iIf the outboard motor’s serial number plate contains the CE mark in the lowerleft‑hand corner, the following statement applies:This outboard motor ma
WARRANTY INFORMATION2Transfer Of WarrantyThe limited warranty is transferable to a subsequent purchaser, but onlyfor the remainder of the unused porti
WARRANTY INFORMATION3CONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGEWarranty coverage is available only to retail customers that purch
WARRANTY INFORMATION4WHAT IS NOT COVEREDThis limited warranty does not cover routine maintenance items, tune ups,adjustments, normal wear and tear, da
WARRANTY INFORMATION5DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AREEXPRESSLY DISCLAIME
WARRANTY INFORMATION6CONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGEWarranty coverage is available only to retail customers that purch
WARRANTY INFORMATION7WHAT IS NOT COVEREDThis limited warranty does not cover electrical system corrosion; corrosionresulting from damage, corrosion, w
WARRANTY INFORMATION8Warranty Coverage and Exclusions for MercuryRacing Outboard and Sterndrive ProductsThe purpose of this section is to help elimina
WARRANTY INFORMATION97. Use of other than Mercury Precision or Quicksilver parts when makingwarranty repairs.8. Engine noise does not necessarily indi
WARRANTY INFORMATION10DURATION OF COVERAGE: This limited warranty provides coverage forthe components of the emissions control systems of new, 2001 mo
WARRANTY INFORMATION11WHAT IS NOT COVERED: This limited warranty does not cover routinemaintenance items, tune ups, adjustments, normal wear and tear,
iiThank Youfor your purchase of one of the finest outboards available. You have madea sound investment in boating pleasure. Your outboard has
WARRANTY INFORMATION123. Ignition Systema. Spark plugsb. Magneto or electronic ignition systemc. Spark advance/retard systemd. Ignition coil and/or co
WARRANTY INFORMATION13CALIFORNIA AIR RESOURCES BOARD EXPLANATION OFYOUR CALIFORNIA EMISSION CONTROL WARRANTYSTATEMENTYOUR WARRANTY RIGHTS AND OBLI
WARRANTY INFORMATION14Star LabelOutboards are labeled on the cowl with one of the following star labels.The Symbol for Cleaner Marine Engines Means:Cl
GENERAL INFORMATION15Boater's ResponsibilitiesThe operator (driver) is responsible for the correct and safe operation ofthe boat and safety o
GENERAL INFORMATION16Do not overpower or overload your boat. Most boats will carry a requiredcapacity plate indicating the maximum acceptable po
GENERAL INFORMATION17! WARNINGAvoid serious injury or death from a sudden unexpected accelerationwhen starting your engine. The design of thi
GENERAL INFORMATION18Lanyard Stop SwitchThe purpose of a lanyard stop switch is to turn off the engine when theoperator moves far enough away fro
GENERAL INFORMATION19Accidental or unintended activation of the switch during normal operationis also a possibility. This could cause any, or all, of
GENERAL INFORMATION20Exhaust EmissionsBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide is present in the exhaust fumes of all internal combustione
GENERAL INFORMATION21WHILE BOAT IS STATIONARYob00317aba - Running the engine when the boat is moored in a confined space.b - Mooring close to another
iiiMercury Premier ServiceMercury evaluates the service performance of its dealers and assigns itshighest rating of "Mercury Premier" to tho
GENERAL INFORMATION22Persons on the front deck could easily be thrown overboard or personsdangling their feet over the front edge could get their legs
GENERAL INFORMATION23Wave And Wake JumpingOperating recreational boats over waves and wake is a natural part ofboating. However, when this
GENERAL INFORMATION24Impact With Underwater HazardsReduce speed and proceed with caution whenever you drive a boat inshallow water areas, o
GENERAL INFORMATION25The boat should also be checked for any hull fractures, transom fractures,or water leaks.Operating a damaged outboard could cause
GENERAL INFORMATION26Know and obey all nautical rules and laws of the waterways. Boat operatorsshould complete a boating safety course. Courses are of
GENERAL INFORMATION27Report accidents. Boat operators are required by law to file a BoatingAccident Report with their state boating l
GENERAL INFORMATION28Description SpecificationsNeutral Rev Limit 1900 rpmFull ThrottleRPM Range20 in. (Torque/SportMaster)5500 – 6300 rpm25 in. (Torqu
GENERAL INFORMATION29NOTE: Where applicable, specifications are derived at sea level.Special Tools and KitsDescription Part NumberStainless Steel Til
GENERAL INFORMATION30Component Identification250xs1234567891011121335401 - Top cowl2 - Side cowl latches (bothsides)3 - Front cowl latch4 - Auxiliary
