Precision or Quicksilver replacementparts and Genuine Lubricants.

EPA RegulationsAll new outboards manufactured by Mercury Marine are certified to the UnitedStates Environmental Protection Agency, as conforming to the requirements ofthe regulations for the control of air pollution from new outboard motors. Thiscertification is contingent on certain adjustments being set to factory standards.For this reason, the factory procedure for servicing the product must be strictlyfollowed and, wherever practicable, returned to the original intent of the design.Maintenance, replacement, or repair of the emission control devices andsystems may be performed by any marine spark ignition (SI) enginerepair establishment or individual.

MAINTENANCE

36 eng

EPA EmissionsEMISSION CERTIFICATION LABELAn emission certification label, showing emission levels and enginespecifications directly related to emissions, is placed on the engine at time ofmanufacture.

a - Idle speedb - Engine horsepowerc - Timing specificationd - Recommended spark plug and gape - Valve clearance (if applicable)f - Family numberg - Maximum emission output for the engine familyh - Piston displacementi - Date of manufacture

OWNER RESPONSIBILITYThe owner/operator is required to have routine engine maintenance performedto maintain emission levels within prescribed certification standards.The owner/operator is not to modify the engine in any manner that would alterthe horsepower or allow emission levels to exceed their predetermined factoryspecifications.

Inspection and Maintenance ScheduleDAILY CHECKS• Check the engine oil level• Check the lanyard stop switch• Inspect the fuel system for leaks• Inspect the engine tightness on the transom• Check the steering system for binding• Check the propeller for damage

EMISSION CONTROLINFORMATION

TIMING (IN DEGREES):

FAMILY:FEL:cc

IDLE SPEED:hp

GAP :

g/kW h

Standard spark plug:Suppressor spark plug:

This engine conforms to model year EPA regulations for Marine SI engines.Refer to Owner's Manual for required maintenance.

Valve Clearance (Cold) mm IntakeExhaust

abc

de

fg

h

i28405

MAINTENANCE

eng 37

• Inspect the hydraulic steering fittings and hoses for leaks or signs ofdamage, if equipped

• 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 lubricant• Inspect the corrosion control anodes• Replace all filters on the suction side of the fuel system—dealer item• Lubricate the driveshaft splines—dealer item• Lubricate the propeller shaft splines—dealer item• Check the tightness on all the fasteners—dealer item• Check the torque of the outboard mounting hardware—dealer item• Check the battery condition and tightness of the battery cable connection

—dealer item

THREE YEARS OR 300 HOURS• Replace the spark plugs• Replace the water pump impeller—dealer item• Inspect the carbon fiber reeds—dealer item• Inspect the wire harness connectors—dealer item• Check the remote control cable adjustment, if applicable—dealer item• Replace the high‑pressure fuel filter—dealer item• Replace the accessory drive belt—dealer item• Check the power trim fluid level—dealer item• Inspect the engine motor mounts—dealer item

Flushing the Cooling SystemFlush the internal water passages of the outboard with fresh water after eachuse in salt, polluted, or muddy water. This will help prevent a buildup ofdeposits from clogging the internal water passages.Use a Mercury Precision or Quicksilver accessory (or equivalent) flushingattachment.

MAINTENANCE

38 eng

1. Remove the water plug from the motor, and install in the flushingattachment (hose adapter).

2. Attach a hose to the flushing attachment.3. Turn on the water and adjust the flow so water is exiting the water pump

indicator hose.

a - Flushing attachmentb - Water pump indicator hose

4. Continue flushing the outboard for five minutes.5. Turn off the water and remove the flushing attachment. Install the water

plug.

Top Cowl Removal And InstallationREMOVAL1. Unlock the rear latch by pushing lever down.

27084

2. Lift rear of cowl and disengage front hook.

27091

61081

a

b

MAINTENANCE

eng 39

INSTALLATION1. 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.

