Mercury 9.9 BigFoot Manual
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Mercury 9.9 BigFoot Manual

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See also: Service Manual , Operation & Maintenance Manual
Thank You
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 Marine, 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 performance,
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
outboard and wish you many years of happy and safe
boating.
Again, thank you for your confidence in 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.
eng
WARNING
!
i

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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 outboard and wish you many years of happy and safe boating.
  • Page 2 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...
  • Page 3 Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Tohatsu Marine Corporation (TMC) Mercury Marine Joint Venture Address: Shimodaira 4495‑9 Town: Komagane‑City, Post Code: 399‑4101...
  • Page 4 Conformity assessment ☐ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G ☒ H module used for exhaust emissions: Conformity assessment ☐ A ☐ Aa ☐ G ☒ H module used for noise emissions: Other Community Directives applied: Safety of Machinery Directive 2006/42/EC;...
  • Page 5 I declare on behalf of the engine manufacturer that the engines mentioned preceding complies with all applicable essential requirements in the way specified. Name / function: Mark D. Schwabero, President, Mercury Outboard Date and place of issue: May 10, 2012 Fond du Lac, Wisconsin, USA...

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration..............1 Transfer of Warranty..............2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada......... 2 FourStroke Outboard Limited Warranty........3 FourStroke Outboard Limited Warranty........7 FourStroke Outboard Limited Warranty........11 3 Year Limited Warranty Against Corrosion......15 Warranty Coverage and Exclusions..........
  • Page 8 General Information Boater's Responsibilities............28 Before Operating Your Outboard..........28 Boat Horsepower Capacity............29 High‑Speed and High‑Performance Boat Operation....29 Outboard Remote Control Models ..........30 Remote Steering Notice............. 30 Lanyard Stop Switch..............31 Protecting People in the Water..........35 Passenger Safety Message ‑...
  • Page 9 Fuel Recommendations............. 55 Low Permeation Fuel Hose Requirement ......... 57 EPA Pressurized Portable Fuel Tank Requirements....57 Fuel Demand Valve (FDV) Requirement........57 Mercury Marine's Pressurized Portable Fuel Tank....58 Filling Fuel Tank................ 59 Engine Oil Recommendations........... 60 Checking Engine Oil..............61 Features and Controls Tiller Handle Features...............
  • Page 10 Maintenance Outboard Care................92 EPA Emission Regulations............92 Inspection and Maintenance Schedule........93 Flushing the Cooling System............. 95 Top Cowl Removal And Installation........... 98 Battery Inspection ..............98 Exterior Care................99 Fuel System................99 Steering Link Rod Fasteners........... 100 Corrosion Control Anode ............102 Propeller Replacement ............
  • Page 11 Owner Service Assistance Local Repair Service..............122 Service Away from Home............122 Parts and Accessories Inquiries..........122 Service Assistance..............122 Mercury Marine Service Offices..........123 Engine Installation Boat Horsepower Capacity............125 Start in Gear Protection............125 Selecting Accessories for Your Outboard........ 126 Low Permeation Fuel Hose Requirement .......

  • Page 13: Warranty Information

    You may change your 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 14: Transfer Of Warranty

    To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and...

  • Page 15: Fourstroke Outboard Limited Warranty

    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. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
  • Page 16 WARRANTY 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 17 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 18 No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation, or warranty regarding the product, other than those contained in this limited warranty, and...

  • Page 19: Fourstroke Outboard Limited Warranty

    EUROPE AND CONFEDERATION OF INDEPENDENT STATES Outside Europe and Confederation of Independent States ‑ check with local distributor. WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
  • Page 20 WARRANTY 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 21 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 22 No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and...

  • Page 23: Fourstroke Outboard Limited Warranty

    RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. FourStroke Outboard Limited Warranty MIDDLE-EAST AND AFRICA WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below.
  • Page 24 WARRANTY 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 25 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 26 No individual or entity, including Mercury Marine authorized dealers, has been given authority by 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.

  • Page 27: Year Limited Warranty Against Corrosion

    WARRANTY 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 28 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 29 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 30: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
  • Page 31 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants, or fluids changed as a matter of normal...

