Mercury XR2 User manual

XR2 XR2 SS
1998, Mercury Marine90Ć848717980 298
for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Ma-
rine, a world leader in marine technology and outboard
manufacturing since 1939. These years of experience
have been committed to the goal of producing the finest
quality products. This led to Mercury Marine’s reputation
for strict quality control, excellence, durability, lasting per-
formance and being the best at providing after-the-sale
support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use and care of your outboard.
All of us at Mercury Marine took pride in building your out-
board and wish you many years of happy and safe boat-
ing.
Again, thank you for your confidence in Mercury Marine.
Mercury Hi-Performance,
N7480 County Road “UU”
Fond du Lac, WI 54935-9585

0

1
TABLE OF CONTENTS
General Information
Boater’s Responsibilities 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating Your Outboard 4. . . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed And High-Performance Boat Operation 5. . . . . . . . .
Outboard Remote Control 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Steering Notice 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lanyard Stop Switch 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 10. . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Emissions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Accessories For Your Outboard 13. . . . . . . . . . . . . . . .
Safe Boating Suggestions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording Serial Number 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Requirements 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
Installing Outboard 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting
Trailering Boat/Outboard 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel & Oil
Gasoline Recommendations 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Recommendation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline/Oil Mixture 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Fuel Tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features & Controls
Remote Control Features 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning System 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim And Tilt 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(continued on next page)

2
TABLE OF CONTENTS
Operation
Pre-Starting Check List 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Operating Instructions 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Break-in Procedure 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting The Engine 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shifting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping The Engine 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Outboard Care 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Replacement Parts For Your Outboard 38. . . . . . . . . .
EPA Emissions Regulations 38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Maintenance Schedule 39. . . . . . . . . . . . . . . . . . .
Flushing The Cooling System 41. . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Cowl Removal And Installation 42. . . . . . . . . . . . . . . . . . . . . .
Fuel System 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod Fasteners 45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion Control Anode 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Replacement 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubrication 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Submerged Outboard 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage
Storage Preparation 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 56. . . . . . . . . . . . . . . . . .
Protecting External Engine Components 56. . . . . . . . . . . . . . . . .
Gear Case 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Storage 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(continued on next page)

3
TABLE OF CONTENTS
Troubleshooting 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Wiring Diagram 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Log 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The description and specifications contained herein were in effect at
the time this manual was approved for printing. Mercury Marine,
whose policy is one of continued improvement, reserves the right to
discontinue models at any time, to change specifications, designs,
methods, or procedures without notice or incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A. Litho in U.S.A.
1998 Mercury Marine
Following are registered trademarks of Brunswick Corporation: AutoBlend,
Force, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury,
Mercury Marine, Mercury Hi-Performance, Quicksilver, RideGuide and
Thruster

4
GENERAL INFORMATION
oba1
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 strong-
ly 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.
obb1
Before Operating Your Outboard
Read this manual carefully. Learn how to operate your outboard
properly. If you have any questions, contact your dealer.
Safety and operating information that is practiced along with using
good common sense can help prevent personal injury and product
damage.
This manual as well as safety labels posted on the outboard use the
following safety alerts to draw your attention to special safety instruc-
tions that should be followed.
DANGER
!
DANGER – Immediate hazards which WILL result in severe
personal injury or death.
WARNING
!
WARNING – Hazards or unsafe practices which COULD result
in severe personal injury or death.
CAUTION
!
CAUTION – Hazards or unsafe practices which could result in
minor injury or product or property damage.

5
GENERAL INFORMATION
12
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
obc1
Boat Horsepower Capacity
1Do not overpower or overload your boat. Most boats will carry a
required capacity plate indicating the maximum acceptable pow-
er and load as determined by the manufacturer following 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 designed flotation
characteristics of the boat or 3. cause the boat to break apart
particularly around the transom area. Overpowering a boat
can result in serious injury, death, or boat damage.
hbd1
High-Speed And High-Performance Boat
Operation
2If your outboard is to be used on a high-speed or high-perfor-
mance boat with which you are unfamiliar, we recommend that
you never operate it at its high speed capability without first re-
questing an initial orientation and familiarization demonstration
ride with your dealer or an operator experienced with your boat/
outboard combination. For additional information, read the
“Guide to Hi-Performance Boat Operation” booklet included in
your literature package.

