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Mercury 200 OptiMax DTS Manual

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See also: Owner's Manual , Installation Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at
peak efficiency for maximum performance and economy. The enclosed Owner's Registration
Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for
full details of your warranty coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and
full contact information are displayed.
Is
your
engine
properly
www.marinepower.com. If necessary, please contact your local dealer.
Declaration of Conformity - Optimax
Manufacturer:
Authorized Representative:
If the CE mark is accompanied by a notified body number, the following Recreational Craft
Directive applies:
Recreational Craft Directive:
Applicable Requirement
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engines starting (A.5.1.4)
General steering system (A.5.4.1)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Module used for exhaust emission assessment: Module H; Certification No. RCD-H-2
Module used for noise emission assessment: Module H; Certification No. RCD-H-2
Name of Notified Body for exhaust emission assessment and noise emission assessment:
Det Norske Veritas AS
Veritasveien 1
1322 Hovik
Norway
Notified Body Number: 0575
Engine type: Outboard Fuel type: Gasoline
Engine Family Manufacture Location Horsepower
registered
for
warranty
Mercury Marine
W6250 Pioneer Road P.O. Box 1939
Fond du Lac, WI 54935-1939 USA ,
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-2800 Verviers - Belgium,
2003/44/EC amending 94/25/EC
Standards Applied
EN ISO 10240:2004
EN ISO 8665:1995
EN ISO 11547:1995
ABYC P-17; EN ISO 10592:1995
EN ISO 8178-1: 1996
EN ISO 8665:1995
EN ISO 14509:2000
Combustion cycle: 2
stroke, direct injection
Starting Serial
Number
i
purpose?
Please
check
Brands: Mercury,
Mariner
Module H Noise
and Exhaust
Certificate
on

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Summary of Contents for Mercury 200 OptiMax DTS

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
  • Page 2 Vehicles, boats and internal combustion engine driven devices - radio disturbance characteristics CISPR 12; EN 55012:2002/A1:2005 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.
  • Page 3 Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006. European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer Of Warranty..........................1 Warranty Registration United States And Canada................. 1 Warranty Registration Outside The United States And Canada............. 1 Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle-East and Africa....................... 2 3 Year Limited Warranty Against Corrosion...................
  • Page 6 TABLE OF CONTENTS Features and Controls Panel Mount Control Features and Operation..................24 Single Handle Console Control Features and Operation..............26 Slim Binnacle Control Features and Operation..................29 Dual Handle Console Control Features and Operation................ 32 Dual Handle Console Control with CAN Trackpad Features and Operation........35 Shadow Mode Control Features and Operation...................
  • Page 7 Engine Starts But Will Not Shift Into Gear.................... 82 Engine Runs Erratically........................82 Performance Loss..........................83 Battery Will Not Hold Charge........................ 83 Owner Service Assistance Local Repair Service..........................84 Service Away From Home........................84 Parts And Accessories Inquiries......................84 Service Assistance..........................84 Mercury Marine Service Offices......................84...
  • Page 8 viii...

  • Page 9: Warranty Information

    Outside United States and Canada - Check with your local distributor. 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.

  • Page 10: Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation Of Independent States, Middle-East And Africa

    Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre–delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 11: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 12 Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 13: Warranty Coverage And Exclusions

    All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 14: General Information

    GENERAL INFORMATION 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 strongly 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.

  • Page 15: High-Speed And High-Performance Boat Operation

    Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start in gear protection is provided by the control system. This prevents the engine from starting when the shift is actuated in any position other than neutral.
  • Page 16 When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local authorized Mercury dealer.

  • Page 17: Remote Steering Notice

    GENERAL INFORMATION PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats. Stainless steel is over five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies.
  • Page 18 GENERAL INFORMATION The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) 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.

  • Page 19: Protecting People In The Water

    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. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 20: Wave And Wake Jumping

    GENERAL INFORMATION WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over. Stay back from the front end of the deck and remain seated while the boat is in motion. BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed.