  • Page 32: 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, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at...

  • Page 33: California Emissions Limited Warranty

    California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System...
  • Page 34 Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
  • Page 35 Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Marine's sole and...
  • Page 36 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 37: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    Also included may be hoses, belts, connectors, and other emission‑related assemblies. Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.

  • Page 38: Emission Certification Star Label

    WARRANTY INFORMATION 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. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists.
  • Page 39 WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust 42538 emission standards.

  • Page 40: General Information

    GENERAL INFORMATION 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 strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 41: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

  • Page 42: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death.

  • Page 43: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat.
  • Page 44 GENERAL INFORMATION The lanyard is a cord 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 snap on the other end for attaching to the operator. 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 45 GENERAL INFORMATION 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 46 GENERAL INFORMATION 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.

  • Page 47: 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. 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 48: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 49: Wave And Wake Jumping

    GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

  • Page 50: Impact With Underwater Hazards

    GENERAL INFORMATION WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.
  • Page 51 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.

  • Page 52: Exhaust Emissions

    GENERAL INFORMATION Models with Clamp Screws: Some outboards come with transom bracket clamp screws. The use of clamp bracket screws alone, is insufficient to properly and safely secure the outboard to the transom. Proper installation of the outboard includes bolting the engine to the boat through the transom.
  • Page 53 GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains or forward hatches to remove fumes. 21622 Example of desired air flow through the boat 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 54: Selecting Accessories For Your Outboard

    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.
  • Page 55 GENERAL INFORMATION 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 56: Recording Serial Number

    Model designation XXXX Year manufactured Certified Europe Insignia (as 38780 applicable) 8/9.9 FourStroke Specifications Models 9.9 BigFoot/ProKicker 5.88 kw (8 Power 7.28 kw (9.9 hp) Number of cylinders Full throttle RPM range 5000–6000 RPM Idle speed in forward 900 RPM gear Piston displacement 209.8 cc (12.8 cid)
  • Page 57 GENERAL INFORMATION Models 9.9 BigFoot/ProKicker Cylinder bore 55 mm (2.17 in.) Piston stroke 44 mm (1.73 in.) Valve clearance (cold) Intake valve 0.13–0.17 mm (0.0051–0.0067 in.) Exhaust valve 0.18–0.22 mm (0.0071–0.0087 in.) Recommended spark NGK DCPR6E plug Spark plug gap 0.8–0.9 mm (0.031–0.035 in.)

  • Page 58: Component Identification - Standard Models

    GENERAL INFORMATION Component Identification ‑ Standard Models STARBOARD SIDE VIEW Cowl latch Throttle only button Throttle friction adjustment knob Water pump indicator hole Oil drain plug Transom angle preset knob Engine flush plug Gear lubricant level plug Water inlet Gear lubricant fill/ drain plug Trim tab 38541...
  • Page 59 GENERAL INFORMATION FRONT VIEW 28527 Choke/fast idle knob Fuel primer Oil pressure light Fuel line connector Start switch (electric tiller handle) Lanyard safety switch Trim/tilt position indicator...
  • Page 60 GENERAL INFORMATION PORT VIEW 38571 Tiller lock release lever Start switch (electric tiller handle model) Steering friction adjustment lever (tiller model only) Tilt lock knob...

  • Page 61: Component Identification - Bigfoot/Prokicker Models

    GENERAL INFORMATION Component Identification ‑ BigFoot/ProKicker Models 38533 Transom bracket Tilt support lever Gear lubricant level plug Primary water inlet Gear lubricant fill/drain plug Secondary water inlet Anti‑ventilation plate Engine flush plug Water pump indicator hole Cowl latch Oil drain screw...
  • Page 62 GENERAL INFORMATION Power tilt -Kicker strap Throttle only button Throttle grip friction knob Power tilt button...

  • Page 63: Transporting

    TRANSPORTING Carrying, Storing, and Transporting Your Outboard when Removed from Boat IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. With the outboard still in the water, disconnect the remote fuel line and run engine until it stops.

