Mercury 300 XS OptiMax Manual
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Mercury 300 XS OptiMax Manual

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Welcome
You have selected one of the finest outboards 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.
This manual contains specific instructions for using and maintaining your
product. We recommend 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
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. This certification is contingent on certain adjustments
being set to factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, wherever practicable,
returned to the original intent of the design. Maintenance, replacement, or
repair of the emission control devices and systems may be performed by
any marine engine repair establishment or individual.
Engines are labeled with an emission control information decal as
permanent evidence of EPA certification.
The engine exhaust from this product contains chemicals known to the
state of California to cause cancer, birth defects or other reproductive
harm.
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
Information section of this manual. The warranty statement 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 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, and to change specifications, designs, methods, or
procedures without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
eng
WARNING
!
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Summary of Contents for Mercury 300 XS OptiMax

  • Page 1 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.
  • Page 2 Printed in the U.S.A. Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of Mercury Premier to those demonstrating an exceptional commitment to service. Earning a Mercury Premier Service rating means a dealer: •...

  • Page 3: Table Of Contents

    Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada.................. 2 3 Year Limited Warranty Against Corrosion............2 Mercury Racing Division Two Year Limited Warranty United States and Canada ..........................4 U.S. EPA Emissions Limited Warranty............... 7 Emission Control System Components..............
  • Page 4 Low Permeation Fuel Hose Requirement ............43 EPA Pressurized Portable Fuel Tank Requirements........43 Fuel Demand Valve (FDV) Requirement............43 Mercury Marine's Pressurized Portable Fuel Tank........... 44 Filling Remote Oil Tank..................45 Filling Engine Mounted Oil Reservoir Tank............45 Filling Fuel Tank....................46 Features and Controls Remote Control Features.................
  • Page 5 Maintenance Power Package Care..................65 Replacement Parts for Your Power Package........... 65 EPA Emissions Regulations................65 Inspection and Maintenance Schedule............. 66 Flushing the Cooling System (Powerhead)............68 Flushing the Cooling System (Lower Unit)............69 Top Cowl Removal and Installation..............70 Cleaning Care for Top Cowl................
  • Page 6 Service Away from Home................. 98 Parts and Accessories Inquiries............... 98 Service Assistance................... 98 Ordering Literature..................101 Outboard Installation Mercury Marine Validated Engine Mounting Hardware........103 Boat Horsepower Capacity................103 Start in Gear Protection.................. 104 Selecting Accessories for Your Outboard............104 Fuel System....................104 Installation Specifications................

  • Page 7: Warranty Information

    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.

  • Page 8: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    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.
  • Page 9 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.

  • Page 10: Mercury Racing Division Two Year Limited Warranty United States And Canada

    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.
  • Page 11 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.
  • Page 12 • Improper service • Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product • Operation with fuels, oils, or lubricants that are not suitable for use with the product.

  • Page 13: U.s. Epa Emissions Limited Warranty

    U.S. 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,...

  • Page 14: California Emissions Limited Warranty

    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).
  • Page 15 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.

  • Page 16: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    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.

  • Page 17: Emission Certification Star Label

    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.

  • Page 18: Warranty Policy-Australia And New Zealand

    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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 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...

  • Page 22: Global Warranty Charts Outboard And Jets

    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.
  • Page 23 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 (300 XS) 2 years 3 years...
  • Page 24 WARRANTY INFORMATION ASIA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 1 year 3 years Contact the Marine FourStroke 1 year 3 years Power Service Center OptiMax 1 year 3 years closest to you Verado 1 year...
  • Page 25 WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Contact the Marine Verado 350 SCi 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.
  • Page 26 WARRANTY INFORMATION SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 year 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years closest to you Verado...

  • Page 27: General Information

    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.

  • Page 28: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 29: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice 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.
  • Page 30 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.
  • Page 31 GENERAL INFORMATION 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.

  • Page 32: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 33 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.

  • Page 34: Wave And Wake Jumping

    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.

  • Page 35: Impact With Underwater Hazards

    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.

  • Page 36: Exhaust Emissions

    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...
  • Page 37 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.

  • Page 38: Selecting Accessories For Your Outboard

    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.
  • Page 39 (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.

  • Page 40: Recording Serial Number

    It is important to record this number for future reference. The serial number is located on the outboard as shown. Serial Number XXXXXXX MMM 20XX XXXXX XX Max RPM XXXX Mercury Marine Brunswick Corp. Fond du Lac, WI 54935 Assembled in the USA from US and foreign components 30933 Serial number...