  • Page 21: Impact With Underwater Hazards

    GENERAL INFORMATION Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom.
  • Page 22 GENERAL INFORMATION WARNING Avoid the combination of a running engine and poor ventilation. 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. 21622 Example of desired air flow through the boat POOR VENTILATION...

  • Page 23: Selecting Accessories For Your Outboard

    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 24: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. rial Numb XXXXXXXX XXXX RP M 23884 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) 200/225 OptiMax DTS Specifications Models Horsepower...

  • Page 25: Component Identification

    GENERAL INFORMATION Component Identification ob01582 Top cowl Anode plate Bottom cowl Auxiliary tilt switch Water pump indicator hole Transom brackets Driveshaft housing Gearcase Anti-ventilation plate Cooling water intake holes...

  • Page 26: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.

  • Page 27: Propeller Selection

    INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information - Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed.

  • Page 28: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.

  • Page 29: Fuel And Oil

    The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 30: Fuel Requirements

    Recommended Oil MercuryOptimax/DFI or Quicksilver DFI 2-Cycle Engine Oil Mercury Optimax/DFI or Quicksilver DFI 2-Cycle Engine Oil is recommended for your engine. If Mercury Optimax/DFI or Quicksilver DFI 2-Cycle engine oil is not available, we recommend using Mercury or Quicksilver TC-W3 Premium Plus 2-Cycle Oil. Severe engine damage may result from use of an inferior oil.
  • Page 31 FUEL AND OIL Remove the top cowl. Loosen the fill cap on the engine oil reservoir tank. Run the engine until all the air has been vented out of the oil reservoir tank and tank is filled with oil to the point of overflow. Re-tighten the fill cap.

  • Page 32: Features And Controls

    FEATURES AND CONTROLS Panel Mount Control Features and Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
  • Page 33 FEATURES AND CONTROLS Throttle only button - Allows the boat operator to increase engine RPM for warm-up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.

  • Page 34: Single Handle Console Control Features And Operation

    FEATURES AND CONTROLS Detent tension adjustment screw - This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to tension desired. 5171 Detent tension adjustment screw Control handle tension adjustment...
  • Page 35 FEATURES AND CONTROLS Detent tension adjustment screw - This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to the desired tension. ob01170 Detent tension adjustment screw Control handle tension adjustment...
  • Page 36 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One person helm transfer should only be performed while engine is in neutral.

  • Page 37: Slim Binnacle Control Features And Operation

    FEATURES AND CONTROLS Slim Binnacle Control Features and Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
  • Page 38 FEATURES AND CONTROLS Detent tension adjustment screw - This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to the desired tension. ob01170 Detent tension adjustment screw Control handle tension adjustment...
  • Page 39 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One person helm transfer should only be performed while engine is in neutral.

  • Page 40: Dual Handle Console Control Features And Operation

    FEATURES AND CONTROLS Dual Handle Console Control Features and Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed.
  • Page 41 FEATURES AND CONTROLS Throttle only/station select button - Allows the boat operator to increase engine RPM for warm- up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent.
  • Page 42 FEATURES AND CONTROLS HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One person helm transfer should only be performed while engine is in neutral.

  • Page 43: Dual Handle Console Control With Can Trackpad Features And Operation

    FEATURES AND CONTROLS Dual Handle Console Control with CAN Trackpad Features and Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed.
  • Page 44 FEATURES AND CONTROLS 1 lever button - Pressing the "1 LEVER" button initiates single lever mode. Single lever mode enables the throttle and shift functions of both engines to be controlled by the port control handle. To turn off single lever mode, shift the engine into neutral and press the "1 LEVER" button. Sync button - Pressing the "SYNC"...
  • Page 45 FEATURES AND CONTROLS SYNCHRONIZING ENGINES The auto synchronizing feature, when engaged, will automatically adjust all engine speeds to match the speed of the starboard engine. Press the "SYNC" button on the CAN trackpad to turn auto synchronization on or off. When the sync LED is yellow, the "SYNC"...