Corrosion Control AnodeYour outboard has a corrosion control anode installed on the gearcase. Ananode helps protect the outboard against galvanic corrosion by sacrificing itsmetal to be slowly corroded instead of the outboard metals.The anode requires periodic inspection especially in saltwater which willaccelerate the erosion. To maintain this corrosion protection, always replacethe anode before it is completely eroded. Never paint or apply a protectivecoating on the anode as this will reduce effectiveness of the anode.

27092

Exterior CareYour outboard is protected with a durable baked enamel finish. Clean and waxoften using marine cleaners and waxes.

Fuel System

! WARNINGFuel is flammable and explosive. Ensure that the key switch is off and thelanyard is positioned so that the engine cannot start. Do not smoke or allowsources of spark or open flame in the area while servicing. Keep the workarea well ventilated and avoid prolonged exposure to vapors. Always checkfor leaks before attempting to start the engine, and wipe up any spilled fuelimmediately.

Before servicing any part of the fuel system, stop the engine and disconnectthe battery. Drain the fuel system completely. Use an approved container tocollect and store fuel. Wipe up any spillage immediately. Material used tocontain spillage must be disposed of in an approved receptacle. Any fuelsystem service must be performed in a well‑ventilated area. Inspect anycompleted service work for sign of fuel leakage.

MAINTENANCE

40 eng

FUEL LINE INSPECTIONVisually inspect the fuel line and primer bulb for cracks, swelling, leaks,hardness, or other signs of deterioration or damage. If any of these conditionsare found, the fuel line or primer bulb must be replaced.

CLEANING THE FUEL FILTERS AND THE FUEL TANKThe fuel filter is located between the fuel valve and the fuel pump.

28857

• Drain all fuel from the fuel tank. Remove the fuel lines from the fuel filter.• Inspect the fuel filter.• If there is water or dirt inside, replace the filter. Install the filter in the same

orientation as it was removed.

a - Fuel filter

• For external tanks, loosen the fuel pickup elbow, remove it and clean thefuel filter.

a - Fuel tank filterb - Fuel pickup elbow

• Fuel tank: Water or dirt in the fuel tank will cause engine performanceproblems. Check and clean the tank at specified time or after the motorhas been stored for a long period of time (over three months).

41074

a

41045

a

b

MAINTENANCE

eng 41

Propeller Replacement

! WARNINGRotating propellers can cause serious injury or death. Never operate the boatout of the water with a propeller installed. Before installing or removing apropeller, place the drive unit in neutral and engage the lanyard stop switchto prevent the engine from starting. Place a block of wood between thepropeller blade and the anti‑ventilation plate.

1. Remove the spark plug lead to prevent the engine from starting.

26899

2. Move the gear shift lever into neutral.

RF

N

27020

3. Straighten and remove the cotter pin.4. Place a block of wood between the gearcase and the 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 anauthorized dealer.

IMPORTANT: To prevent the propeller hub from corroding and seizing to thepropeller shaft (especially in saltwater), always apply the recommendedlubricant to the entire propeller shaft at the recommended maintenanceintervals and also each time the propeller is removed.

MAINTENANCE

42 eng

6. Apply Quicksilver or Mercury Precision Lubricants Extreme Grease or2‑4‑C with PTFE to the entire propeller shaft and splines.

27095

Tube RefNo. Description Where Used Part No.

95 2-4-C with PTFE Propeller shaft 92-802859A 1

Extreme Grease Propeller shaft 8M0071842

7. Install the front thrust washer, propeller, rear thrust hub, and propeller nutonto the shaft.

8. Place a block of wood between the gearcase and the propeller to preventrotation and tighten the propeller nut. Secure the propeller nut to the shaftwith a cotter pin.

a - Cotter pinb - Propeller nutc - Rear thrust hubd - Propellere - Front thrust washer

Propeller SelectionThe propeller must be selected that will allow the engine to reachrecommended RPM when cruising at wide‑open throttle.

Wide‑open throttle RPM range4500–5500

a

bc

d

e 27094

MAINTENANCE

eng 43

Recommended propellers are listed under Propeller Recommendation in theAccessories section of this manual.

