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Mercury XR2 User Manual

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for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Ma-
rine, a world leader in marine technology and outboard
manufacturing since 1939. These years of experience
have been committed to the goal of producing the finest
quality products. This led to Mercury Marine's reputation
for strict quality control, excellence, durability, lasting per-
formance and being the best at providing after-the-sale
support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use and care of your outboard.
All of us at Mercury Marine took pride in building your out-
board and wish you many years of happy and safe boat-
ing.
Again, thank you for your confidence in Mercury Marine.
Mercury Hi-Performance,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585

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  • Page 1 This manual has been prepared to assist you in the operation, safe use and care of your outboard. All of us at Mercury Marine took pride in building your out- board and wish you many years of happy and safe boat- ing.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information Boater’s Responsibilities ....... . Before Operating Your Outboard .
  • Page 4 TABLE OF CONTENTS Operation Pre-Starting Check List ....... . Special Operating Instructions .
  • Page 5 ........The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, to change specifications, designs, methods, or procedures without notice or incurring obligation.

  • Page 6: General Information

    GENERAL INFORMATION oba1 Boater’s Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strong- ly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person on board is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 7: Boat Horsepower Capacity

    GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY obc1 Boat Horsepower Capacity Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable pow- er and load as determined by the manufacturer following certain federal guidelines.

  • Page 8: Outboard Remote Control

    GENERAL INFORMATION obe1 Outboard Remote Control The remote control connected to your outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting when the outboard is in gear. WARNING Avoid serious injury or death from a sudden unexpected ac- celeration when starting your engine.

  • Page 9: Lanyard Stop Switch

    GENERAL INFORMATION hbg1 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.
  • Page 10 GENERAL INFORMATION Lanyard Stop Switch (Continued) 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.
  • Page 11 GENERAL INFORMATION Lanyard Stop Switch (Continued) Accidental or unintended activation of the switch during normal op- eration is also a possibility. This could cause any, or all, of the follow- ing potentially hazardous situations: 1. Occupants could be thrown forward due to unexpected loss of forward motion –...

  • Page 12: Protecting People In The Water

    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. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 13: Exhaust Emissions

    GENERAL INFORMATION Courtesy of ABYC Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal com- bustion engines including the outboards, stern drives and inboard engines that propel boats, as well as the generators that power vari- ous boat accessories.
  • Page 14 GENERAL INFORMATION Courtesy of ABYC Exhaust Emissions (Continued) 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 unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of car-...

  • Page 15: Selecting Accessories For Your Outboard

    Mercury Marine Quicksilver accessories are available from Mercury Marine dealers. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard oper- ating system. Acquire and read the installation, operation, and main- tenance manuals for all your selected accessories.
  • Page 16 GENERAL INFORMATION Safe Boating Suggestions (Continued) Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2) The Power Squadron, (3) The Red Cross and (4) your state boating law enforcement agency.

  • Page 17: Recording Serial Number

    GENERAL INFORMATION Safe Boating Suggestions (Continued) Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

  • Page 18: Torque Requirements

    GENERAL INFORMATION Torque Requirements ITEM TORQUE Connecting Rods 30 lb. ft. (41 N·m) 271 Loctite Crankcase Cover to Block 3/8 in. -- 40 lb. ft. (54 N·m) Light Oil 5/16 in. -- 200 lb. in. (23 N·m) Light Oil Exhaust Divider Plate Cover 200 lb.

  • Page 19: Specifications

    GENERAL INFORMATION Specifications MODEL Horsepower 180 (134kw) Propshaft Kilowatts Full Throttle RPM Range 6000-7000 Idle RPM in Forward Gear 650-750 Weight 350 lbs. (159 kg) Piston Displacement 122 cu. in. (2.0L/1998cc) Bore 3.125 in. (79.5 mm) Stroke 2.65 in. (67 mm) Recommended Spark Plug NGK-BUHW (P/N 33-97180) Firing Order...

  • Page 20: Component Identification

    GENERAL INFORMATION Component Identification 1. Top Cowl 8. Transom Brackets 2. Cowl Latch 9. Trim Adjustment Bolt 3. Bottom Cowl 10. Gear Case 4. Water Pump Indicator Hose I di 11 W t 11. Water Discharge Di h (Tell-Tale) (Tell Tale) 12 Cooling Water Intake Holes 12.

  • Page 21: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with four mounting bolts shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.

  • Page 22: Propeller Selection

    INSTALLATION ghc3 OUTBOARD MOUNTING HEIGHT Use the following chart to determine the proper mounting height (a) for your outboard. Gear Case Minimum Height Maximum Height Application Sport Master 27” (68cm) 30” (76cm) ocb1 Propeller Selection For best all around performance from your outboard/boat combi- nation, select 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 Specifications).