  • Page 41: Specifications-300 Xs Optimax

    GENERAL INFORMATION Specifications—300 XS OptiMax Specifications Propeller shaft horsepower 300 HP (224 kw) Engine displacement 3160 cc (193 cid) 20 in. 218 kg (480 lb) (Torque Master) 20 in. 229 kg (505 lb) (Sport Master) 25 in. Engine weight 239 kg (527 lb) (Torque Master) 25 in.
  • Page 42 Torque Master 1.75:1 Gear ratio 1.62:1 Sport Master 1.75:1 Fleet Master 1.75:1 Premium unleaded Required fuel 91 R+M/2 octane (96 RON) Recommended oil Mercury Racing 2‑Stroke Oil Gearcase oil Mercury Racing Gear Lube Gearcase lubricant capacity 710 ml (24 fl oz)

  • Page 43: Special Tools And Kits

    *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

  • Page 44: Component Identification

    Conversely, propping the engine at the lower end of the range may increase top boat speed but hinder acceleration. Mercury Marine recommends selecting a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information ‑...
  • Page 45 GENERAL INFORMATION If full throttle operation is below the recommended full throttle range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause higher than normal wear or damage. Generally, there is a 200–300 RPM change between propeller pitches.

  • Page 46: Transporting

    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.

  • Page 47: Fuel And Oil

    (fuel tanks, fuel lines, and fittings). Fuel containing alcohol may increase: Mercury Racing does not recommend using leaded gasoline. Read the information in the Fuel Containing Alcohol section. Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available;...

  • Page 48: Oil Recommendation

    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.

  • Page 49: Avoiding Fuel Flow Restrictions

    FUEL AND OIL Avoiding Fuel Flow Restrictions NOTICE Adding components to the fuel supply system can damage the engine. These additions can restrict fuel flow, stall the engine at low speeds, and create lean fuel conditions at high speeds. Follow all regulations for fuel system installation and do not add any additional components to the fuel system.

  • Page 50: Mercury Marine's Pressurized Portable Fuel Tank

    FUEL AND OIL 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.

  • Page 51: Filling Remote Oil Tank

    FUEL AND OIL 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.

  • Page 52: Filling Fuel Tank

    FUEL AND OIL 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.

  • Page 53: Features And Controls

    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. 26800 Control handle –...

  • Page 54: Zero Effort Control Features

    FEATURES AND CONTROLS Zero Effort Control Features Throttle lever Trim switch Shift lever 4090 Warning System WARNING HORN SIGNALS When the key switch is turned to the "ON" position, the horn will turn on for a moment as a test to indicate the horn is working. There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.
  • Page 55 2. Engage the throttle. If the engine does not respond, repeat step one. 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.

  • Page 56: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt NOTE: Outboard position can be adjusted by pressing trim switch. This range is used while operating your boat on plane. 2726 Trim switch Trim range Tilt range • Pressing (DN): Moves the outboard in closer to the boat transom, called trimming in or down.
  • Page 57 FEATURES AND CONTROLS 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. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully.

  • Page 58: Power Tilt Operation (Single-Ram Systems)

    FEATURES AND CONTROLS To limit trim in on models with a single‑ram trim system, use the cadmium plated bolt shipped with the engine. 15923 Stainless steel tilt pin (Three‑Ram trim system) Bolt shipped with engine (Single‑Ram trim system) Trimming out or up can: •...

  • Page 59: Auxiliary Tilt Switch

    FEATURES AND CONTROLS 1. Engage the tilt support lever by pushing the metal stop and rotating the knob to bring the support lever upward. 37214 Tilt support lever Metal stop Knob 2. Lower the outboard to rest on the tilt support lever. 3.
  • Page 60 FEATURES AND CONTROLS 1. Turn out the manual tilt release valve three turns (counterclockwise). This allows manual tilting of the outboard. 2728 2. Tilt the outboard to the desired position and tighten the manual tilt release valve. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

  • Page 61: Operation

    OPERATION Important Information 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.

  • Page 62: Engine Break-In Fuel Mixture

    OPERATION 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. Break‑in Procedure Always vary throttle settings during Break‑in 1st Hour • Allow engine to warm‑up for 30–60 seconds.

  • Page 63: Operating In Saltwater Or Polluted Water

    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.

