Mercury outboards manual

DOWNLOAD Mercury Outboard Repair Manuals & Service Manuals

This INSTANT REPAIR MANUAL DOWNLOAD for the Mercury outboard engines were designed primarily for factory service Mercury outboard technicians in a properly equipped shop. However, enough information in Mercury outboard repair manuals is given for do-it-yourself or apprentice mechanics to correctly and safely perform repair work to their Mercury outboard motor and components. Individuals using this Mercury outboard marine repair manual should possess basic knowledge of tools and mechanical theory. The outboard marine mechanic should carefully read the text and become familiar with the Mercury marine engine service manual procedures before beginning the work. Some repair procedures in this Mercury outboard downloadable manual may require the use of special tools. Its recommended to only use the exact tools, as specified in the factory Mercury outboard manual. Most tools can be rented at local parts stores.

There’s nothing these Mercury repair manuals doesn’t cover. From Mercury maintenance procedures to complete Mercury outboard engine overhaul, these Mercury manual covers it all. The following list is a tiny sample of repair operations you’ll learn how to do:

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Best Mercury Outboard motor Remote Controls Service Manual

Original Mercury Remote Controls Service Manual
Models covered:
Side Mount Control:
– 76334A10 through A40
– MerCruiser 55722A2 (215E)
– 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control
– MerCruiser 55722A2, 63063A1 Electric Remote Control
– Commander 2000 Series
– Commander 3000 Series
– Commander 4000 Series
– Commander 4500 Series
– “Hot Foot” Throttle Controls
– Chrysler and Force Remote Controls
– Jet Drive Control
– DTS (Digital Trottle and Shift
– Zero Effort Controls

Manual Part Number: 90-814705R03

Manual includes hi-resolution diagrams as well as detailed step-by-step instructions and setup procedures.

Manual chapters:
1. Special Information
– Section 1A – Throttle and Shift Cable
2. Standard Single Lever Full Gear Shift Control
– Section 2A – Standard Single Lever Full Gear Shift Remote Control
3. Side Mount Control
– Section 3A – Side Mount Control 76334A10 through A40
– Section 3B – Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control
– Section 3C – Side Mount Mercury MerCruiser 55722A2, 63063A1 Electric Remote Control Electrical Tests
4. Commander Controls
– Section 4A – Commander Panel Mount Controls
– Section 4B – Commander Side Mount Control
– Section 4C – Commander 2000 Side Mount Control
– Section 4D – Commander Console Mount Control
– Section 4E – Commander Two Lever Recessed Console Control
– Section 4F – Commander Two Lever Console Control
– Section 4G – Commander 3000 Series
5. Commander 4000/4500 Controls
– Section 5A – Commander 4000 Series Remote Control
– Section 5B – Commander 4500 Series Remote Control
6. Foot Throttle Control
– Section 6A – “Hot Foot” Throttle Controls
7. Chrysler and Force Remote Controls
– Section 7A – Chrysler Remote Controls
– Section 7B – Force Remote Control
8. Jet Drive Control
– Section 8A – Sport Jet Remote Controls
9. Digital Throttle and Shift (DTS) Electronic Remote Controls
– Section 9A – DTS Panel Mount Remote Control
– Section 9B – DTS Single Handle Console Remote Control
– Section 9C – DTS Slim Binnacle Single Handle Console Control
– Section 9D – DTS Dual Handle Console Remote Control
– Section 9E – DTS Shadow Mode Console Remote Control
– Section 9F – DTS Dual Engine Console Control with CAN Pad
– Section 9G – DTS Shadow Mode Console Control with CAN Pad
– Section 9H – DTS Dual Handle Yacht Console Remote Controls
10. Zero Effort Controls
– Section 10A – Non-DTS Quadrant Controls
– Section 10B – DTS Zero Effort Controls

Manual PDF file is deeply indexed and searchable.

Certified High Quality Manual

To find information in PDF file please use “Ctrl+F” or “Command+F” for Mac and enter keywords you need to find in a manual.

File will be available for download in minutes!

Number of pages: 659
File Size: 29.35 Mb
Approximate Download Times:

  • Connection 56.6Kb/s: 9 Min. 6 sec.
  • Connection 512Kb/s: 1 Min. 1 sec.
  • Connection 1.5Mbps: 20 sec.
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If you see missing pages in PDF manual – they were deleted blank pages.

Anything below this line is NOT a product description. All information below is for explanation/promotion purposes only and may not reflect product details.

Android/iOS Compatible manual

“Best Mercury Outboard motor Remote Controls Service Manual” manual can be saved to any computer hard drive, flash storage, burned to a CD or DVD ROM or any other digital media.
Once manual is downloaded any number of pages could be printed or it could be printed in whole.
Manual could be opened on any mobile device (like iPad, iPhone or Android device etc.) any computer capable of viewing a PDF files including IBM compatible computers running Windows, Linux (or any other flavor of UNIX). Apple Computers have native support for PDF files.

Reference and Info files
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Top quality manual downloaded for servicing marine equipment. Easy download process. No glitches. Saved several hours.

