Mercury 300XS OptiMax User Manual
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Mercury 300XS OptiMax User Manual

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See also: Operation, Maintenance and Installation Manual
If the outboard motor's serial number plate contains the CE mark in the
lower left-hand corner, the following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI,
USA or Marine Power Europe Inc. Park Industrel, de Petit-Rechain,
Belgium complies with the requirements of the following directives and
standards, as amended:
Recreational Craft Directive:
Machinery Directive:
EMC Directive:
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine,
Fond du Lac, WI USA

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.
94/25/EC; std. ISO 8665, ISO
11547
98/37/EC,
89/336/EC; std. EN50081-1,
SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000
PT4-2, IEC 61000 PT4-3
i

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Summary of Contents for Mercury 300XS OptiMax

  • Page 1: Epa Emissions Regulations

    If the outboard motor’s serial number plate contains the CE mark in the lower left-hand corner, the following statement applies: This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park Industrel, de Petit-Rechain,...
  • Page 2 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 3 Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier"...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Warranty Registration United States And Canada......1 Transfer Of Warranty..............1 Mercury Racing Division 2 Year Limited Warranty (OptiMax XS Series Outboards)................2 Products Sold to Government Agencies........6 3 Year Limited Warranty Against Corrosion........6 Warranty Coverage and Exclusions for Mercury Racing Outboard Products..................10...
  • Page 6 TABLE OF CONTENTS Transporting Trailering Boat/Outboard ............38 Fuel and Oil Avoiding Fuel Flow Restrictions..........39 Fuel Requirements..............39 Oil Recommendation..............41 Filling Remote Oil Tank.............41 Filling Engine Mounted Oil Reservoir Tank.......42 Filling Fuel Tank................42 Features and Controls Remote Control Features............44 Zero Effort Control Features............45 Warning System................45 Overspeed Rev Limit..............48 Power Trim And Tilt..............48...
  • Page 7 TABLE OF CONTENTS Operating in Shallow Water............57 Starting The Engine..............58 Gear Shifting................61 Stopping The Engine..............61 Maintenance Power Package Care..............62 Submerged Power Package............62 Replacement Parts for Your Power Package......62 EPA Emissions Regulations............63 Inspection And Maintenance Schedule........64 Flushing the Cooling System (Powerhead).......66 Flushing the Cooling System (Lower Unit)........67 Top Cowl Removal and Installation...........68 Cleaning Care for Top Cowl............68...
  • Page 8 Battery Will Not Hold Charge.............94 Water Discharge from Idle Exhaust during Off-Idle Operation ....................95 Owner Service Assistance Local Repair Service..............96 Service Away From Home............96 Parts And Accessories Inquiries..........96 Service Assistance..............96 Mercury Marine Service Offices..........97 Ordering Literature..............98 Maintenance Log Maintenance Log..............100 viii...

  • Page 9: Warranty Information

    1. 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 10: Mercury Racing Division 2 Year Limited Warranty (Optimax Xs Series Outboards)

    Fond du Lac, WI 54936-1939 920-929-5054 Fax 920-929-5893 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 11 Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products...
  • Page 12 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 13 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,...

  • Page 14: Products Sold To Government Agencies

    OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Products Sold to Government Agencies Contact the Mercury Racing Sales Department for a copy of the Government Agencies Warranty Packet Kit which explains the conditions required for government agencies to receive warranty when purchasing Mercury Racing Outboard or Sterndrive product.
  • Page 15 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 pre-delivery inspection process is completed and documented.
  • Page 16 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 17 Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.

  • Page 18: Warranty Coverage And Exclusions For Mercury Racing Outboard Products

    Warranty is limited to defects in material or workmanship, but 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 pre-delivery inspection process is completed and documented.

  • Page 19: California Emissions Limited Warranty

    6. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 7. Engine noise does not necessarily indicate a serious engine problem.
  • Page 20 Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
  • Page 21 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 22 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 non-exempted add-on or modified part will not be covered.