6
GENERAL INFORMATION
21 a
a
obe1
Outboard Remote Control
1The remote control connected to your outboard must be
equipped with a start-in-gear protection device. This prevents the
engine from starting when the outboard is in gear.
WARNING
!
Avoid serious injury or death from a sudden unexpected ac-
celeration when starting your engine. The design of this out-
board requires that the remote control used with it must have
a built in start-in-gear protection device.
obf1
Remote Steering Notice
2The steering link rod that connects the steering cable to the en-
gine must be fastened utilizing self-locking nuts (a). These self-
locking 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 a steering link rod can result in the boat tak-
ing a full, sudden, sharp turn. This potentially violent action
can cause occupants to be thrown overboard exposing them
to serious injury or death.

7
GENERAL INFORMATION
21
hbg1
Lanyard Stop Switch
1The purpose of a lanyard stop switch is to turn off the engine
when the operator moves far enough away from the operator’s
position (as in accidental ejection from the operator’s position) to
activate the switch. Tiller handle outboards and some remote
control units are equipped with a lanyard stop switch. A lanyard
stop switch can be installed as an accessory – generally on the
dashboard or side adjacent to the operator’s position.
2The lanyard is a cord usually between 4 and 5 feet (1220 and
1524 mm) 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. The lanyard is coiled to make
its at-rest condition as short as possible so as to minimize the li-
kelihood of lanyard entanglement with nearby objects. It is made
as long as it is in its stretched condition to minimize the likelihood
of accidental activation should the operator choose to move
around in an area close to the normal operator’s position. If it is
desired to have a shorter lanyard, wrap the lanyard around the
operator’s wrist or leg, or tie a knot in the lanyard.
Read the following Safety Information before proceeding.
(continued on next page)

8
GENERAL INFORMATION
Lanyard Stop Switch (Continued)
Read the following Safety Information before proceeding.
Important Safety Information: The purpose of a lanyard stop
switch is to stop the engine when the operator moves far enough
away from the operator’s position to activate the switch. This would
occur if the operator accidentally falls overboard or moves within the
boat a sufficient distance from the operator’s position. Accidental
ejections and falls overboard are more likely to occur in certain types
of boats such as low sided inflatables or bass boats, high-perfor-
mance boats and light, sensitive-handling fishing boats operated by
hand-tiller. Accidental ejections and falls overboard are also likely to
occur as a result of poor operating practices such as sitting on the
back of the seat or gunwale at planing speeds, standing at planing
speeds, sitting on elevated fishing boat decks, operating at planing
speeds in shallow or obstacle-infested waters, releasing your grip on
a steering wheel or tiller handle that is pulling in one direction, drink-
ing alcohol or consuming drugs, or daring, high-speed boat maneu-
vers.
While activation of the lanyard stop switch will stop the engine im-
mediately, a boat will continue to coast for some distance depending
upon the velocity and degree of any turn at shut-down. However, the
boat will not complete a full circle. While the boat is coasting, it can
cause injury to anyone in the boat’s path as seriously as the boat
would when under power.
We strongly recommend that other occupants be instructed on prop-
er starting and operating procedures should they be required to oper-
ate the engine in an emergency (e.g. if the operator is accidentally
ejected).
!WARNING
Should the operator fall out of the boat, the possibility of
serious injury or death from being run over by the boat
can be greatly reduced by stopping the engine immediate-
ly. Always properly connect both ends of the stop switch
lanyard – to the stop switch and the operator.
(continued on next page)

9
GENERAL INFORMATION
Lanyard Stop Switch (Continued)
Accidental or unintended activation of the switch during normal op-
eration is also a possibility. This could cause any, or all, of the follow-
ing potentially hazardous situations:
1. Occupants could be thrown forward due to unexpected loss of
forward motion – a particular concern for passengers in the front
of the boat who could be ejected over the bow and possibly struck
by the gear case or propeller.
2. Loss of power and directional control in heavy seas, strong cur-
rent or high winds.
3. Loss of control when docking.
!WARNING
Avoid serious injury or death from deceleration forces re-
sulting from in accidental or unintended stop switch ac-
tivation. The boat operator should never leave the opera-
tor’s station without first disconnecting the stop switch
lanyard from the operator.

10
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.
Always slow down and exercise extreme caution any time you are
boating in an area where there might be people in the water.
Whenever a boat is moving (coasting) and the outboard gear shift is
in neutral position, there is sufficient force by the water on the propel-
ler to cause the propeller to rotate. This neutral propeller rotation can
cause serious injury.
WHILE BOAT IS STATIONARY
Shift outboard into neutral and shut off the engine before allowing
people to swim or be in the water near your boat.
WARNING
!
Stop your engine immediately whenever anyone in the water
is near your boat. Serious injury to the person in the water is
likely if contacted by a rotating propeller, a moving boat, a
moving gear case, or any solid device rigidly attached to a
moving boat or gear case.

