and

Manual
Operation

Installation
Maintenance
8M0114067 1215 eng
© 2016 Mercury Marine 4/5/6 FourStroke
eng
Welcome
You have selected one of the finest marine power packages available. It
incorporates numerous design features to ensure operating ease and durability.
With proper care and maintenance, you will enjoy using this product for many
boating seasons. To ensure maximum performance and carefree use, we ask
that you thoroughly read this manual.
The Operation and Maintenance Manual contains specific instructions for using
and maintaining your product. We suggest that this manual remain with the
product for ready reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely hope your boating
will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:
John Pfeifer, President,
Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your
dealer. Your dealer can also provide a demonstration of actual starting and
operating procedures.

Notice
Throughout this publication, and on your power package, warnings, cautions,

and notices, accompanied by the International Hazard Symbol ! , may be

used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict
compliance with these special instructions while performing the service, plus
common sense operation, are major accident prevention measures.

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.

eng i
 NOTICE
Indicates a situation which, if not avoided, could result in engine or major
component failure.

IMPORTANT: Identifies information essential to the successful completion of

the task.
NOTE: Indicates information that helps in the understanding of a particular step
or action.
IMPORTANT: The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard, and the safety of all occupants
aboard. We strongly recommend that the operator read this Operation and
Maintenance Manual and thoroughly understand the operational instructions for
the power package and all related accessories before the boat is used.

! WARNING
The engine exhaust from this product contains chemicals known to the state
of California to cause cancer, birth defects or other reproductive harm.

The serial numbers are the manufacturer’s keys to numerous engineering

details that apply to your Mercury Marine power package. When contacting
Mercury Marine about service, always specify model and serial numbers.
Descriptions and specifications contained herein were in effect at the time this
was approved for printing. Mercury Marine, whose policies are based on
continuous improvement, reserves the right to discontinue models at any time
or to change specifications or designs without notice and without incurring
obligation.

Warranty Message
The product you have purchased comes with a limited warranty from Mercury
Marine; the terms of the warranty are set forth in the Warranty Manual included
with the product. The Warranty Manual contains a description of what is
covered, what is not covered, the duration of coverage, how to best obtain
warranty coverage, important disclaimers and limitations of damages, and
other related information. Please review this important information.

Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in
part 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 Waves
Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury
Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft,
Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're
Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a
trademark of Brunswick Corporation. Mercury Product Protection is a registered
service mark of Brunswick Corporation.

ii eng
Identification Records
Please record the following applicable information:

Outboard
Engine Model and Horsepower
Engine Serial Number
Gear Ratio
Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

eng iii
eng iv
 General Information

Boater's Responsibilities..................................................................................... 1
Before Operating Your Outboard........................................................................ 1
Boat Horsepower Capacity................................................................................. 1
Lanyard Stop Switch........................................................................................... 2
Protecting People in the Water........................................................................... 5
Exhaust Emissions............................................................................................. 5
Selecting Accessories for Your Outboard........................................................... 7
Safe Boating Recommendations........................................................................ 7
Recording Serial Number................................................................................. 10
4/5/6 Specifications........................................................................................... 10

Installation

Installing Outboard............................................................................................ 12

Transporting

Carrying, Storing, and Transporting Your Outboard When Removed from Boat
.......................................................................................................................... 13
Trailering Your Boat.......................................................................................... 14

Fuel and Oil

Fuel Requirements........................................................................................... 15
Low Permeation Fuel Hose Requirement ........................................................ 16
EPA Pressurized Portable Fuel Tank Requirements........................................ 16
Fuel Demand Valve (FDV) Requirement.......................................................... 16
Mercury Marine's Pressurized Portable Fuel Tank........................................... 17
Filling Fuel Tank............................................................................................... 18
Engine Oil Recommendations.......................................................................... 18
Checking Engine Oil......................................................................................... 19

Features and Controls

Features and Controls...................................................................................... 21

Tilting Outboard................................................................................................ 23
Shallow Water Operation ................................................................................. 24
Setting the Operating Angle of Your Outboard ................................................ 25
Engine Overspeed Protection System.............................................................. 25

eng v
 Operation

Prestarting Check List....................................................................................... 26

Operating in Freezing Temperatures................................................................ 26
Operating in Saltwater or Polluted Water......................................................... 26
Engine Break‑in Procedure............................................................................... 27
Starting the Engine........................................................................................... 27
Gear Shifting .................................................................................................... 31
Stopping the Engine ........................................................................................ 32
Emergency Starting.......................................................................................... 32

Maintenance

Outboard Care.................................................................................................. 35
EPA Emission Regulations............................................................................... 35
Inspection and Maintenance Schedule............................................................. 36
Flushing the Cooling System............................................................................ 37
Top Cowl Removal and Installation.................................................................. 38
Corrosion Control Anode.................................................................................. 38
Exterior Care..................................................................................................... 39
Fuel System...................................................................................................... 39
Propeller Replacement..................................................................................... 40
Spark Plug Inspection and Replacement.......................................................... 42
Lubrication Points............................................................................................. 43
Changing Engine Oil ........................................................................................ 45
Gearcase Lubrication........................................................................................ 46
Submerged Outboard....................................................................................... 48

Storage

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

vi eng
 Owner Service Assistance

Local Repair Service......................................................................................... 51

Service Away from Home................................................................................. 51
Parts and Accessories Inquiries....................................................................... 51
Service Assistance........................................................................................... 51
Ordering Literature............................................................................................ 53

Maintenance Log

Maintenance Log.............................................................................................. 55

eng vii
eng viii
 GENERAL INFORMATION
Boater's Responsibilities
The operator (driver) is responsible for the correct and safe operation of the
boat and the safety of its occupants and general public. It is strongly
recommended that each operator read and understand this entire manual
before operating the outboard.
Be sure that at least one additional person onboard is instructed in the basics
of starting and operating the outboard and boat handling in case the driver is
unable to operate the boat.

Before Operating Your Outboard

Read this manual carefully. Learn how to operate your outboard properly. If you
have any questions, contact your dealer.
Safety and operating information that is practiced, along with using good
common sense, can help prevent personal injury and product damage.
This manual as well as safety labels posted on the outboard use the following
safety alerts to draw your attention to special safety instructions that should be
followed.

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.

NOTICE
Indicates a situation which, if not avoided, could result in engine or major
component failure.