Spark Plug Inspection And Replacement

! WARNINGDamaged spark plug boots may emit sparks that can ignite fuel vapors underthe 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 ormetal tool to remove the spark plug boots.

1. Remove the spark plug boot. Twist the rubber boot slightly and pull off.

26899

2. Remove the spark plug to inspect. Replace spark plug if electrode is wornor the insulator is rough, cracked, broken, blistered or fouled.

26946

3. Set the spark plug gap to specification.

26947

Spark Plug Spark plug gap 1.0 mm (0.040 in.)

4. 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 tospecifications.

MAINTENANCE

44 eng

Description Nm lb. in. lb. ft.Spark plug 27 20

Lubrication Points1. Lubricate the following with Quicksilver or Mercury Precision Lubricants

2‑4‑C with PTFE.


95 2-4-C with PTFECo-pilot threads, swivel bracket,

transom clamp screws, tiller handlebushing, shift handle detent

92-802859A 1

• Co‑Pilot ‑ Lubricate threads.• Swivel Bracket ‑ Lubricate through fittings.

a - Co‑pilotb - Swivel bracket

• Transom Clamp Screws ‑ Lubricate threads.

27097

NOTE: Lubricating the tiller handle bushing and shift handle detent requiresdisassembly of the product. These points should be lubricated at least once ayear by an authorized dealer.

• Tiller Handle Rubber Bushing ‑ Lubricate internal diameter.

27098

a b

28862

MAINTENANCE

eng 45

• Shift Handle Detent ‑ Lubricate detent.

27099

2. Lubricate the following with Light Weight Oil.• Tilt Pivot.

28863

3. Lubricate the following with Quicksilver or Mercury Precision LubricantsExtreme Grease or 2‑4‑C with PTFE.


95 2-4-C with PTFE Propeller shaft 92-802859A 1

Extreme Grease Propeller shaft 8M0071842

• Propeller Shaft ‑ Refer to Propeller Replacement for removal andinstallation of the propeller. Coat the entire propeller shaft withlubricant to prevent the propeller hub from corroding to the shaft.

27095

MAINTENANCE

46 eng

Gearcase LubricationWhen adding or changing gearcase lubricant, visually check for the presence ofwater in the lubricant. If water is present, it may have settled to the bottom andwill drain out prior to the lubricant, or it may be mixed with the lubricant, giving ita milky colored appearance. If water is noticed, have the gearcase checked byyour dealer. Water in the lubricant may result in premature bearing failure or, infreezing temperatures, will turn to ice and damage the gearcase.Examine the drained gearcase lubricant for metal particles. A small amount ofmetal particles indicates normal gear wear. An excessive amount of metalfilings or larger particles (chips) may indicate abnormal gear wear and shouldbe checked by an authorized dealer.

DRAINING GEARCASE1. Tilt the outboard so that the oil drain plug is at the lowest point.2. Place the drain pan below the outboard.3. Remove the vent plug and fill/drain plug and drain lubricant.

a - Vent plugb - Fill/drain plug

GEARCASE LUBRICANT CAPACITYGearcase lubricant capacity is approximately 195 cc (6.6 fl. oz.).

GEARCASE LUBRICANT RECOMMENDATIONMercury or Quicksilver Premium or High Performance Gear Lubricant.

CHANGING GEAR OIL1. Place outboard in a vertical operating position.2. Remove the oil drain plugs (upper and lower), and completely drain the

gear oil into a pan.

a

b

27146

MAINTENANCE

eng 47

NOTE: If water in the oil, giving it a milky colored appearance, contact yourdealer.

a - Oil drain plug (upper)b - Oil drain plug (lower)

3. Insert the oil tube nozzle into the lower oil plug hole, and fill with gear oilby squeezing the oil tube until oil flows out of the upper plug hole.

41072

a

b

4. Replace the oil plug gasket with a new one. Install the upper oil plug, andthen remove oil tube nozzle and install the lower oil plug.