  • Page 23: Transporting

    TRANSPORTING odc1 Trailering Boat/Outboard Trailer your boat with the outboard tilted down (vertical operating po- sition). If additional ground clearance is required, the outboard should be tilted up using an outboard support bar. Additional clearance may be required for railroad crossings, driveways and trailer bouncing. IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailer- ing.

  • Page 24: Fuel & Oil

    FUEL & OIL Gasoline Recommendations UNITED STATES AND CANADA Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 87. Mid-grade automotive gasolines that con- tain fuel injector cleaner are preferred for added internal engine cleanliness.

  • Page 25: Oil Recommendation

    FUEL & OIL Oil Recommendation Use Mercury Hi-Performance Synthetic Blend 2-Cycle Oil. Emergency Use Only: If the Hi-Performance 2-Cycle Oil is not avail- able, Quicksilver NMMA Certified Premium TC-W3 or Premium Plus TC-W3 2-Cycle Oil may be substituted. These oils should not be used on a regular basis.

  • Page 26: Features & Controls

    FEATURES & CONTROLS gog142 Side Mount Console Panel oge5 Remote Control Features Your boat may be equipped with one of the Quicksilver remote con- trols shown. If not, consult your dealer for a description of the func- tions and operations of the remote control. Control Handle –...

  • Page 27: Warning System

    FEATURES & CONTROLS gog67 ogb32 Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control (a) or under the dash (b) connected to the ignition key switch. The system is designed for the warning horn to emit either a continu- ous beep or intermittent short beeps.
  • Page 28 FEATURES & CONTROLS Warning System (Continued) THE WARNING HORN SOUNDS CONTINUOUSLY Problem – Engine overheat. The warning system is activated when the engine temperature is too hot. If the engine overheats, immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole (a).

  • Page 29: Power Trim And Tilt

    FEATURES & CONTROLS Power Trim And Tilt WARNING Avoid possible serious injury or death. Do not trim outboard beyond its normal trim range above 2000 RPM. In order to sig- nificantly raise the strength of the Hi-Performance transom assembly, the electric trim limit and trim indicator sending unit mounting positions have been eliminated.
  • Page 30 FEATURES & CONTROLS Power Trim And Tilt (Cont.) POWER TRIM OPERATION With most boats, operating around the middle of the “trim” range will give satisfactory results. However, to take full advantage of the trim- ming capability there may be times when you choose to trim your out- board all the way in or out.
  • Page 31 FEATURES & CONTROLS Power Trim And Tilt (Cont.) POWER TRIM OPERATION (CONT.) 5. In excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow-steer- ing”...
  • Page 32 FEATURES & CONTROLS 1-2-3 Power Trim And Tilt (Cont.) TILTING OPERATION (IF EQUIPPED) To tilt outboard, shut off the engine and press the trim/tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position.

  • Page 33: Pre-Starting Check List

    OPERATION Pre-Starting Check List Operator knows safe navigation, boating, and operating proce- dures. 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.
  • Page 34 OPERATION Special Operating Instructions (Cont.) OPERATING IN SALT WATER 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 “Flushing The Cooling System”...
  • Page 35 OPERATION og124 Special Operating Instructions (Cont.) onk2 OPERATING IN SHALLOW WATER When operating your boat in shallow water, you can tilt the out- board beyond the maximum trim range to prevent hitting bottom. a. Reduce engine speed below 2000 RPM. b.

  • Page 36: Engine Break-In Procedure

    OPERATION Engine Break-in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. Operate your outboard at varied throttle settings – not to exceed 1/2 throttle (3000-3500 RPM) during the first hour or ten gallons of En- gine Gasoline/Oil Mixture.

  • Page 37: Starting The Engine

    OPERATION Starting The Engine Before starting, read the Pre-Starting Check List, Special Operating Instructions, and Engine Break-in Procedure on the first three pages in the Operation Section. CAUTION Prevent damage to the water pump (running dry) or overheat- ing of the engine. Never start or run your outboard (even mo- mentarily) without water circulating through all the cooling water intake holes in the gear case.
  • Page 38 OPERATION Starting The Engine (Continued) Shift outboard to neutral (N) position. The engine can be manually primed by pushing in on the key choke switch (if so equipped) or a remote choke switch can be connected to the yel/blk wire at the engine harness connector. (Refer to wiring diagram).

  • Page 39: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle. • Do not shift outboard into Reverse when the engine is not running. Your outboard has three gear shift positions to provide operation. Forward (F), Neutral (out of gear) and Reverse (R).

  • Page 40: Maintenance

    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.

  • Page 41: Inspection And Maintenance Schedule

    MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE 1. Check that lanyard stop switch stops the engine. 2. Visually inspect the fuel system for deterioration or leaks. 3. Check outboard for tightness on transom. 4. Check steering system for binding or loose components. 5.
  • Page 42 MAINTENANCE Inspection And Maintenance Schedule (Cont.) EVERY 25 HOURS OF USE OR ONCE A MONTH 1. Lubricate all lubrication points. (page 50) 2. Check level and condition of gear case lubricant. (page 53) 3. Inspect battery. (page 49) 4. Check corrosion control anodes. (page 46) 5.