  • Page 64: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Some boat performance can be improved by dropping to a lower pitch propeller, but engine performance will still remain lower. In some cases, a gear ratio reduction may be more beneficial. To optimize engine performance, prop the engine to allow it to operate at or near the top end of the recommended maximum RPM range at wide‑open throttle with a normal boat load.

  • Page 65: Oil Injection System

    OPERATION Oil Injection System FILLING THE OIL TANKS 1. Remove the fill cap from the remote oil tank and fill the tank with the recommended oil. Install the fill cap and tighten securely. Fill cap 2683 IMPORTANT: Do not remove the vent cap from the engine‑mounted oil reservoir tank when filling the tank.
  • Page 66 OPERATION PRIMING THE OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. 7747 Oil injection pump Oil supply hose IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump.

  • Page 67: Starting The Engine

    OPERATION 3. Turn the ignition key switch to the "ON" position. 26846 4. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times. This will automatically start the priming process.
  • Page 68 OPERATION STARTING PROCEDURE 1. Lower the outboard to the "RUN" position. Make sure all the cooling water intake holes are submerged. 26837 2. Open fuel tank filler cap vent screw (manual venting fuel tanks). 19748 3. Squeeze the fuel line primer bulb several times until it feels firm. 19779 4.
  • Page 69 OPERATION 5. Shift the outboard to the neutral position. 26838 6. Do not advance the neutral fast idle speed feature on the remote control for starting (if equipped). 27242 7. Turn the ignition key to the "START" position. Release the key when the engine starts.

  • Page 70: Gear Shifting

    No obstruction may indicate a water pump failure or blockage in the cooling system, which can overheat the engine. Have an authorized Mercury Marine dealer check the system. Gear Shifting IMPORTANT: Never shift into gear unless the engine is at idle. Never shift into reverse without the engine running.

  • Page 71: Power Package Care

    Mercury recommends using original Mercury Precision replacement parts and 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.

  • Page 72: Inspection And Maintenance Schedule

    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):...
  • Page 73 MAINTENANCE • Wash the power package exterior (cowl, midsection, and gearcase) with fresh water. • Flush the propeller and gearcase exhaust outlet with fresh water. • Remove the cowl and wipe off any saltwater spray with a damp cloth. EVERY 25 HOURS OR EVERY 30 DAYS OF SALTWATER OR POLLUTED WATER USE •...

  • Page 74: Flushing The Cooling System (Powerhead)

    MAINTENANCE EVERY 200 HOURS OR ONCE EVERY TWO YEARS, WHICHEVER OCCURS FIRST • Replace the water separating fuel filter. • Check the spark plug gap and replace if necessary. BEFORE PERIODS OF STORAGE • Refer to Storage section. Flushing the Cooling System (Powerhead) Flush the internal water passages of the engine with fresh water after each use in salt, polluted, or muddy water.

  • Page 75: Flushing The Cooling System (Lower Unit)

    MAINTENANCE Flushing the Cooling System (Lower Unit) 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.

  • Page 76: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation REMOVAL Release the front and side cowl latches. Lift the top cowl from the outboard. 2732 INSTALLATION Position the top cowl over the engine. Make sure the bottom rubber seal fits properly and lock the front and side latches. Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches.
  • Page 77 MAINTENANCE IMPORTANT: Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Before servicing any part of the fuel system: • Stop engine and disconnect the battery. •...
  • Page 78 MAINTENANCE Removal O‑ring seals Filter Raised bosses 1. Disconnect the link rod. 2. Use the shaft of a screwdriver between the filter cap bosses and unscrew the filter. Installation 1. Lubricate the O‑ring seals with oil. 2. Install the fuel filter and tighten securely. 3.
  • Page 79 IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber. If you experience multiple issues with water in the fuel system over a short period of time, see your authorized Mercury dealer.

  • Page 80: Steering Link Rod Fasteners

    MAINTENANCE Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113). Never replace locknuts with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.

  • Page 81: Fuses

    MAINTENANCE Description lb‑in. lb‑ft Cable coupler nylon insert locknut Tighten locknut until it seats, then "d" loosen ¼ turn. Head bolt nylon insert locknut "b" – Special washer head bolt – Fuses IMPORTANT: Always carry spare 2‑, 15‑, and 20‑amp fuses. The electrical wiring circuits on the engine are protected from overload by fuses in the wiring.

  • Page 82: Corrosion Control Anode

    Anodes made of insufficiently pure aluminum alloys may not adequately protect critical drive components from corrosion. We recommend using anodes sold through Mercury Precision Parts only. Anodes help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of other metals.