  • Page 64: Transporting Portable Fuel Tanks

    TRANSPORTING 3. Carry, transport, or store the outboard in any of the three positions shown. These positions will prevent oil from draining out of the crankcase. Upright position Tiller handle down Front side down 39056 4. Never carry, store, or transport the outboard in the two positions shown.

  • Page 65: Trailering Boat/Outboard - Models With Power Tilt

    TRANSPORTING MANUAL VENTING TYPE FUEL TANK Close fuel tank air vent when transporting tank. This will prevent escape of fuel or vapors from tank. 26793 AUTO-VENTING TYPE FUEL TANK 1. Disconnect the remote fuel line from tank. This will close the air vent and prevent escape of fuel or vapors from tank.

  • Page 66: Trailering Boat/Outboard - Models Without Power Tilt

    TRANSPORTING 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. Additional clearance may be required for railroad crossings, driveways and trailer bouncing. 26792 IMPORTANT: Do not rely on the power tilt system or tilt support lever to maintain proper ground clearance for trailering.

  • Page 67: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum.
  • Page 68 FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 69: Low Permeation Fuel Hose Requirement

    FUEL AND OIL 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 70: Mercury Marine's Pressurized Portable Fuel Tank

    46273 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.

  • Page 71: Filling Fuel Tank

    FUEL AND OIL REMOVING THE FUEL CAP Fuel cap Manual vent screw Tab lock 46290 IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening. 1. Open the manual vent screw on top of the fuel cap. 2.

  • Page 72: Engine Oil Recommendations

    Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions. Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC‑W certified 10W‑30 4‑Stroke Outboard Oil for general, all‑temperature use. If NMMA certified synthetic blend 25W‑40 4‑Stroke outboard oil is preferred, use Mercury or Quicksilver...

  • Page 73: Checking Engine Oil

    FUEL AND OIL IMPORTANT: The use of detergent 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.
  • Page 74 FUEL AND OIL 4. Reinstall the oil filler cap and tighten securely. Dipstick Oil filler cap 4914...

  • Page 75: Features And Controls

    FEATURES AND CONTROLS Tiller Handle Features IMPORTANT: Avoid engine flooding ‑ Do not rotate the throttle grip while engine is not running. Doing so will inject fuel into the engine and cause a possible hard starting flooded condition. • Tiller handle ‑ Handle can be tilted 180° for convenient handling during transportation and storage.
  • Page 76 FEATURES AND CONTROLS • Tiller handle lock cap ‑ Remove the lock cap on top of tiller handle to lock in up position. Push tiller lock release lever to release the handle from the locked up position. 3273 Lock cap Locking mechanism •...
  • Page 77 FEATURES AND CONTROLS • Engine stop switch ‑ Push in to stop engine. 28537 • Power tilt switch ‑ Push to tilt engine up/down. 4639 • Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction or turn knob counterclockwise to loosen friction.
  • Page 78 FEATURES AND CONTROLS • Throttle only button ‑ Pressing the button in while the outboard is in neutral disables the gear shift control of the tiller handle. 28550 • Throttle grip ‑ Controls engine speed and shifting. Reverse Forward 28543 •...
  • Page 79 FEATURES AND CONTROLS • Low oil pressure warning light ‑ Warns the operator the engine has low oil pressure. When the low oil pressure light is on or is blinking, the engine will run rough and will not exceed 3000 RPM. 28549 •...
  • Page 80 FEATURES AND CONTROLS • Steering friction adjustment ‑ Adjust this lever to achieve the desired steering friction (drag) on the tiller handle. Move lever to the left to tighten, or move lever to the right to loosen. Tighten Loosen 39175 •...
  • Page 81 FEATURES AND CONTROLS • Kicker strap (power tilt models) ‑ Prevents the engine from turning while tilted up. 4676...

