Mercury 200 VERADO Installation Manual
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Mercury 200 VERADO Installation Manual

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200/225/250/275 VERADO 4-STROKE
INSTALLATION MANUAL

Table of Contents

Notice to Installer ................................................... 2
Bulb ....................................................................... 2
Avoiding Fuel Flow Restriction .............................. 2
Boat Horsepower Capacity .................................... 2
Fuel Tanks ............................................................. 3
Portable Fuel Tank ........................................... 3
Permanent Fuel Tank ....................................... 3
Height .................................................................... 4
Installing Outboard ................................................ 5
Installation Specifications..................................5
Drilling Outboard Mounting Holes......................6
Lifting Outboard.................................................7
Fastening Outboard...........................................8
Power Steering Installation .................................. 10
Power Steering System...................................10
Installation Procedure......................................10
Helm................................................................12
Steering Pump.................................................14
Cylinder............................................................15
Running...........................................................19
Running...........................................................21
Fuel Hose Connection.....................................23
Wiring And Installation ......................................... 24
Wire Color Code Abbreviations.......................24
Components....................................................24
Data Harness Pulling Procedure.....................24
Page 1 / 51
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.
Junction Box (If Equipped)...............................25
Wiring Accessories..........................................26
System Wiring Reference Points.....................26
Engine..............................................................29
.........................................................................30
Single Engine...................................................31
Dual Engine/Single Helm.................................34
Battery Information..........................................35
Harness...........................................................36
DTS Wiring - Single Engine.............................42
DTS Wiring - Dual Engine................................44
Propeller Installation ........................................... 45
Equipped) ............................................................ 47
Parts Provided ................................................ 47
Selecting Location .......................................... 47
Transom Angle Requirements ........................ 48
Installing Bracket ............................................ 48
Routing the Cable ........................................... 49
Wiring Connections ......................................... 50
© 2004 Mercury Marine
90-10238051 JUNE 2004

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Summary of Contents for Mercury 200 VERADO

  • 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: Selecting Accessories For Your Outboard

    Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.

  • Page 4: Determining Recommended Outboard Mounting Height

    200/225/250/275 VERADO 4-STROKE Determining Recommended Outboard Mounting Height 66.0 cm (26 in.) 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.) ob01470 The solid line is recommended to determine the outboard mounting height.

  • Page 5: Installing Outboard

    200/225/250/275 VERADO 4-STROKE Increasing the mounting height will usually: • Increase top speed • Increase boat stability • Cause propeller to break loose during planing or turning Installing Outboard Installation Specifications 4241 Minimum transom opening Engine center line for dual engine - 66.0 cm (26 in.) Minimum Transom Opening Single engine 99.0 cm (39 in.)

  • Page 6: Drilling Outboard Mounting Holes

    200/225/250/275 VERADO 4-STROKE MAXIMUM STATIC WATERLINE The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE" mark on the idle relief grommet (located at the rear of the outboard) when the outboard is fully tilted in/down. If waterline is above "MAX STATIC WATERLINE" mark, adjust boat load forward or increase (raise) outboard mounting height to correctly place mark above waterline.

  • Page 7: Lifting Outboard

    200/225/250/275 VERADO 4-STROKE 2. Place masking tape directly onto the boat where the mounting holes will be drilled to help keep the fiberglass from chipping. 3973 3. Using the drill guide holes on the transom drilling fixture, drill four 13 mm (17/32 in.) holes perpendicular to and through the transom.

  • Page 8: Fastening Outboard

    200/225/250/275 VERADO 4-STROKE 5. Refer to Determining Recommended Outboard Mounting Height, and install outboard to the nearest recommended mounting height. 3731 Lifting eye Mounting bolts Lifting Eye 91-895343T01 6. Fasten outboard with mounting hardware provided. Refer to Fastening Outboard. Fastening Outboard 1.
  • Page 9 200/225/250/275 VERADO 4-STROKE CAUTION To avoid loss of outboard, ensure that a minimum of two full threads of bolt extend beyond locknut after tightening locknut. Ensure mounting nut is tightened against transom, not the shank of the mounting bolt. 5552 Transom bolts (1/2 x 20) (4) Flat washers - inner (4) Flat washers - outer (4)

  • Page 10: Power Steering Installation

    200/225/250/275 VERADO 4-STROKE Power Steering Installation Power Steering System ob01457 Steering helm Power steering pump Steering cylinder on outboard Installation Procedure NOTE: On some large/heavy dual outboard boats the steering forces generated in extreme maneuvers may create loads that exceed the pump's pressure capacity. If the happens, the operator may feel intermittent periods of load feedback at the steering wheel.
  • Page 11 200/225/250/275 VERADO 4-STROKE • To reduce noise on aluminum or metal hulls, isolate steering hoses from hull with suitable non-abrasive hangers. • Steering hoses from steering wheel helm must be free of twists or stress. Gently secure hose bundle together with a cable tie, located approximately 25.4 cm (10 in.) from the steering wheel helm.

