1965-1989 Service Manual Application: 2 hp To 40hp 2 Stroke 1 & 2 cylinder engines. A Typical Mercury-Mariner Service Manual Contains The Following Chapters: Subjects may differ depending on year/model. RELATED MERCURY - MARINER OUTBOARD SEARCHES: Carburetor Models: CARBURETOR Theory of Operations Prime Start System This carburetor assembly uses the PrimeStart system for precise fuel delivery during start-up, at all temperatures.

• Mercury 1750 Price
• Mercury 1750 Black Max

Two electrothermal valves are installed on the carburetor assembly. Yamaha 950 tourer. The upper electrothermal valve controls fuel flow for carburetors #1 and #2, and the lower valve controls fuel flow for carburetors #3 and #4. Before start-up, the electrothermal ram (needle) is retracted (the fuel enrichment valve is opened) according to the temperature, allowing a high percentage of fuel to flow form the flat chamber into the venturi during start-up.

During start-up, the electrothermal ram (needle) is still retracted (the fuel enrichment valve is opened) according to the temperature, allowing a rich air/fuel mixture to be fed to the cylinders. After start-up, the current supplied form the electric power source and then flows to the electrothermal valves causing the wax in the valves to heat up. As the wax heats up the electrothermal ram (needle) begins to extend, partially closing the fuel enrichment valve, and reducing the flow of fuel from the float chamber into the venturi.

After a few minutes, the electrothermal ram (needle) is fully extended, the fuel enrichment valve is fully closed, and enrichment ceases. A - Electrothermal Valve b - Fuel Enrichment Valve c - Electrothermal Ram (needle) d - Carburetor #1 and #3 e - Carburetor #2 and #4 Acceleration This carburetor assembly uses an accelerator pump to ensure that the proper amount of fuel reaches all of the carburetors during rapid throttle openings (preventing temporary lean conditions). As the throttle is opened, the throttle lever rotates and pushes the throttle lever link rod. The throttle lever link rod then pushes the diaphragm in the dashpot, forcing out the air.

The air flows through the in-line, one-way valve, and then to all of the carburetors. This additional air flows into the carburetors and mixes with the fuel from the main jets. This air/fuel mixture is then injected into the venturi, ensuring that enough fuel reaches the engine.

As the throttle is closed, the throttle lever rotates back and the throttle lever link rod returns, causing the diaphragm in the dashpot to move back, As the diaphragm moves back, suction causes the air from the venturi of carburetor #4 to flow through a one-way valve in the carburetors and back to the dashpot. The in-line, one-way valve prevents the air in the hoses from flowing back to the dashpot. Also, the diaphragm functions as a coasting enrichener during quick deceleration, preventing the engine form stalling. A - Throttle Lever b - Throttle Lever Link Rod c - Diaphragm d - Dashpot e - In-Line, One-Way Valve f - To Carburetor #1 g - To Carburetor #2 h - To Carburetor #3 i - Main Jet j - One-Way Valve Carburetor Adjustments Float Level 1. With carburetor turned upside down, and carb scale seated on inner edge, check float level from top of float to float bowl flange as shown. Adjust tab if out of specification.

NOTE: Measure float level without gasket. NOTE: Bend tab to adjust float height.

Idle Speed NOTE: Outboard should be completely warmed up for the idle speed adjustment. With the outboard in forward gear, adjust idle speed screw to obtain the specified idle speed. NOTE: Turning idle speed adjustment screw; -clockwise will increase engine idling speed.counterclockwise will decrease engine idling speed. CYLINDER HEAD Adjustments Valve Clearance NOTE: Valve clearance adjustment should be made on a cold engine at room temperature.

Remove flywheel cover and spark plug cover. Disconnect spark plug leads and fuel hoses. A - Screw (2) M6 x 20 b - Flywheel Cover c - Screw (5) M6 x 16 d - Spark Plug Cover e - Fuel Hoses 3.

Align timing marks on driven cams. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. Loosen timing belt tensioner bolt and remove tensioner spring. A - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring 5. Remove timing belt and driven sprockets.

Remove cylinder head cover and spark plugs. A - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) e - Breather Hose f - Screw (14) M6 x 30 g - Cylinder Head Cover h - Rubber Gasket 7.

Re-install driven sprockets and timing belt. NOTE: Make sure timing marks are still aligned.

