Mercury Outboard 2016 Owners Manual
. Outboard Operation Maintenance Warranty Installation Manual. Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC Name of engine manufacturer: Mercury Marine Address: W6250 Pioneer Road, P.O. Box 1939 Town: Fond du Lac, WI Post Code: Country: USA Name of authorized representative: Brunswick Marine in EMEA Inc. Identification of Engines Covered by This Declaration of Conformity Unique engine EC Module H Name of engine family identification number: certificate number starting serial number Verado 6 cylinder 200, 225, 0P401000 or RCD‑H‑2 Rev 4 250, 275, 300, 350, 400R hp 1B227000 Verado 4 cylinder 135, 150, 0P401000.
Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. Please review this important information. The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, to change specifications, designs, methods, or procedures without notice and without incurring obligation. WARRANTY INFORMATION Warranty Registration United States and Canada.1 Transfer of Warranty United States and Canada.1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada. 2 3 Year Limited Warranty Against Corrosion.2 Warranty Coverage and Exclusions.4 U.S. Low Permeation Fuel Hose Requirement.40 EPA Pressurized Portable Fuel Tank Requirements.40 Fuel Demand Valve (FDV) Requirement.41 Mercury Marine's Pressurized Portable Fuel Tank.
41 Filling Fuel Tank.42 Engine Oil Recommendations.43 Checking and Adding Engine Oil.43 Features and Controls Remote Control Features. Maintenance Outboard Care.59 EPA Emissions Regulations.59 Inspection and Maintenance Schedule. 60 Maintenance Schedule Decal (150 FourStroke).63 Flushing the Cooling System.64 Top Cowl Removal and Installation.65 Cleaning Care for Top and Bottom Cowls.65 Cleaning Care for the Powerhead (Saltwater Use). 66 Battery Inspection. Owner Service Assistance Service Assistance. 89 Ordering Literature. 91 Outboard Installation Mercury Marine Validated Engine Mounting Hardware.93 Accessories Mounted to the Transom Clamp Bracket.93 Important Information.97 Boat Horsepower Capacity.97 Start in Gear Protection.98 Fuel System.
98 Installation Specifications. Federal Safety Act be required.
You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.
Oils, lubricants, or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use warranty, whichever occurs first, to the retail customer, that the engine is designed, built. Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved). Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered. As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates. Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au. Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this.
You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department. WARRANTY INFORMATION Standard Limited Standard Limited Product Corrosion Warranty Warranty OptiMax jet drive (200 and 250 hp) 1 year 3 years Racing Product Standard Limited Standard Limited (Recreation use only) Warranty Corrosion Warranty OptiMax (250 XS) 2 years 3 years OptiMax (225 Sport XS) 2 years 3 years OptiMax (300 XS). WARRANTY INFORMATION Outside of South Pacific For product purchased outside of the South Pacific region, contact the distributor in your country, or the Marine Power Service Center closest to you. ASIA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion. WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Contact the Marine Verado 400R 2 years 3 years Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you. WARRANTY INFORMATION SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 years 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years closest to you Verado. GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public.
It is strongly recommended that each operator read and understand this entire manual before operating the outboard. When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer.
GENERAL INFORMATION IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats. Stainless steel is over five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies. GENERAL INFORMATION Remote Steering Notice Models with steering link rod ‑ The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.
These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage. GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.
GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water. GENERAL INFORMATION Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom.
The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed. Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
Exhaust Emissions. GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system.
Read the installation, operation and maintenance manuals for all your selected accessories. (refer to your boat's capacity plate). Know your boat's operating and loading limitations.
Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated. GENERAL INFORMATION 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 unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. GENERAL INFORMATION Specifications Models Horsepower Kilowatts Full throttle RPM range 5000–5800 650 RPM Idle speed in neutral gear Number of cylinders Piston displacement 3.0 L (183 cid) Cylinder bore 101.6 mm (4.0 in.) Stroke 92 mm (3.62 in.) Intake 0.075 mm (0.003 in.) Valve clearance Exhaust 0.25 mm (0.010 in.). GENERAL INFORMATION Component Identification 47824 Top cowl Engine flush Bottom cowl Auxiliary tilt switch Transom brackets Cooling water intake holes Gearcase Anti‑ventilation plate Driveshaft housing Engine oil drain Water pump indicator hole.
TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum. Fuel Additives To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container. Vent/water drain holes 46273 Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements.
These fuel tanks are available as an accessory or are provided with certain portable outboard models. FUEL AND OIL REMOVING THE FUEL CAP Fuel cap Manual vent screw Tab lock 46290 IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening. Open the manual vent screw on top of the fuel cap.
IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives are not recommended. FUEL AND OIL 4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way.
Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (between the top bar and bottom bar). FUEL AND OIL IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 58240 Trim/tilt switch –. FEATURES AND CONTROLS It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present.
For visual display of the specific engine functions and additional engine data, refer to SmartCraft Product information, following. FEATURES AND CONTROLS SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.
FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down.
Lower the outboard. Tilt support lever Knob 47705 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. FEATURES AND CONTROLS 1.
Reduce the engine speed below 2000 RPM. Tilt the outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range. OPERATION Important Daily Inspection Before Each Use Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose.
A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use.
Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes. OPERATION EXAMPLE: An engine running at an elevation of 8,000 feet will have over a 30% power loss while a loss of engine power on a hot and humid day could be as much as 14%.
These losses apply to normally aspirated and supercharged engines. OPERATION Models with a single‑ram trim system: The outboard will remain at the selected tilt position, regardless of engine RPM. Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. OPERATION 3.
Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. Set the lanyard stop switch to the RUN position.
Refer to General Information ‑ Lanyard Stop Switch. Shift outboard to neutral (N) position.
OPERATION NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the ON position for approximately five seconds. Turn the key to the START position and release it, the engine will crank for a maximum of eight seconds. OPERATION Gear Shifting IMPORTANT: Observe the following:. Never shift the outboard into gear unless the engine speed is at idle. Do not shift the outboard into reverse when the engine is not running. Your outboard has three gear shift positions to provide operation: forward (F), neutral (N), and reverse (R).
Genuine Lubricants. 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 set to factory standards. MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear).
MAINTENANCE. Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retorque the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard transom brackets. MAINTENANCE Description lb‑in. Lb‑ft Outboard mounting locknuts and bolts ‑ standard boat transom Outboard mounting locknuts and bolts ‑ metal lift plates and setback brackets. Check corrosion control anodes.
Check more frequently when used in saltwater. See Corrosion Control Anode. MAINTENANCE Maintenance Schedule Decal (150 FourStroke) The following table shows the icons and a general description of the maintenance schedule decal located on the engine. 58260 Icon Definition Icon Definition Replace Inspect 9 Engine oil and filter Gearcase lubricant.
MAINTENANCE Icon Definition Icon Definition Accessory drive belt Water pump impeller 8 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. MAINTENANCE Top Cowl Removal and Installation REMOVAL Unlock the top cowl by pulling out on the rear cowl latch. Lift the top cowl off the engine. 47632 INSTALLATION 1.
Lower the top cowl over the engine. Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply pressure to the back of the cowl to lock it in place. Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.
MAINTENANCE Fuel System WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.
Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. MAINTENANCE 2.
Move the lift handle so that the locking tab clears the bracket. 47535 Lift handle Locking tab secured under bracket 3. Use the lift handle and pull the fuel filter out of its opening. If necessary, move the fuel hose so that it clears the bracket while lifting the fuel filter. MAINTENANCE 6. Remove the fuel filter from the lift handle. 47441 Fuel hose release tab Low‑pressure fuel filter Hose holder Installation 1.
Place the lift handle onto the fuel filter. Install the new fuel filter so the arrow points towards the engine. MAINTENANCE Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 47569 Propeller Replacement WARNING Rotating propellers can cause serious injury or death.
2016 Mercury 9.9 Outboard Owners Manual
Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. MAINTENANCE 3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.
MAINTENANCE 2. Place the locknut retainer over the raised pins on the drive sleeve adapter and tighten the locknut to the specified torque. Secure the locknut by bending the tabs up against the locknuts. 45232 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer. MAINTENANCE 3.
Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter. 45248 Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer Locknut Tabs bent into grooves Description lb‑in. Lb‑ft Propeller nut –.