  • Page 23: Exhaust System

    TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. If you have any questions regarding your warranty rights and responsibilities, should contact Mercury Marine 1-920-929-5040.
  • Page 24 If any emission related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Marine. OWNER'S WARRANTY RESPONSIBILITIES: As the outboard engine owner, you are responsible for the performance of the required maintenance listed in the Maintenance section.

  • Page 25: Star Label

    WARRANTY INFORMATION You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.
  • Page 26 WARRANTY INFORMATION Two Stars - Very Low Emission The Two Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards. Engines 22532 meeting these standards have 20% lower emissions than One Star - Low Emission engines.

  • Page 27: 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. 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 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. ob00307 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 WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start in neutral only protection device. ob00308 Remote Steering Notice The steering link rod that connects the steering cable to the engine...

  • Page 30: Lanyard Stop Switch

    GENERAL INFORMATION 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. A lanyard stop switch can be installed as an accessory - generally on the dashboard or side adjacent to the operator's position.

  • Page 31: Protecting People In The Water

    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 32: Exhaust Emissions

    GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or any solid device rigidly attached to a moving boat or gearcase.
  • Page 33 GENERAL INFORMATION 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 enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 34: 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 35: Wave And Wake Jumping

    GENERAL INFORMATION Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. ob00313 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 re-enters the water.

  • Page 36: Impact With Underwater Hazards

    GENERAL INFORMATION 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. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward.

  • Page 37: Selecting Accessories For Your Outboard

    Have the outboard thoroughly inspected and any necessary repairs made. Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

  • Page 38: Safe Boating Suggestions

    GENERAL INFORMATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories. Safe Boating Suggestions...
  • Page 39 GENERAL INFORMATION Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Just shifting the outboard into neutral is not sufficient. Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing.

  • Page 40: Recording Serial Number

    20XX XXXX ob00319 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation Specifications - 300XS OptiMax Attribute Specifications Propshaft Horsepower 300 HP (224 kw) Engine Displacement 3158 cc (193 cid) 20 in. 218 kg (480 lb.) (Torque Master) 20 in.
  • Page 41 Cylinder Configuration 60 Degree V6 Cylinder Bore 92.075 mm (3.625 in.) Stroke 78.9 mm (3.110 in.) RecommendedSpark Plug NGK IZFR7M (Mercury Part Number: 8M0009927)) Spark Plug Gap 0.81 mm (0.032 in.) Firing Order 1-2-3-4-5-6 Maximum Timing Controlled by PCM Idle Timing...

  • Page 42: Special Tools And Kits

    GENERAL INFORMATION Attribute Specifications 1.62:1 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 Premium Plus TC-W3 2-Cycle Gearcase Oil Hi-Performance Gear Lube Gearcase Lubricant Capacity 710 ml (24 fl oz) 1000-MCA (Marine Cranking Amps) 800-CCA (Cold Cranking Amps) 105 Amp...

  • Page 43: Component Identification

    GENERAL INFORMATION Component Identification 22453 Top cowl Skeg Side cowl latches (both Anode plate sides) 10 - Anti-ventilation plate Front cowl latch 11 - Drive shaft housing Auxiliary tilt switch 12 - Water pump indicator Clamp/Swivel bracket 13 - Bottom cowl Gearcase Cooling water intake (location dependen t on...

  • Page 44: Propeller Selection

    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 - Specifications).
  • Page 45 GENERAL INFORMATION Check full-throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced-steering condition (steering effort equal in both directions) without causing the propeller to break loose.

  • Page 46: Trailering Boat/Outboard

    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. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.

  • Page 47: Fuel And Oil

    MINIMUM POSTED OCTANE 96 RON Unleaded premium 1. Mercury Racing does not recommend using leaded gasoline. Read the information in the Fuel Containing Alcohol section. 2. Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, exhaust passageway corrosion may occur due to the accumulation of exhausted lead particles.
  • Page 48 Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section. These reformulated fuels are acceptable for use in your Mercury engine. FUEL CONTAINING ALCOHOL If the fuel in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur.

