Mercury Two-stroke series User manual

1
D
IMPORTANT
INFORMATION
OUTBOARD INSTALLATION

90-830234R3 DECEMBER 19971D-0 - IMPORTANT INFORMATION
Table of Contents Page
Determining Recommended Outboard
Mounting Height 1D-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notice to Installer and Owner 1D-2. . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 1D-2. . . . . . . . . . . . . . . . .
Outboard Remote Control 1D-2. . . . . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 1D-2. . . . .
Selecting Steering Cables and Remote Control
Cables 1D-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locate Center line Of The Outboard 1D-3. . . . . . . . .
Drilling Outboard Mounting Holes 1D-3. . . . . . . . . . . .
Lifting Outboard 1D-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening Outboard To The Transom 1D-4. . . . . . . .
Single Steering Cable and Steering Link
Rod Installation 1D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Ride Guide Steering Cable to the
Outboard 1D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod Installation 1D-5. . . . . . . . . . . . . . .
Co-Pilot Installation (Tiller Handle models) 1D-6. . . . . . .
Remote Control Installation 1D-7. . . . . . . . . . . . . . . . . . . .
Required Side Mount Remote Control or Ignition
Key Switch Assembly 1D-7. . . . . . . . . . . . . . . . . . . . . . . . .
Boats Equipped with Side Mount
Remote Control 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Boats Equipped with Panel Or Console Mount
Remote Control 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Remote Wiring Harness to the Engine 1D-7
Shift and Throttle Cable Installation to the Outboard1D-8
Shift Cable Installation 1D-8. . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation 1D-9. . . . . . . . . . . . . . . . . .
Battery Connections 1D-10. . . . . . . . . . . . . . . . . . . . . . . . .
Set Up Instructions For Oil Injection System 1D-10. . . .
Filling The Oil Injection System 1D-10. . . . . . . . . . . . .
Bleeding Air From The Oil Injection System 1D-11. .
Adjusting The Oil Injection Pump 1D-11. . . . . . . . . . .
Trim Tab Adjustment 1D-12. . . . . . . . . . . . . . . . . . . . . . . . .

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-1
Notice to Installer and Owner
This manual as well as safety labels posted on the
outboard use the following safetyalerts to draw your
attention to special safety instructions that should be
followed.
WARNING
WARNING – Hazards or unsafe practices which
COULD result in severe personal injury or death.
CAUTION
CAUTION–Hazardsorunsafepracticeswhichcould
result in minor injury or product or property damage.
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 your boat. Most boats
will carry a required capacity plate indicating the
maximum acceptable power and loadas determined
by the manufacturer following certain federal guide-
lines.Ifindoubt,contactyourdealerortheboatman-
ufacturer.
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 tran-
som altering the designed flotation characteris-
ticsof the boat or3. cause the boatto break apart
particularly around the transom area. Overpow-
ering a boat can result in serious injury, death, or
boat damage.
Outboard Remote Control
Theremote controlconnected toyour outboardmust
be equipped with a start-in-gear protection device.
This prevents the engine from starting when the out-
board is in gear.
WARNING
Avoid serious injury or death from a sudden un-
expected acceleration when starting your en-
gine. The design of this outboard requires that
the remote control used with it must have a built
in start-in-gear protection device.
Selecting Accessories For
The Outboard
Genuine Mercury Marine Quicksilver Accessories
have been specifically designed and tested for your
outboard.
Mercury Marine Quicksilver accessories are avail-
able from Mercury Marine dealers.
Some accessories not manufactured or sold by Mer-
cury Marine are not designed to be safely used with
youroutboardoroutboardoperatingsystem.Acquire
and read the installation, operation, and mainte-
nance manuals for all your selected accessories.
WARNING
Check with your dealer before installation of ac-
cessories. The misuse of acceptable accesso-
ries or the use of unacceptable accessories can
result in serious injury, death, or product failure.
Selecting Steering Cables
and Remote Control Cables
Refer to “Quicksilver Accessories Guide” to deter-
mine correct length of steering cables and remote
control cables.
IMPORTANT: Steering cables and remote control
cables must be the correct length. Sharp bends
on too-short cables result in “kinks”; too-long
cables require unnecessary bends and/or loops.
Both conditions place extra stress on the cables.