MAINTENANCE 2. Remove the spark plugs to inspect. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode. IMPORTANT: The color of the plug may not accurately reflect its condition. MAINTENANCE a.
All of the spark plugs should have the gap checked and corrected as necessary before installation. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap. MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse.
If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating.
47408 Cover Spare fuse holders Fuse holder Fuse 4 ‑. MAINTENANCE Alternator Drive Belt Inspection 1. Remove the three screws that fastens the flywheel cover to the engine. Lift the flywheel cover off the engine.
Flywheel cover Screws (3) 47585 2. Inspect the alternator drive belt.
Alternator drive belt 47588 3. MAINTENANCE Lubrication Points 1. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1. Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. MAINTENANCE.
Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 47651 Fitting Steering cable end WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Remove the fill cap and check fluid level.
The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
MAINTENANCE 3. Use a 16 mm (5/8 in.) wrench and loosen the oil drain valve so that it can be turned by hand. Be careful not to open the valve too far allowing oil to drain. Attach a 12 mm (7/16 in.) I.D. Drain hose to the oil drain valve.
Position the opposite end of the hose into an appropriate container. MAINTENANCE 5. Clean the oil filter mounting base.
Apply a film of clean oil to the filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. Loosen Oil filter Oil trough Drain hose 47562 OIL FILLING.
Right‑hand rotation 830 ml (28.1 fl oz) Left‑hand rotation GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place the outboard in a vertical operating position. Remove the vent plug/sealing washer.
MAINTENANCE 3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole. 22693 Vent hole Fill hole IMPORTANT: Replace the sealing washers if damaged. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
Stabilizer Protecting External Outboard Components. Touch up any paint nicks. See your dealer for touch‑up paint.
Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref Description Where Used Part No. STORAGE Protecting Internal Engine Components IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacement for correct procedure for removing spark plugs. Change the engine oil and filter. Remove the spark plugs.
2016 Mercury Outboard Owners Manual
Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole. TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES. Lanyard stop switch not in 'RUN' position.
Blown 15 amp fuse. Check 14 pin remote control harness/cowl trim switch/main power relay fuse. Refer to Maintenance section. Outboard is not shifted to neutral position.
TROUBLESHOOTING Performance Loss POSSIBLE CAUSES. Overheating ‑ Warning horn not working. Low oil pressure. Check oil level. Throttle not opening fully. Damaged propeller or improper propeller size.
Incorrect engine timing, adjustment, or setup. Boat overloaded or load improperly distributed. STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages. OWNER SERVICE ASSISTANCE RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.
Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894. OWNER SERVICE ASSISTANCE Mercury Marine Submit the following Attn: Publications Department order form with payment W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI Ship To: (Copy this form and print or type–This is your shipping label) Name. 51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the same fasteners that secure the outboard to the transom or jack plate. OUTBOARD INSTALLATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
OUTBOARD INSTALLATION. The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners. OUTBOARD INSTALLATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat.
Do not mount an accessory to the transom clamp bracket in an unsupported condition. Rigging boats, which includes proper engine installation has become more complex over the years. As a result, Mercury Marine recommends that engines be installed only by Mercury authorized dealers.
If you intend to disregard this recommendation, and install the engine yourself, please make sure to read and comply with these instructions. OUTBOARD INSTALLATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. OUTBOARD INSTALLATION EPA PRESSURIZED PORTABLE FUEL TANK REQUIREMENTS The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following:. OUTBOARD INSTALLATION Priming the FSM with a Fuel Pressure Gauge The use of a purge tool for priming the FSM is the preferred method, but is not always practical.
The objective is to purge the air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port. OUTBOARD INSTALLATION 4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel. 58370 Fuel pressure gauge purge valve Schrader valve Purge hose to appropriate container 5.
Open the fuel pressure gauge purge valve and turn the ignition key on. The fuel pumps will run for approximately three to five seconds.