  • Page 12: Connection Of The Hydraulic Hoses To The Steering Helm

    200/225/250/275 VERADO 4-STROKE 2. Mount the power steering pump at the selected location, using appropriate fastening hardware suitable for the type of material and thickness of the mounting surface. ob01459 Mounted on internal bulkhead Mounted on floor Lag screws or thru-bolts (3 or 4) Mounting hardware Connection of the Hydraulic Hoses to the Steering Helm NOTE: Hoses must be routed up through steering helm opening in dash and secured to...
  • Page 13 200/225/250/275 VERADO 4-STROKE 3. Ensure O-ring seals are in place on end of steering helm fittings. ob01460 O-ring seals (4) Plug - not used 4. Make the hose connections to the steering helm as shown. Use a thin wrench and hold the helm fittings from turning while tightening hoses.

  • Page 14: Connection Of The Hydraulic Hoses To The Power Steering Pump

    200/225/250/275 VERADO 4-STROKE Helm Fitting ID Mark Hose ID Mark Description R-STAR Hose connects to starboard side of steering cylinder L-PORT Hose connects to port side of steering cylinder Connection of the Hydraulic Hoses to the Power Steering Pump 1. Remove and discard the yellow protector cap from end of tank low pressure fitting. 2.

  • Page 15: Connection Of The Hydraulic Hoses To The Steering Cylinder

    200/225/250/275 VERADO 4-STROKE 4. Connect the high pressure hydraulic hose from the steering helm to the pump as shown. ob01463 O-ring High pressure hydraulic steering hose Connection of the Hydraulic Hoses to the Steering Cylinder 1. Route the hydraulic hoses to the outboard steering cylinder. Bulkhead fittings are available if an opening does not exist in the engine well.
  • Page 16 200/225/250/275 VERADO 4-STROKE 2. Position the 90° hose fittings to the desired direction. Loosen fastening nuts in order to rotate. Position fittings and re-tighten fastening nuts. ob01465 Position fittings Straight fitting 90° fitting 3. Remove and discard the shipping caps from the two fittings on the steering cylinder. Ensure O-ring seals did not lift off with shipping caps.

  • Page 17: Electrical Connections To The Steering Pump

    200/225/250/275 VERADO 4-STROKE Electrical Connections to the Steering Pump NOTE: For single engine installation, the power steering pump battery cables should be connected directly to the outboard starting battery. 4250 Single Engine Application Engine Power steering pump Battery cable Driver module DTS power harness Power steering pump ground harness...
  • Page 18 200/225/250/275 VERADO 4-STROKE NOTE: On multiple installations, the Automatic Battery Switch (ABS) (87-895091K01), must be used to connect all outboard starting batteries to the power steering pump. The ABS allows battery voltage to be drawn from the starting battery with the highest state of charge.

  • Page 19: Filling Power Steering System With Engine Not Running

    SAE 0W-30 Full Synthetic Power Steering Fluid as soon as possible, to avoid loss of performance in power steering system. Fluid Type Capacity Mercury Part Number SAE 0W-30 Full Synthetic Power 1 - 2 liters (1 - 2 quarts) depending on length 92-858002K01...
  • Page 20 200/225/250/275 VERADO 4-STROKE 4. Fill the pump tank with recommended power steering fluid. 4101 Fill cap Full level Filter IMPORTANT: The power steering module primer has two switches, "POWER" - "ON" and "OFF", and "PUMP" - "ON" and "OFF". To power up and activate the power steering pump, there are two steps: 1) Turn the "POWER"...

  • Page 21: Filling Power Steering System With Engine Running

    200/225/250/275 VERADO 4-STROKE 9. Open bleed valve to release any remaining air in the power steering system. Allow adequate time, depending on length of power steering hose, for air to escape from system. Tighten bleed valve securely and remove bleed hose. 3640 Bleed hose Bleed valve in steering cylinder...

  • Page 22: Routing Connections Through The Cowl

    NOTE: Mercury Marine suggests routing the wiring, cables and fuel hose through a rigging hose or flexible sleeve from the engine to the boat's gunnel or motor well. Follow the installation instructions included with the Rigging Hose or Flexible Sleeve Kit.

  • Page 23: Fuel Hose Connection

    200/225/250/275 VERADO 4-STROKE 1. Pull out the grommet fitting from the front cowl opening. Route the wiring harnesses, battery cables, and fuel hose through the correct openings in the rubber grommet as shown. 3723 Rubber grommet Fuel hose 14 pin data harness DTS power harness, vessel sensor harness, power steering pump harness Large diameter battery cables Small diameter battery cables...

