Mercury Four Stroke User Manual

1
D
OUTBOARD MOTOR INSTALLATION
90-888465 JUNE 2002 Page 1D-1
IMPORTANT INFORMATION
Section 1D - Outboard Motor Installation
Table of Contents
Electric Fuel Pump 1D-1. . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . . .
Start in Gear Protection 1D-2. . . . . . . . . . . . . . . . . .
Warning Horn Requirement 1D-2. . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 1D-2. . .
Dual Engine Center Line Dimension 1D-2. . . . . . .
Lifting Outboard 1D-3. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable Seal 1D-4. . . . . . . . . . . . . . . . . . . . .
Steering Link Rod 1D-5. . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard 1D-6. . . . . . . . . . . . . . . . . . . . . .
Front Cable Clamp Assembly 1D-7. . . . . . . . . . . . .
Remote Wiring Harness 1D-8. . . . . . . . . . . . . . . . . .
Battery Cable Connections to the Engine 1D-9. . .
Battery Cable Connections to the Battery 1D-10. . .
Fuel Hose Connection 1D-11. . . . . . . . . . . . . . . . . . .
Shift Cable Installation 1D-12. . . . . . . . . . . . . . . . . . .
Throttle Cable Installation 1D-14. . . . . . . . . . . . . . . .
Propeller Installation 1D-15. . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 1D-16. . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine.
If necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
U.S. COAST GUARD CAPACITY
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1.
cause loss of boat control 2. place too much weight at the transom, altering the de-
signed flotation characteristics of the boat or 3. cause the boat to break apart, par-
ticularly around the transom area. Overpowering a boat can result in serious injury,
death, or boat damage.

Mercury Four Stroke Specifications

General

Engine Type	4-Stroke
Fuel Induction System	Electronic Fuel Injection (EFI) or Carbureted, depending on model
Starting System	Manual, Electric
Steering	Tiller, Remote
Alternator	Varies by model
Full Throttle RPM Range	Varies by model
Weight	Varies by model
Gear Ratio	Varies by model
Warranty	Varies by region and model (e.g., 3 to 5 years)
Cylinders	1 - 6
Shaft Length	15", 20", 25"

Summary

Outboard Motor Installation

Electric Fuel Pump

Details on electric fuel pump pressure regulation and the need for a pressure regulator if necessary.

Boat Horsepower Capacity

Information on maximum horsepower, person capacity, and weight limits for boats.

Start in Gear Protection

Requirement for remote controls to have a built-in start-in-gear protection device.

Warning Horn Requirement

Mandatory wiring of a warning horn with the remote control or key switch assembly.

Selecting Accessories For The Outboard

Guidance on using genuine parts and accessories designed for the outboard.

Dual Engine Center Line Dimension

Diagram and measurements for positioning dual outboard engines relative to each other.

Lifting Outboard

Instructions for safely lifting the outboard using a 3-point lift strap.

Steering Cable

Procedure for lubricating the steering cable end prior to installation.

Steering Cable Seal

Steps for installing the O-ring seal and cap onto the steering cable.

Steering Link Rod

Installation details for the steering link rod, emphasizing correct hardware and safety.

Installing Outboard

Instructions for mounting the outboard to the boat transom with specified hardware.

Front Cable Clamp Assembly

Procedure for bundling and securing fuel line, battery cables, and wiring with a clamp.

Remote Wiring Harness

Steps for routing, connecting, and securing the remote wiring harness.

Battery Cable Connections to the Engine

Instructions for routing and connecting battery cables to the engine terminals.

Battery Cable Connections to the Battery

Guidance on connecting positive and negative battery cables to the starting batteries.

Fuel Hose Connection

Instructions for routing fuel hose through the cable clamp and connecting it to the engine.

Shift Cable Installation

Detailed steps for installing and adjusting the shift cable for proper gear engagement.

Throttle Cable Installation

Procedure for installing and adjusting the throttle cable to align with the engine's throttle cam.

Propeller Installation

Instructions for installing the propeller, including torque specifications and safety warnings.

Trim Tab Adjustment

How to adjust trim tabs to compensate for steering torque based on boat pull.