GENERAL INFORMATION31Propeller SelectionPropping the engine at the higher end of the RPM range may increaseacceleration, but decrease top boat
iv
TRANSPORTING32Trailering Boat/OutboardTrailer your boat with the outboard tilted down in a vertical operatingposition.If additional ground
FUEL AND OIL33Avoiding Fuel Flow Restrictions! CAUTIONAvoid engine damage. Adding components to the fuel supply system,such as filters, valves, f
FUEL AND OIL34FUEL CONTAINING ALCOHOLIf the fuel in your area contains either methanol (methyl alcohol) or ethanol(ethyl alcohol), you should be aware
FUEL AND OIL35TC‑W3 Premium Plus Outboard Oil is a higher grade oil that providesincreased lubrication and extra resistance to carbon build
FUEL AND OIL36NOTE: Filling this tank is only necessary if the oil level should ever dropand the low oil warning system is activated.Filling Fuel Tank
FEATURES AND CONTROLS37Remote Control FeaturesYour boat may be equipped with one of the Mercury Precision orQuicksilver remote controls
FEATURES AND CONTROLS38Zero Effort Control Featuresabc4090a - Throttle leverb - Trim switchc - Shift leverWarning SystemThe warning system incorpor
FEATURES AND CONTROLS39The warning horn will emit either a continuous beep or intermittent shortbeeps. This will alert the operator and help i
FEATURES AND CONTROLS40Problem HornMonitorDisplayGuardianActivatedPercentage ofFull EnginePowerAvailableBattery VoltageOut of LimitsSingleBeep...Conti
FEATURES AND CONTROLS41Upon reaching the rev limit, the Guardian System activates the warninghorn. If the operator does not reduce engine speed within
TABLE OF CONTENTSvWarranty InformationWarranty Registration United States And Canada...1Mercury Racing Demonstrator Po
FEATURES AND CONTROLS42Power Trim OperationWith most boats, operating around the middle of the trim range will givesatisfactory results. Trimming y
FEATURES AND CONTROLS43! WARNINGAvoid possible injury or death. Always perform a water test to examineboat handling and steering after making any trim
FEATURES AND CONTROLS44Power Tilt Operation (Single‑Ram Systems)To tilt the outboard, shut off the engine and press the trim/tilt switch or theauxilia
FEATURES AND CONTROLS45Auxiliary Tilt SwitchThis switch can be used to tilt the outboard up or down using the powertrim system.or54-1aa - Auxiliary ti
FEATURES AND CONTROLS462. Tilt the outboard to the desired position and tighten the manual tiltrelease valve.NOTE: The manual tilt release valve mu
OPERATION47Engine Break‑in! CAUTIONSevere damage to the engine can result by not complying with the enginebreak‑in proceedure. Engine damage may not b
OPERATION48Fuel tank vent cap open or fuel drain valve on.Fuel supply OKLanyard stop switch in "RUN" position and cord connected.Remote cont
OPERATION49Effects of Elevation and Weather on PerformanceThe following conditions lower engine performance and cannot becompensated by the en
OPERATION50Setting Trim Angle While Running Engine at IdleSpeedSubmerging the exhaust relief hole on the outboard can happen on someboats if you trim
OPERATION51Starting The Engine! CAUTIONNever start or operate your outboard (even momentarily) without watercirculating through all the cooling water
TABLE OF CONTENTSviFuel and OilAvoiding Fuel Flow Restrictions...33Fuel Requirements...
OPERATION523. Squeeze the fuel line primer bulb several times until it feels firm.ob003494. Set the lanyard stop switch to the "RUN" positio
OPERATION537. Turn the ignition key to the "START" position. Release the key whenthe engine starts. If the engine fails to start in ten seco
OPERATION54Gear ShiftingIMPORTANT: Never shift into gear unless the engine is at idle. Never shiftinto reverse without the engine running.• Your outb
MAINTENANCE55Power Package Care! WARNINGAvoid equipment damage, serious injury or death from improper orneglected maintenance, repairs or ins
MAINTENANCE56EMISSION CERTIFICATION LABELAn emission certification label, showing emission levels and enginespecifications directly related to
MAINTENANCE57AFTER EACH SALTWATER OR POLLUTED WATER USE• Flush all internal passages with fresh water.• Wash the power package exterior (cowl, mid sec
MAINTENANCE58• Remove engine deposits with Power Tune Engine Cleaner.EVERY 100 HOURS OR ONCE A YEAR, WHICHEVEROCCURS FIRST• Replace water pump impe
MAINTENANCE59Flushing the Cooling System (Lower Unit)! WARNINGTo avoid possible injury when flushing, remove the propeller. Refer toPropeller Replacem
MAINTENANCE60Top Cowl Removal and InstallationREMOVALRelease the front and side cowl latches. Lift the top cowl from the outboard.or38INSTALLATIONPosi