  • Page 49: Oil Recommendation

    FUEL AND OIL CAUTION When operating a Mercury engine with fuel containing alcohol, avoid storing the fuel in the fuel tank for long periods of time. Long storage periods, common to boats, create unique problems. In cars, alcohol-blend fuels are normally consumed before they can absorb enough moisture to cause trouble.

  • Page 50: Filling Engine Mounted Oil Reservoir Tank

    FUEL AND OIL IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air leak will prevent oil flow to the engine. or27 Filling Engine Mounted Oil Reservoir Tank Remove the top cowl. Loosen the fill cap on the engine oil reservoir tank.
  • Page 51 FUEL AND OIL • Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled. WARNING Avoid serious injury or death from a gasoline fire or explosion.

  • Page 52: 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. ob00329 Control handle - forward, neutral, reverse.

  • Page 53: Zero Effort Control Features

    FEATURES AND CONTROLS Zero Effort Control Features 4090 Throttle lever Trim switch Shift lever Warning System The warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or under the dash connected to the ignition key switch. ob00662 Inside the remote control Under the dashboard...
  • Page 54 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. Refer to the Troubleshooting section for specific information. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft product information.
  • Page 55 Failure Injector Failure SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this power package. A few functions some of the instrument packages will display are engine RPM, coolant temp, water pressure, battery voltage, fuel consumption and engine operating hours.

  • Page 56: Overspeed Rev Limit

    FEATURES AND CONTROLS Overspeed Rev Limit The PCM does not allow the engine to exceed the rev limit. Refer to Specifications to determine this engine’s RPM limit. Upon reaching the rev limit, the Guardian System activates the warning horn. If the operator does not reduce engine speed within five seconds, the Guardian Systems reduces available engine power.

  • Page 57: Power Trim Operation

    FEATURES AND CONTROLS • The term trim generally refers to the adjustment of the outboard within the first 20° range of travel. • The term tilt generally refers to adjusting the outboard further up out of the water. With the engine turned off, the outboard can be tilted out of the water.
  • Page 58 FEATURES AND CONTROLS LIMITING TRIM IN In rare circumstances, the owner may decide to limit the trim in to avoid unsafe handling or steering conditions at planing speeds. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out.

  • Page 59: 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 60: 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. or33-1 Tilt support lever Metal stop Knob 2. Lower the outboard to rest on the tilt support lever. 3.

  • Page 61: Manual Tilt Operation

    FEATURES AND CONTROLS Manual Tilt Operation If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be tilted manually. 1. Turn out the manual tilt release valve three turns (counter-clockwise). This allows manual tilting of the outboard.

  • Page 62: Operation

    OPERATION Engine Break-in CAUTION Severe damage to the engine can result by not complying with the engine break-in proceedure. Engine damage may not be covered by the limited warranty. WARNING Avoid loss of boat control or an unsafe boat handling situation. Increasing trim under can place greater load on an engine and enhance breakin.

  • Page 63: Pre-Starting Check List

    OPERATION Pre-Starting Check List Engine lowered to run position with all water intake holes submerged Fuel tank vent cap open or fuel drain valve on. Fuel supply OK Lanyard stop switch in "RUN" position and cord connected. Remote control in neutral Top cowl latches secure.

  • Page 64: Operating At High Elevations

    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 65: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Some boat performance can be regained 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 66: Starting The Engine

    OPERATION 2. Tilt outboard up. Make sure all the cooling water intake holes stay submerged at all times. 3. Operate the engine at slow speed only. Models with a three-ram trim system: If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range.
  • Page 67 OPERATION STARTING PROCEDURE 1. Lower the outboard to the "RUN" position. Make sure all the cooling water intake holes are submerged. ob00347 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.
  • Page 68 OPERATION 5. Shift the outboard to the neutral position. ob00351 6. Do not advance the neutral fast idle speed feature on the remote control for starting (if equipped). ob00560 7. Turn the ignition key to the "START" position. Release the key when the engine starts.