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Online Mercury outboard motors service and repair manuals.

Mercury outboard motors service and repair manuals.

Please select manual from the list below

1965-1989 Mercury 90-300HP outboards repair manual. – $8.95

Mercury Outboard motors repair manual – NOT a Seloc manual. Covers all from 1965 to 1989 90-300 hp >>

1965-1989 Mercury outboards 45-115hp. Service Manual – $8.95

Mercury/Mariner Outboard Workshop Manual – this is NOT a Seloc manual. Covers all maintenance and repair (everything including wiring diagrams) of outboard motors 1 and 2 cylinder 2 stroke models from 1965 thru 1989 (see below) from 45p to 115hp >>

1977-1989 Mariner outboard motors repair manual. – $8.95

Workshop Repair Manual for your MERCURY or MARINER Outboard Motors – NOT a Seloc manual. This is the best manual you can find to repair your outboard motor. This repair manual will guide you in any steps from maintenance to more complicated steps like rebuilding the engine >>

1984-1986 Mercury Force 4HP Outboards Service Manual – $8.95

Original Mercury Service manual covers the following Mercury Force models: 4HP Manual part number: OB4126 >>

1984-1986 Mercury Force 9.9 and 15HP Outboards Service Manual – $8.95

Original Mercury Service manual covers the following Mercury Force models: 9.9HP and 15HP >>

1985 Mercury Outboard V-300 V-3.4L Shop Service Manual – $8.95

Original Mercury Shop manual covers 1985 models: V-300 – V3.4 Litre >>

1986+ Mercury 6/8/9.9/10/15HP 2-stroke Factory Service Manual – $8.95

Original 1986+ Mercury 6/8/9.9/10/15HP 2-stroke Factory Service Manual. Starting Model Year 1986 >>

1987-1993 Mercury Mariner Outboards 70/75/80/90/100/115HP 3 and 4-cylinder Factory Service Manual – $8.95

Original 1987-1993 Mercury Mariner Outboards 70/75/80/90/100/115HP 4-cylinder Service Manual. 1987-1993 70 / 75 / 75 Marathon >>

1988-1992 Mercury Force 5HP Outboards Service Manual – $8.95

Factory Service manual for 1988-1992 Mercury Force 5HP outboard motors Part #: 90-823263 492 >>

1988-1995 Mercury Force 5HP Outboards Service Manual, 90-823263 793 – $8.95

Factory Service manual for 1988-1995 Mercury Force 5HP outboard motors Part #: 90-823263 793 >>

Mercury Mariner 4, 5 – 102CC Sail 1990 Outboard Service Shop Manual – $8.95

Original Mercury Service manual covers the following Mercury Mariner models with Serial Number: United States >>

Mercury Mariner V-250 V-275 Outboard Service Shop Manual 1990 – $8.95

Original Mercury Mariner Service manual covers the following models: V-250 >>

1992-2000 Mercury Mariner 105-225HP outboards Factory Service Manual – $11.95

Original Mercury Service manual covers the following models: MODELS: 105/140 JET, 135, 150, 175, 200, 225 >>

Mercury Force 9.9, 15HP Outboards Service Manual – $8.95

Original Mercury Force Service manual covers the following models: – 9.9 HP >>

1995 Mariner Mercury Outboards Service Manual 50HP 4-Stroke – $8.95

Original Mercury Shop manual covers 1995 outboard motor: 50 HP Models >>

1996 Mercury Force 25 HP Service Manual 90-830894 895 – $8.95

Factory Service manual for 1996 Mercury Force 25HP outboard motors with starting Serial Number 0E127700 and Up Part #: 90-830894 895 >>

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1998 Mercury 9.9/15HP 4-stroke outboards factory service manual – $8.95

Models covered: Mercury/Mariner >>

1998+ Mercury Mariner 25HP Bigfoot Service Manual – $8.95

Original high quality 1998+ Mercury Mariner 25HP Bigfoot Service Manual. Starting Model Year: 1998 >>

Mercury Mariner 4 and 5HP 4-Stroke Outboards Service Shop Manual 1999 – $8.95

Original Mercury Service manual covers the following Mercury Mariner models with Serial Number: Starting serial numbers OR000001 and Above >>

2002-2004 Mercury 40HP, 50HP, 60HP, Factory Service Repair Manual – $8.95

Original 2002-2004 Mercury 40HP, 50HP, 60HP, Factory Service Repair Manual. Starting Model Year: 2002 >>

2002+ Mercury 40/50/60 BigFoot 40 Jet EFI 4-Stroke Outboard Service Manual – $8.95

Original Mercury Service Manual for 40/50/60 BigFoot 40 Jet EFI FourStroke 4 Cylinder models. Manual includes high resolution diagrams, images, detailed instruction and technical recommendations and more >>

2002+ Mercury Mariner 150/175/200 EFI 2-stroke Factory Service Manual – $8.95

Original 2002+ Mercury Mariner 150/175/200 EFI 2-stroke Factory Service Manual. Mercury Mariner 150/175/200 Electronic Fuel Injection >>