  • Page 83: Spark Plug Inspection And Replacement

    MAINTENANCE This model has three corrosion control anodes—two above and one below the anti‑ventilation plate. A fourth anode is located on the bottom of the clamp/ swivel bracket assembly. Corrosion control anodes (three on gearcase) Corrosion control anode (one on clamp/swivel bracket) All anodes require periodic inspection, especially in saltwater (refer to the Inspection and Maintenance Schedule).
  • Page 84 MAINTENANCE IMPORTANT: The color of the plug may not accurately reflect its condition. To accurately diagnose a faulty plug, inspect the precious metal on the plug's electrode. If no precious metal is visible, replace the plug. 9381 Precious metal 3. Set the spark plug gap. Refer to Specifications. 27848 a.

  • Page 85: Battery Inspection

    With the fusible link open, the engine can be started; however, the run time is limited, because the alternator is not charging the boat battery. If the fusible link circuit becomes open, contact your authorized Mercury Marine dealer. 3797...

  • Page 86: Replacing The Propeller

    Choose a propeller that allows the engine to operate at the specified wide open throttle RPM. Mercury Racing applications use 19‑spline propeller shafts and require installation of the Heavy‑Duty Propeller Hub kit, included with most Mercury Racing propellers.
  • Page 87 MAINTENANCE IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of Extreme Grease to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 1.

  • Page 88: Lubrication Points

    MAINTENANCE Lubrication Points Lubricate the following with Extreme Grease and 2‑4‑C with PTFE. 5517 Tube Ref Description Where Used Part No. Extreme Grease Trim rod ball ends, propeller shaft 8M0071842 2-4-C with PTFE Swivel bracket, tilt support lever, tilt tube 92-802859A 1 NOTE: Turn the ball ends to work the lubricant into the ball sockets.

  • Page 89: Single-Ram Trim System

    MAINTENANCE WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. Lubricate the steering link with lightweight oil. Lubricate the belt tensioner pulley and steering cable with 2‑4‑C with PTFE. 4833 Tube Ref Description...
  • Page 90 MAINTENANCE Optional Accessories Assembly Part Number Floor Mount Kit 842109A01 Bracket Assembly 87762A2 POWER TRIM OPERATION (SINGLE-RAM SYSTEM) The trim system has no trim out limits. Exercise care that engine is not trimmed out beyond safe operation limits. 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.
  • Page 91 MAINTENANCE CHECKING POWER TRIM FLUID (SINGLE-RAM TRIM SYSTEMS) 1. Place outboard in the full down/in position. or52 2. Check the fluid level in the trim pump reservoir. The level should be between the "MIN" and "MAX" level marks on the reservoir. 3.

  • Page 92: Three-Ram Trim System

    MAINTENANCE Three‑Ram Trim System GENERAL INFORMATION The power trim system was filled prior to shipment and is ready for use. The outboard can be raised or lowered manually by loosening the manual release valve four turns. Manual release valve 2687 The trim out angle of this outboard is not adjustable.
  • Page 93 MAINTENANCE With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability, there may be times when you choose to trim your outboard all the way in or out.
  • Page 94 MAINTENANCE CHECKING POWER TRIM FLUID (THREE-RAM TRIM SYSTEMS) 1. Tilt outboard to the full up position and engage the tilt support lock. or47-1 Tilt support lock Tube Ref. No. Description Where Used Part Number Power Trim and Fill hole 92‑802880A1 Steering Fluid 2.

  • Page 95: Gearcase Lubricant

    Fill/drain hole Fill/drain plug Tube Ref Description Where Used Part No. SAE 85W90 Mercury Gearcase 8M0078015 Racing Gear Oil 1. Place the outboard in a vertical operating position. 2. Remove the vent plug (upper plug) and sealing washer. 3. Remove the fill/drain plug (lower plug).
  • Page 96 MAINTENANCE 7. Remove lubricant tube and reinstall cleaned (lower) fill/drain plug and sealing washer. Water in gear lubricant may: • Settle to bottom and drain out with the lubricant • Be mixed with lubricant giving a milky color to the lubricant Water in gear lubricant will: •...

  • Page 97: Submerged Power Package

    MAINTENANCE Submerged Power Package A submerged power package requires prompt service by an authorized dealer after recovery. This immediate attention is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 98: Storage

    IMPORTANT: Fuel containing alcohol (ethanol or methanol) can cause a formation of acid during storage that can damage the fuel system. If the fuel being used contains alcohol, Mercury Marine recommends draining as much of the remaining fuel as possible from the fuel tank, remote fuel line, and engine fuel system.