OUTBOARD INSTALLATION Priming the FSM (Ran out of Fuel Condition) The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is void of fuel volume, it can be primed without the use of a purge tool. OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.2 cm (33 in.) Dual engine 149.9 cm (59 in.) Lifting Outboard 1. Remove the top cowl. OUTBOARD INSTALLATION Flywheel Puller/Lifting Ring 91‑895343T02 Removes flywheel from engine. Used for lifting powerhead/engine.
14869 Shipping Bracket Removal 1. Remove the two top screws and loosen the two bottom screws. Slide the shipping bracket off the bottom screws. Tighten the bottom screws to the specified torque. 47720 Shipping bracket Top screws.
OUTBOARD INSTALLATION Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate O‑ring seal and entire cable end. 3724 Tube Ref Description Where Used Part No. 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1 2.
Insert steering cable into tilt tube. OUTBOARD INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures. OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 47710 The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions. OUTBOARD INSTALLATION NOTICE 1.
The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions. OUTBOARD INSTALLATION Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description.
OUTBOARD INSTALLATION Available Outboard Mounting Bolts Part Number Description 67755‑2 ½‑20 x 6.50 in. Long (2.75 in. Thread) 8M0028080 ½‑20 x 7.50 in. Long (2.75 in. Thread) 8M0032860 ½‑20 x 8.00 in. Long (2.75 in.
Thread) CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. OUTBOARD INSTALLATION Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate. Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area. OUTBOARD INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts.
40952 0.500 in. Diameter outboard mounting bolt (4) 0.875 in. Flat washer (4) Nylon insert locknut (4) 1.500 in. Flat washer (4) Marine sealer –. OUTBOARD INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Electrical, Fuel Hose, and Control Cables RIGGING GROMMET Installation IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, that are routed between the rigging grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched. OUTBOARD INSTALLATION 1.
Route the hoses, wiring, and cables through the rigging adapter and correct opening in the rigging grommet as shown. 47374 Screw (2) Rigging adapter Rigging grommet Speedometer tube opening Remote 14 pin boat harness opening Battery cable opening Accessory harness opening Shift cable opening Fuel hose opening.
OUTBOARD INSTALLATION NOTICE Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring harnesses. Cable tie 47753 Description lb‑in.
Lb‑ft Screws for attaching the rigging adapter REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the rigging grommet. OUTBOARD INSTALLATION SMARTCRAFT HARNESS AND VESSEL HARNESS CONNECTION If the boat is equipped with a SmartCraft and/or vessel (accessory) harness, route the wiring harness through the rigging grommet and connect it to the connector on the engine. Vessel (accessory) harness connector SmartCraft harness connector 47723. OUTBOARD INSTALLATION Maximum Length American Wire Gauge (AWG) Meter (Feet) 19.6 m (64 ft) 24.4 m (80 ft) Single Outboard Red sleeve ‑ positive Black sleeve ‑ negative (–) Cranking battery 15496. OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ positive (+) Black sleeve ‑ negative (–) Ground cable Cranking battery FUEL HOSE CONNECTION Fasten the remote fuel hose to fitting with a hose clamp.
OUTBOARD INSTALLATION Fuel Hose Size Minimum fuel hose inside diameter (ID) is 9.5 mm (3/8 in.) with separate fuel hose/fuel tank pickup for each engine. Hose clamp Remote fuel hose 47751 SHIFT CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control. OUTBOARD INSTALLATION 3. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position.
Slowly return the handle back to the neutral position. OUTBOARD INSTALLATION 8. Secure the shift cable to the anchor pin with the bow tie clip retainer. 47743 Shift cable end guide Bow tie clip retainer Center mark Cable barrel Barrel cup. OUTBOARD INSTALLATION 9.
Lock the barrel in place with the cable latch. 47744 Cable latch 10.
Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. OUTBOARD INSTALLATION 1.
Shift remote control into the neutral (N) position. Fit the throttle cable through the rigging grommet. Install the throttle cable to the throttle arm with the bow tie clip retainer. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop. OUTBOARD INSTALLATION 5.
Place the barrel cup onto the barrel. Place the cable barrel and barrel cup into the barrel retainer. 47747 Bow tie retainer Throttle cable end guide Cable barrel Barrel cup 6. Lock the cable in place with the cable latch. Cable latch 47748. MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here.
Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours.
Date Save View Size Time Lang.