  • Page 69: Gear Shifting

    No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat. Have the outboard checked by your authorized Mercury Marine dealer. Operating the engine while overheated will cause engine damage. Gear Shifting IMPORTANT: Never shift into gear unless the engine is at idle.

  • Page 70: Maintenance

    If you are not familiar with proper maintenance or service procedures, have the work performed by an authorized Mercury Marine dealer. To ensure safety and retain dependability, keep your power package in the best operating condition by performing the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule.

  • Page 71: Epa Emissions Regulations

    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. This certification is contingent on certain adjustments set to factory standards.

  • Page 72: Inspection And Maintenance Schedule

    MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.
  • Page 73 MAINTENANCE • Visually check steering link rod fasteners for wear. Lubricate all components (refer to the Installation Manual for lubrication specifications). Check all attachment hardware for proper torque tightness. • Check level and condition of gearcase lubricant. • Check alternator belt tension. EVERY 50 HOURS OR ONCE A YEAR, WHICHEVER OCCURS FIRST •...

  • Page 74: Flushing The Cooling System (Powerhead)

    MAINTENANCE EVERY 200 HOURS OR ONCE EVERY TWO YEARS, WHICHEVER OCCURS FIRST • Replace 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 To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. or37-1 Fleet Master and Water hose Torque Master Flushing attachments gearcase Sport Master gearcase 1. Remove the propeller. Refer to Propeller Replacement. 2.

  • Page 76: Top Cowl Removal And Installation

    MAINTENANCE 7. Check for water coming out of the water pump indicator hole. Continue flushing for three to five minutes, carefully monitoring water supply at all times. 8. Stop the engine, turn off the water, and remove the flushing attachment. Re-install the propeller. Top Cowl Removal and Installation REMOVAL Release the front and side cowl latches.

  • Page 77: Fuel System

    MAINTENANCE 4. Wax the surface using a non-abrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. Fuel System FUEL SYSTEM SERVICE INFORMATION WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions.
  • Page 78 MAINTENANCE Removal or39-1 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 MAINTENANCE DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If a sufficient amount of water accumulats in the fuel filter chamber, the engine's warning system alerts the operator with the warning horn. Some SmartCraft gauges are capable of alerting the operator of this and other operating conditions/faults.

  • Page 80: Steering Link Rod Fasteners

    If you experience multiple issues with water in the fuel system over a short period of time, see your authorized Mercury dealer. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering...

  • Page 81: Fuses

    MAINTENANCE WARNING Avoid equipment damage, serious injury or death. Visually inspect all steering attachment components for wear, lubricate all attachment hardware, and check for proper torque tightness in accordance with the inspection and maintenance schedule. or79 Special washer head Flat washer (2) bolt (P/N 10-849838) Nylon Locknut - used on Nylon Locknut - used on...

  • Page 82: Corrosion Control Anode

    Corrosion Control Anode CAUTION Avoid corrosion damage. Mercury Marine recommends using anodes sold through Mercury Precision Parts only. Some other manufacturers of aluminum anodes use alloys that are insufficiently pure to adequately protect critical drive components for the duration of the anodes' expected life.

  • 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. or42-1 Corrosion control anodes (three on gearcase) Corrosion control anode (one on clamp/swivel bracket) All anodes require periodic inspection, especially in salt water (refer to the Inspection and Maintenance Schedule).

  • Page 84: Battery Inspection

    MAINTENANCE 1. Remove the spark plug leads. Twist the rubber boots slightly and pull off. ob00375 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3.

  • Page 85: Charging System Fusible Link

    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. 59364 Replacing the Propeller WARNING Avoid serious injury or death.
  • Page 86 An under-propped engine may occasionally initiate the rev limiter. This may result in internal powerhead damage. 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 1. Lubricate the propeller shaft splines with Anti-Corrosion Grease. 2. Install the propeller hub assembly, propeller, washer, Belleville washer, washer, and propeller nut onto the propeller shaft. 2693 Propeller hub Belleville washer assembly Washer Propeller Propeller nut Washer Tube Ref No. Description Where Used Part No.