Boat Horsepower Capacity

! WARNING
Exceeding the boat's maximum horsepower rating can cause serious injury
or death. Overpowering the boat can affect boat control and flotation
characteristics or break the transom. Do not install an engine that exceeds
the boat's maximum power rating.

eng 1
 GENERAL INFORMATION
Do not overpower or overload your boat. Most boats will carry a required
capacity plate indicating the maximum acceptable power and load as
determined by the manufacturer following certain federal guidelines. If in doubt,
contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator
moves far enough away from the operator's position (as in accidental ejection
from the operator's position) to activate the switch. Tiller handle outboards and
some remote control units are equipped with a lanyard stop switch. A lanyard
stop switch can be installed as an accessory ‑ generally on the dashboard or
side adjacent to the operator's position.
A decal near the lanyard stop switch is a visual reminder for the operator to
attach the lanyard to their personal flotation device (PFD) or wrist.

2 eng
 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. Its stretched‑out length is made to
minimize the likelihood of accidental activation should the operator choose to
move around in an area close to the normal operator's position. If it is desired
to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg,
or tie a knot in the lanyard.
ATTACH LANYARD
RUN
b
OFF

a
c

53910

a - Lanyard cord clip

b - Lanyard decal
c - Lanyard stop switch

Read the following Safety Information before proceeding.

Important Safety Information: The purpose of a lanyard stop switch is to stop
the engine when the operator moves far enough away from the operator's
position to activate the switch. This would occur if the operator accidentally falls
overboard or moves within the boat a sufficient distance from the operator's
position. Falling overboard and accidental ejections are more likely to occur in
certain types of boats such as low sided inflatables, bass boats, high
performance boats, and light, sensitive handling fishing boats operated by a
hand tiller. Falling overboard and accidental ejections are also likely to occur as
a result of poor operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting on elevated
fishing boat decks, operating at planing speeds in shallow or obstacle infested
waters, releasing your grip on a steering wheel or tiller handle that is pulling in
one direction, drinking alcohol or consuming drugs, or daring high speed boat
maneuvers.

eng 3
 GENERAL INFORMATION
While activation of the lanyard stop switch will stop the engine immediately, a
boat will continue to coast for some distance depending upon the velocity and
degree of any turn at shut down. However, the boat will not complete a full
circle. While the boat is coasting, it can cause injury to anyone in the boat's
path as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting
and operating procedures should they be required to operate the engine in an
emergency (if the operator is accidentally ejected).

! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the
possibility of serious injury or death from being struck by the boat. Always
properly connect the operator to the stop switch using a lanyard.

! WARNING
Avoid serious injury or death from deceleration forces resulting from
accidental or unintended stop switch activation. The boat operator should
never leave the operator's station without first disconnecting the stop switch
lanyard from the operator.

Accidental or unintended activation of the switch during normal operation is

also a possibility. This could cause any, or all, of the following potentially
hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward
motion ‑ a particular concern for passengers in the front of the boat who
could be ejected over the bow and possibly struck by the gearcase or
propeller.
• Loss of power and directional control in heavy seas, strong current, or
high winds.
• Loss of control when docking.
KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD
OPERATING CONDITION
Before each use, check to ensure the lanyard stop switch works properly. Start
the 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 good
working 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 any
damaged or worn lanyard cords.

4 eng
 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.
Whenever a boat is moving (coasting) and the outboard gear shift is in neutral
position, there is sufficient force by the water on the propeller to cause the
propeller to rotate. This neutral propeller rotation can cause serious injury.
WHILE THE BOAT IS STATIONARY

! WARNING
A spinning propeller, a moving boat, or any solid device attached to the boat
can cause serious injury or death to swimmers. Stop the engine immediately
whenever anyone in the water is near your boat.

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

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

eng 5
 GENERAL INFORMATION
! WARNING
Inhaling engine exhaust gases can result in carbon monoxide poisoning,
which can lead to unconsciousness, brain damage, or death. Avoid exposure
to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat
well‑ventilated while at rest or underway.

STAY CLEAR OF EXHAUST AREAS

41127

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of

concentrated engine exhaust gases. When engines are running, keep
swimmers away from the boat, and do not sit, lie, or stand on swim platforms or
boarding ladders. While underway, do not allow passengers to be positioned
immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust
concentration, but also subjects them to the possibility of injury from the boat
propeller.
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. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and
passengers in an open area of a stationary boat that contains, or is near, a
running engine may be exposed to a hazardous level of carbon monoxide.

6 eng
 GENERAL INFORMATION
1. Examples of poor ventilation while the boat is stationary:

a
b

21626

a - Operating the engine when the boat is moored in a confined space

b - Mooring close to another boat that has its engine operating

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

a b

21628

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

Selecting Accessories for Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have been specifically
designed and tested for your outboard. These accessories are available from
Mercury Marine dealers.
IMPORTANT: Check with your dealer before installing accessories. The misuse
of approved accessories or the use of nonapproved accessories can damage
the product.
Some accessories not manufactured or sold by Mercury Marine are not
designed to be safely used with your outboard or outboard operating system.
Acquire and read the installation, operation and maintenance manuals for all
your selected accessories.

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other
governmental boating regulations and restrictions and consider the following
suggestions.
Know and obey all nautical rules and laws of the waterways.

eng 7
 GENERAL INFORMATION
• We recommend that all powerboat operators complete a boating safety
course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron,
the Red Cross, and your state or provincial boating law enforcement
agency provide courses. For more information in the U.S., call the Boat
U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
• 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‑sea
boating.
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 not
sufficient.
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 accessible
for every person onboard, plus a throwable cushion or ring. We strongly
advise that everyone wear a life jacket at all times while in the boat.
Prepare other boat operators.

8 eng
 GENERAL INFORMATION
• Instruct at least one person onboard in the basics of starting and
operating the engine and boat handling in case the driver becomes
disabled or falls overboard.
Do not overload your boat.
• Most boats are rated and certified for maximum load (weight) capacities
(refer to your boat's capacity plate). Know your boat's operating and
loading limitations. Know if your boat will float if it is full of water. When in
doubt, contact your authorized Mercury Marine dealer or the boat
manufacturer.
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 unexpected
acceleration, sudden stopping, unexpected loss of boat control, or sudden
boat movement could cause a person to be thrown overboard or into the
boat. Ensure that all passengers have a proper seat and are in it before
any boat movement.
Never operate a boat while under the influence of alcohol or drugs. It is
the 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 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. 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 to
attend to the skier. The operator should always have the down skier in
sight and never back up to the skier or anyone in the water.
Report accidents.

eng 9
 GENERAL INFORMATION
• Boat operators are required by law to file a boating accident report with
their state boating law enforcement agency when their boat is involved in
certain boating accidents. A boating accident must be reported if 1) there
is loss of life or probable loss of life, 2) there is personal injury requiring
medical treatment beyond first aid, 3) there is damage to boats or other
property where the damage value exceeds $500.00, or 4) there is
complete loss of the boat. Seek further assistance from local law
enforcement.