A - Pin (2) b - Washer (2) c - Driven Sprocket (2) d - Driven Sprocket Screw (2) M10 x 35 e - Timing Marks Aligned Driven Sprocket Screw Torque - 44 lb-ft (60 Nm) 8. Install tensioner spring and tighten timing belt tensioner. A - Timing Belt Tensioner Screw M10 x 45 b - Tensioner Spring Timing Belt Tensioner Screw Torque - 29 lb-ft (40 Nm) 9. Measure intake and exhaust valve clearance using the Valve Clearance Measurement Steps below. VALVE CLEARANCE MEASUREMENT STEPS: a. Turn flywheel clockwise until cylinder #1’s piston is at TDC.

Measure and record the intake valve clearance for cylinders #1 and #2. Measure and record the exhaust valve clearance for cylinders #1 and #3. Turn the flywheel 360° clockwise.

Measure and record the intake valve clearance for cylinders #3 and #4. Measure and record the exhaust valve clearance for cylinders #2 and #4. If adjustment of intake or exhaust valve clearance is necessary (out of specification) follow Changing Pad Thickness below. If no adjustment is necessary skip to step #11 on. CHANGING PAD THICKNESS 1.

Align timing marks on driven cams. Loosen timing belt tensioner and remove tensioner spring. NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts). Keep individual cylinder parts together.

A - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring 3. Remove timing belt and driven sprockets. Remove camshaft caps and camshafts.

IMPORTANT: Remove camshaft cap bolts in reverse sequence (ex. A - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) e - Screw (4) M7 x 48 f - Screw (16) M7 x 37 g - Camshaft Cap - Top (2) h - Camshaft Cap (8) i - Oil Seal (2) j - Camshaft (2) 5. Carefully pry up the valve pad and remove it. Measure and record (in the Measurement Table) the thickness of the removed valve pad with a micrometer. A - Valve Pad b - Screwdriver c - Measure Valve Pad Thickness With a Micrometer a. Select a proper replacement valve pad by calculating its thickness with the following formula. Removed Pad Thickness + Measured Valve Clearance – Specified Valve Clearance = New Pad Thickness NOTE: Measure the thickness of the new valve pads with a micrometer (thickness is not indicated on the pad).

NOTE: Lubricate the valve pads with molybdenum disulfide before installing. Insert the proper valve pad into the valve lifter. Install camshafts and camshaft caps IMPORTANT: Install camshaft cap bolts in the proper sequence and torque. A - Screw (4) M7 x 48 b - Camshaft Cap Top (2) c - Screw (16) M7 x 37 d - Camshaft Cap (8) e - Oil Seal (2) f - Camshaft - Intake g - Camshaft - Exhaust h - Pink Identification i - Exhaust Cam Tang 8. Install driven sprockets and timing belt. Tighten timing belt tensioner and install tensioner spring.

Re-check valve clearance using Valve Clearance Measurement Steps. NOTE: If any valve clearance is still out of specification, repeat all the valve clearance adjustment steps until the specified clearance is obtained.

Loosen timing belt tensioner screw and remove tensioner spring. Remove driven sprockets and timing belt. Install cylinder head cover and driven sprockets. A - Rubber Gasket b - Cylinder Head Cover c - Screw (14) M6 x 30 d - Breather Hose e - Pin (2) f - Driven Sprocket (2) g - Washer (2) h - Driven Sprocket Screw (2) M10 x 35 Cylinder Head Cover Screw Torque - 70 lb-in.

(8 Nm) Driven Sprocket Screw Torque - 44 lb-ft (60 Nm) 14. Install timing belt and spark plugs. Install tensioner spring and tighten timing belt tensioner bolt. Connect fuel hoses and spark plug leads. Install spark plug cover and flywheel cover. A - Fuel Hoses b - Spark Plug Cover c - Screw (5) M6 x 16 d - Flywheel Cover e - Screw (2) M6 x 20.

. Welcome Aboard!

Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA. TABLE OF CONTENTS Warranty Information Transfer Of Warranty.1 Warranty Registration United States And Canada. 1 Warranty Registration Outside The United States And Canada. 1 Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States.2 Outboard Limited Warranty (Middle-East, and Africa).3 3 Year Limited Warranty Against Corrosion.

TABLE OF CONTENTS Operation Pre-Starting Check List. 29 Operating In Freezing Temperatures.29 Operating In Salt Water Or Polluted Water. 29 Operating at High Elevations. 29 Setting Trim Angle While Running Engine at Idle Speed.29 Engine Break-in Procedure.30 Starting The Engine. TABLE OF CONTENTS Parts And Accessories Inquiries.51 Service Assistance.51 Mercury Marine Service Offices.51 Outboard Installation Important Information.53 Avoiding Fuel Flow Restriction.53 Electric Fuel Pump.53 Boat Horsepower Capacity.53 Start in Gear Protection.54 Selecting Accessories For Your Outboard. 54 Fuel Tanks. Warranty Registration United States And Canada 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.