NOTE: Use Mercury or Quicksilver gear oil or the recommended gear oil (APIGL‑5:SAE #80 to #90). Required volume: approx. 195 mL

Submerged OutboardA submerged outboard will require service within a few hours by an authorizeddealer once the outboard is recovered from the water. This immediate attentionby a servicing dealer is necessary once the engine is exposed to theatmosphere to minimize internal corrosion damage to the engine.

41070

a

b

MAINTENANCE

48 eng

Storage PreparationThe major consideration in preparing your outboard for storage is to protect itfrom rust, corrosion, and damage caused by freezing of trapped water.The following storage procedures should be followed to prepare your outboardfor out of season storage or prolonged storage (two months or longer).


FUEL SYSTEMIMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause aformation of acid during storage and can damage the fuel system. If thegasoline being used contains alcohol, it is advisable to drain as much of theremaining gasoline as possible from the fuel tank, remote fuel line, and enginefuel system.Fill the fuel tank and engine fuel system with treated (stabilized) fuel to helpprevent formation of varnish and gum. Proceed with the following instructions.• Pour the required amount of gasoline stabilizer (follow instructions on

container) into the fuel tank. Tip fuel tank back and forth to mix stabilizerwith the fuel.

• Place the outboard in water or connect flushing attachment for circulatingcooling water. Start the outboard and operate at idle RPM in neutral forfive minutes to allow stabilized fuel to reach the carburetor.

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).


120 Corrosion Guard External metal surfaces 92-802878 55

Protecting Internal Engine ComponentsNOTE: Make sure the fuel system has been prepared for storage. Refer to FuelSystem, preceeding.IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacementfor correct procedure for removing spark plug boots.

STORAGE

eng 49

• Place the outboard in water. Start the engine and let it run in neutral towarm up.

• With engine running at fast idle, stop the fuel flow by closing the fuelshut‑off valve. When engine begins to stall, quickly spray Quicksilver orMercury Precision Lubricants Storage Seal into carburetor until enginestops from lack of fuel.

• Remove the spark plug and inject a five second spray of storage sealaround the inside of the cylinder.

• Rotate the flywheel manually several times to distribute the storage sealin the cylinder. Reinstall spark plug.

Gearcase• Drain and refill the gearcase lubricant (refer to Gearcase Lubrication).

Positioning Outboard for StorageStore outboard in an upright (vertical) position to allow water to drain out of theoutboard.

NOTICEStoring the outboard in a tilted position can damage the outboard. Watertrapped in the cooling passages or rain water collected in the propellerexhaust outlet in the gearcase can freeze. Store the outboard in the full downposition.

STORAGE

50 eng

Local Repair ServiceAlways return your outboard to your local authorized dealer should the need forservice arise. Only he has the factory trained mechanics, knowledge, specialtools, equipment, and genuine parts and accessories to properly service yourengine should the need occur. He knows your engine best.

Service Away from HomeIf you are away from your local dealer and the need arises for service, contactthe nearest authorized dealer. Refer to the Yellow Pages of the telephonedirectory. If, for any reason, you cannot obtain service, contact the nearestMercury Marine Service Office.

Parts and Accessories InquiriesAll inquiries concerning genuine replacement parts and accessories should bedirected to your local authorized dealer. The dealer has the necessaryinformation to order parts and accessories for you. When inquiring about partsand accessories, the dealer requires the model and serial number to order thecorrect parts.

Service AssistanceYour satisfaction with your outboard product is very important to your dealerand to us. If you ever have a problem, question or concern about your outboardproduct, contact your dealer or any authorized Mercury Marine dealership. Ifadditional assistance is required, take these steps.1. Talk with the dealership's sales manager or service manager. If this has

already been done, then contact the owner of the dealership.2. Should you have a question, concern, or problem that cannot be resolved

by your dealership, please contact Mercury Marine Service Office forassistance. Mercury Marine will work with you and your dealership toresolve all problems.

The following information will be needed by the service office:• Your name and address• Daytime telephone number• Model and serial number of your outboard• The name and address of your dealership• Nature of problem

Mercury Marine Service OfficesFor assistance, call, fax, or write. Please include your daytime telephonenumber with mail and fax correspondence.