MAINTENANCE61Fuel SystemFUEL SYSTEM SERVICE INFORMATION! WARNINGAvoid serious injury or death from gasoline fire or explosion. Carefullyfollow all fue
TABLE OF CONTENTSviiSubmerged Power Package...55Replacement Parts for Your Power Packa
MAINTENANCE62Removalor39-1abca - O‑ring sealsb - Filterc - Raised bosses1. Disconnect the link rod.2. Use the shaft of a screwdriver between th
MAINTENANCE63DRAINING WATER FROM THE FUEL FILTER CHAMBERNOTE: If a sufficient amount of water has accumulated in the fuel filterchamber, th
MAINTENANCE64! WARNINGDisengagement of a steering link rod can result in the boat taking a full,sudden, sharp turn. This potentially violent action ca
MAINTENANCE65Description Nm lb. in. lb. ft.Special washer head bolt 27 20FusesIMPORTANT: Always carry spare 5 and 20 amp fuses.The electrical wiring c
MAINTENANCE66Corrosion Control Anode! CAUTIONAvoid corrosion damage. Mercury Marine recommends using anodessold through Mercury Precision Parts
MAINTENANCE67Spark Plug Inspection and Replacement! WARNINGAvoid serious injury or death from fire or explosion caused by damagedspark plug boots. Dam
MAINTENANCE681. Turn off the engine before servicing the battery.2. Add water as necessary to keep the battery full.3. Make sure the battery is secure
MAINTENANCE69NOTE: If propeller is seized to the shaft and cannot be removed, consultyour authorized Mercury Marine dealer.1. Shift outboard to neutra
MAINTENANCE70! CAUTIONAvoid engine damage. Prop the engine so engine speed is limited to therequired full throttle rpm range. An under‑propped
MAINTENANCE71Tube Ref No. Description Where Used Part No.94Anti-Corrosion Grease Propeller shaft splines92-802867A13. Place a block of wood between th
TABLE OF CONTENTSviiiOwner Service AssistanceLocal Repair Service...85Serv
MAINTENANCE72Lubrication Points55173494959595Tube Ref. No. Description Where Used Part Number34Special Lubricant 101 Trim Rod Ball Ends 92‑802865A1952
MAINTENANCE73! WARNINGAvoid serious injury or death. The end of the steering cable must be fullyretracted into the outboard tilt tube before ad
MAINTENANCE743. If necessary, remove the yellow fill cap and add Power Trim andSteering Fluid until the level in the reservoir reaches the
MAINTENANCE75Checking Power Trim Fluid (Three‑Ram TrimSystems)1. Tilt outboard to the full up position and engage the tilt support lock.a114or47-1a -
MAINTENANCE76Gearcase LubricantCHECKING/REFILLING GEARCASE LUBRICANTor49-1abcdefcd87a - SportMaster gearcase(vertical operating position)b - Fleet/Tor
MAINTENANCE777. Remove lubricant tube and reinstall cleaned (lower) fill/drain plug andsealing washer.Water in gear lubricant may:• Settle to bottom a
STORAGE78Storage PreparationThe major consideration in preparing your outboard for storage is to protectit from rust, corrosion, and damage caused by
STORAGE79NOTE: If little or no liquid drains from the hose, loosen the red filter to ventthe chamber.ob01352abca - Drain screwb - Drain hosec - Right
STORAGE806. Premix the following in a container:• 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleenlubricant.• 8 cc (0.27 oz.) o
STORAGE81Positioning Outboard For StorageStore outboard in an upright (vertical) position to allow water to drain outof outboard.! CAUTIONIf outboard
WARRANTY INFORMATION1Warranty Registration United States And CanadaOutside United States and Canada ‑ Check with your local distributor.1. You may c
TROUBLESHOOTING82Starter Motor Will Not Crank the EnginePOSSIBLE CAUSES• Blown 20 amp fuse in the starting circuit. Refer to Maintenance.• Outboard is
TROUBLESHOOTING83b. Fuel tank filter obstructed.c. Stuck anti‑siphon valve on built in fuel tank.d. Fuel line is kinked or pinched.e. Injector plugged
TROUBLESHOOTING84• High engine temperature or low block water pressure.• Cooling system clogged.• Incorrect transom height (water pickups not ge
OWNER SERVICE ASSISTANCE85Local Repair ServiceAlways return your outboard to your local authorized dealer should theneed for service aris
OWNER SERVICE ASSISTANCE86Mercury Marine Service OfficesFor assistance, call, fax, or write. Please include your daytime telephonenumber with mail and
OWNER SERVICE ASSISTANCE87Europe, Middle East, AfricaTelephone Fax Marine Power - Europe, Inc.Parc Industriel de Petit-RechainB-4800Verviers,Belgium(3
OWNER SERVICE ASSISTANCE88OUTSIDE THE UNITED STATES AND CANADAContact your nearest dealer or Marine Power Service Center forinformation on
MAINTENANCE LOG89Maintenance LogRecord all maintenance performed on your outboard here. Be sure to saveall work orders and receipts.Date Maintenance P
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