2003+ Mercury Mariner 225 HP EFI 4-Stroke Service Manual – $8.95

Complete Service manual for the Mercury: 4 Stroke 225HP EFI Models This manual is your source for repair and service information >>

2005+ Mercury Verado 4 Stroke 200/225/250/275 6 gear housing Service Manual – $8.95

Original Mercury service manual for Verado 4 Stroke 200/225/250/275 6 gear housing outboard motors. – Starting year 2005 >>

Mercury Electric Outboards 222 Thruster Service Manual – $8.95

Original Mercury Shop manual covers outboard motors: Electric Outboards 222 Thruster Models >>

Mercury Mariner Outboards 45 Jet 50 55 60 HP Models Service Manual – $8.95

Original Mercury Mariner Outboards Service and Repair Manual. It covers everything to fix/repair your Mercury Mariner Outboard. This is a complete manual with detailed instructions, diagrams and more. Manual is deeply indexed and searchable. It includes very descriptive diagrams, detailed repair and diagnostic procedures with appropriate part numbers and all required references >>

Mercury 35/40HP 2 Cylinder Outboards Service Manual PN 90-42794–1 – $8.95

Original Mercury service manual is searchable and indexed for easy access to information. Publication #: 90-42794–1 >>

1997+ Mercury 35/40HP 2 Cylinder Outboards Service Manual PN 90-826148R2 – $8.95

Original service manual with hundreds of high quality diagrams. Manual is searchable and indexed. This is the Official Service Manual that the dealers and shops use. This manual cover specifications, diagnosis and testing, component removal, teardown and rebuild >>

Mercury Outboards Remote Controls Service Manual – $8.95

Original Mercury Remote Controls Service Manual Models covered >>

Mercury Mariner 200, 225 Optimax Outboards Service Manual, 90-855348 – $8.95

Factory Service manual for Mariner 200, 225 Optimax outboard motors Part #: 90-855348 >>

2001 Mercury Mariner 50-60HP Factory Service Manual – $8.95

Original 2001 Mercury Mariner 50-60HP Factory Service Manual. 2001 (01) Mercury-Mariner models 50 HP (50HP) & 60 HP (60HP) 4-Stroke (Four Stroke) Outboard Engines With Serial Numbers 0T178500 and Above >>

Mercury Mariner 25HP 4-Stroke Outboard Service Manual 1997 – $8.95

Original Mercury Mariner Service manual covers the following models: 25HP 4-stroke Manual part number: P/N P/N 90-854785, Year 1997 >>

Mercury Mariner 30/40 4-Stroke Outboard Service Manual 1998 – $8.95

Original Mercury Mariner Service manual covers the following models: 30/40 ELPT >>

Mercury Mariner 4, 5, and 6HP 4-Stroke Factory Service Manual – $8.95

Original Mercury Mariner 4, 5, and 6HP 4-Stroke Factory Service Manual. Manual is indexed and searchable with high-resolution diagrams and images >>

Mercury Mariner 8/9.9HP 4-Stroke Factory Service Manual – $8.95

Original Mercury Mariner 8/9.9 4-Stroke Factory Service Manual in PDF format for immediate download. MODELS COVERED >>

Mercury Mariner Models 135 150 175 200 Service Manual – $8.95

Original Mercury Mariner Outboards Service and Repair Manual. It covers everything to fix/repair your Mercury Mariner Outboard. This is a complete manual with detailed instructions, diagrams and more. Manual is deeply indexed and searchable. It includes very descriptive diagrams, detailed repair and diagnostic procedures with appropriate part numbers and all required references >>

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Mercury Mariner Outboard 225 3 Litre Service Manual 1994 – $8.95

Original Mercury Mariner Service manual covers the following models: 225HP, with serial numbers 0D280813 and up (U.S. motors) Manual part number: P/N 90-822900 194, Year 1994 >>

Mercury Mariner Outboards 2.2 / 2.5 / 3.0 Service Shop Manual – $8.95

Original Mercury Shop manual covers outboard motors: 2.2/2.5/30 HP Models >>

Mercury Mariner Service Manual 6, 8, 9.9 210CC Sailpower – $8.95

Original Mercury Shop manual covers outboard motors: 210CC Sailpower Models >>

Mercury Mariner Outboard 40/50/55/60 2-stroke Service Manual – $8.95

Original Mercury Service Manual for 40/50/55/60 2-stroke models. Manual includes high resolution diagrams, images, detailed instruction and technical recommendations and more >>

Mercury Optimax – 115, 135, 150, 175, DFI year 2000 and up service manual. – $8.95

Mercury Optimax service manual 115, 135, 150, 175, DFI year 2000 and up Covers models starting with Serial Number OG960500 >>

Mercury Optimax – Models 135, 150, Direct Fuel Injection. – $8.95

Mercury Optimax – Models 135, 150, Direct Fuel Injection. Serial numbers OG590000 and Above >>

Mercury Optimax – 200, 225, DFI 1997-1999 Service Manual. – $8.95

Mercury Optimax Service Manual 200/225 Direct Fuel Injection >>

Mercury Optimax – 200/225 from year 2000 Service Manual. – $8.95

Mercury Optimax 200/225 Direct Fuel Injection Service Manual. Starting model year 2000 >>