90-830234R3 DECEMBER 19971D-2 - IMPORTANT INFORMATION
Determining Recommended
Outboard Mounting Height WARNING
Boat instability can occur at high speeds by
installing engine at the wrong transom height.
Contact the boat manufacturer for their recom-
mendations for a specific engine installation.
20 in.
21 in.
22 in.
23 in.
24 in.
25 in.
26 in.
19 in.
10 20 30 40 50 60 70 80
(660m
m)
(635m
m)
(609m
m)
(584m
m)
(560m
m)
(533m
m)
(508m
m)
(482m
m)
e
e
a
c
b
d
f
NOTE: Add 5 in. (127mm) for XL models and 10 in.
(254mm)forXXLmodelstolistedoutboardmounting
height.
a. This solid line is recommended to determine
the outboard mounting height.
IMPORTANT: Increasing the height of outboard
generally will provide the following: 1) Less
steering torque, 2) more top speed, 3) greater
boat stability, but, 4) will cause more prop “break
loose” which may be particularly noticeable
when planing off or with heavy load.
b. Thesebrokenlinesrepresenttheextremesof
known successful outboard mounting height
dimensions.
c. This line may be preferred to determine out-
board mounting height dimension, if maxi-
mum speed is the only objective.
d. This line may be preferred to determine out-
board mounting height dimension for dual
outboard installation.
e. Outboard mounting height (height of out-
board transom brackets from bottom of boat
transom). For heights over 22 in. (560mm), a
propeller,thatis specificallydesigned forsur-
facingoperation,suchasthe“Laser”and“Mi-
rage” series, usually are preferred.
f. Maximum boat speed anticipated.

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-3
Locating Center Line Of The
Outboard
Locate (and mark with pencil) the vertical centerline
(a) of boat transom.
BA
DC a
a - Centerline of Transom
NOTE: Dimensions“A”&“B”and“C” & “D” are equal
length.
IMPORTANT: During installation of dual outboards,
the following is recommended. A minimum of 221/2
inches (570mm) centerline to centerline width is rec-
ommended. This is required to alleviate cowling in-
terference during lock to lock turns if one outboard
would be in the full tilt position, while the other out-
board(s) are in the vertical running position.
Drilling Outboard Mounting Holes
IMPORTANT: Before drilling any mounting holes,
carefully read “Determining Recommended Out-
board Mounting Height,” preceding. There is a
3/4 inch (19mm) difference between outboard
mounting holes in transom brackets.
WARNING
DO NOT, under any circumstances, allow upper
outboard mounting bolts to be closer than 1 inch
(25.4mm) from top of boat transom. Upper
mounting bolts must never be installed thru
shims.
NOTE: When drilling into a fiberglass boat, place
masking tape directly onto boat where mounting
holes will be drilled to help prevent fiberglass from
chipping.
Use a 17/32 inch (13.5mm) diameter drill bit and drill
4 mounting holes perpendicular to and thru transom.
IMPORTANT: If using “Transom Drilling Fixture”
(part number 91–98234A2), use drill guide holes
marked “A” when drilling outboard mounting
holes.
b
a
a – Centerline of Transom
b – Transom Drilling Fixture (91–98234A2)

90-830234R3 DECEMBER 19971D-4 - IMPORTANT INFORMATION
Lifting Outboard
WARNING
Verify that the lifting ring is threaded into the fly-
wheel a minimum of 5 turns and that hoist has a
maximum lift capacity over 500 lbs. (227 kg) BE-
FORE lifting outboard.
1. Electric Start Models – Remove plastic cap from
centerofflywheel.Threadliftingringintoflywheel
hubaminimumof5turns.Replaceplasticcapaf-
ter installation.
ab
a - Lifting Ring
b - Plastic Cap – Replace After Installation
2. Manual Start Models – Use lifting eye on engine
and lift outboard on boat transom.
Installing Outboard To Boat
Transom
IMPORTANT:Ifboatisequippedwiththrutilttube
steering, steering cable end must be installed
into tilt tube of outboard (port outboard only for
dual outboard installations) before securing out-
board to transom. Refer to ”Steering Cable and
Steering Link Rod Installation” following.
Refer to “Determining Recommended Outboard Mo-
tor Mounting Height”, preceding and position out-
board on boat transom, to align mounting holes in
transom bracket that will place the outboard nearest
to the recommended mounting height.
CAUTION
Marine sealer must be used on shanks bolts to
make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when
tightening transom bolts.
Apply marine sealer to shanks of mounting bolts (not
threads)andsecureoutboardtotransomwith4bolts,
flat washers and locknuts, as shown. Be sure that in-
stallation is water-tight.
WARNING
Beforeoperation,theoutboard must becorrectly
installedwithfour mountingboltsshown. Failure
to correctly fasten outboard could result in out-
board ejecting off boat transom causing serious
injury, death, or property damage.
a
b
b
ca
c
a - 1/2 Inch Diameter Bolts
b - Flat Washers
c - Locknuts