11
ob GENERAL INFORMATION
Courtesy of ABYC
1
ob
Exhaust Emissions
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide is present in the exhaust fumes of all internal com-
bustion engines including the outboards, stern drives and inboard
engines that propel boats, as well as the generators that power vari-
ous boat accessories. Carbon monoxide is a deadly gas that is odor-
less, colorless and tasteless.
Early symptoms of carbon monoxide poisoning which should not be
confused with seasickness or intoxication, include headache, dizzi-
ness, drowsiness, and nausea.
WARNING
!
Avoid the combination of a running engine and poor ventila-
tion. 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.
1Example of desired air flow through the boat.

12
ob GENERAL INFORMATION
a
c
b
d
Courtesy of ABYC
2
Exhaust Emissions (Continued)
POOR VENTILATION
Under certain running and/or wind conditions, permanently enclosed
or canvas enclosed cabins or cockpits with insufficient ventilation
may draw in carbon monoxide. Install one or more carbon monoxide
detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and
passengers in an unclosed area of a stationary boat that contains or
is near a running engine may be exposed to a hazardous level of car-
bon monoxide.
2Examples of Poor Ventilation:
While boat is stationary
a. Running the engine when the boat is moored in a confined
space.
b. Mooring close to another boat that has its engine running.
While boat is moving
c. Running the boat with the trim angle of the bow too high.
d. Running the boat with no forward hatches open (station wag-
on effect).

13
GENERAL INFORMATION
Selecting Accessories For Your Outboard
Genuine Mercury Marine Quicksilver Accessories have been specifi-
cally designed and tested for your outboard.
Mercury Marine Quicksilver accessories are available from Mercury
Marine dealers.
Some accessories not manufactured or sold by Mercury Marine are
not designed to be safely used with your outboard or outboard oper-
ating system. Acquire and read the installation, operation, and main-
tenance manuals for all your selected accessories.
WARNING
!
Check with your dealer before installation of accessories. The
misuse of acceptable accessories or the use of unacceptable
accessories can result in serious injury, death, or product fail-
ure.
obk1
Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local
and other governmental boating regulations and restrictions, and
consider the following suggestions.
Use flotation devices. Have an approved personal flotation device
of suitable size for each person aboard (it is the law) and have it
readily accessible.
Do not overload your boat. Most boats are rated and certified for
maximum load (weight) capacities (refer to your boat capacity plate).
If in doubt, contact your dealer or the boats manufacturer.
Perform safety checks and required maintenance. Follow a regu-
lar schedule and ensure that all repairs are properly made.
(continued on next page)

14
ob GENERAL INFORMATION
Safe Boating Suggestions (Continued)
Know and obey all nautical rules and laws of the waterways.
Boat operators should complete a boating safety course. Courses
are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2)
The Power Squadron, (3) The Red Cross and (4) your state boating
law enforcement agency. Inquiries may be made to the Boating Hot-
line, 1-800-368-5647 or the Boat U.S. Foundation information num-
ber 1-800-336-BOAT.
Make sure everyone in the boat is properly seated. Don’t allow
anyone to sit or ride on any part of the boat that was not intended for
such use. This includes backs of seats, gunwales, transom, bow,
decks, raised fishing seats, any rotating fishing seat; anywhere that
sudden unexpected acceleration, sudden stopping, unexpected loss
of boat control or sudden boat movement could cause a person to be
thrown overboard or into the boat.
Never be under the influence of alcohol or drugs while boating
(it is the law). They impair your judgment and greatly reduce your
ability to react quickly.
Prepare other boat operators. Instruct at least one person on board
in the basics of starting and operating the outboard and boat handling
in case the driver becomes disabled or falls overboard.
Passenger boarding. Stop the engine whenever passengers are
boarding, unloading or are near the back (stern) of the boat. Just
shifting the outboard into neutral is not sufficient.
Be alert. The operator of the boat is responsible by law to “maintain
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 operators view when operating the
boat above idle speed.
Never drive your boat directly behind a water skier in case the
skier falls. As an example, your boat traveling at 25 miles per hour
(40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet
(61m) in front of you. (continued on next page)