Mercury Optimax – 75, 90, 115, DFI starting year 2004 service manual. – $8.95

Mercury Optimax 75, 90, 115, DFI – starting year 2004 service manual. Covers models starting model year 2004, Serial Number 0T8010000 and Up >>

Mercury Optimax – Diagnostic Guide. – $8.95

Diagnostic Guide covers technical procedures and tests as well as symptoms which will help troubleshooting Mercury Optimax motors and drives >>

2005 Mercury Outboard 40 ELPTO – 1043412DD 2005 mercury 225 xl optimax electrical service manual manuel 6cv mercury pdf 1997 mercury 9.9 2 stroke specs mercury outboard 150 manual 2001.
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Repair manual by serial number mariner outboard 1990 60hp 3 cylinder outboard repair manuals mercury 9.9 4 stroke owners manual Mercury Marine Manuals Mercury Outboard Wiring Schematic Diagram.
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Innovation doesn’t stop with our outboards, Mercury propellers : a performance revolution – Mercury Marine 90-850416009 User Manual

background image

towing power no matter the size or style of your boat.

U N M ATC H E D D E A L E R

C O V E R A G E A N D S U P P O R T

Every Mercury outboard is developed to deliver outstanding

reliability and performance. However, if there comes a time when

you do need to visit a dealer, it’s reassuring to know that Mercury

has more factory-trained, authorized dealers in North America

than any other outboard manufacturer. So if you’re coming in

for routine maintenance or just to find out about the latest

Mercury Marine has a dealer near you

P R E C I S I O N

S E T S U S A PA R T

Boaters choose Mercury outboards because of their

superior fuel economy, performance and durability.

Mercury Precision Parts

and fluids

to protect your investment, so the performance and

durability that you expect on day one will be

enjoyed for years to come.

X7 alloy is 30% stronger

four times more durable

than conventional stainless

steel. This allows us to design props that deliver
a combination of top speed and acceleration that
other props cannot.

If the propeller strikes an underwater object, our

Flo-Torq

II system

sacrifices itself to

protect the outboard’s lower unit. Plus, the Flo-Torq II
system makes our props compatible with other
outboards, so even non-Mercury owners can enjoy
an improvement in performance.

Before we introduce any new propeller,

we subject

them to rigorous fatigue testing

to make sure that

Mercury Propellers lead the marketplace in durability,
performance and satisfaction.

Maintenance products like

Mercury Quickleen

and our Fuel System Treatment and Stabilizer

work together to deliver the fuel efficiency and
engine performance you expect year after year.

Water is merciless on your engine components.

high-performance gear lube

emulsifiers and tackifiers to deliver protection against
corrosion and wear and tear.

The best way to keep your engine clean and running

efficiently is to choose

Mercury Precision Oils

Unlike automotive blends, our oils are specifically
designed to protect against the brutal conditions of
the marine environment. So whether it’s the
custom-formulated, FC-W-certified Verado oil or
our carbon deposit-reducing OptiMax oil, Mercury
Precision Oils are designed to work seamlessly
with your Mercury outboard.

More dealerships mean more convenience

service network is the largest in North America with
over 5,500 authorized dealers.

• Each authorized dealer incorporates the same procedures

consistent, quality experience,

of location. This includes:

• Performing pre-delivery inspection.

• Utilizing specialized diagnostic tools to quickly

diagnose engine performance issues.

• Employing a dedication to delivering a higher

level of customer service.

• Training at Mercury University, which allows the dealer to

stay informed on the latest Mercury products and technology.

customer service call center

with product specialists to help answer both dealer
and customer questions about their outboards.

W I T H C O N F I D E N C E

SmartCraft uses digital technology based on a simple premise:

making boating easier. Using the latest field-tested digital technology

including waterproof connectors, redundant control systems, Engine

Guardian programming and a complete line of SmartCraft gauges,

you can be sure to enjoy more boating and less work

Intuitive Engine Guardian Mode

protects you and

your investment by detecting and compensating for
unexpected shift events (DTS models only).

With over one million hours of customer use, Mercury has

become the leader in user-friendly digital control systems.
Our

SmartCraft SC1000 and MercMonitor gauges

use easy-to-comprehend messages to provide real-time
information on your outboard systems.

Corrosion-resistant, sealed waterproof connectors

provide years of maintenance-free performance at the helm.

Every component that bears the SmartCraft logo

has been tested and validated to ensure
consistent, seamless operation.

Mercury outboards manual (1962-1972)

FIDENT course.When returning, keep the red buoys on your right; black buoys on your left.

Red nun and spar buoys

Black-and-white vertically striped buoys indicate middle of channel; always pass close t o them, either side. Black-and-red horizontally striped buoys indicate obstruction; gb;e them a wide berth.

Keep practicing water SAFETY night-and-day by observing the following simple rules: Do not operate boat near swimmers. skin divers or fishermen. Keep clear on’ sailing craft and rob oats. yielding rig way. to the right; show courtesy at all times.