Recording Serial Number

It is important to record this number for future reference. The serial number is
located on the outboard as shown.
Model Number
- -

XXXXXXX
- . - --
b
a -

Serial Number

XXXXXXL
XX
XXXX XXX
HP XXX KW XXX
LB XXX KG XXX
Me rc ury Marine
Brunswick Corp.

d c
Made in Japan

XX 45646

a- Model designation
b- Serial number
c- Year manufactured
d- Certified Europe Insignia (as applicable)

4/5/6 Specifications
Models 4 5 6
Power 2.94 kw (4 hp) 3.68 kw (5 hp) 4.41 kw (6 hp)
Full throttle RPM range 4500–5500 5000–6000
1100 RPM in Forward Gear, 1300 RPM in
Idle speed
Neutral
Number of cylinders 1
Piston displacement 123 cc (7.51 cid)
Cylinder bore 59 mm (2.32 in.)
Piston stroke 45 mm (1.77 in.)
Valve clearance (cold)
Intake valve 0.06–0.14 mm (0.002–0.005 in.)
Exhaust valve 0.11–0.19 mm (0.004–0.007 in.)
Engine oil capacity 450 ml (15 fl oz)
Recommended spark plug NGK DCPR6E

10 eng
 GENERAL INFORMATION
Models 4 5 6
Spark plug gap 0.9 mm (0.035 in.)
Gearcase lubricant capacity 195 ml (6.6 fl oz)
Gear ratio 2.15:1
Recommended gasoline Refer to Fuel and Oil
Emission control system Engine modification (EM)
Sound at drivers ear
82.2
(ICOMIA 39‑94) bBA
Tiller handle vibration
7.3
(ICOMIA 38‑94) m/s²

eng 11
 INSTALLATION
Installing Outboard
BOAT TRANSOM HEIGHT REQUIREMENT
Measure the transom height of your boat. The anti‑ventilation plate should be
25–50 mm (1–2 in.) below the bottom of the boat.

a a - Anti‑ventilation plate

27004

INSTALLING OUTBOARD ON TRANSOM

1. Place the outboard on the centerline of the transom.

27005

2. Tighten the transom clamp handles.

45603

12 eng
 TRANSPORTING
Carrying, Storing, and Transporting Your Outboard When
Removed from Boat
1. Remote fuel tank models ‑ Disconnect the remote fuel line. Install the
protector cap over the fuel connector.

a
45604

a - Remote fuel line

b - Protector cap

2. With the outboard still in the water, move the fuel valve to the "OFF"
(closed) position. Run the engine until it stops. This will drain fuel from the
carburetor. Close the fuel tank vent.

45605

a - Fuel valve "OFF" position

b - Fuel tank vent

3. Remove the outboard and hold it upright until the water is drained out.
Keep the outboard in an upright position when carrying.

eng 13
 TRANSPORTING
4. Carry, transport, or store the outboard only in the upright position or tiller
handle down position. These positions will prevent oil from draining out of
the crankcase.

NOTICE
a - Upright position

37-892904-010
THIS SIDE UP
b - Tiller handle down position
a
b

45595

NOTE: Never carry, store, or transport the outboard in these positions. Engine
damage could result from oil draining out of the crankcase.

45596

Trailering Your Boat

IMPORTANT: The tilt lock mechanism is not intended to support the outboard
in the tilted up position when trailering your boat. Use of the tilt lock mechanism
could allow the outboard to bounce and drop down causing damage to the
outboard.
Your boat should be trailered with the outboard tilted down (normal operating
position).
If additional ground clearance is required, remove the outboard from the boat
and store securely. Additional clearance may be needed for railroad crossings,
driveways, and trailer bouncing.
Set the gear shift into forward gear. This prevents the propeller from spinning
freely.

45597

14 eng
 FUEL AND OIL
Fuel Requirements
IMPORTANT: Use of improper gasoline can damage your engine. Engine
damage resulting from the use of improper gasoline is considered misuse
of the engine and will not be covered under the limited warranty.
FUEL RATINGS
Mercury outboard engines will operate satisfactorily with any major brand of
unleaded gasoline that meets the following specifications:
USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for
most models. Premium gasoline 91 (R+M)/2 octane is also acceptable for most
models. 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 for
all models. Do not use leaded gasoline.
USING REFORMULATED (OXYGENATED) GASOLINE (USA ONLY)
Reformulated gasoline is required in certain areas of the USA and is
acceptable for use in your Mercury Marine engine. The only oxygenate
currently in use in the USA is alcohol (ethanol, methanol, or butanol).
GASOLINE CONTAINING ALCOHOL
Bu16 Butanol Fuel Blends
Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury
Marine fuel rating requirements are an acceptable substitute for unleaded
gasoline. Contact your boat manufacturer for specific recommendations on
your boat's fuel system components (fuel tanks, fuel lines, and fittings).
Methanol and Ethanol Fuel Blends
IMPORTANT: The fuel system components on your Mercury Marine engine will
withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your
boat's fuel system may not be capable of withstanding the same percentage of
alcohol. Contact your boat manufacturer for specific recommendations on your
boat'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)

eng 15
 FUEL AND OIL
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or
death. Periodically inspect all fuel system components for leaks, softening,
hardening, swelling, or corrosion, particularly after storage. Any sign of
leakage or deterioration requires replacement before further engine
operation.

IMPORTANT: If you use gasoline that contains or might contain methanol or

ethanol, you must increase the frequency of inspection for leaks and
abnormalities.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing
methanol or ethanol, do not store the gasoline in the fuel tank for long periods.
Cars normally consume these blended fuels before they can absorb enough
moisture to cause trouble; boats often sit idle long enough for phase separation
to take place. Internal corrosion may occur during storage if alcohol has
washed protective oil films from internal components.

Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered for sale in the
United States.
• The Environmental Protection Agency (EPA) requires that any outboard
manufactured after January 1, 2009, must use low permeation fuel hose
for the primary fuel hose connecting the fuel tank to the outboard.
• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not
exceeding 15 g/m²/24 h with CE 10 fuel at 23 °C as specified in SAE J
1527 ‑ marine fuel hose.

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:
• An air inlet that opens to allow air to enter as the fuel is drawn out of the
tank.
• An air outlet that opens (vents) to the atmosphere if pressure exceeds
34.4 kPa (5.0 psi).

Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve is required to
be installed in the fuel hose between the fuel tank and primer bulb. The fuel
demand valve prevents pressurized fuel from entering the engine and causing
a fuel system overflow or possible fuel spillage.