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-5
Single Steering Cable and
Steering Link Rod
Installation
NOTE:Theseinstructionsareforsinglecable–single
outboardinstallations.Instructionsfor mounting dual
engines are included with the applicable dual engine
attaching kit. Refer to “Quicksilver Accessories
Guide” to determine correct kit.
Refer to “Quicksilver Accessories Guide” to deter-
mine correct length of steering cable.
IMPORTANT: Steering cable must be correct
length. Sharp bends on too-short of a cable re-
sultin“kinks;”too-longofacablerequire unnec-
essary bends and/or loops. Both conditions
place extra stress on the cable.
Install steering mount and steering wheel in accor-
dance with installation instructions that accompany
each.
Installing Ride Guide Steering Cable
To The Outboard
IMPORTANT: Before installing steering cable in
tilt tube, lubricate entire cable end with Quicksil-
ver 2-4-C Marine Lubricant.
NOTE: Ride Guide steering cable is lubricated at the
factoryand requires noadditional lubrication atinitial
installation.
1. Lubricate seal (a) inside of outboard tilt tube and
entire cable end (b) with Quicksilver 2-4-C Ma-
rine Lubricant.
2. Insert steering cable end thru outboard tilt tube
andsecuresteeringcabletotilttubewithsteering
cable attaching nut (c), as shown. Torque nut to
35 lb. ft. (47.5 N·m).
95 2-4-C With Teflon (92-825407A12)
95 a
b
95
c
Steering Link Rod Installation
IMPORTANT: The steering link rod that connects
thesteering cable totheenginemustbe fastened
using special washer head bolt (“a” – Part Num-
ber 10-14000) and self locking nuts (“b”& “c”–
Part Number 11-34863). These locknuts must
never be replaced with common nuts (non lock-
ing) as they will work loose and vibrate off free-
ing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result
in the boat taking a full, sudden, sharp turn. This
potentiallyviolentactioncancauseoccupantsto
be thrown overboard exposing them to serious
injury or death.
3. Assemble steering link rod to steering cable with
two flat washers (d) and nylon insert locknut (“b”
–PartNumber11-34863).Tightenlocknut(b)un-
til it seats, then back nut off 1/4 turn.
4. Assemble steering link rod to engine with special
washer head bolt (“a” – Part Number 10-14000)
and nylon insert locknut (“c”– Part Number
11-34863). First torque bolt (a) to 20 lb. ft. (27.0
N·m), then torque locknut (c) to 20 lb. ft. (27.0
N·m).
a
c
b
d
WARNING
After installation is complete (and before operat-
ing outboard), check that boat will turn right
when steering wheel is turned right and that boat
will turn left when steering wheel is turned left.
Check steering thru full range (left and right) and
atall tilt angles to assure interference-free move-
ment.

90-830234R3 DECEMBER 19971D-6 - IMPORTANT INFORMATION
Co-Pilot Installation (Tiller
Handle models)
WARNING
Avoid possible serious injury or death from loss
of boat control. The Co-pilot assembly must be
installed and adjusted to maintain sufficient
steering friction to prevent the outboard from
steering into a full turn if the tiller handle is re-
leased.
1. Thread the friction collar (a) onto the starboard
side of the tilt tube. Tighten securely and position
the adjustment knob toward front of outboard.
2. Insert pilot rod (b) into the friction collar.
a
b
IMPORTANT:Theco-pilotlinkrod(c)mustbefas-
tened using self locking nylon insert locknuts
(“f”& “g”– Part Number 11-45592).These lock-
nuts must never be replaced with common nuts
(non locking) as they will work loose and vibrate
off freeing the link rod to disengage.
WARNING
Disengagement of the co-pilot link rod can result
in the boat taking a full, sudden, sharp turn. This
potentiallyviolentactioncancauseoccupantsto
be thrown overboard exposing them to serious
injury or death.
3. Lubricate both ends of the link rod with Quicksil-
ver 2-4-C w/Teflon Marine Lubricant. Install link
rod between the tiller handle mount and pilot rod
as shown.
d
e
g
c
e
f
c - Co-Pilot Link Rod
d - Spacer (Hidden) - Place in the Upper Mounting Hole
For The Link Rod.
e - Flat Washer
f - Locknut - Torque to 120 lb. in. (13.6 N·m)
g - Locknut - Tighten Until it Seats; DO NOT exceed 120 lb.
in. (13.6 N·m), Then Back Off The Locknut 1/4 Turn.