  • Page 43: Flushing The Cooling System

    MAINTENANCE 1–4 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. A nose cone flushing attachment for the Sport Master Gear Case P/N 848998A1 is available thru Quicksilver Accessories.

  • Page 44: Top Cowl Removal And Installation

    MAINTENANCE Flushing The Cooling System (Cont.) IMPORTANT: Stop engine before shutting off water. Never op- erate engine without cooling water. Even momentary engine op- eration without water could cause severe engine damage. Stop the engine, turn off the water, and remove the flushing at- tachment.

  • Page 45: Fuel System

    MAINTENANCE Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system, stop engine and discon- nect the battery.
  • Page 46 MAINTENANCE Fuel System (Continued) WATER SEPARATING FUEL FILTER (NOT INCLUDED WITH ENGINE) A water separating fuel filter is not included with your engine but is recommended. This filter removes moisture and also debris from the fuel and should be mounted before the fuel pump sup- plied with your engine.

  • Page 47: Steering Link Rod Fasteners

    MAINTENANCE ohi1 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a” – Part Number 10-14000) and self locking nylon insert locknuts (“b” & “c” – Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off freeing the link rod to disengage.

  • Page 48: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your outboard has three corrosion control anodes. One of the anodes is the round plate installed on the antiventilation plate (a), a second one is located just above the antiventilation plate (b), and the third is installed on the bottom of the transom bracket assembly (c). An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard met- als.

  • Page 49: Propeller Replacement

    MAINTENANCE 4–5 ohl8 Propeller Replacement WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propel- ler, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.
  • Page 50 MAINTENANCE 9-10 Propeller Replacement (Cont.) Coat the propeller shaft with Quicksilver Anti-Corrosion Grease. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always ap- ply a coat of Quicksilver Anti-Corrosion Grease to the entire shaft at the recommended maintenance intervals and also each time the propeller is removed.

  • Page 51: Spark Plug Inspection

    MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect spark plug boots and replace if cracked. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, bro- ken, blistered, or fouled.

  • Page 52: Lubrication Points

    MAINTENANCE Lubrication Points LUBRICATE POINT 1 WITH QUICKSILVER ANTI-CORROSION GREASE. 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 and seizing to the shaft. LUBRICATE POINTS 2 AND 3 WITH QUICKSILVER 2-4-C MA- RINE LUBRICANT OR SPECIAL LUBRICANT 101.
  • Page 53 MAINTENANCE Lubrication Points (Continued) WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly re- sulting in serious injury or death.

  • Page 54: Checking Power Trim Fluid

    MAINTENANCE Checking Power Trim Fluid Place outboard in the full down (in) position. Remove fill/vent screw (a). Wipe with a clean, lint-free cloth and reinstall - DO NOT THREAD INTO PUMP. Remove fill/vent screw and note oil level. Oil level must be between the “ADD” (c) and “FULL”...

  • Page 55: Gear Case Lubrication

    MAINTENANCE Gear Case Lubrication When adding or changing gear case 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.

  • Page 56: Submerged Outboard

    MAINTENANCE Gear Case Lubrication (cont.) CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE Place outboard in a vertical operating position. Remove fill plug/sealing washer (a) and top vent plug/sealing washer (c). Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent hole (d).

  • Page 57: Storage

    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).

  • Page 58: Protecting Internal Engine Components

    STORAGE Fuel System (Cont.) 1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline.

  • Page 59: Gear Case

    STORAGE Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance pro- cedure). Battery Storage 1. Follow the battery manufacturers instructions for storage and re- charging. 2. Remove the battery from the boat and check water level. Re- charge if necessary.

  • Page 60: Troubleshooting

    TROUBLESHOOTING – STARTER MOTOR WILL NOT CRANK THE ENGINE POSSIBLE CAUSES • Outboard gearshift not in neutral position. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure. • Wiring or electrical connection faulty. • Starter motor or starter solenoid failure.
  • Page 61 TROUBLESHOOTING – ENGINE RUNS ERRATICALLY POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance Section. • Incorrect setup and adjustments. • Fuel pump failure. • Fuel is being restricted to the engine. d. Engine Fuel filter is obstructed. Refer to Maintenance Sec- tion.
  • Page 62 ENGINE WIRING DIAGRAM...

  • Page 63: Maintenance Log

    MAINTENANCE LOG Record all maintenance performed on your outboard. Be sure to save all work orders and receipts. DATE MAINTENANCE PERFORMED ENGINE HOURS...
  • Page 64 MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS...

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