16 eng
 FUEL AND OIL
The fuel demand valve has a manual release. The manual release can be used
(pushed in) to open (bypass) the valve in case of a fuel blockage in the valve.

b a - Fuel demand valve ‑ installed in the

a fuel hose between the fuel tank and
primer bulb
b - Manual release
c 46273
c - Vent/water drain holes

Mercury Marine's Pressurized Portable Fuel Tank

Mercury Marine has created a new portable pressurized fuel tank that meets
the preceding EPA requirements. These fuel tanks are available as an
accessory or are provided with certain portable outboard models.
SPECIAL FEATURES OF THE PORTABLE FUEL TANK
• The fuel tank has a two‑way valve which allows air to enter the tank as
the fuel is drawn to the engine, and also opens to vent to the atmosphere
if internal pressure in the tank exceeds 34.4 kPa (5.0 psi). A hissing noise
may be heard as the tank vents to the atmosphere. This is normal.
• The fuel tank includes a fuel demand valve that prevents pressurized fuel
from entering the engine and causing a fuel system overflow or possible
fuel spillage.
• When installing the fuel tank cap, turn the cap to the right until you hear a
click. This signals that the fuel cap is fully seated. A built‑in device
prevents overtightening.
• The fuel tank has a manual vent screw which should be closed for
transportation and open for operation and cap removal.
Since sealed fuel tanks are not vented, they will expand and contract as the
fuel expands and contracts during heating and cooling cycles of the outside air.
This is normal.
REMOVING THE FUEL CAP

b a - Fuel cap
a b - Manual vent screw
c - Tab lock

c
46290
IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to
relieve pressure before opening.

eng 17
 FUEL AND OIL
1. Open the manual vent screw on top of the fuel cap.
2. Turn the fuel cap until it contacts the tab lock.
3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the
pressure.
4. Press down on the tab lock again and remove the cap.
DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK
1. When installing the fuel tank cap, turn the cap to the right until you hear a
click. This signals that the fuel cap is fully seated. A built‑in device
prevents overtightening.
2. Open the manual vent screw on top of the cap for operation and cap
removal. Close the manual vent screw for transportation.
3. For fuel hoses that have quick disconnects, disconnect the fuel line from
the engine or fuel tank when not in use.
4. Follow Filling Fuel Tank instructions for fueling.

Filling Fuel Tank

! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Use caution
when filling fuel tanks. Always stop the engine and do not smoke or allow
open flames or sparks in the area while filling fuel tanks.

Fill the fuel tanks outdoors away from heat, sparks, and open flames.
Remove the portable fuel tanks from the boat to fill them.
Always stop the engine before filling the tanks.
Do not completely fill the fuel tanks. Leave approximately 10% of the tank
volume unfilled. Fuel will expand in volume as its temperature rises and can
leak under pressure if the tank is completely filled.
PORTABLE FUEL TANK PLACEMENT IN THE BOAT
Place the fuel tank in the boat so the vent is higher than the fuel level under
normal boat operating conditions.

Engine Oil Recommendations

Mercury or Quicksilver NMMA FC‑W certified SAE 10W‑30 4‑Stroke Marine
Engine Oil is recommended for general, all‑temperature use. If NMMA certified
synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W‑40
Synthetic Blend Marine 4‑Stroke Engine Oil. If the recommended Mercury or
Quicksilver NMMA FC‑W certified outboard oils are not available, a major
FC‑W certified 4‑stroke outboard oil may be used.

18 eng
 FUEL AND OIL
IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than
Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W
certified oil), synthetic oils, low quality or oils that contain solid additives are not
recommended.

a b Recommended SAE viscosity for

F° C°
engine oil
a - Mercury or Quicksilver SAE
+100 +38 25W‑40 Synthetic Blend Marine
4‑Stroke Engine Oil may be used
+80 +27 at temperatures above 4 °C
(40 °F)
+60 +16 b - Mercury or Quicksilver SAE
10W‑30 4‑Stroke Marine Engine
+40 +4 Oil is recommended for use in all
temperatures
+20 –7

0 –18

26795

Checking Engine Oil

IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted)
when checking the oil.
1. Position the outboard vertical and remove the top cowl.
2. Remove the oil filler cap. Wipe oil off the dipstick and screw the oil filler
cap back into the oil fill hole completely. Remove the oil filler cap and
check oil level on dipstick. Oil must be between full mark and add mark. If
oil level is low, add oil to bring level no higher than the full mark.
NOTE: If oil level is at the add mark, add 100 ml (3 oz) of oil.

a a - Full mark
b - Add mark

45609

eng 19
 FUEL AND OIL
NOTE: Under certain conditions, the operating temperature of four‑stroke
outboard engines may not get hot enough to evaporate the normal fuel and
moisture that accumulate in the crankcase. These conditions include operating
at idle for long periods, repeated short trips, slow speed or quick stop‑and‑go
operation, and operating in cooler climates. This additional fuel and moisture
that collects in the crankcase eventually ends up in the oil sump and will add
to the total volume of oil that appears on the dipstick reading. This increase in
oil volume is known as oil dilution. Outboard engines can typically handle large
amounts of oil dilution without causing durability problems. However, to ensure
extended life of the outboard engine, Mercury recommends that the oil be
changed regularly following the oil change interval and using the
recommended oil quality. It is further recommended that if your outboard is
operated frequently in the conditions described above, that more frequent oil
change intervals be considered.
3. Install the oil filler cap and tighten securely.

20 eng
 FEATURES AND CONTROLS
Features and Controls
Fuel shut‑off valve for internal fuel tank ‑ Turn valve up to close or down to
open. If an optional remote fuel tank is used, turn valve up when using the
remote fuel tank. Turn valve down when using the internal fuel tank.
• Using internal fuel tank ‑ Turning valve up to "OFF" (stops fuel flow).
Turning valve down to "ON" (opens fuel flow).
• Using optional remote fuel tank ‑ Turn valve up to the "OFF" position
when using the remote fuel tank. Disconnect the remote fuel hose when
using the internal fuel tank.

a
c

b
45611

a - Fuel shut‑off valve

b - "ON" (open) position
c - "OFF" (closed) position

Choke knob ‑ Pull completely out when starting a cold engine. Push halfway in
as engine is warming up. Push in completely after engine is warmed up.
Oil pressure indicator ‑ If oil pressure drops too low, the oil pressure indicator
light will turn on. If the oil pressure indicator light turns on while the engine is
running, stop the engine as soon as possible. Check oil level and add oil as
needed. If the oil pressure indicator light should stay on when the oil level is
correct, consult your dealer.
Engine stop switch/lanyard stop switch ‑ Push in or pull lanyard to stop engine.
The engine will not start unless the lanyard is engaged with the stop switch.