  • Page 46: Shadow Mode Control Features And Operation

    FEATURES AND CONTROLS Synchronizing Helms Prior To Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash.
  • Page 47 FEATURES AND CONTROLS Turning off one of the outer engines while underway will cause the center engine to go into forced neutral/ idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral position and then re-engaging.
  • Page 48 FEATURES AND CONTROLS Starboard Inner Starboard Outer Control Handle Port Outer Engine Port Inner Engine Engine Engine Function Port outer engine throttle and shift = controlled by port control handle Running Running Starboard outer engine throttle and shift = controlled by starboard control handle Port inner engine...
  • Page 49 FEATURES AND CONTROLS TRIM SWITCH AND KEY PAD FEATURES Trim switch (if equipped) - Operates the trim for all engines. An accessory trim switch panel is required for trimming engines individually. 13853 Throttle only/station select button - Allows the boat operator to increase engine RPM for warm- up, without shifting the engine into gear.
  • Page 50 FEATURES AND CONTROLS Sync LED - The "SYNC" LED illuminates when the RPM of the engines are being synchronized by the DTS system. NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT 13854 Neutral LEDS Sync LED Select button Throttle only/station select button Arrow trackpad Active LED SYNCHRONIZING ENGINES...

  • Page 51: Shadow Mode Control With Can Trackpad Features And Operation

    FEATURES AND CONTROLS NOTE: There is a 10 second time frame to complete a helm transfer. If the helm transfer is not completed, the action will be cancelled and a double beep will sound. Pressing the throttle only/station select button again will re-initiate a helm transfer.
  • Page 52 FEATURES AND CONTROLS Port Engine Center Engine Starboard Engine Control Handle Function Starboard and center engine throttle and shift = Running Running controlled by starboard control handle Port engine throttle and shift = controlled by port control handle Running Running Starboard engine throttle and shift = controlled by starboard control handle...
  • Page 53 FEATURES AND CONTROLS Starboard Inner Starboard Outer Control Handle Port Outer Engine Port Inner Engine Engine Engine Function Starboard inner and outer engine throttle and shift = Running Running controlled by starboard control handle Port inner engine Off (ignition key throttle and shift = Running Running...
  • Page 54 FEATURES AND CONTROLS If a failure should occur while underway which causes the starboard outer engines into forced neutral/ idle condition, the inner starboard engine will also be forced to neutral/idle. Operation to the inner engine can be restored by moving the starboard control handle back into neutral and then re-engaging. If a failure should occur while underway which causes the port outer engines into forced neutral/idle condition, the inner port engine will also be forced to neutral/idle.
  • Page 55 FEATURES AND CONTROLS Sync button - Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22945 Neutral LEDS Throttle only Troll button 1 lever button Transfer button Sync button Dock button Control handle tension adjustment screw - This screw can be adjusted to increase or decrease...
  • Page 56 FEATURES AND CONTROLS Press the "SYNC" button on the CAN trackpad to turn auto synchronization on or off. When the sync LED is yellow, the "SYNC" button has been pressed, but the conditions are not right for auto synchronization to engage. When the sync LED turns red, engine synchronization has been engaged. The engines will remain synchronized as long as engine speed is over 900 RPM for two seconds, remote control handles are positioned within 10% of each other, and the engines are below 95% throttle opening.

  • Page 57: Warning System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn is located under the dash within the wiring harness. WARNING HORN SIGNALS When the key switch is turned to the "ON" position, the horn will turn on for a moment as a test to show the horn is working.
  • Page 58 Moving the throttle lever back to the idle position will reset the system. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption and engine operating hours.

  • Page 59: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.
  • Page 60 FEATURES AND CONTROLS 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 or tiller handle.
  • Page 61 FEATURES AND CONTROLS Disengage the tilt support lever, by raising the outboard off the support lever and rotating the tilt support lever down. Lower the outboard. ob00664 Tilt support lever Knob MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.
  • Page 62 FEATURES AND CONTROLS Reduce engine speed below 2000 RPM. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range.

