Page 1: Table Of Contents
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.
Page 2: Notice To Installer
Installation of this product will require electronic calibration. This calibration must not be attempted by anyone other than the Original Equipment Manufacturer (OEM) or a Mercury technician trained in Digital Throttle and Shift systems (DTS) at an authorized Mercury dealership. Improper installation and calibration of the DTS product will result in a system which is inoperable or unsafe for use.
Page 3: Electric Fuel Pump
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
Page 4: Installation Specifications
200/225 OPTIMAX DTS Installation Specifications Ob01471 Minimum transom opening Engine center line for dual engine - 66.0 cm (26 in.) Minimum Transom Opening Single engine 99.0 cm (39 in.) Dual engine 165.0 cm (65 in.) Lifting the Outboard WARNING Avoid possible serious injury or death. Before lifting the outboard, verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight.
Page 5: Applying Counter Rotation Decals
200/225 OPTIMAX DTS 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Applying Counter Rotation Decals IMPORTANT: For dual outboard counter rotation installation, the left- hand rotation outboard is generally placed on the port sided of the transom.
Page 6: Steering Link Rod Fasteners
200/225 OPTIMAX DTS Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a" - Part Number 10-849838) and self-locking nylon insert locknuts ("c"...
Page 7: Determining Recommended Outboard Mounting Height
200/225 OPTIMAX DTS Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 3728 The solid line is recommended to determine the outboard mouting height.
Page 8: Drilling Outboard Mounting Holes
200/225 OPTIMAX DTS Drilling Outboard Mounting Holes IMPORTANT: Before drilling any mounting holes, carefully read Determining Recommended Outboard Mounting Height and install outboard to the nearest recommended mounting height. 1. Use transom drilling fixture or attach (tape) engine mounting template to boat transom.
Page 9: Front Clamp Assembly
200/225 OPTIMAX DTS 4. Fasten outboard with provided mounting hardware. 3729 Flat washer (4) Locknut (4) 1/2 in. diameter bolt (4) Flat washer (4) Shank of bolt Front Clamp Assembly Removal Remove two screws with retainer and open the front clamp.
Page 10 200/225 OPTIMAX DTS 1. Place the neoprene wrap around the wiring, hoses, and control cables. 3766 2. Secure both halves of clamp with cables ties. 3764 3. Secure clamp assembly into bottom cowl with retainer and two screws. 3765 Screws (2)
Page 11: Wiring And Installation
If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than 12.2 m (40 ft.), contact Mercury Marine for more information. Data Harness Pulling Procedure IMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads, and spark plugs), high power VHF coax or radios.
Page 12: Junction Box (If Equipped)
Weather cap (859318T 2) DTS Command Module harness Junction box Non-Mercury Marine Provided Ignition Switch CAUTION Prevent unexpected engine start-up. Non-Mercury Marine ignition switches may allow sufficient current leakage to cause engine to start unexpectedly. Page 12 / 42 90-10234050...
Page 13: Wiring Accessories
200/225 OPTIMAX DTS IMPORTANT: Correct ignition key switch must be used. If a non-Mercury Marine ignition key switch is being used, make sure that the ignition switch being used meets the requirement listed. IMPORTANT: Current leakage exceeding 5 mA at 12 volts could cause engine to start unexpectedly.
Page 14: Connecting 14 Pin Data Harness - Single Engine
200/225 OPTIMAX DTS • Control Area Network (CAN) link harness - Must be installed between command module harness for dual engine installation. 3769 14 pin data harness CAN link harness (dual engine application) Vessel sensor harness DTS power harness Battery cables...
Page 15: Connecting 14 Pin Data Harness - Dual Engine
200/225 OPTIMAX DTS DUAL HELM 3682 14 pin data harness Dual helm adapter (Y harness) Helm 2 (upper helm) - auxilary Clamp or cable tie Helm 1 (lower helm) - primary Connecting 14 Pin Data Harness - Dual Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness.
Page 16: Installing Dts Command Module And Harness - Single Engine
200/225 OPTIMAX DTS DUAL HELM 3978 Helm 2 (upper helm) Dual helm adapter (Y harness) Helm 1 (lower helm) Clamp or cable tie 14 pin data harness Installing DTS Command Module and Harness - Single Engine HARNESS INSTALLATION • Locate a routing path for the harness connections so they reach their installation points.