  • Page 99: Protecting Internal Engine Components

    7. Tighten drain screw and reattach the hose. 8. Premix the following in a container: • 8 cc (0.3 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant. • 8 cc (0.3 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer.

  • Page 100: 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.

  • Page 101: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20‑amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure.

  • Page 102: Performance Loss

    TROUBLESHOOTING d. Fuel line is kinked or pinched. e. Injector plugged. • Threaded connection of an air hose is loose. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged propeller or improper propeller size. •...

  • Page 103: Battery Will Not Hold Charge

    TROUBLESHOOTING Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. • Worn out or inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator. •...

  • Page 104: Owner Service Assistance

    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.
  • Page 105 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.
  • Page 106 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...

  • Page 107: Ordering Literature

    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...
  • Page 108 OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total Total Due...

  • Page 109: Outboard Installation

    OUTBOARD INSTALLATION Mercury Marine Validated Engine Mounting Hardware IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability issues that can lead to safety concerns.

  • Page 110: Start In Gear Protection

    Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.
  • Page 111 OUTBOARD INSTALLATION 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.

  • Page 112: Installation Specifications

    OUTBOARD INSTALLATION FILLING THE FUEL SYSTEM For the 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: 1. Squeeze the fuel line primer bulb until it feels firm. 2.

  • Page 113: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. Lifting eye 28495 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead assembly from the driveshaft...

  • Page 114: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 2. Insert the steering cable into the tilt tube. 3725 3. Tighten the nut to the specified torque. 3727 Description lb‑in. lb‑ft 47.5 – Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).

  • Page 115: Rear-Mounted Steering Rams Or Tie Bars

    OUTBOARD INSTALLATION WARNING Worn, loose, or seized steering components can lead to loss of boat control. Inspect all steering attachment components for wear, lubricate all attachment hardware, and check all fasteners for proper tightness in accordance with the inspection and maintenance schedule. 2767 Special washer head bolt (P/N 10‑849838) Nylon insert locknut (P/N 11‑826709113) ‑...

  • Page 116: Determining Outboard Mounting Height

    OUTBOARD INSTALLATION • Do not install the steering brackets to the powerhead studs (upper studs). • Trim the port and starboard bottom cowls as needed. NOTICE Attaching rear‑mounted steering rams or tie bars to the powerhead studs may cause cylinder distortion and premature engine failure. Attach steering brackets to the correct installation locations.
  • Page 117 OUTBOARD INSTALLATION MOUNTING HEIGHT - TORQUE MASTER GEARCASE WARNING Improper installation of an outboard can result in serious injury or death. Do not allow the upper outboard mounting bolts to be closer than 25 mm (1 in.) from the top of the boat transom, not including any shims used to increase transom mouting height.
  • Page 118 OUTBOARD INSTALLATION Item Model Recommended Mounting Height Range 20 in. driveshaft models 635–686 mm (25–27 in.) MOUNTING HEIGHT - SPORT MASTER GEARCASE WARNING Improper installation of an outboard can result in serious injury or death. Do not allow the upper outboard mounting bolts to be closer than 25 mm (1 in.) from the top of the boat transom, not including any shims used to increase transom mouting height.
  • Page 119 OUTBOARD INSTALLATION IMPORTANT: The recommended mounting height is based on performance testing with a single‑engine application on a hull with no stepped or notched transoms. Your performance results may vary, depending on hull design. For best overall performance on boats with Sport Master gearcases, try to mount the outboard so the propeller shaft centerline is even with the bottom of the boat, as this gearcase is designed for surfacing applications.
  • Page 120 OUTBOARD INSTALLATION MOUNTING HEIGHT - FLEET MASTER GEARCASE WARNING Improper installation of an outboard can result in serious injury or death. Do not allow the upper outboard mounting bolts to be closer than 25 mm (1 in.) from the top of the boat transom, not including any shims used to increase transom mouting height.

  • Page 121: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION Item Model Recommended Mounting Height Range 25 in. driveshaft models 533–609 mm (21–24 in.) 30 in. driveshaft models 660–736 mm (26–29 in.) Drilling Outboard Mounting Holes IMPORTANT: Before drilling any mounting holes, carefully read Determining Recommended Outboard Mounting Height and install outboard to the nearest recommended mounting height.