  • Page 82: Remote Control Features

    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 83: Warning System

    FEATURES AND CONTROLS Warning System The warning system on this engine does not have a warning horn. Instead, there is an oil pressure light located on the front of the engine. If oil pressure drops below 25 kPa (3.6 PSI) the oil pressure light will illuminate, the Engine Guardian System will be activated, and engine RPM will be limited to 3000.
  • Page 84 FEATURES AND CONTROLS TILTING OPERATION To tilt the outboard, shut off the engine and press the tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. Tiller handle models have a kicker strap located on each side of the outboard, preventing the outboard from turning when tilted up.

  • Page 85: Setting The Transom Angle Of Your Outboard

    FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and lifting the knob. Lower the outboard. Tilt support lever Knob 4650 Setting The Transom Angle Of Your Outboard The vertical transom angle of your outboard is adjusted by changing the position of the preset tilt knob in one of the three adjustment holes provided.
  • Page 86 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 28533 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.

  • Page 87: Adjusting Transom Angle

    FEATURES AND CONTROLS Adjusting the outboard away from the boat transom can: • Lift the bow out of the water. • Generally increase top speed. • Increase clearance over submerged objects or a shallow bottom. • Increase steering torque or pull to the left at a normal installation height.

  • Page 88: Tilting Outboard

    FEATURES AND CONTROLS 2. To release the shallow water drive, stop engine and tilt outboard up to one of the tilt release position. Gently lower the outboard to the preset transom angle. 28592 Shallow water drive positions Tilt release positions Water Intake Tilting Outboard 1.

  • Page 89: Trim Tab Adjustment

    FEATURES AND CONTROLS 5. Raise the outboard to the tilt release position and gently lower the outboard to the preset trim position. Tilt lock knob in lock position Tilt lock knob in unlock position Tilt range indicator 28587 Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction.
  • Page 90 FEATURES AND CONTROLS If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right, move the trailing edge of trim tab to the right.

  • Page 91: Operation

    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.

  • Page 92: 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 93: Engine Break-In Procedure

    OPERATION 2. Check the engine oil level. 27233 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. 3. Make sure the cooling water intake is submerged. 26837 Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures...

  • Page 94: Starting The Engine - Tiller Handle Models

    OPERATION 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 ‑ Tiller Handle Models Before starting, read the pre‑starting check list, special operating instructions, and engine break‑in procedure in the Operation section.
  • Page 95 OPERATION 4. Set the tiller handle gear shift to neutral ("N") position. 28577 5. If the engine is cold, press the fuel primer in twice. IMPORTANT: Avoid engine flooding ‑ Do not press in the fuel primer if engine is warm. This will inject fuel into the engine and may cause a hard starting flooded condition.
  • Page 96 OPERATION 7. Manual starting models ‑ 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. After the engine has started, push in the choke knob. 28586 8.

  • Page 97: Starting The Engine - Remote Control Models

    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.
  • Page 98 OPERATION 3. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 4. Set the remote control handle to neutral position. IMPORTANT: Avoid engine flooding ‑ Do not advance the throttle while engine is not running. This will inject fuel into the engine and may cause a hard starting flooded condition.

  • Page 99: Starting A Hot Engine

    OPERATION NOTE: Starting Flooded Engine ‑ lift the neutral fast idle lever to full up and continue to crank the engine for starting. 6. Turn the ignition key to the "START" position and start the engine. If the engine is cold, push in on the key to choke the engine while cranking.

  • Page 100: Gear Shifting

    OPERATION 2. Crank the engine with the recoil rope or with the electric start button. 3. Push in the choke knob after engine has started to warm up. REMOTE CONTROL MODELS 1. Crank the engine over while pushing the key in to engage the choke solenoid.

  • Page 101: Stopping The Engine

    OPERATION Stopping the Engine 1. Remote control models ‑ Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843 2. Tiller handle models ‑ Reduce engine speed and shift outboard to neutral position. Push in the engine stop button or turn ignition key to "OFF"...
  • Page 102 OPERATION 4. Remove the three screws holding the flywheel cover on. 28614 Flywheel cover screws (3) Recoil neutral interlock Fuse holder 5. Remove the flywheel cover. 6. Remote Control models ‑ Ensure the key switch is in the "ON" position. WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.
  • Page 103 OPERATION 8. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 28616 9. Pull the starter rope quickly.