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WHITE STERN LIGHT VISIBLE 360″

rine, Fond dw L,ac, Wisconsin 54935 U.S.A.

TABLE o f C O N T E N T SPage Specifications 3 Section 1 .General Information . . . . . . . . . . . . . . . . . . . . . . 5 1.1 . Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 . Directional References . . . . . . . . . . . . . . . . . . . . . . 5 1.3 . Periodic Checkup 5 5 1 4. Write a Letter of Explanation 1.5 Service Recommendations 5 1-6 . Serial Number 6 1.7 . Motor and Boat Insurance 6 1.8 . Recording Electric Starting Key Number . . . . . . . . . . . 6 Section 2 .Motor Installation . . . . . . . . . . . . . . . . . . . . . . . 6 2.1 . Outboard Motor Mounting . . . . . . . . . . . . . . . . . . .6

2.2 . T i l t Pin Adjustment . . . . . . . . . . . . . . . . . . . . . . . 8 2.3 . Tilt-Up and Shallow Water Troll Lever Operation 9 2.4 . Tilt Stop Lever . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 5 . Conditions Affecting Operation 10 2-6 . Adjusting Co-Pilot . . . . . . . . . . . . . . . . . . . . . . . 10 Section 3 .Propeller Recommendations . . . . . . . . . . . . . . . . 1’1 3.1 . Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2 . Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . 11 3.3 . Installing Propeller . . . . . . . . . . . . . . . . . . . . . . . 11 6 C y l . Models and 4 X y l . Merc 800-650 . . . . . . . . . . . 12 1 Merc 650 ( 3 C y l. 7972) . . . . . . . . . . . . . . . . . . . . 12 Merc 5 0 M 8 2 4 0 ( 2 4 3l 1 and 350 . . . . . . . . . . . . . 13 Merc 200-1 10-75-40-39 . . . . . . . . . . . . . . . . . . . . 13 3 4 . How to Remove Propeller . . . . . . . . . . . . . . . . . . . 1 3 3.5 . Propeller Repair . . . . . . . . . . . . . . . . . . . . . . . . 93

Section 4 .Accessories Installation . . . . . . . . . . . . . . . . . . . 1 4.1 . Remote Control Attachment (Single Lever) . . . . . . . . . 1 A l l 1966-thru-1972 Models. except Merc 200-110-756040-39 1 Merc 200-1 10-75-60-40-39 . . . . . . . . . . . . . . . . . 1 42 . Dual Motor Installation 1 Section 5 . Fuel Mixture and Fuel System 1 5.1 . Installing Fuel Tank 1 5.2 . Rewmmended Fuel Mixture . . . . . . . . . . . . . . . . . 1 1, 5.3 . Correct Fuel Mixing Procedure 5 4. Importance of Consistent Fuel Mixtures 1; Section 6 .Starting and Stopping 1′, 61 . Description .Electric Starting . . . . . . . . . . . . . . . . . l! . 8 2 Electric Starting Procedure . . . . . . . . . . . . . . . . . . I! 6 3 . Emergency Starting Procedure (Elec. Start Models) . . . . 2′ 6 4 . Manual Starting Procedure (Manual Starting Models) . . . 2: 6 5 . Stopping 2. 6-6 . Removing Motor from Boat 2: 4 Section 7 .Opwation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 21 7.1 . Throttle and Shift

Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjustable T i m Tab and Galvanic Corrosion lnhibotor . . 25 Power Trim Operation . . . . . . . . . . . . . . . . . . . . . 2 : 7 How t o Tell Whether Water Pump Is Operating . . . . . . . 2 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Shallow Water Operation . . . . . . . . . . . . . . . . . . . 28 Operation i n Sak Water . . . . . . . . . . . . . . . . . . . . 28

. Fuel System Maintenance . . . . . . . . . . . . . . . . . . 28Removing Cowling . . Carburetor Adjustment

8.2 .. 83 . A p p r o x

m a t e . Initial Setting 8 4 . L o w Speed Adjustment . . 8 5 . Servicing Fuel Tank Filter .

. . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . . . . . 31

86 . Servicing Motor Fuel Filter . . . . . . . . . . . . . . . . . . 31 .

Section 9 .Lubrication . . . . . . . . . . . . . . 9.1 . Mercury Outboards Lubrication Chart

. . . . . . . . . . . . 32 . . . . . . . . . . . . 32 9.2 . Lower Drive Unit Lubrication . . . . . . . . . . . . . . . . 33 Section 1 0 .Ignition Maintenance . . . . . . . . . . . . . . . . . . . . 35 10.1 . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10.2 . Servicing Spark Plugs . . . . . . . . . . . . . . . . . . . . . . 35. Battery .Electric Start Models . . . . . . . . . . . . . . . . 35 . Maintenance of Battery . . . . . . . . . . . . . . . . . . . . 36 10.5 . Winter Storage Care of Battery . . . . . . . . . . . . . . . . 36 10.6 . Electrical Accessories Connections . . . . . . . . . . . . . . 36 Section 11 .Special Care Required . . . . . . . . . . . . . . . . . . . 37 11.1 . Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . 37 2 11 . . Preparation for Storage . . . . . . . . . . . . . . . . . . . . 3710.3 10.4 11.3 . A t t e n t i o n Required following Operation i n Salt Water

