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Mercury 25 4-Stroke User Manual

Mercury 25 4-Stroke
72 pages
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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.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
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: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive: 98/37/EC,
EMC Directive: 89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
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
© 2004 Mercury Marine 25 4-Stroke 90-10183R50 304

Table of Contents

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Mercury 25 4-Stroke Specifications

General IconGeneral
Engine Type4-Stroke
Horsepower25 hp
Cylinders2
Fuel Induction SystemElectronic Fuel Injection (EFI)
Full Throttle RPM Range5000-6000 RPM
Starting SystemElectric
SteeringRemote or Tiller
Shaft Length15 in / 20 in
Dry Weight157 lbs
Fuel Tank CapacityExternal
Oil Capacity1.5 L (with filter)

Summary

Welcome and Introduction

Manufacturer's Compliance Statement

Details the outboard motor's compliance with European directives and standards.

Warranty Information

Warranty Transfer and Registration

Covers transferring warranty and registration process in US/Canada and internationally.

Limited Warranty Coverage Details

Details 2-year European, 1-year CIS/ME/Africa, and 3-year corrosion limited warranties.

General Warranty Exclusions and Limitations

Lists common exclusions, disclaimers, and limitations applicable to all warranties.

General Information and Safety

Boater Responsibilities and Pre-Operation Checks

Outlines operator duties, safety alerts, and checks before operating the outboard.

Boat Safety and Operation Guidelines

Covers horsepower limits, high-speed operation, remote controls, and lanyard stop switch.

Safe Boating Practices and Hazard Avoidance

Advises on protecting people, avoiding underwater hazards, and wave jumping.

Technical Specifications and Component Identification

Lists engine specifications and identifies key outboard components.

Installation Procedures

Installing the Outboard Motor

Provides instructions and warnings for correctly installing the outboard motor.

Propeller Selection for Optimal Performance

Guides on selecting a propeller to optimize performance based on RPM range.

Transporting Your Outboard

Trailering Boat and Outboard

Details trailering procedures for models with and without power trim.

Safe Transport of Portable Fuel Tanks

Provides safety instructions for transporting portable fuel tanks.

Fuel and Oil Management

Gasoline Recommendations and Concerns

Advises on gasoline types, octane ratings, and concerns with alcohol content.

Fuel Tank Filling and Engine Oil Checks

Covers safe fuel tank filling and procedures for checking and adding engine oil.

Engine Oil Recommendations

Recommends specific SAE viscosity and API classifications for engine oil.

Features and Controls

Remote Control and Warning System Overview

Identifies remote control functions and the outboard warning system.

Engine Overheat and Low Oil Pressure Warnings

Explains actions for engine overheat and low oil pressure warnings.

Tilt, Trim, and Shallow Water Operation

Details manual and power tilt, trim adjustments, and shallow water drive features.

Steering, Throttle, and Trim Tab Adjustments

Covers adjustments for steering friction, throttle grip, and trim tabs.

Operation Procedures

Pre-Starting Checks and Procedures

Lists essential checks, operating conditions, and initial steps before starting the engine.

Starting the Engine and Break-in

Details engine break-in procedures and steps for starting with remote or tiller controls.

Gear Shifting, Stopping, and Emergency Starting

Covers gear shifting, engine shutdown, and emergency starting methods.

Maintenance Schedule and Procedures

Routine Outboard Care and Parts Selection

Emphasizes routine care, maintenance schedule, and using genuine replacement parts.

Cooling System, Cowl, and Fuel System Maintenance

Details flushing cooling system, cowl removal, and fuel system inspection.

Steering, Corrosion, and Propeller Maintenance

Covers steering link fasteners, corrosion anodes, and propeller replacement.

Spark Plugs, Fuses, Belts, and Lubrication

Guides on spark plugs, fuses, timing belt inspection, and lubrication points.

Fluid Checks and Gearcase Maintenance

Details checking power trim fluid, changing engine oil, and gearcase lubrication.

Storage Preparation

Preparing Fuel System and Components for Storage

Covers fuel system stabilization and protecting external/internal engine components.

Gearcase, Positioning, and Battery Storage

Advises on gearcase preparation, storage position, and battery storage procedures.

Troubleshooting Common Issues

Engine Starting and Running Problems

Lists causes and solutions for starter issues and engines that won't start or run erratically.

Performance Loss and Battery Charging Issues

Identifies causes for performance loss and battery not holding charge.

Owner Service Assistance

Obtaining Service and Parts

Guides on seeking local service, parts inquiries, and general assistance.

Mercury Marine Service Office Contacts

Provides contact information for Mercury Marine service offices in the US, Canada, and international locations.

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