  • Page 104: Outboard Care

    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.

  • Page 105: Inspection And Maintenance Schedule

    FAMILY : FEL : HC+NOx= HP : MAXIMUM POWER : LOW-PERM/HIGH-PERM : TIMING : IDLE SPEED (IN GEAR) : MERCURY MARINE 43058 Piston displacement Maximum emission output for the engine family Percent of fuel line permeation Timing specification Family number Engine family description Engine power ‑...
  • Page 106 MAINTENANCE • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. • Remote control models ‑ Visually check steering link rod fasteners for proper tightness. See Steering Link Rod Fasteners.

  • Page 107: Flushing The Cooling System

    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. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.
  • Page 108 MAINTENANCE 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 109 MAINTENANCE 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 27259 3. Start the engine and run it at idle speed in neutral shift position.

  • Page 110: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal And Installation REMOVAL 1. Pull out the front cowl latch. 4936 2. Lift front of cowl to clear front latch and push toward the rear to clear rear hook. 3. Lift top cowl to remove. INSTALLATION 1.

  • Page 111: Exterior Care

    MAINTENANCE 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.

  • Page 112: Steering Link Rod Fasteners

    MAINTENANCE FUEL LINE FILTER Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. 28620 IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod...
  • Page 113 MAINTENANCE WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

  • Page 114: Corrosion Control Anode

    MAINTENANCE Assemble steering link rod to steering cable with flat washer and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with bolt, locknut and spacer and flat washers. Torque locknut to specifications. Corrosion Control Anode Your outboard has a corrosion control anode installed to the gearcase.
  • Page 115 MAINTENANCE 1. Remove the spark plug lead to prevent engine from starting. 26899 2. Move gear shift lever into neutral (N). 28595 Reverse Neutral 26838 Forward 3. Straighten and remove cotter pin. 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut.

  • Page 116: Fuse Replacement - Electric Start Models

    MAINTENANCE 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. 27095 Tube Description Where Used Part No. Ref No. Anti-Corrosion Propeller shaft 92-802867Q 1 Grease 2-4-C with Propeller shaft 92-802859A 1 PTFE 7.

  • Page 117: Spark Plug Inspection And Replacement

    MAINTENANCE The electric starting circuit is protected from overload by a 20 amp fuse. If the fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. 28618 Spare fuse Circuit protecting fuse...

  • Page 118: Timing Belt Inspection

    MAINTENANCE 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3.

  • Page 119: Changing Engine Oil

    MAINTENANCE a. Cracks in the back of the belt or in the base of the belt teeth. b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. 27578 Changing Engine Oil ENGINE OIL CAPACITY...

  • Page 120: Lubrication Points

    2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Special Lubricant 101.
  • Page 121 MAINTENANCE Tube Description Where Used Part No. Ref No. Swivel bracket, transom clamp Special screws, tilt tube, throttle and 92-802865Q02 Lubricant 101 shift cables, steering cable grease fitting Swivel bracket, transom clamp 2-4-C with screws, tilt tube, throttle and 92-802859A 1 PTFE shift cables, steering cable grease fitting...
  • Page 122 MAINTENANCE • Lubricate the throttle and shift cable moving components, pivot locations, and shift detent. Throttle and shift cables Shift detent 28621 • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube.

  • Page 123: Gearcase Lubrication

    MAINTENANCE 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Description Where Used Part No. Ref No. Anti-Corrosion Propeller shaft 92-802867Q 1 Grease 2-4-C with Propeller shaft 92-802859A 1 PTFE • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller.
  • Page 124 GEARCASE LUBRICANT CAPACITY Standard model gearcase: Approximately 320 ml (10.8 fl. oz.). Bigfoot model gearcase: Approximately 370 ml (12.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position.
  • Page 125 MAINTENANCE 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. 28659 IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5.

  • Page 126: Checking Power Tilt Fluid

    2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

  • Page 127: 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 128: 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 Description Where Used Part No.