eng 21
 FEATURES AND CONTROLS
Remote the fuel tank connector ‑ For optional remote fuel tank.

a - Choke knob
b - Oil pressure indicator
b c d light
a c - Lanyard stop switch
d - Remote fuel connector
e - Lanyard

e
45613
Throttle grip friction knob ‑ Turn the friction knob to set and maintain the throttle
at desired speed. Turn the knob clockwise to tighten friction or turn the knob
counterclockwise to loosen friction.

a a - Throttle grip friction knob

b - Loosen friction (counterclockwise)
c - Tighten friction (clockwise)

b c 45614

! WARNING
Insufficient friction adjustment can cause serious injury or death due to loss
of boat control. When setting the friction adjustment, maintain sufficient
steering friction to prevent the outboard from steering into a full turn if the
tiller handle or steering wheel is released.

Steering friction adjustment ‑ Adjust this knob to achieve the desired steering
friction (drag) on the tiller handle. Turn knob clockwise to tighten friction and
counterclockwise to loosen friction.

a - Loosen friction
(counterclockwise)
b - Tighten friction (clockwise)
c - Steering friction knob

a b

c
45615

22 eng
 FEATURES AND CONTROLS
Shift handle ‑ Controls the gear shift.
N

R F

45917

a - Shift handle

Tilting Outboard
TILTING TO FULL UP POSITION
1. Stop the engine. Shift the outboard into forward gear.
2. Take hold of the top cowl grip and raise the outboard to the full up
position.

54600

3. The spring loaded tilt lock lever will engage automatically and lock the
outboard in full up position.
LOWERING TO RUN POSITION
Raise the outboard and pull up on the tilt release lever. Gently lower the
outboard down.

a - Tilt release lever

b - Tilt lock lever

b
a 45616

eng 23
 FEATURES AND CONTROLS
Shallow Water Operation
This outboard has a shallow water drive position. This will allow you to tilt the
outboard to a higher position to prevent hitting bottom.
ENGAGING SHALLOW WATER DRIVE
1. Reduce the 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
tilt lock lever will engage automatically and lock the outboard in the
shallow water drive position.

45599

2. Ensure the cooling water intake is submerged.

27029

IMPORTANT: Operate outboard at slow speed for shallow water operation

and keep the cooling water intake submerged.
3. To release outboard back down to run position, tilt outboard up slightly
and pull up on the tilt release lever. Gently lower the outboard down.

a - Tilt release lever

b - Tilt lock lever

b
a 45616

24 eng
 FEATURES AND CONTROLS
Setting the Operating Angle of Your Outboard
The vertical operating angle of your outboard is adjusted by changing the
position of the tilt pin in the adjustment holes provided. Proper adjustment
allows the boat to achieve optimum performance, stability, and minimize
steering effort.
The tilt pin should be adjusted so the outboard is positioned to run
perpendicular to the water when the boat is running at full speed. This allows
the boat to be driven parallel to the water.
Arrange passengers and load in the boat so the weight is distributed evenly.

a - Tilt pin

45617
IMPORTANT: Do not operate the outboard with the tilt pin removed.

Engine Overspeed Protection System

The engine overspeed protection system is activated if the engine speed
should exceed the maximum allowable limit. This will protect the engine from
mechanical damage.
Anytime the engine overspeed protection system is activated, the engine speed
is automatically reduced to within the allowable limit. If engine overspeed
continues, have the outboard checked by your dealer.
NOTE: Your engine speed should never reach the maximum limit to activate
the system unless the propeller is ventilating, an incorrect propeller is being
used, or the propeller is faulty.

eng 25
 OPERATION
Prestarting Check List
• Operator knows safe navigation, boating, and operating procedures.
• An approved personal flotation device of suitable size for each person
aboard and readily accessible (it is the law).
• A ring type life buoy or buoyant cushion designed to be thrown to a
person in the water.
• Know your boats' maximum load capacity. Look at the boat capacity plate.
• Fuel supply OK.
• 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 Temperatures

When using your outboard or having your outboard moored in freezing or near
freezing temperatures, keep the outboard tilted down at all times so the
gearcase is submerged. This prevents the trapped water in the gearcase from
freezing and causing possible damage to the water pump and other
components.
If there is a chance of ice forming on the water, the outboard should be
removed and drained completely of water. If ice should form at the water level
inside the outboard driveshaft housing, it will block water flow to the engine
causing possible damage.

Operating in Saltwater or Polluted Water

We recommend that you flush the internal water passages of your outboard
with fresh water after each use in salt or polluted water. This will prevent a
buildup of deposits from clogging the water passages. Refer to Maintenance ‑
Flushing the Cooling System.
If you keep your boat moored in the water, always tilt the outboard so the
gearcase is completely out of water (except in freezing temperatures) when not
in 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.

26 eng
 OPERATION
Engine Break‑in Procedure
IMPORTANT: Failure to follow the engine break‑in procedures can result in
poor performance throughout the life of the engine and can cause engine
damage. Always follow break‑in procedures.
1. For the first hour of operation, run the engine at varied throttle settings up
to 2000 RPM or at approximately half throttle.
2. For the second hour of operation, run the engine at varied throttle settings
up to 3000 RPM or at three‑quarter throttle, and at full throttle for
approximately one minute every ten minutes.
3. For the next eight hours of operation, avoid continuous operation at full
throttle for more than five minutes at a time.

Starting the Engine

Before starting, read the Pre‑Starting Check List, special operating
instructions, and Engine Break‑in Procedure in the Operation section.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other
components will overheat and suffer damage. Provide a sufficient supply of
water to the water inlets during operation.

1. Ensure the cooling water intake is submerged.

27029

2. Check the engine oil level.

27030

eng 27
 OPERATION
3. Shift the outboard to neutral (N) position.
N

R F

45602

NOTE: The engine will not start unless the lanyard is engaged with the stop
switch.
4. Attach the lanyard to the stop switch. Refer to General Information ‑
Lanyard Stop Switch.

a - Lanyard
b - Stop switch

b
a

45619
5. Starting procedure when using the internal fuel tank for fuel:
a. Open the fuel cap vent on the internal fuel tank.
b. Move the fuel valve to the "ON" (open) position.

a
b

45621

a - Fuel valve "ON" (open) position

b - Fuel tank vent

6. Starting procedure when using optional remote fuel tank:

28 eng
 OPERATION
a. Close the fuel cap vent on the internal fuel tank.
b. Move the fuel valve to the "OFF" (closed) position.