OWNER SERVICE ASSISTANCE

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United States, Canada

Telephone English ‑ (920) 929‑5040Français ‑ (905) 636‑4751

Mercury MarineW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939Fax English ‑ (920) 929‑5893

Français ‑ (905) 636‑1704Website www.mercurymarine.com

Australia, PacificTelephone (61) (3) 9791‑5822 Brunswick Asia Pacific Group

41–71 Bessemer DriveDandenong South, Victoria 3175Australia

Fax (61) (3) 9706‑7228

Europe, Middle East, AfricaTelephone (32) (87) 32 • 32 • 11 Brunswick Marine Europe

Parc Industriel de Petit-RechainB-4800 Verviers,Belgium

Fax (32) (87) 31 • 19 • 65

Mexico, Central America, South America, CaribbeanTelephone (954) 744‑3500 Mercury Marine

11650 Interchange Circle NorthMiramar, FL 33025U.S.A.

Fax (954) 744‑3535

JapanTelephone 072‑233‑8888 Kisaka Co., Ltd.

4-130 Kannabecho Sakai-shi Sakai-ku5900984 Osaka,Japan

Fax 072‑233‑8833

Asia, SingaporeTelephone (65) 65466160 Brunswick Asia Pacific Group

T/A Mercury Marine Singapore Pte Ltd29 Loyang DriveSingapore, 508944

Fax (65) 65467789

OWNER SERVICE ASSISTANCE

52 eng

Maintenance LogRecord all maintenance performed on your outboard here. Be sure to save allwork orders and receipts.

Date Maintenance Performed Engine Hours

MAINTENANCE LOG

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Propeller RecommendationUse Mercury/Quicksilver propeller.A propeller must be selected so that the engine RPM measured at wide‑openthrottle while cruising is within the recommended range: 4500–5500 RPM.

Light boats ‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑ Heavy boatsSize as indicated on propeller 9 8 7

Propeller size (mm)Diameter x pitch (in.)

200 x 2297.9 x 9.0

198 x 2037.8 x 8.0

198 x 1787.8 x 7.0

Model Optional 4.9/5B‑DS, L, UL

4CS, L

Transom height: S (short), L (long), UL (extra long):

Tool Kit and Spare PartsA listed tools and spare parts below are provided with the motor.

Items Quantity Dimensions Remark

Service tools

Tool bag 1Pliers 1Socket wrench 1 10 x 13 mmSocket wrench 1 21 mmSocket wrenchhandle 1

screwdrivers 1 Cross andstraight point

Screwdriverhandle 1

Spare parts

Rope 1 1000 mm

Spark plug 1 NGK BPR7HS10

Cotter pin 1

Parts packagedwith engine

Fuel tank 12 L 1 5B‑D onlyPrimer bulb 1set 5B‑D only

ACCESSORIES

54 eng

Optional Accessories

41075

a b

c

d

e

f

g

h

ij

ACCESSORIES

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a - Alternator (12 V, 60 W)b - Extension cord for light (Lights are available on the market.)c - Rectifierd - Gear oil (500 mL)e - Flushing attachmentf - Grease (250 g)g - Vertical starterh - Remote control boxi - Touch up paint (300 mL)j - Engine oil (0.4 L, 1 L, 4 L, 20 L)

ACCESSORIES

56 eng

ACCESSORIESNotes:

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Wiring Diagram

41076

a

b c

d

fe

g

hi

jk

l

ACCESSORIES

58 eng

a - Batteryb - Extension cord (optional)c - Rectifier (optional)d - Light extension cord (optional)e - Lighting unit (optional)f - Pulser coilg - CD unith - Ignition coili - Spark plugj - Stop switch (optional)

Wire Color Code Abbreviations

Wire Color AbbreviationsBLK Black

BLU BlueBRN Brown GRY GrayGRN Green ORN or ORG OrangePNK Pink PPL or PUR PurpleRED Red TAN TanWHT White YEL YellowLT or LIT Light DK or DRK Dark

ACCESSORIES

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operation maintenance and installation

Documents