114 . Attention Required following Complete SubmersionSection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . 39 12 .Trouble Chart . . . . . . . . . . . . . . . . . . . . . . . . 41or Silt

.411 informntion herein Ifins in effect when this hook war printed . Wercury .I.lnrinc?.whose policy is one o f continuous improvement, reserves the right to discontinue models at any time o r t o chnnge specifications or designs without notice and without incurring ohligatio n

Figure l Merc 402 ModelPage 2

– 1966 thru 1972 M E R C M O D E L SPoint Bore Stroke

1 lCUJlHP Displ

5000-5400 5000-5400 4500-5500 4500-5500 5000-5400 5000-5400 4500-5500 4500-5500 5000-5400 5000-5400 4500-5500 5000-5400 5000-5400 4800-5500 4800-5200 4800-5300 4800-5300 4800-5300 5200-5600 5200-5600 5200-5600 4800-5500Metric Conversion: 1 “=

2″ 2″ 2″ 2″ 1-314″ 1-314″ 2″ 2″ 2″ 2″ 2″ 2-9/16″ 2-9116″ 2-9/16” 3″ 3″ 2-718″ 2-718″ 2-9/16” 2-9/16″ 2-9/16″ 2-7I *

1-314″ 1-314″ 1-314″ 1-314″ 1-112″ 1-112″ 1-314″ 1-314″ 1-314″ 1-314″ 1-314″ 2-118″ 2-118″ 2-118″ 2.3″ 2.3” 2-9116″ 2-9/16″ 2-118″ 2-118″ 2-118″ 2-1I *

.020u.020″ ,020” .020″ .020″ ,020” .020″ .020″ .020″ ,020” 020″ “020” ,020” ,020″ ,020” None None 010*,

Mercury Joystick Piloting for Outboards Manual

Manual for Mercury Joystick Piloting for Outboards Marine Equipment (54 pages)

Joystick Piloting for Outboards File Specifications:

  • Manufacturer: Mercury
  • Category of Device: Marine Equipment
  • Document: Manual , File Type: PDF
  • Count of Pages: 54

Mercury Joystick Piloting for Outboards Manual Transcription:

Section 6 – Predelivery (PDI) and Customer Delivery (CDI) Checklists Page 48 90-8M0093150 eng MAY 2014 Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages equipped with joystick piloting. For engine packages not equipped with Joystick Piloting for Ouboard, use the outboard PDI checklist located on the MercNet website. Perform these tasks before the Customer Delivery Inspection (CDI). N/A Check/ Adjust Check Before Running:   Service bulletin updates or repairs completed  Drain plug installed and drain valves closed  Engine mount…

Section 3 – Troubleshooting Page 36 90-8M0093150 eng MAY 2014 Check VesselView First Your VesselView display is the primary information source for the various functions of your boat. Consult the VesselView display if you suspect something is wrong. VesselView displays faults and other information that can be helpful in determining the current status of various systems that could be causing your concern and the solution to the problem. Diagnosing DTS Problems Your author…

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Section 1 – Getting to Know the Joystick Piloting for Outboard Page 8 90-8M0093150 eng MAY 2014 2. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired. a – Detent tension adjustment b – Control handle tension adjustment Joystick Piloting for Outboard—Basic Operation NOTICE The vessel personali…

Section 3 – Troubleshooting 90-8M0093150 eng MAY 2014 Page 37 Symptom Remedy The ERC lever controls the engines, but they do not reach wide‑open throttle. If the engine reaches only 50% of available power, check the dock button on the DTS trackpad. If the light is on, put the handles in neutral and push the button to disengage. Check VesselView to see if cruise control is enabled. Disable cruise control. Check for damage to the propeller, and change the propeller if damage is found. Contact your autho…

Section 2 – On the Water Page 26 90-8M0093150 eng MAY 2014 • For quad‑engine applications, this must be at least one port and one starboard engine (i.e., both outers, both inners, port inner and starboard outer, or port outer and starboard inner). Skyhook will not operate with only the two starboard or the two port engines running. 3. Ensure that the ERC levers are in neutral. 4. Confirm that the area around the boat is clear of swimmers and obstacles. 5. Press the Skyhook button. NOTE: A double horn beep sounds if the Skyhook mode…

Section 2 – On the Water Page 30 90-8M0093150 eng MAY 2014 Track Waypoint ! WARNING Avoid serious injury or death. Inattentive boat operation can result in a collision with other watercraft, obstacles, swimmers, or underwater terrain. The autopilot navigates a preset course, and does not automatically respond to hazards in the vicinity of the boat. The operator must stay at the helm, ready to evade hazards and warn passengers of course changes. Track waypoint allows the boat to automatically navigate to a specific waypoint or sequence of waypoints, called a waypoint route. This feature is in…