  • Page 122: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION 2. 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 8M0033366 Outboard mounting bolt ½‑20 x 5.00 in. long (3.25 in. thread) 826711‑17 Nylon insert locknut ½‑20...
  • Page 123 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 124 OUTBOARD INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 125 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.
  • Page 126 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 –...

  • Page 127: Electrical, Hoses, Control Cables, And Front Clamp

    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, Hoses, Control Cables, and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl.
  • Page 128 OUTBOARD INSTALLATION BATTERY INFORMATION WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.
  • Page 129 OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard Red sleeve ‑ positive Black sleeve ‑ negative (–) Cranking battery (-) (-) 15496 Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑...
  • Page 130 OUTBOARD INSTALLATION HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate fuel line/fuel tank pickup for each engine. Fasten the remote fuel hose to the fitting with a hose clamp. Oil Hoses Connect the remote oil hoses to the engine hose connections.
  • Page 131 OUTBOARD INSTALLATION Make the water pressure gauge hose connection to the tubing as shown. 29069 Water pressure tube Speedometer water pickup tube (if required) Coupler Plug Barb hose fitting Speedometer hose or tubing Water pressure tube Remote fuel hose Hose clamp Oil hose with blue stripe Oil hose without blue stripe Cable tie...
  • Page 132 OUTBOARD INSTALLATION a. Move the remote control handle from neutral into forward and advance the handle to the full speed position. Ensure the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the handle back to the neutral detent position. c.
  • Page 133 OUTBOARD INSTALLATION 4. Align the cable end guide against this center mark when installing the cable to the engine. 5. Position the remote control and outboard into neutral position. 6. Slide the anchor pin forward until resistance is felt, then slide the anchor pin toward the rear until resistance is felt.
  • Page 134 OUTBOARD INSTALLATION 3. Secure the shift cable to the anchor pin with the retainer clip. 28749 Cable barrel Shift cable retainer Retainer clip 4. Check the shift cable adjustments as follows: a. Shift the remote control to forward while turning the propeller shaft. If the propeller shaft does not lock in gear, adjust the cable barrel closer to the cable end guide.
  • Page 135 OUTBOARD INSTALLATION Description lb‑in. lb‑ft Throttle cable locknut "b" Tighten, then loosen 1/4 turn 3. Adjust the cable barrel so the installed throttle cable will hold the idle stop screw against the stop. 28751 Barrel sleeve Cable barrel Idle stop screw 4.
  • Page 136 OUTBOARD INSTALLATION 5. Lock the barrel holder in place with the cable latch. 2682 FRONT CLAMP ASSEMBLY INSTALLATION IMPORTANT: There must be sufficient slack in the engine wiring harness, battery cables, fuel hose, and oil hoses, between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.
  • Page 137 OUTBOARD INSTALLATION 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties. 29074 Top half of the front clamp Cable ties 4. Secure the front clamp into the bottom cowl with the retainer and two screws.

  • Page 138: Oil Injection Set-Up

    OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1. Fill the remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten the fill cap. Fill cap 2683 2. Remove the cap and fill the engine oil tank with oil. Install the fill cap. Engine oil tank Fill cap 7745...
  • Page 139 OUTBOARD INSTALLATION PRIMING OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. 3768 Oil supply hose Oil injection pump IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump.

  • Page 140: Engine Well Inlet Cover Installation (Models With Remote Trim Pump)

    OUTBOARD INSTALLATION d. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. 26846 e. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. f.
  • Page 141 OUTBOARD INSTALLATION • Within easy access to the filler cap. 15870 Transom Trim lines Engine centerline Engine well cover IMPORTANT: The power trim hoses must be able to extend to the rear edge of the transom to connect to the engine. 2.
  • Page 142 OUTBOARD INSTALLATION 4. Install the gasket and cover using four 10‑32 screws, lockwashers, and hex nuts. Cut off excess screw lengths. 15871 Screw (4) Nut (4) Lockwasher (4) Cover Gasket 5. Route the trim pump harness end through the cover and cowl and attach the harness to the pump and the main engine harness.

  • Page 143: Trim In Pin

    OUTBOARD INSTALLATION 8. Connect the trim hoses to the fittings on the transom bracket as shown below. 14628 Power trim down circuit Power trim up circuit Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat.
  • Page 144 OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow‑down planing condition called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower. Tilt pin (not included with engine) 2688 Stainless Steel Tilt Pin 17‑49930A 1...

  • Page 145: Maintenance Log

    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...

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