45605

a - Fuel valve "OFF" (closed) position

b - Fuel cap vent

c. Connect the remote fuel line to the outboard.

d. Position the fuel line primer bulb so the arrow on the side of the bulb is
pointing up. Squeeze the fuel line primer bulb several times until it
feels firm.

b
45623

a - Remote fuel hose

b - Primer blub

e. Open the fuel tank vent on manual venting type tanks.

19748

7. Position the throttle grip as follows:

• Cold engine ‑ Move to the START position.

eng 29
 OPERATION
• Warm engine ‑ Move to the RE‑START position.

RE-START a a - Warm engine start

START b b - Cold engine start

45624

8. If engine is cold, completely pull out the choke. Push in the choke halfway
as the engine is warming up. Push in completely after engine is warmed
up.

a - Choke

45625
NOTE: Starting flooded engine ‑ Push in the choke knob. Wait 30 seconds,
then continue to crank engine for starting.
9. Pull the starter rope slowly until you feel the starter engage, then pull
rapidly to crank the engine. Allow rope to return slowly. Repeat until
engine starts.

a a - Starter rope

45626
10. Check for a steady stream of water flowing out of the water pump
indicator hole.

30 eng
 OPERATION
IMPORTANT: If no water is coming out of the water pump indicator hole, stop
engine and check cooling water intake for obstruction. No obstruction may
indicate a water pump failure or blockage in the cooling system. These
conditions will cause the engine to overheat. Have the outboard checked by
your dealer. Operating the engine while overheated may cause serious engine
damage.

45601

Gear Shifting
Your outboard has three gear shift positions to provide operation: Forward (F),
Neutral (N), and Reverse (R).
Reduce the throttle speed to idle speed.
Always shift the outboard into gear with a quick motion.
N

R F

45602

eng 31
 OPERATION
Stopping the Engine
Reduce the engine speed and push in the stop switch or pull the lanyard.

a - Lanyard
b - Stop switch

b
a

45619

Emergency Starting
If the starter rope should break or the rewind starter fails, use the spare starter
rope (provided) and follow this procedure.
1. Shift the outboard to neutral position.

45629

! WARNING
The neutral‑speed‑protection device is inoperative when starting the engine
with the emergency starter rope. Set the engine speed at idle and the gear
shift in neutral to prevent the outboard from starting in gear.

32 eng
 OPERATION
2. Disconnect the linkage from the rewind starter assembly.

b
45630

a - Rewind starter assembly

b - Linkage

3. Remove the three 10 mm bolts and rewind starter assembly.

a - 10 mm wrench ‑
provided with
outboard
a

45631

! WARNING
The exposed moving flywheel can cause serious injury. Keep your hands,
hair, clothing, tools, and other objects away from engine when starting or
running the engine. Do not attempt to reinstall the rewind starter assembly
or top cowl when engine is running.
4. Place the starter rope knot into the starter cup notch and wind the rope
clockwise around the cup.

eng 33
 OPERATION
5. Pull the starter rope to start the engine.

a - Starter rope ‑ provided with outboard

45632

34 eng
 MAINTENANCE
Outboard Care
To keep your outboard in the best operating condition, it is important that your
outboard receive the periodic inspections and maintenance listed in the
Inspection and Maintenance Schedule. We urge you to keep it maintained
properly to ensure the safety of you and your passengers, and retain its
dependability.
Record maintenance performed in the Maintenance Log at the back of this
book. Save all maintenance work orders and receipts.
SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD
We recommend using original Mercury Precision or Quicksilver replacement
parts and Genuine Lubricants.

EPA Emission 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. 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 spark ignition (SI) engine
repair establishment or individual.

eng 35
 MAINTENANCE
EMISSION CERTIFICATION LABEL
An emission certification label, showing emission levels and engine
specifications directly related to emissions, is placed on the engine at time of
manufacture.

2008 EMISSION CONTROL INFORMATION 2008

THIS ENGINE CONFORMS TO 2010 CALIFORNIA AND U.S. EPA EMISSION
JAN REGULATIONS FOR SPARK IGNITION MARINE ENGINES. REFER TO OWNER’S JUL
a FEB
MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
PLEASE PERFORM THE ENGINE MAINTENANCE CORRECTLY. AUG
e
DISPLACEMENT : FAMILY :
b MAR
FEL : HC+NOx= CO= HP :
SEP f
APR OCT
c LOW-PERM/HIGH-PERM : MAXIMUM POWER : g
MAY NOV
TIMING : IDLE SPEED (IN GEAR) :
d JUN
MERCURY MARINE DEC h
43058

a- Piston displacement
b- Maximum emission output for the engine family
c- Percent of fuel line permeation
d- Timing specification
e- Family number
f- Engine family description
g- Engine power ‑ kilowatts
h- Idle speed

OWNER RESPONSIBILITY
The owner/operator is required to have routine engine maintenance performed
to maintain emission levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter
the horsepower or allow emission levels to exceed their predetermined factory
specifications.

Inspection and Maintenance Schedule

DAILY 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
• Inspect the hydraulic steering fittings and hoses for leaks or signs of
damage, if equipped

36 eng
 MAINTENANCE
• Check the hydraulic steering fluid level, if equipped
AFTER EACH USE
• Wash the power package exterior with fresh water
• Flush the outboard cooling system, saltwater or brackish water only
ANNUALLY OR 100 HOURS
• Grease the engine, if applicable
• Change the engine oil and filter, if equipped
• Inspect the thermostat, saltwater or brackish water only
• Add Quickleen to the fuel tank, once per year, per engine
• Apply anti‑seize to the spark plug threads
• Replace the gear 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 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.
NOTE: Do not run the engine while flushing the cooling system.
1. Remove the plug and gasket.

eng 37
 MAINTENANCE
2. Install the hose coupling into the plug opening.
3. Attach a water hose to the hose coupling. Turn on the water gently and
flush the cooling system for 3–5 minutes.
4. Remove the hose coupling and install the plug and gasket.

a
45633

a - Plug and gasket

b - Hose coupling

Top Cowl Removal and Installation

REMOVAL
1. Release the rear latch.
2. Lift up the rear of the cowl and push it towards the front of the engine to
clear the front hook.

45638

INSTALLATION
1. Engage the front hook and position the cowl over the engine.
2. Lock the rear latch.

Corrosion Control Anode

Your outboard has a corrosion control anode installed on the gearcase. An
anode helps protect the outboard against galvanic corrosion by sacrificing its
metal to be slowly corroded instead of the outboard metals.