Mercury Joystick Piloting for Outboards Section 2 – On the Water 90-8M0093150 eng MAY 2014 Page 29 NOTE: The joystick must move over 50% of its travel for the movement to be recognized as input. A beep will sound. 24707 Adjusting heading to starboard To Resume a Heading The resume light is on if the previous course heading is available to resume. IMPORTANT: The previous heading can only be resumed within four minutes of the auto heading being disengaged by turning the wheel past the detent or if the vessel has been turned no more than 90°. Press the resume button to resume the previous heading, if you turned the steering wheel and disengaged au…

Mercury Joystick Piloting for Outboards Section 1 – Getting to Know the Joystick Piloting for Outboard 90-8M0093150 eng MAY 2014 Page 1 Section 1 – Getting to Know the Joystick Piloting for Outboard Table of Contents Vessel Personality. 2 Features and Controls. 2 Instrumentation. 2 VesselView . 2 SmartCraft Digital Gauges . …

Section 4 – Maintenance 90-8M0093150 eng MAY 2014 Page 39 Section 4 – Maintenance Table of Contents Outboard Care. 40 Anti‑Collision Link Cables and Springs. 40 Fuses. 40 Checking Power Steering Fluid. 40 4 …

Mercury Joystick Piloting for Outboards Section 2 – On the Water Page 34 90-8M0093150 eng MAY 2014 7. If you are not in a previously set waypoint arrival zone, waypoint sequence mode starts auto sequencing to the waypoints in the route. Acknowledge that you understand the information presented in the VesselView pop‑up warning, and press the waypoint sequence button. 51889 8. Stay alert. The boat turns automatically in this mode. You must know if it is safe to turn when the vessel is entering a waypoint arrival zone…

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Section 1 – Getting to Know the Joystick Piloting for Outboard 90-8M0093150 eng MAY 2014 Page 11 Function Description Resume Resumes previous auto heading course if the boat’s direction has not been changed 90° or more. NOTE: Moving the steering wheel will always override the autopilot, and the operator will assume control of the vessel. A slight resistance in the wheel gives the operator feedback that he is taking control from the autopilot. Shifting using the electronic remote control (ERC) lever will also disable the autopilot mode. Transporting a Joystick Piloting for…

Section 1 – Getting to Know the Joystick Piloting for Outboard Page 10 90-8M0093150 eng MAY 2014 ! WARNING Avoid serious injury from collision with other boats, running aground, or striking objects in the water. Always maintain a diligent lookout while the boat is operating in any Precision Pilot mode. The Precision Pilot system cannot react to avoid other boats, shallow water, or objects in the water. The autopilot trackpad gives the operator control over the listed features. Autopilot trackpad a – Skyhook b – Turn to port or starboard …

Mercury Joystick Piloting for Outboards Section 2 – On the Water Page 22 90-8M0093150 eng MAY 2014 Helm Transfer Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to another helm. ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be pe…

Section 2 – On the Water Page 16 90-8M0093150 eng MAY 2014 • Be alert. The operator of the boat is responsible by law for maintaining a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator’s view when operating the boat above idle or planing transition speed. Watch out for others, keep your eyes on the water, and be aware of your wake. • Never drive your boat directly behind a water‑skier in case the skier falls. In five second…

Mercury Joystick Piloting for Outboards Section 6 – Predelivery (PDI) and Customer Delivery (CDI) Checklists Page 50 90-8M0093150 eng MAY 2014 N/A Completed Operation of equipment—explain and demonstrate:  E‑stop switch / lanyard stop switch operation (all helms)  Cause and effect of steering torque or pull; instruct the customer on using a firm steering grip; explain boat spin‑out and how to trim for neutral steering.   U.S. Coast Guard capacity plate  Proper seating  Importance of personal flotation devices (PFDs or life vests) and throwable PFDs (th…

Mercury Joystick Piloting for Outboards Section 2 – On the Water 90-8M0093150 eng MAY 2014 Page 23 • Requesting a helm transfer places the autopilot into standby mode. Any required inputs will need to be re‑entered at the newly active helm. • If engaged, Skyhook will disengage when the transfer button is pressed the second time. If desired, Skyhook must be re‑engaged at the newly active helm. • The resume feature for the auto heading function does not transfer automatically. After engaging the previous auto heading course at the newly active helm, the resume feature works the…

Page ii 90-8M0093150 eng MAY 2014 Section 4 – Maintenance Outboard Care. 40 Anti‑Collision Link Cables and Springs. 40 Fuses. 40 Checking Power Steering Fluid. 40 Section 5 – Customer Assistance Information Service Assistance. 44 Local Repair Service. …

Section 3 – Troubleshooting 90-8M0093150 eng MAY 2014 Page 35 Section 3 – Troubleshooting Table of Contents Check VesselView First. 36 Diagnosing DTS Problems. 36 Engine Guardian System. 36 Troubleshooting Charts. 36 Joystick. …

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Section 6 – Predelivery (PDI) and Customer Delivery (CDI) Checklists 90-8M0093150 eng MAY 2014 Page 47 Section 6 – Predelivery (PDI) and Customer Delivery (CDI) Checklists Table of Contents Predelivery Inspection (PDI). 48 Customer Delivery Inspection (CDI). 49 6 …