  • Page 88: Lubrication Points

    MAINTENANCE Description lb. in. lb. ft. Propeller nut 4. Disengage the safety stop switch by placing it in the "RUN" position and return the keys to the ignition switch. Lubrication Points 5517 Tube Ref. No. Description Where Used Part Number Special Lubricant 101 Trim Rod Ball Ends 92-802865A1...
  • Page 89 MAINTENANCE Tube Ref. No. Description Where Used Part Number Prop Shaft Swivel Bracket 2-4-C with Teflon 92-802859A1 Tilt Support Lever Tilt Tube NOTE: Turn the ball ends to work the lubricant into the ball sockets. Lubricate through fittings WARNING Avoid serious injury or death. The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant.

  • Page 90: Checking Power Trim Fluid (Single-Ram Trim Systems)

    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.

  • Page 91: Checking Power Trim Fluid (Three-Ram Trim Systems)

    MAINTENANCE 4. Trim the outboard down to bleed air out of the system. The fluid level may drop. Add more Power Trim and Steering Fluid if necessary, but do not overfill past the "MAX" level mark. 5. Replace the fill cap. Checking Power Trim Fluid (Three-Ram Trim Systems) 1.

  • Page 92: Gearcase Lubricant

    MAINTENANCE Gearcase Lubricant CHECKING/REFILLING GEARCASE LUBRICANT or49-1 SportMaster gearcase Vent plug and sealing (vertical operating washer position) Fill/drain hole Fleet/Torque Master Fill/drain plug gearcase (vertical operating position) Vent hole Tube Ref. No. Description Where Used Part Number High Performance Gear Fill/Drain Hole 92-802854A1 Lube 1.
  • Page 93 MAINTENANCE NOTE: Examine the magnetic fill/drain plug for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) should be checked by an authorized dealer. 7.
  • Page 94 MAINTENANCE 3. Remove the vent plug (upper plug) and sealing ring. 4. Remove the fill/drain plug (lower plug) and sealing ring and drain lubricant. GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 oz).

  • Page 95: 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 96 STORAGE 2. Remove the drain hose from the aft hose fitting (right side of the chamber). Hold the unattached end of the hose over a suitable container. ob01352 Filter drain screw Drain hose Aft hose fitting 3. Loosen the filter drain screw (left side of the chamber) and allow the contents to drain.
  • Page 97 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. 9. Remove the fuel filter. Refer to Fuel System in the Maintenance section of this manual.

  • Page 98: Protecting Internal Engine 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 No. Description Where Used Part No.

  • Page 99: Battery Storage

    STORAGE CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. Battery Storage • Follow the battery manufacturer's instructions for storage and recharging.

  • Page 100: 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. •...

  • Page 101: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • 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. b. Fuel tank filter obstructed. c.

  • Page 102: Warning Horn Activates (No Power Loss)

    TROUBLESHOOTING • Throttle position sensor failure. • Continuous horn sound: • The oil level in the engine-mounted oil reservoir tank is critically low. Refill the reservoir tank and the remote oil tank. Refer to Fuel and Oil for details. • The oil pump has failed, halting the oil supply to the engine. •...

  • Page 103: Water Discharge From Idle Exhaust During Off-Idle Operation

    TROUBLESHOOTING Water Discharge from Idle Exhaust during Off-Idle Operation Normal operation. This outboard is designed to discharge water though the idle exhaust boot (located at the aft end of the bottom cowl) when operating at speeds above idle. The volume of discharged water increases with boat speed as a result of the engine cooling system.

  • Page 104: Owner Service Assistance

    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 105: Mercury Marine Service Offices

    Model and serial number of your outboard • 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 Telephone Mercury Marine W6250 W.

  • Page 106: Ordering Literature

    Serial Model year: Number: UNITED STATES AND CANADA For information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature contact your nearest dealer or contact: MERCURY MARINE Telephone Mail Mercury Marine...
  • Page 107 OWNER SERVICE ASSISTANCE OUTSIDE THE UNITED STATES AND CANADA Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature.

  • Page 108: 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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