38 eng
 MAINTENANCE
The anode requires periodic inspection especially in saltwater which will
accelerate the erosion. To maintain this corrosion protection, always replace
the anode before it is completely eroded. Never paint or apply a protective
coating on the anode as this will reduce effectiveness of the anode.

27092

Exterior Care
Your outboard is protected with a durable baked enamel finish. Clean and wax
often using marine cleaners and waxes.

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. Always check
for leaks before attempting to start the engine, and wipe up any spilled fuel
immediately.

Before servicing any part of the fuel system, stop the engine and disconnect
the battery. Drain the fuel system completely. Use an approved container to
collect and store the fuel. Wipe up any spillage immediately. Material used to
contain the 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.

eng 39
 MAINTENANCE
FUEL LINE FILTER
Inspect the fuel line filter. If the filter appears to be contaminated, remove and
replace.

45639

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
are found, the fuel line or primer bulb must be replaced.

Propeller Replacement
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat
out of the water with a propeller installed. Before installing or removing a
propeller, place the drive unit in neutral and engage the lanyard stop switch
to prevent the engine from starting. Place a block of wood between the
propeller blade and the anti‑ventilation plate.

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

26899

40 eng
 MAINTENANCE
2. Move the gear shift lever into neutral.

45629

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 propeller straight off the shaft. If propeller is seized to the shaft and
cannot be removed, have the propeller removed by an authorized dealer.
IMPORTANT: To prevent the propeller hub from corroding and seizing to the
propeller shaft (especially in saltwater), always apply a coat of the
recommended lubricant to the entire propeller shaft at the recommended
maintenance intervals and also each time the propeller is removed.
6. Coat the propeller shaft with Extreme Grease or 2‑4‑C with PTFE.

27095

Tube Ref
Description Where Used Part No.
No.

Extreme Grease Propeller shaft 8M0071842

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

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

eng 41
 MAINTENANCE
8. Place a block of wood between the gearcase and the propeller and
tighten the propeller nut. Secure the propeller nut to the shaft with a cotter
pin.

a a- Cotter pin
b- Propeller nut
c- Rear thrust hub
d- Propeller
e- Front thrust washer

b
c e 27094

d
Spark Plug Inspection and Replacement
! WARNING
Damaged spark plug boots may emit sparks that can ignite fuel vapors under
the engine cowl, resulting in serious injury or death from a fire or explosion.
To avoid damaging the spark plug boots, do not use any sharp object or
metal 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 worn
or the insulator is rough, cracked, broken, blistered, or fouled.

26946

42 eng
 MAINTENANCE
3. Set the spark plug gap to specification.

26947

Spark Plug
Spark plug gap 0.9 mm (0.035 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 to
specifications.

Description Nm lb‑in. lb‑ft

Spark plug 27 20

Lubrication Points
1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease.

Tube Ref
Description Where Used Part No.
No.
Co-pilot, swivel bracket, transom clamp
95 2-4-C with PTFE screws, tiller handle bushing, shift 92-802859A 1
handle detent
Co-pilot, swivel bracket, transom clamp
Extreme Grease screws, tiller handle bushing, shift 8M0071842
handle detent

• Co‑pilot ‑ lubricate threads.

• Swivel bracket ‑ lubricate through fittings.

a - Swivel bracket lubrication fittings

b - Co‑pilot

b
45640

eng 43
 MAINTENANCE
• Transom clamp screws ‑ lubricate threads.

a - Transom clamp screws

a
45641

NOTE: Lubricating the tiller handle bushing and shift detent shaft requires
disassembly of the product. These points should be lubricated at least once a
year by an authorized dealer.
• Tiller handle rubber bushing ‑ lubricate internal diameter.

a - Tiller handle rubber

bushing
a

45642
• Shift detent ‑ lubricate detent shaft.

a - Shift detent

45648

44 eng
 MAINTENANCE
2. Lubricate the tilt pivot points with lightweight oil.

a - Tilt pivot points

a 45643

3. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE.

Tube Ref
Description Where Used Part No.
No.

Extreme Grease Propeller shaft 8M0071842

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

• Propeller shaft ‑ refer to Propeller Replacement for removal and

installation of the propeller. Coat the entire propeller shaft with
lubricant to prevent the propeller hub from corroding to the shaft.

27095

Changing Engine Oil

ENGINE OIL CAPACITY
Engine oil capacity is approximately 450 ml (15 fl oz).
OIL CHANGING PROCEDURE
1. Place the outboard in an upright (not tilted) position.
2. Turn the outboard to gain access to the drain plug. Remove the drain plug
and drain the engine oil into an appropriate container. Lubricate the seal
on the drain plug with oil and install.

eng 45
 MAINTENANCE
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.

a - Drain plug

45644

OIL FILLING
IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted)
when checking oil.
Remove the oil fill cap and refill with 450 ml (15 fl oz) of oil. Install the oil fill
cap.
Idle engine for five minutes and check for leaks. Stop engine and check the oil
level on the dipstick. Add oil if necessary.

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

DRAINING GEARCASE
1. Tilt the outboard so that the oil drain plug is at the lowest point.
2. Place the drain pan below the outboard.

46 eng
 MAINTENANCE
3. Remove the vent plug and fill/drain plug and drain lubricant.

a - Vent plug
a
b - Fill/drain plug

27146

GEARCASE LUBRICANT CAPACITY

Gearcase lubricant capacity is approximately 195 ml (6.6 fl oz).

GEARCASE LUBRICANT RECOMMENDATION

Mercury or Quicksilver Premium or High Performance Gear Lubricant.

CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE

1. Place the outboard in a vertical operating position.
2. Remove the vent plug from the vent hole.
3. Place the lubricant tube into the fill hole and add lubricant until it appears
at the vent hole.

a - Vent plug
b - Lubricant at vent hole
c - Fill/drain plug

a
b

c
27148
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer before
removing the lubricant tube.
5. Remove the lubricant tube and install cleaned fill/drain plug and sealing
washer.

eng 47
 MAINTENANCE
Submerged Outboard
A submerged outboard will require service within a few hours by an authorized
dealer once the outboard is recovered from the water. This immediate attention
by a servicing dealer is necessary once the engine is exposed to the
atmosphere to minimize internal corrosion damage to the engine.

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

NOTICE
Without sufficient cooling water, the engine, the water pump, and other
components will overheat and suffer damage. Provide a sufficient supply of
water to the water inlets during operation.

FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a
formation of acid during storage and can damage the fuel system. If the
gasoline being used contains alcohol, it is advisable to drain as much of the
remaining gasoline as possible from the fuel tank, remote fuel line, and engine
fuel system.
Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help
prevent 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 the fuel tank back and forth to mix the
stabilizer with the fuel.
• Place the outboard in water. Run the engine for ten minutes to fill the
engine fuel system.

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).

Tube Ref
Description Where Used Part No.
No.

120 Corrosion Guard External metal surfaces 92-802878 55

Protecting Internal Engine Components

• Remove the spark plug and inject a small amount of engine oil inside the
cylinder.
• Rotate the flywheel manually several times to distribute the oil in the
cylinder. Install spark plug.
• Change the engine oil.

eng 49
 STORAGE
Gearcase
• Drain and refill the gearcase lubricant (refer to Gearcase Lubrication).

Positioning Outboard for Storage

NOTICE
Storing the outboard in a tilted position can damage the outboard. Water
trapped in the cooling passages or rain water collected in the propeller
exhaust outlet in the gearcase can freeze. Store the outboard in the full down
position.

1. Carry, transport, or store the outboard only in the following two positions.
These positions will prevent oil from draining out of the crankcase.

NOTICE
a - Upright
37-892904-010

THIS SIDE UP
b - Tiller side down
a
b

45595

2. Never carry, store, or transport the outboard in the positions shown below.
Engine damage could result from oil draining out of the crankcase.

27012

50 eng
 OWNER SERVICE ASSISTANCE
Local Repair Service
Always return your outboard to your local authorized dealer should the need for
service arise. Only he has the factory trained mechanics, knowledge, special
tools, equipment, and genuine parts and accessories to properly service your
engine should the need occur. He knows your engine best.

Service Away from Home

If you are away from your local dealer and the need arises for service, contact
the nearest authorized dealer. Refer to the Yellow Pages of the telephone
directory. If, for any reason, you cannot obtain service, contact the nearest
Mercury Marine Service Office.

Parts and Accessories Inquiries

All inquiries concerning genuine replacement parts and accessories should be
directed to your local authorized dealer. The dealer has the necessary
information to order parts and accessories for you. When inquiring about parts
and accessories, the dealer requires the model and serial number to order the
correct parts.

Service Assistance
LOCAL REPAIR SERVICE
If you need service for your Mercury‑outboard‑powered boat, take it to your
authorized dealer. Only authorized dealers specialize in Mercury products and
have factory‑trained mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your engine.
NOTE: Quicksilver parts and accessories are engineered and built by Mercury
Marine specifically for your power package.
SERVICE AWAY FROM HOME
If you are away from your local dealer and the need arises for service, contact
the nearest authorized dealer. If, for any reason, you cannot obtain service,
contact the nearest Regional Service Center. Outside the United States and
Canada, contact the nearest Marine Power International Service Center.
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.
ATTENTION REQUIRED AFTER SUBMERSION
1. Before recovery, contact an authorized Mercury dealer.
2. After recovery, immediate service by an authorized Mercury dealer is
required to reduce the possibility of serious engine damage.

eng 51
 OWNER SERVICE ASSISTANCE
REPLACEMENT SERVICE PARTS

! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system
components on Mercury Marine products comply with federal and
international standards to minimize risk of fire or explosion. Do not use
replacement electrical or fuel system components that do not comply with
these standards. When servicing the electrical and fuel systems, properly
install and tighten all components.

Marine engines are expected to operate at or near full throttle for most of their
lives. They are also expected to operate in both fresh and saltwater
environments. These conditions require numerous special parts.
PARTS AND ACCESSORIES INQUIRIES
Direct any inquiries concerning Quicksilver replacement parts and accessories
to your local authorized dealer. The dealer has the necessary information to
order parts and accessories for you if they are not in stock. Only authorized
dealers can purchase genuine Quicksilver parts and accessories from the
factory. Mercury Marine does not sell to unauthorized dealers or retail
customers. When inquiring about parts and accessories, the dealer requires the
engine model and serial numbers to order the correct parts.
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. Talk with the dealership's sales manager or service manager. Contact the
owner of the dealership if the sales manager and service manager have
been unable to resolve the problem.
2. If your question, concern, or problem cannot be resolved by your
dealership, please contact the Mercury Marine Service Office for
assistance. Mercury Marine will work with you and your dealership to
resolve all problems.
The following information will be needed by the Customer Service:
• Your name and address
• Your daytime telephone number
• The model and serial numbers of your power package
• The name and address of your dealership
• The nature of the problem

52 eng
 OWNER SERVICE ASSISTANCE
CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER
SERVICE
For assistance, call, fax, or write to the geographic office in your area. Please
include your daytime telephone number with mail and fax correspondence.

United States, Canada

English +1 920 929 5040 Mercury Marine
Telephone
Français +1 905 636 4751 W6250 Pioneer Road
English +1 920 929 5893 P.O. Box 1939
Fax Fond du Lac, WI 54936-1939
Français +1 905 636 1704
Website www.mercurymarine.com

Australia, Pacific
Telephone +61 3 9791 5822 Brunswick Asia Pacific Group
41–71 Bessemer Drive
Fax +61 3 9706 7228 Dandenong South, Victoria 3175
Australia

Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe
Parc Industriel de Petit-Rechain
Fax +32 87 31 19 65 B-4800 Verviers,
Belgium

Mexico, Central America, South America, Caribbean

Telephone +1 954 744 3500 Mercury Marine
11650 Interchange Circle North
Fax +1 954 744 3535 Miramar, FL 33025
U.S.A.

Japan
Telephone +072 233 8888 Kisaka Co., Ltd.
4‑130 Kannabecho, Sakai‑ku
Fax +072 233 8833 Sakai‑shi, Osaka 590‑0984, Japan

Asia, Singapore
Telephone +65 65466160 Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
Fax +65 65467789 29 Loyang Drive
Singapore, 508944

Ordering Literature
Before ordering literature, have the following information about your power
package available:

eng 53
 OWNER SERVICE ASSISTANCE
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 Fax Mail
Mercury Marine
(920) 929‑5110 (920) 929‑4894 Attn: Publications Department
(USA only) (USA only) P.O. Box 1939
Fond du Lac, WI 54936-1939

OUTSIDE THE UNITED STATES AND CANADA

Contact your nearest Mercury Marine authorized service center to order
additional literature that is available for your particular power package.

Mercury Marine
Submit the following Attn: Publications Department
order form with payment W6250 Pioneer Road
to: P.O. Box 1939
Fond du Lac, WI 54936-1939
Ship To: (Copy this form and print or type–This is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country

Quantity Item Stock Number Price Total

. .
. .
. .
. .
. .
Total Due .

54 eng
 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

eng 55