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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. 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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. WHAT MERCURY WILL DO: Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or 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 previously manufactured.

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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration. WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.

Water entering engine through the fuel intake, air intake or exhaust system or submersion. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high or trimmed too far out. 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. When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer.

RPM is within the recommended range, select a replacement or upgrade propeller with the same pitch as the current propeller. Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200. Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200. 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 Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. GENERAL INFORMATION The lanyard is a cord usually between 122 and 152 cm (4 and 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.

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. GENERAL INFORMATION WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over.

Stay back from the front end of the deck and remain seated while the boat is in motion. 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. GENERAL INFORMATION Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. GENERAL INFORMATION WARNING Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death.

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. 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. GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. Rial Numb XXXXXXXX XXXX RP M 23884 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) Specifications Models Horsepower.

GENERAL INFORMATION Component Identification 3403 Top cowl Auxiliary tilt switch Bottom cowl Transom brackets Water pump indicator hole Gearcase Driveshaft housing Cooling water intake holes Anti-ventilation plate. 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. 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). FUEL AND OIL IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3. FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion.

Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill fuel tanks outdoors away from heat, sparks, and open flames. Remove portable fuel tanks from boat to refill them. 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. 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. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following.

Warning Horn Function Sound. FEATURES AND CONTROLS SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard.

A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption and engine operating hours. FEATURES AND CONTROLS Consider the following lists carefully. Trimming In or Down Can:.

Lower the bow. Result in quicker planing off, especially with a heavy load or a stern heavy boat.

Mercury 1750 Price

Generally improve the ride in choppy water. FEATURES AND CONTROLS NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard. 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.

OPERATION Engine Break-in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. GASOLINE/OIL BREAK-IN MIXTURE Do not use pre-mixed gas and oil during break-in. Oil from the oil injection system will supply adequate lubrication during engine break-in. OPERATION Squeeze the fuel line primer bulb several times until it feels firm.

19779 Set the lanyard stop switch to 'RUN' position. Refer to General Information - Lanyard Stop Switch.

19791 Shift outboard to neutral 'N' position. Ob00351 NOTE: It is not necessary to use the neutral fast idle speed feature on the remote control to increase engine speed for starting and warm up. OPERATION. Your outboard has three gear shift positions to provide operation.

Forward (F), Neutral (N) and Reverse (R). When shifting, always stop at neutral position and allow the engine speed to return to idle. Always shift outboard into gear with a quick motion. Record maintenance performed in the Maintenance Log at the back of this book.

Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure. MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE.

Check that the lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom. Check steering system for binding or loose components. MAINTENANCE Remove the plug from fitting in the bottom cowl. Ob01084 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes.

Ob01085 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. Ob01086 Lift up the rear cowl latch. MAINTENANCE Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions.

MAINTENANCE WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Ob00676 Special washer head bolt (10-849838) Nylon insert locknut (13) Flat washer (2) Nylon insert locknut (13). MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse.

If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 3395 Good fuse Accessories - 20 AMP fuse Blown fuse Ignition coil circuit - 20 AMP fuse SmartCraft data bus circuit - 5 AMP.

MAINTENANCE Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed.

Positive to positive and negative to negative. Make sure the battery is equipped with a non-conductive shield to prevent accidental shorting of battery terminals. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. MAINTENANCE Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft.

Ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications. 1/4 turn or torque to specifications. Description lb. Spark plug Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants Special Lubricant 101. Description Where Used Part No. Special Lubricant 101.

Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. Ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. Description Where Used Part No. MAINTENANCE.

Mercury 1750 Black Max

Tilt Support Lever - Lubricate through fitting. Ob00683 Swivel bracket Tilt support lever. Tilt Tube - Lubricate through fitting ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. 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.

Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 fl. GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position.

Remove vent plug. 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). STORAGE. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes).

Description Where Used Part No. Corrosion Guard External metal surfaces 92-802878Q55 Gearcase. Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase Lubrication). 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. TROUBLESHOOTING.

Damaged or improper size propeller. Incorrect engine timing, adjustments, or setup. Boat overloaded or load improperly distributed. Excessive water in bilge. Boat bottom is dirty or damaged.

Battery Will Not Hold Charge POSSIBLE CAUSES. Should you have a question, concern, or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems. Telephone (954) 744-3500 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way. Mercury or Quicksilver Premium 2-Cycle TC-W3 Outboard Oil IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine.

For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3. Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.

Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories. OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine center line for dual engine - 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33-3/8 in.) Dual engine 151.8 cm (59-3/4 in.) Lifting the Outboard WARNING Avoid possible serious injury or death. Before lifting the outboard, verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight. OUTBOARD INSTALLATION Lifting Eye 91-90455-1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine for removal/ installation. 2756 Steering Cable - Starboard Side Routed Cable Lubricate O-ring seal and entire cable end. 3724 Tube Ref No.

OUTBOARD INSTALLATION Torque nut to specification. 3727 Description lb. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10-849838) and self-locking nylon insert locknuts (P/N 13). OUTBOARD INSTALLATION 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 bolt (P/N Flat washer (2) 10-849838) Nylon Locknut - used on cable coupler. OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 24305 The solid line is recommended to This line may be preferred to determine determine the outboard mounting outboard mounting height dimension for. OUTBOARD INSTALLATION Mark four mounting holes on the transom using the transom drilling fixture. Or69-1 Drill guide holes Transom centerline Transom drilling fixture Transom Drilling Fixture 91-98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 Drill four 13.5 mm (17/32 in.) mounting holes. OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware - Supplied with Outboard Part Number Part Name Description 10-67755-1 Transom bolt 1/2-20 x 4.50 in.

Long (2.25 in. Thread) 11-826711-17 Nylon insert locknut 1/2-1 Washer - Inner 0.516 in. OUTBOARD INSTALLATION NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. 20860 Large transom washer Transom reinforcement plate Description Part Number Large transom washer 67-896392 Transom reinforcement plate 67-896305.

OUTBOARD INSTALLATION Electrical, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove screws and open the front clamp assembly. 7644 Screw (2) Front clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp. Connect remote harness to the 14 pin connector on the engine harness. OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard or86 Red sleeve - positive (+) Cranking battery Black sleeve - negative (–) Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. Or87 Red sleeve - positive (+) Ground cable. OUTBOARD INSTALLATION FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel Hose Size - Minimum fuel line inside diameter (I.D.) is 8mm (5/16 in.), with separate fuel line/fuel tank pickup for each engine.

Fasten remote fuel hose to fitting with hose clamp. Connect the remote oil hoses to the engine hose connections. OUTBOARD INSTALLATION Make the water pressure gauge hose connection to this tubing as follows: 7728 Speedometer water pick-up tube Barb hose fitting Water pressure tube Speedomer hose Coupler Water pressure tube Plug Shift and Throttle Cable COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gearcases can be identified by a 'L' stamped into the end of the propeller shaft. OUTBOARD INSTALLATION On counter rotation outboards, the shift linkage moves in the opposite direction compared to a standard rotation outboards. 24498 Standard rotation outboards Forward gear Reverse gear 24497 Counter rotation outboards Forward gear Reverse gear Installing the Shift Cable IMPORTANT: The shift cable is the first cable to move when the remote control handle is moved out of neutral, so install/connect it to the engine first.

OUTBOARD INSTALLATION Mark the reverse position as follows: a. Move the remote control handle into reverse and advance the handle to the full speed position. Ensure that the throttle control lever is touching the throttle control lever stop screw.

Slowly return the handle back to the neutral detent position. OUTBOARD INSTALLATION ADJUSTING THE SHIFT CABLE To adjust the shift cable: Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable. 4362 Center mark Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder. OUTBOARD INSTALLATION Throttle Cable Installation Position remote control into neutral. Ob00351 Attach throttle cable to the throttle lever. Secure with washer and locknut. 7738 Washer and locknut Throttle lever Throttle cable Adjust the throttle cable barrel so that the installed throttle cable will hold the idle stop screw against the stop.

OUTBOARD INSTALLATION IMPORTANT: The idle stop screw must be touching the stop. 7740 Idle stop screw Idle stop Lock the barrel holder in place with the cable latch. Front Clamp Reassembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched. OUTBOARD INSTALLATION Fasten clamp together with two screws.

7644 Screw (2) Front clamp Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: Squeeze the fuel line primer bulb until it feels firm. OUTBOARD INSTALLATION Remove cap and fill engine oil tank with oil. Reinstall the fill cap. 7745 Engine oil tank Fill cap PRIMING THE OIL INJECTION PUMP Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. OUTBOARD INSTALLATION Fill the engine fuel system with fuel.

Connect fuel hose and squeeze primer bulb until it feels firm. 19779 Turn the ignition key switch to the 'ON' position. Ob00364 Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times. OUTBOARD INSTALLATION Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft. Ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque to specifications.

OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow- down planing condition called plowing. Plowing can cause bow steering or over steering and inefficiently consumes horsepower. Or116 Tilt pin (not included with engine) Stainless Steel Tilt Pin 17-49930A 1 Limits the down trim angle of the power trim.