15
ob GENERAL INFORMATION
Safe Boating Suggestions (Continued)
Watch fallen skiers. When using your boat for water skiing or similar
activities, always keep a fallen or down skier on the operator’s side
of the boat while returning to attend the skier. The operator should
always have the down skier in sight and never back up to the skier
or anyone in the water.
Report accidents. Boat operators are required by law to file a Boat-
ing Accident Report with their state boating law enforcement agency
when their boat is involved in certain boating accidents. A boating ac-
cident must be reported if (1) there is loss of life or probable loss of
life, (2) there is personal injury requiring medical treatment beyond
first aid, (3) there is damage to boats or other property where the
damage value exceeds $500.00 or (4) there is complete loss of the
boat. Seek further assistance from local law enforcement.
obl2
Recording Serial Number
It is important to record this number for future reference. The serial
number is located on the outboard as shown.
a - Serial Number
b - Model Year
c - Model Designation
d - Year Manufactured
e - Certified Europe Insignia
19XX
XX
OGXXXXXX
XXXX
a
c
b
d
e

16
GENERAL INFORMATION
Torque Requirements
ITEM TORQUE
Connecting Rods 30 lb. ft. (41 N·m) 271 Loctite
Crankcase Cover to Block 3/8 in. -- 40 lb. ft. (54 N·m)
Light Oil
5/16 in. -- 200 lb. in. (23 N·m)
Light Oil
Exhaust Divider Plate Cover 200 lb. in. (23 N·m)
Lower End Cap 100 lb. in. (11 N·m) 271 Loctite
Upper End Cap 200 lb. in. (23 N·m) 271 Loctite
Reed Block to Adaptor 100 lb. in. (11 N·m) 271 Loctite
Carburetor Adaptor to Reed
Housing 100 lb. in. (11 N·m) 271 Loctite
Stator Screws 40 lb. in. (5 N·m) 271 Loctite
Ignition Coil Screws Tighten Securely
Cylinder Head Bolts 30 lb. ft. (41 N·m) + 90°or 1/4
Turn, Light Oil
Flywheel Nut 150 lb. ft. (203 N·m)
Spark Plugs 20 lb. ft. (27 N·m)
Exhaust Megaphone 25 lb. ft. (34 N·m) 271 Loctite
Powerhead to Driveshaft Hous-
ing 35 lb. ft. (47 N·m) 271 Loctite
Gearcase to Driveshaft Hous-
ing Tighten Securely

17
GENERAL INFORMATION
Specifications
MODEL XR2
Horsepower 180 (134kw)
Propshaft Kilowatts1194
Full Throttle RPM Range 6000-7000
Idle RPM in Forward Gear 650-750
Weight 350 lbs. (159 kg)
Piston Displacement 122 cu. in. (2.0L/1998cc)
Bore 3.125 in. (79.5 mm)
Stroke 2.65 in. (67 mm)
Recommended Spark Plug NGK-BUHW (P/N 33-97180)
Firing Order 1-2-3-4-5-6
Maximum Timing 25°BTDC
Idle Speed Pickup Timing 2°ATDC
Fuel Pressure 5 - 6 psi
Gear Ratio 1.87:1
Recommended Gasoline Refer to Fuel Section
Recommended Oil Refer to Fuel Section
Recommended Gear Case
Oil Quicksilver Hi-Performance Gear Lube (92-816026A4)
Gear Case Lubricant Ca-
pacity 22.5 fl. oz. (666 ml)
Battery Rating Minimum reserve capacity rating of
100 minutes and CCA of 350
Charging System Output 16 amps @ 7000 RPM
Transom Height Short Shaft = 15” (381mm)
Long Shaft = 20” (508mm)
Water Pres. @ WOT 15 PSI (103.4 kPa)
1Measured at the propshaft in accordance with ICOMIA28

18
ob GENERAL INFORMATION
1
23
4
5
6
7
8
9
10
12
7
11
13
Component Identification
1. Top Cowl 8. Transom Brackets
2. Cowl Latch
B Cl
9. Trim Adjustment Bolt
G C
3. Bottom Cowl
4WtP IditH
10. Gear Case
11 W t Di h
4. Water Pump Indicator Hose
(
Tell-Tale
)
11. Water Discharge
12 Cooling Water Intake Holes
(Tell Tale)
5. Drive Shaft Housing 12.
C
oo
li
ng
W
ater
I
nta
k
e
H
o
l
es
13 Skeg
5. Drive Shaft Housing
6. Anti-Ventilation Plate
13
.
Sk
eg
7. Corrosion Anode