  • Page 24: 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 25: 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. 90-10238051 Page 25 / 51...

  • Page 26: Wiring Accessories

    200/225/250/275 VERADO 4-STROKE 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 27: Battery Cable Size For Outboard Models

    200/225/250/275 VERADO 4-STROKE • 14 pin data harness - Connects between the command module harness and engine. 3675 14 pin data harness Power steering pump harness Vessel sensor harness Battery cables DTS power harness 5 Amp fuse Battery Cable Size For Outboard Models IMPORTANT: Only use copper battery cables.
  • Page 28 200/225/250/275 VERADO 4-STROKE 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.) 4.0 m (13 ft.) 4.3 m (14 ft.)

  • Page 29: Connecting 14 Pin Data Harness - Single Engine

    200/225/250/275 VERADO 4-STROKE Connecting 14 Pin Data Harness - Single Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.). 3619 14 pin data harness Clamp or cable tie DUAL HELM 3682 14 pin data harness Dual helm adapter (Y harness)

  • Page 30: Connecting 14 Pin Data Harness - Dual Engine

    200/225/250/275 VERADO 4-STROKE Connecting 14 Pin Data Harness - Dual Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.). 3977 14 pin data harness Clamp or cable tie DUAL HELM 3978 Helm 2 (upper helm) Dual helm adapter (Y harness)

  • Page 31: Installing Dts Command Module And Harness - Single Engine

    200/225/250/275 VERADO 4-STROKE Installing DTS Command Module and Harness - Single Engine 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 32 200/225/250/275 VERADO 4-STROKE 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 Helm 2 (upper helm) CAN 1 connector Helm 1 (lower helm)
  • Page 33 200/225/250/275 VERADO 4-STROKE • 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 34: Installing Dts Command Module And Harness - Dual Engine/Single Helm

    200/225/250/275 VERADO 4-STROKE 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 35: Battery Information

    200/225/250/275 VERADO 4-STROKE • 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 Information CAUTION Hex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power.

  • Page 36: Connecting Battery Cables And Dts Power Harness

    200/225/250/275 VERADO 4-STROKE Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. NOTICE - DTS &...
  • Page 37 200/225/250/275 VERADO 4-STROKE 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) Junction box Vessel sensor harness DTS power harness (optional)
  • Page 38 200/225/250/275 VERADO 4-STROKE DUAL ENGINE - BATTERY AT STERN 3680 Red sleeve (positive) Ground cable Black sleeve (negative) Data cable Battery Vessel sensor harness DTS power harness (provided) Page 38 / 51 90-10238051...

  • Page 39: Connecting Fuel Tank And Speed Sensor

    200/225/250/275 VERADO 4-STROKE 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 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 40 200/225/250/275 VERADO 4-STROKE IMPORTANT: Metal fuel tanks must be grounded to hull or battery ground in accordance to coast guard regulations. PNK/BLK BLK/ORG 5759 Paddle wheel kit Fuel tank Vessel harness To second fuel tank Black/orange wire connection, if equipped Page 40 / 51 90-10238051...

  • Page 41: Switched 12V Accessory Connection

    200/225/250/275 VERADO 4-STROKE 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 90-10238051 Page 41 / 51...

  • Page 42: Dts Wiring - Single Engine

    200/225/250/275 VERADO 4-STROKE 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) Displace harness Foot throttle (optional) Page 42 / 51...
  • Page 43 200/225/250/275 VERADO 4-STROKE 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) 90-10238051 Page 43 / 51...

  • Page 44: Dts Wiring - Dual Engine

    200/225/250/275 VERADO 4-STROKE 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 Horn To starboard engine Accessory power relay (optional)

  • Page 45: 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 46 200/225/250/275 VERADO 4-STROKE Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft splines 92-802867A1 2-4-C Marine Lubricant with Propeller shaft splines 92-802859A1 Teflon 2. Flo-Torq II Drive Propellers - Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft. ob00421 Propeller nut Propeller...

  • Page 47: Paddle Wheel Speed Sensor Installation (If Equipped)

    200/225/250/275 VERADO 4-STROKE 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) Paddle wheel Clamp (2) Selecting Location...

  • Page 48: Transom Angle Requirements

    200/225/250/275 VERADO 4-STROKE 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 49: Routing The Cable

    200/225/250/275 VERADO 4-STROKE 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.) Caulking #10 screw Routing the Cable...

  • Page 50: Installing And Removing The Paddle Wheel

    200/225/250/275 VERADO 4-STROKE 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.) Installing and Removing the Paddle Wheel Installation - Slide the pins into the slots in the bracket and snap the tabs into place.

  • Page 51: Template - Paddle Wheel Speed Sensor

    200/225/250/275 VERADO 4-STROKE 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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