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-7
Remote Control Installation
Refer to “Quicksilver Accessories Guide” to deter-
mine correct length of remote control cables.
IMPORTANT:Remotecontrolcablesmustbecor-
rect length. Sharp bends on too-short cables re-
sult in “kinks;” too-long cables require unneces-
sary bends and/or loops. Both conditions place
extra stress on the cables.
IMPORTANT: Install control cables to remote
control and mount remote control BEFORE at-
taching control cables to engine. Refer to instal-
lation instructions included with remote control.
Required Side Mount
Remote Control or Ignition
Key Switch Assembly
Boats Equipped with Side Mount
Remote Control
A Quicksilver Commander 2000 series Side Mount
Remote Control equipped with a warning horn must
beused with this outboard.This warning horn isnec-
essary for the engine warning system.
a
a -Warning Horn
Boats Equipped with Panel Or
Console Mount Remote Control
A Quicksilver Ignition Key/Choke Assembly
equipped with a warning horn must be used with this
engine. This warning horn is necessary for the en-
gine warning system. a
a - Warning Horn
Shift and Throttle Cable
Installation To The Outboard
Install the shift cable and throttle cable into the re-
mote control and mount the remote control following
instructions which are provided the remote control.
NOTE:Installtheshiftcablebeforethethrottlecable.
The shift cable is the first cable to move when the re-
mote control handle is moved into gear.
Shift Cable Installation
1. Pull up the cowl seal and remove the port side
rubber grommet (a).
a
2. Position the remote control and outboard into
neutral.
3. Slide shift actuator (b) toward the rear of engine
(reverse gear) until resistance is felt. Measure
distance (c) between mounting stud and barrel
retainer.
4. Push the cable end (d) in (towards cable barrel)
until resistance is felt. Adjust the cable barrel (e)
to attain distance (c).
e
c
b
d

90-830234R3 DECEMBER 19971D-8 - IMPORTANT INFORMATION
5. Place cable barrel into retainer and fasten the
cable end to mounting stud with nylon washer (f)
andlocknut(g).Tightenlocknutagainstthenylon
washer, then back-off the locknut 1/4 turn.
6. Check shift cable adjustments as follows:
a. With remote control in forward the propshaft
should lock solidly in gear. If it does not, ad-
just the cable barrel closer to the cable end
guide.
b. Shift remote control into neutral. The prop-
shaft should turn freely without drag. If not,
adjust the barrel away from the cable end
guide. Repeat steps a and b.
c. Shiftremotecontrolintoreversewhileturning
propeller.Thepropshaft shouldlock solidlyin
gear. If not, adjust the barrel away from the
cable end guide. Repeat steps a thru c.
d. Return remote control handle to neutral. The
propeller should turn freely without drag. If
not, adjust the barrel closer to the cable end
guide. Repeat steps a thru d.
Throttle Cable Installation
NOTE: Attach Shift cable to engine prior to attaching
throttle cable.
1. Position the remote control handle into neutral
detent.
2. Position adjustment screw (a) against the stop.
3. Adjustthrottlecablebarrel(b)sothebarrelwillbe
able to slip into the retainer when the cable end
is on the mounting stud and there is a slight pre-
load against the stop.
4. Check preload on throttle cable by placing a thin
piece of paper between adjustment screw and
stop.Preloadiscorrectwhenthepapercanbere-
moved without tearing, but has some drag in it.
Readjust cable barrel if necessary.
5. Placethethrottlecablebarrelintothetopretainer
hole and the cable end on the cable mounting
stud. Fasten throttle cable to the mounting stud
with nylon washer (c) and locknut (d). Tighten
locknut against the nylon washer, then back-off
the locknut 1/4 turn.
6. Lock the cable barrels in-place with cable latch
(e).
b
e
cd
a
7. Lubricate the port side rubber grommet and rein-
stall into cowl. Slip the grommet over the control
cables. Push the cowl seal back into place.