  • Page 129: Positioning Outboard For Storage

    STORAGE 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. •...
  • Page 130 STORAGE • Store the battery in a cool, dry place. • Periodically check the water level and recharge the battery during storage.

  • Page 131: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 132: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Low oil pressure. Check oil level. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section.
  • Page 133 TROUBLESHOOTING • Defective rectifier, alternator, or voltage regulator.

  • Page 134: Owner Service Assistance

    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.

  • Page 135: Mercury Marine Service Offices

    • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English ‑ (920) 929‑5040...
  • Page 136 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944...

  • Page 137: Engine Installation

    ENGINE INSTALLATION 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.

  • Page 138: Selecting Accessories For Your Outboard

    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.
  • Page 139 ENGINE INSTALLATION BOAT TRANSOM HEIGHT REQUIREMENT 1. Measure the transom height of your boat. The boat bottom should be aligned or be within 25 mm (1 in.) above the anti‑ventilation plate of the outboard. Anti‑ventilation plate 27151 INSTALLING OUTBOARD ON TRANSOM 1.
  • Page 140 ENGINE INSTALLATION 3. Non‑power tilt models ‑ To prevent a loss of the outboard, secure the outboard to the transom with the two transom bracket clamp screws and two mounting bolts. Drill two 7.9 mm (5/16 in.) holes through the transom bracket mounting holes.

  • Page 141: Remote Control Installation

    ENGINE INSTALLATION Description lb. in. lb. ft. Transom bracket mounting bolts 13.5 Remote Control Installation STEERING CABLE 1. Lubricate the entire cable end with Mercury Precision or Quicksilver 2‑4‑C with PTFE. 28722 Tube Description Where Used Part No. Ref No.

  • Page 142: Steering Link Rod Fasteners

    ENGINE INSTALLATION Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using the steering link rod fastening hardware supplied with engine. Never replace the locknuts (11‑16147‑‑3) with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 143 ENGINE INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat.

  • Page 144: Remote Wire Harness Connection

    ENGINE INSTALLATION Assemble steering link rod to steering cable with flat washer and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with bolt, locknut and spacer and flat washers. Torque locknut to specifications. Remote Wire Harness Connection 1.
  • Page 145 ENGINE INSTALLATION 2. Route the remote wiring harness through the rubber grommet. 3. Open up the clamp in the bottom cowl and position the remote wiring harness below the clamp. Connect the 8 pin connector to the engine harness. Push the clamp down and secure the remote wiring harness into the bottom cowl.

  • Page 146: Control Cable Installation

    ENGINE INSTALLATION 4. Reinstall the cable receptacle bracket with two bolts and hex nuts. Tighten the bolts to the specified torque. Cable receptacle bracket 29044 Description lb. in. lb. ft. Cable receptacle bracket Control Cable Installation THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 147 ENGINE INSTALLATION IMPORTANT: Make sure that the throttle cable end guide does not contact the remote wiring harness when the throttle cable is at full throttle position. If necessary, reposition and clamp the remote wiring harness. 28079 Cotter pin retainer Flat washer Full Throttle stop Throttle lever...
  • Page 148 ENGINE INSTALLATION a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark ("a") on the cable next to the end guide. b.
  • Page 149 ENGINE INSTALLATION 6. Position the shift cable into the rubber grommet and place the cable barrel into the barrel receptacle. 28096 Flat washer Cotter pin retainer End guide Center mark Rubber grommet Shift cable cable barrel Barrel receptacle...
  • Page 150 ENGINE INSTALLATION 7. Reinstall the access cover with two bolts. Tighten the bolts to the specified torque. 28097 Access cover Description lb. in. lb. ft. Access cover bolt 8. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear.

  • Page 151: Battery Installation - Electric Start Models

    ENGINE INSTALLATION Battery Installation ‑ Electric Start Models MOUNTING BATTERY Follow the battery manufacturer's instructions carefully. Mount battery in the boat so it is secured against movement, preferably in a battery box. Make sure battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.

  • Page 152: Propeller Installation

    Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/ Quicksilver products: Tube...

  • Page 153: 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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