Mercury Joystick Piloting for Outboards Section 2 – On the Water 90-8M0093150 eng MAY 2014 Page 21 NOTE: The joystick does not have detents. It can be positioned at any of the indicated arrows or anywhere in‑between. a – Forward b – Crab to forward by starboard c – Lateral to starboard d – Crab to reverse by starboard e – Reverse f – Crab to reverse by port g – Lateral to port h – Crab to forward by port i – Port yaw j – Starboard yaw Centering the Engines after Joystick Operation Upon releasing the joystick, the engines will remain in their last command…

Section 2 – On the Water Page 18 90-8M0093150 eng MAY 2014 To disengage dock mode: 1. Bring both ERC levers to any detent or neutral. NOTE: Dock mode disengages only when the levers are moved into a detent. 2. Press DOCK. The dock light turns off. Throttle-Only Mode Moving the joystick whenever the engines are running and the ERC levers are in the neutral position will command the boat to move. Throttle‑only mode should be used to disable the joystick if the captain is not in command at the helm. Placing the ERC in throttle‑only mode will avoid unintended gear engagement. The eng…

Section 5 – Customer Assistance Information Page 44 90-8M0093150 eng MAY 2014 Service Assistance Local Repair Service If you need service for your Mercury‑outboard‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package. Service Away F…

© 2014 Mercury Marine Joystick Piloting for Outboards 90-8M0093150 514 Welcome You have selected one of the finest outboard products available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. This manual is a supplement to the owner’s manual provided with your engine. It provides additional, specific information for using and maintaining the Joystick Piloting for Out…

Section 1 – Getting to Know the Joystick Piloting for Outboard Notes: Page 12 90-8M0093150 eng MAY 2014 …

Section 2 – On the Water 90-8M0093150 eng MAY 2014 Page 25 ! WARNING Skyhook is an automatic system. Use of this system does not relieve the operator of the responsibility to remain at the helm and keep watch for changing conditions. The presence of swimmers or other vessels, or if Skyhook becomes disengaged, will require the operator to assume manual control of the vessel. Important Safety Considerations Activities in the water near the vessel while Skyhook is engaged may result in injury. The operator should read and observe the warnin…

Section 6 – Predelivery (PDI) and Customer Delivery (CDI) Checklists 90-8M0093150 eng MAY 2014 Page 49 N/A Check/ Adjust On‑the‑Water Test:  Neutral start safety switch operation  Lanyard stop switch operation (all helms)  Operation of instruments  Fuel, oil, and water leaks  Ignition timing  Forward, neutral, and reverse gear operation  Steering operation throughout range  Acceleration from idle RPM is normal  WOT________ RPM…

Section 1 – Getting to Know the Joystick Piloting for Outboard 90-8M0093150 eng MAY 2014 Page 9 Engine Guardian monitors: • Oil pressure • Coolant temperature • Water pressure • Engine overspeed • Battery voltage Should Engine Guardian engage on your vessel, the SmartCraft instrumentation will display the information and advise you to reduce throttle, if necessary. Engine Guardian may also reduce the engine speed if the situation requires it. To avoid a possible recurrence of the problem you should …

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Section 1 – Getting to Know the Joystick Piloting for Outboard Page 6 90-8M0093150 eng MAY 2014 4. Remove the three M5 screws securing the side cover. 41347 Location of side cover screws 5. Remove the side cover. 6. For adjustment, temporarily install the handle, washer and screw. Finger‑tighten the screw. 7. To adjust the ERC handle detent tension: a. Turn the adjustment screw clockwise to increase tension on the control handle and counter‑clockwise to decrease tension. b. Adjust to the desired tension. 8. To adjust ERC handle tension: a. Turn the adjustment screw…

Section 1 – Getting to Know the Joystick Piloting for Outboard Page 4 90-8M0093150 eng MAY 2014 Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment Operation The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop. Pull the contr…

Section 2 – On the Water Page 24 90-8M0093150 eng MAY 2014 Autopilot Trackpad Lights The autopilot trackpad includes lights to indicate when an autopilot mode is active (engaged) or in standby (disengaged). If the standby light is illuminated, then the autopilot is disengaged (off). If the active light is illuminated, then the autopilot is engaged (on). Pressing the button for auto heading, track waypoint, or Skyhook will engage that mode, turning on both its respective light and the active light. N…

Section 1 – Getting to Know the Joystick Piloting for Outboard 90-8M0093150 eng MAY 2014 Page 3 • Engine operating hours SmartCraft tachometer and speedometer a – Tachometer b – Speedometer c – LCD display The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display. For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the …

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Our portable lineup of Mercury motors for sale includes 2.5hp Mercury boat motors with a built in fuel tank, the 3.5hp Mercury outboard motors which feature choice of 15 inch or 20 inch shaft length, the 4hp featuring digital DCI ignition, and the 5hp Mercury outboards feature a larger carb and prop for increased performance.

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