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-9
NOTE: The rubber grommet has to be lubricated to
ease installation.
f
f
f – Lubricant
Connecting Remote Wiring
Harness To The Engine
1. Pull up the cowl seal (a) and remove the star-
board side rubber grommet (b).
b
a
2. Take hold of the engine connector (c) and install
the remote wiring harness plug (d). Connect
additional wire leads (if equipped) as shown.
NOTE: The rubber grommet can to be lubricated to
ease installation.
cd

90-830234R3 DECEMBER 19971D-10 - IMPORTANT INFORMATION
3. Push the connector and plug into the holder (e).
e
4. Insert the battery cables and remote wiring har-
ness into the rubber grommet. Reinstall the star-
board side rubber grommet into the cowl. Push
the cowl seal back in place.
Battery Connections
CAUTION
For dual outboard installations, the black (–) bat-
tery cable of each engines starter motor ground
circuit, MUST BE connected to each other by a
common circuit (cable) capable of carrying the
starting current of each engine’s starter motor.
[i.e. A locally obtained battery cable connected
between the negative (–) terminal of each out-
boards cranking battery].
CAUTION
Failure to observe correct polarity when con-
necting battery cables to battery, will result in
damage to the charging system.
1. Connect battery cables (from engine) to battery.
Connect red battery cable to positive terminal
and black battery cable to negative (–) battery
terminal.
Set Up Instructions For Oil
Injection System
CAUTION
Oil injected engines additionally, must be run on
a 50:1 gasoline/oil mixture during the engine
break-in period. Refer to engine break-in proce-
dure in the Operation & Maintenance Manual.
CAUTION
If an electric fuel pump is to be used on engines
with oil injection, the fuel pressure at the engine
must not exceed 4 psig. If necessary, install a
pressure regulator between electrical fuel pump
and engine and set at 4 psig maximum.

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1D-11
Filling The Oil Injection System
1. Open the cowl cap (a). Turn the oil fill cap (b) to
the left and remove.
a
b
2. Use the dipstick (c) to check oil level.
3. Hook the dipstick (d) on the tank during filling.
c
d
4. Slowlyfilltheoiltankwiththespecifiedoil.DoNot
overfill – add only enough oil to bring the oil level
up to the bottom of the fill neck (e).
Note:The oil tank capacity for three cylinder models
is 3.2 qt. (3.0 liters) and four cylinder models is 5.13
qt. (4.9 liters).
5. Installoilfillercap(b)andre-tighten.Reinstallthe
cowl cap.
FULL
eb
Bleeding Air From The Oil Injection
System
IMPORTANT: If air exists in either the oil pump in-
let hose (a) or oil pump outlet hose (b), the air
MUST BE bled from the hose(s) or engine dam-
age may occur.
BLEEDING AIR FROM THE OIL PUMP INLET
HOSE
1. With the engine not running, place a shop towel
below the oil pump.
2. Loosenbleed screw (c) four turns and allow oilto
flowoutofthebleedholeuntilnoairbubblesexist
in the inlet hose (a).
BLEEDING AIR FROM THE OIL PUMP OUTLET
HOSE
3. If any air bubbles are present in the outlet hose
(b), they can be purged from the hose by remov-
ing link rod (d) from the oil pump and rotating the
pump arm (e) full clockwise while operating en-
gine at 1000 to 1500 RPM.
bc
a
de

90-830234R3 DECEMBER 19971D-12 - IMPORTANT INFORMATION
Adjusting The Oil Injection Pump
Whencarburetorlinkageisatidleposition,alignment
mark (a) on oil injection arm should be in-line with
mark (b) on pump as shown. If necessary, adjust link
rod (c).
b
c
a
Trim Tab Adjustment
Propeller steering torque will cause your boat to pull
inonedirection.Thissteeringtorqueisanormalthing
that resultsfromyouroutboard notbeingtrimmedso
the propeller shaft is parallel to the water surface.
The trim tab can help to compensate for this steering
torqueinmanycasesand canbeadjustedwithinlim-
its to reduce any unequal steering effort.
NOTE: Trim tab adjustment will have little effect re-
ducingsteeringtorqueiftheoutboardisinstalledwith
the anti-ventilation plate approximately 2 inches
(50mm) or more above the boat bottom.
Operateyourboatatnormalcruisingspeed,trimmed
to desired position. Turn your boat left and right and
note the direction the boat turns more easily.
If adjustment is necessary, loosen trim tab bolt and
make small adjustments at a time. If the boat turns
more easily to the left, move the trailing edge of trim
tabto theleft. Ifthe boatturns moreeasily to theright
move the trailing edge of trim tab to the right. Retigh-
ten bolt and retest.