oti1
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 factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any marine SI
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.
a
c
d
b
e
f
h
i
g
a - Idle Speed
b - Engine Horsepower
c - Timing Specification
d - Recommended Spark Plug & Gap
e - Valve Clearance (if Applicable)
f - Family Number
g - Maximum Emission Output for
the Engine Family
h - Piston Displacement
i - Date of Manufacture
oti7
OWNER RESPONSIBILITY
The owner/operator is required to have engine maintenance performed
to maintain emission levels within prescribed certification standards.
The owner/is not to modify the engine in any manner that
would alter the horsepower or allow emissions levels to exceed their
predetermined factory specifications.
66
MAINTENANCE
ohd9
Inspection And Maintenance Schedule
BEFORE EACH USE
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
(page 73)
6. Check propeller blades for damage.
AFTER EACH USE
1. Flush out the outboard cooling system if operating in salt or polluted
water. (pages 68 and 69)
2. 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. Lubricate all lubrication points. Lubricate more frequently when
used in salt water. (page 78)
2. Inspect and clean spark plugs. (page 77)
3. Check engine fuel filter for contaminants. (pages 71 and 72)
4. Adjust carburetor(s) (if required).*
5. Check engine timing setup.*
6. 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.
67
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 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.
68
MAINTENANCE
goh100
1 2 5
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.
WARNING
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 water
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 necessary) so excess water continues leaking
out from around the rubber cups to ensure the engine is receiving
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 attachment.
Reinstall the propeller.
69
MAINTENANCE
goh227
a
b
1-4
c d
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 disconnected
from the flush connector.
FREEZING TEMPERATURE
The water should be drained out of the engine flush hose If there is
a chance of freezing 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.
70
MAINTENANCE
goh101
1 2
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 proper
engine starting capability.
IMPORTANT: Read the safety and maintenance instructions
which accompany your battery.
1. Turn off the engine before servicing the battery.
2. 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 installed.
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.
71
MAINTENANCE
goh102
1
ohh1
Fuel System
WARNING
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 servicing any part of the fuel system, stop engine and disconnect
the battery. Drain the fuel system completely. Use an approved
container to collect and store fuel. Wipe up any spillage immediately.
Material used to contain spillage must be disposed of in an approved
receptacle. Any fuel system service must be performed in a
well ventilated area. Inspect any completed service work for 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 replaced.
72
MAINTENANCE
goh218
1-5
a
c
b
d
e
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).
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.
73
MAINTENANCE
goh103
a
c
b
d
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” & “c” – Part Number 11-34863). These locknuts
must never be replaced with common nuts (non locking)
as they will work loose and vibrate off freeing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat
taking a full, sudden, sharp turn. This potentially violent action
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 lb. ft. (27.1
N·m), then torque locknut (c) to 20 lb. ft. (27.1 N·m).
74
MAINTENANCE
goh219
1 2
a
b
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 factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any marine SI
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.
a
c
d
b
e
f
h
i
g
a - Idle Speed
b - Engine Horsepower
c - Timing Specification
d - Recommended Spark Plug & Gap
e - Valve Clearance (if Applicable)
f - Family Number
g - Maximum Emission Output for
the Engine Family
h - Piston Displacement
i - Date of Manufacture
oti7
OWNER RESPONSIBILITY
The owner/operator is required to have engine maintenance performed
to maintain emission levels within prescribed certification standards.
The owner/is not to modify the engine in any manner that
would alter the horsepower or allow emissions levels to exceed their
predetermined factory specifications.
66
MAINTENANCE
ohd9
Inspection And Maintenance Schedule
BEFORE EACH USE
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
(page 73)
6. Check propeller blades for damage.
AFTER EACH USE
1. Flush out the outboard cooling system if operating in salt or polluted
water. (pages 68 and 69)
2. 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. Lubricate all lubrication points. Lubricate more frequently when
used in salt water. (page 78)
2. Inspect and clean spark plugs. (page 77)
3. Check engine fuel filter for contaminants. (pages 71 and 72)
4. Adjust carburetor(s) (if required).*
5. Check engine timing setup.*
6. 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.
67
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 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.
68
MAINTENANCE
goh100
1 2 5
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.
WARNING
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 water
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 necessary) so excess water continues leaking
out from around the rubber cups to ensure the engine is receiving
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 attachment.
Reinstall the propeller.
69
MAINTENANCE
goh227
a
b
1-4
c d
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 disconnected
from the flush connector.
FREEZING TEMPERATURE
The water should be drained out of the engine flush hose If there is
a chance of freezing 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.
70
MAINTENANCE
goh101
1 2
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 proper
engine starting capability.
IMPORTANT: Read the safety and maintenance instructions
which accompany your battery.
1. Turn off the engine before servicing the battery.
2. 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 installed.
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.
71
MAINTENANCE
goh102
1
ohh1
Fuel System
WARNING
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 servicing any part of the fuel system, stop engine and disconnect
the battery. Drain the fuel system completely. Use an approved
container to collect and store fuel. Wipe up any spillage immediately.
Material used to contain spillage must be disposed of in an approved
receptacle. Any fuel system service must be performed in a
well ventilated area. Inspect any completed service work for 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 replaced.
72
MAINTENANCE
goh218
1-5
a
c
b
d
e
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).
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.
73
MAINTENANCE
goh103
a
c
b
d
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” & “c” – Part Number 11-34863). These locknuts
must never be replaced with common nuts (non locking)
as they will work loose and vibrate off freeing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat
taking a full, sudden, sharp turn. This potentially violent action
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 lb. ft. (27.1
N·m), then torque locknut (c) to 20 lb. ft. (27.1 N·m).
74
MAINTENANCE
goh219
1 2
a
b