Page 17 200/225 OPTIMAX DTS • Make sure all connections are tight and seal all unused connectors with weather caps. 3622 Single Helm Application DTS command module harness Clamp or cable tie 90-10234050 Page 17 / 42...
Page 18 200/225 OPTIMAX DTS NOTE: For dual helm application - Remove CAN 1 and CAN 2 terminator resistors from helm 1 (helm closest to the engine), and seal connectors with weather caps. Terminator Terminator CAN 2 CAN 1 3677 Dual Helm Application...
Page 19 200/225 OPTIMAX DTS • Ensure the wiring harness connected to the command module will reach all the connection points. 3625 Single Helm Application DTS command module Clamp or cable tie 3678 Dual Helm Application Helm 2 Clamp or cable tie Helm 1 Terminator resistors, blue (CAN1 &...
Page 20: Installing Dts Command Module And Harness - Dual Engine/Single Helm
200/225 OPTIMAX DTS Installing DTS Command Module and Harness - Dual Engine/Single Helm HARNESS INSTALLATION • Locate a routing path for the harness connections so they reach their installation points. • Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.
Page 21: Battery Cable Size For Outboard Models
200/225 OPTIMAX DTS • Ensure the wiring harness connected to the command module will reach all the connection points. 3691 DTS command module CAN link harness Clamp or cable tie Battery Cable Size For Outboard Models IMPORTANT: Only use copper battery cables. Do not use aluminum cables for any outboard marine installations.
Page 22 200/225 OPTIMAX DTS Copper Battery Cable Wire Gauge Size Wire Gauge Size Number SAE Models 6-25 hp 30-115 hp (except OptiMax) 125-250 hp (except OptiMax) OptiMax/Verado 2.4 m (8 ft.) 2.7 m (9 ft.) 3.0 m (10 ft.) 3.4 m (11 ft.) 3.7 m (12 ft.)
Page 23: Battery Information
200/225 OPTIMAX DTS Battery Information CAUTION Hex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power. • Do not use deep cycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA or 180 Ah.
Page 24 200/225 OPTIMAX DTS SINGLE ENGINE - BATTERY AT STERN 3679 Battery Red sleeve (positive) Black sleeve (negative) DTS power harness (provided) SINGLE ENGINE - BATTERY AT HELM 3699 14 pin data harness Red sleeve (Positive) DTS command module harness Black sleeve (Negative)
Page 25 200/225 OPTIMAX DTS DUAL ENGINE - BATTERY AT STERN 3680 Red sleeve (positive) Ground cable Black sleeve (negative) Data cable Battery Vessel sensor harness DTS power harness (provided) 90-10234050 Page 25 / 42...
Page 26: Connecting Fuel Tank, Oil Tank And Speed Sensor
200/225 OPTIMAX DTS DUAL ENGINE - BATTERY AT HELM 3701 Black sleeve (negative) Junction box weather caps Red sleeve (positive) 14 pin data harness DTS power harness (optional) Ground cable DTS command module harness Vessel sensor harness Connecting Fuel Tank, Oil Tank and Speed Sensor IMPORTANT: Do not connect the blk/orn wire, if equipped, to the fuel tank sensor when there is an engine battery ground strap connected to the fuel tank or sender assembly.
Page 27 200/225 OPTIMAX DTS IMPORTANT: Metal fuel tanks must be grounded to hull or battery ground in accordance to coast guard regulations. PNK/ BLK BLK/ ORN 3714 Fuel tank Harness Oil tank Black/orange wire to fuel tank sensor, if equipped Oil tank sender...
Page 28: Switched 12V Accessory Connection
200/225 OPTIMAX DTS Switched 12V Accessory Connection ob01495 Battery Complete kit Fuse - 40 Amp Terminal block Power harness with 40 Amp fuse Accessory power relay Switched 12V DTS Command Module harness Page 28 / 42 90-10234050...
