MERCURY OUTBOARDS 25-30HP MASTER Manual

i Thank You 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 Marine, 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 performance 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 outboard and wish you many years of happy and safe boating. Again, thank you for your confidence in Mercury Marine. EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual. Engines are labeled with an Emission Control Information decal as permanent evidence of EPA certification. ! WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. © 2008 Mercury Marine 25/30 2-Stroke 90-10261080 1008

ii Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information Section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information. 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 and without incurring obligation. Mercury Marine, Fond du Lac, Wisconsin U.S.A. Litho in U.S.A. © 2008, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. Declaration of Conformity 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 Industriel, de Petit‑Rechain, Belgium complies with the requirements of the following directives and standards, as amended: Recreational Craft Directive: 94/25/EC Owner's manual (A.2.5) ISO 10240

iii Handling characteristics (A.4) ISO 8665 Outboard engine starting (A.5.1.4) ISO 11547 Fuel tanks (A.5.2.2) ISO 13591; ISO 8469 General steering system ABYC P‑17 Safety of Machinery Directive 98/37/EC Principles of safety integration (1.1.2) EN 292‑1; EN 292‑2; EN 1050 Noise (1.5.8) ICOMIA 39/94 Vibration ICOMIA 38/94 Electromagnetic Compatibility Directive 89/336/EC Generic emission standard EN 50081‑1 Generic immunity standard EN 50082‑1 Vehicles, boats and internal combustion engine driven devices ‑ radio disturbance characteristics SAE J551 (CISPR 12) Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN 61000‑4‑3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA

iv Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment to service. Earning a Mercury Premier Service rating means a dealer: • Achieves a high 12 month service CSI (Customer Satisfaction Index) score for warranty service. • Possesses all necessary service tools, test equipment, manuals and parts books. • Employs at least one Certified or Master technician. • Provides timely service for all Mercury Marine customers. • Offers extended service hours and mobile service, when appropriate. • Uses, displays and stocks adequate inventory of genuine Mercury Precision Parts. • Offers a clean, neat shop with well organized tools and service literature.

TABLE OF CONTENTS v Warranty Information Transfer of Warranty.................................................................... 1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan............................................................................ 1 Warranty Registration United States And Canada...................... 2 Outboard Limited Warranty.......................................................... 3 3 Year Limited Warranty Against Corrosion................................ 6 Warranty Coverage and Exclusions............................................ 9 GENERAL INFORMATION Boater's Responsibilities............................................................ 12 Before Operating Your Outboard............................................... 12 Boat Horsepower Capacity........................................................ 13 High‑Speed and High‑Performance Boat Operation................. 13 Outboard Remote Control Models............................................. 13 Remote Steering Notice............................................................. 14 Lanyard Stop Switch.................................................................. 15 Protecting People in the Water.................................................. 17 Passenger Safety Message ‑ Pontoon Boats and Deck Boats.. 18 Wave and Wake Jumping.......................................................... 19 Impact with Underwater Hazards............................................... 20 Exhaust Emissions.................................................................... 21 Selecting Accessories for Your Outboard.................................. 23 Safe Boating Suggestions......................................................... 23 Recording Serial Number.......................................................... 25 25/30 Specifications................................................................... 26 Components: 25/30M................................................................ 27 INSTALLATION Installing Outboard..................................................................... 34 Installing the Remote Control Device (Right‑Hand Steering).... 36 Attaching the Steering Link Rod................................................ 45 Battery Installation .................................................................... 46 Propeller Selection..................................................................... 48

TABLE OF CONTENTS vi TRANSPORTING Trailering Boat/Outboard........................................................... 49 Removing the Motor.................................................................. 49 Transporting Portable Fuel Tanks............................................. 50 FUEL & OIL Fuel Recommendations............................................................. 52 Oil Recommendation................................................................. 53 Mixing Fuel and Oil.................................................................... 54 Filling Fuel Tank........................................................................ 54 FEATURES & CONTROLS Remote Control Features.......................................................... 56 Tilting Outboard ........................................................................ 56 Shallow Water Operation........................................................... 57 Trim Adjustment......................................................................... 58 Steering Friction Adjustment...................................................... 59 Trim Tab Adjustment................................................................. 60 OPERATION Pre‑Starting Check List.............................................................. 62 Operating in Freezing Temperatures......................................... 62 Operating in Saltwater or Polluted Water.................................. 62 Operating at High Elevations..................................................... 63 Engine Break‑in Procedure........................................................ 63 Starting the Engine.................................................................... 64 Warm‑Up................................................................................... 70 Gear Shifting.............................................................................. 71 Stopping the Engine.................................................................. 73 Emergency Starting................................................................... 75

TABLE OF CONTENTS vii MAINTENANCE Outboard Care........................................................................... 77 EPA Regulations........................................................................ 77 EPA Emissions.......................................................................... 78 Inspection and Maintenance Schedule...................................... 78 Flushing the Cooling System..................................................... 80 Top Cowl Removal and Installation........................................... 81 Battery Inspection ..................................................................... 82 Fuel System............................................................................... 82 Fuse Replacement ‑ Electric Start Remote Control Models...... 84 Corrosion Control Anode........................................................... 84 Propeller Replacement.............................................................. 85 Spark Plug Inspection and Replacement................................... 89 Lubrication Points...................................................................... 90 Gearcase Lubrication................................................................. 90 Submerged Outboard................................................................ 92 STORAGE Storage Preparation................................................................... 93 Protecting External Outboard Components............................... 94 Protecting Internal Engine Components.................................... 94 Gearcase................................................................................... 95 Positioning Outboard for Storage.............................................. 95 Battery Storage.......................................................................... 95 TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) ................................................................................................... 96 Engine Will Not Start.................................................................. 96 Engine Runs Erratically............................................................. 96 Performance Loss...................................................................... 97 Battery Will Not Hold Charge..................................................... 97

TABLE OF CONTENTS viii ASSOCIATED PARTS Associated Parts........................................................................ 98 ACCESSORIES Accessories............................................................................... 99 WIRING DIAGRAMS Wiring Diagrams...................................................................... 103 OWNER SERVICE ASSISTANCE Local Repair Service................................................................ 112 Service Away from Home........................................................ 112 Parts and Accessories Inquiries.............................................. 112 Service Assistance.................................................................. 112 Mercury Marine Service Offices............................................... 113 MAINTENANCE LOG Maintenance Log..................................................................... 115

WARRANTY INFORMATION 1 Transfer of Warranty The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty registration department. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 929 5893 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you. Transfer of Mercury Product Protection (Extended Service Coverage) Plan The remaining coverage period of the Product Protection Plan is transferable to the subsequent purchaser of the engine within thirty (30) days from the date of sale. Contracts not transferred within thirty (30) days of the subsequent purchase will no longer be valid and the product will no longer be eligible for coverage under the terms of the contract. To transfer the plan to the subsequent owner, contact Mercury Product Protection or authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.

WARRANTY INFORMATION 2 Plan coverage is not transferable from one product to another product or for non‑eligible applications. The Certified Pre‑Owned engine plans are not transferable. For help or assistance, contact Mercury Product Protection Department at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST, Monday ‑ Friday or email mpp_support@mercurymarine.com. Warranty Registration United States And Canada Outside United States and Canada ‑ Check with your local distributor. 1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information. Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax 920-929-5893 NOTE: Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States, should a safety recall notification under the Federal Safety Act be required. 2. To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration.

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MERCURY OUTBOARDS 25-30HP MASTER Manual

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