Page 29: Dts Wiring - Single Engine
200/225 OPTIMAX DTS DTS Wiring - Single Engine PANEL CONTROL BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED 3718 Start/stop switch (optional) Cable adaptor (male to female) SmartCraft System View (optional) Weather caps SmartCraft Link Gauge (optional) Junction box (optional) GPS connection Accessory power relay (optional)
Page 30 200/225 OPTIMAX DTS CONSOLE CONTROL BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED 3717 Start/stop switch (optional) Cable adaptor (male to female) SmartCraft System View (optional) Weather caps SmartCraft Link Gauge (optional) Junction box GPS connection Accessory power relay (optional) Display harness Foot throttle (optional)
Page 31: Dts Wiring - Dual Engine
200/225 OPTIMAX DTS DTS Wiring - Dual Engine CONSOLE CONTROL – 3309 To port engine Remote control connections Terminator resistor Key switch DTS Command Module -Remote control Junction box connection (optional) To port engine Connector - Zero Effort controls Lanyard stop switch...
Page 32: System Wiring Installation Checklist
Verify that all unused receptacles are covered with a weather cap. NON-MERCURY MARINE SUPPLIED IGNITION KEY SWITCH If a non-Mercury Marine ignition key is used, verify that it passes the ingress protection testing per IEC IP66 specification minimum. Ignition switches must pass this specification.
Page 33: Filling The Fuel System
200/225 OPTIMAX DTS 2. Connect the remote oil hoses to the engine hose connections. Fasten hose connections with cable ties. 3767 Hose clamp Oil hose with blue stripe Cable tie Remote fuel hose Oil hose without blue stripe Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system.
Page 34: Priming Oil Injection Pump
200/225 OPTIMAX DTS 2. Tighten the fill cap. or111 Fill cap 3. Remove the cap and fill the engine oil tank with oil. 3763 Fill cap Engine oil tank 4. Reinstall the fill cap. Priming Oil Injection Pump IMPORTANT: DTS helm configuration must be completed before performing the following procedure.
Page 35 200/225 OPTIMAX DTS CAUTION Avoid fuel pump damage. Always fill the engine fuel system with fuel before priming the oil injection pump. Otherwise, the fuel pump will run without fuel during the priming process. 1. Fill the fuel system. Connect fuel hose.
Page 36: Purging Air From The Engine Oil Tank
200/225 OPTIMAX DTS Purging Air From the Engine Oil Tank IMPORTANT: DTS helm configuration must be completed before performing the following procedure. 1. Loosen the fill cap on the engine oil tank. 2. Start the engine. 3. Operate the engine until all the air has vented out and oil starts to flow out of the tank.
Page 37: Trim In Pin
200/225 OPTIMAX DTS 4. Secure propeller nut by bending three of the tabs into the thrust hub grooves. ob00422 Trim In Pin WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel.
Page 38: Paddle Wheel Speed Sensor Installation (If Equipped)
200/225 OPTIMAX DTS Paddle Wheel Speed Sensor Installation (If Equipped) Parts Provided ob01505 Spare pin yoke Flat washer (2) Wire retainer #10 - 19 mm (3/4 in.) screw (4) Connector Cable cap Bracket #6 - 12 mm (1/2 in.) screw (4)
Page 39: Transom Angle Requirements
200/225 OPTIMAX DTS Transom Angle Requirements Standard 13° to 20° transoms - No special adjustment required. ob01507 13° transom angle 20° transom angle Stepped or undercut transom with 3 angles - A small shim of tapered plastic, metal or wood must be fabricated and installed as shown. Mount the paddle wheel on the step for best performance.
Page 40: Routing The Cable
200/225 OPTIMAX DTS 4. Fill any gap between the housing and the transom with a caulking material, as shown. Using a putty knife, smooth the surface to ensure proper water flow. ob01509 Template Flat washer (2) 50 mm (2 in.)
Page 41: Installing And Removing The Paddle Wheel
200/225 OPTIMAX DTS WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL) Route the cable over the transom or through a drain hole that is above the water line. ob01510 Splash well drain hole Cable cap Cable clamp Paddle wheel assembly Distance between first cable clamp and top of paddle wheel - 25.4 mm (1.0 in.)
Page 42: Template - Paddle Wheel Speed Sensor
200/225 OPTIMAX DTS NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs inside the connector. Have the wiring routed through the transom. Push each wire terminal into its respective location in the connector. Push wire in until they snap into place.

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