  • Page 63: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 64: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Setting Trim Angle While Running Engine at Idle Speed Submerging the exhaust relief hole on the outboard can happen on some boats if you trim full in while running at idle speed, resulting in, exhaust restriction, rough idle, excessive smoke, and fouled spark plugs.
  • Page 65 OPERATION CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. Make sure the cooling water intake is submerged. ob00668 Open fuel tank vent on manual venting type tanks.

  • Page 66: Gear Shifting

    OPERATION NOTE: Turn the ignition key switch to the "ON" position for approximately one minute. This operates the fuel lift pump. Turn the ignition key switch back to the "OFF" position and then return the ignition key switch to the "ON" position again for an additional minute. Turn the ignition key switch back to the "OFF" position.
  • Page 67 OPERATION • The outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R). 3427 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position.

  • Page 68: Stopping The Engine

    OPERATION Stopping The Engine IMPORTANT: Turning key to the "START" position while the engine is running will result in engine shut down, while leaving the DTS system active. This will allow the use of the power trim/tilt from the remote control handle.

  • Page 69: Maintenance

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 70: Inspection And Maintenance Schedule

    MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •...

  • Page 71: Flushing The Cooling System

    MAINTENANCE Flushing The Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. NOTE: Engine can be stopped or running at idle speed when flushing the cooling system. Do not flush engine using a water system that exceeds 310.26 kPa (45 psi).

  • Page 72: Alternator Belt Inspection

    MAINTENANCE Wax the surface using a non-abrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. Alternator Belt Inspection Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found.
  • Page 73 MAINTENANCE Fuel Filter Removal/Installation Tool 91-896661 Aids in the removal and installation of the fuel filter cap assembly. 24896 Installation Lubricate the O-ring seals with oil. 3388 Filter O-ring seals Install the fuel filter and tighten securely. IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm, forcing fuel into the filter.

  • Page 74: Steering Link Rod Fasteners

    MAINTENANCE Retighten the drain screw and reattach the hose. 24686 Drain hose Drain screw Side fitting IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber. 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"...

  • Page 75: Fuse Replacement

    MAINTENANCE WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00676 Special washer head bolt (10-849838) Nylon insert locknut (11-826709113) Flat washer (2) Nylon insert locknut (11-826709113)

  • Page 76: Dts Wiring System

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 3328 Good fuse Fuel injector/direct injector/starter slave solenoid/PCM and electric fuel pumps Blown fuse circuit - 20 AMP fuse Depth finder and accessories circuit -...

  • Page 77: Battery Inspection

    MAINTENANCE The gearcase has three anodes. Two anodes are located on each side of the gearcase, and a third is an anode plate installed underneath the anti-ventilation plate. If a trim tab should be installed, this anode plate will be removed. Another anode is installed on the bottom of the transom bracket assembly. or42-1 Corrosion control anodes (gearcase) Corrosion control anode (transom...

  • Page 78: Propeller Replacement

    MAINTENANCE IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements. 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 79 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.
  • Page 80 MAINTENANCE Flo-Torq I Drive Hub Propellers - Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. ob00382 Propeller nut Continuity washer Propeller nut retainer Propeller Rear thrust hub Forward thrust hub Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft.

  • Page 81: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc.

  • Page 82: Lubrication Points

    Rotate the filter 1/4 turn to the lock position. Reinstall the hose and secure with clamp. Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 83 Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 84 MAINTENANCE • Tilt Support Lever - Lubricate through fitting. ob00683 Swivel bracket Tilt support lever • Tilt Tube - Lubricate through fitting. ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant.

  • Page 85: Checking Power Trim Fluid

    Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

  • Page 86: Submerged Outboard

    Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 798 ml (27 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug.

  • Page 87: Storage

    Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on the containers to the fuel tank before the last operation of the boat. Adding fuel stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will help clean and lubricate the fuel injectors.

  • Page 88: Protecting Internal Engine Components

    Retighten the drain screw and reattach the hose. Premix the following in a container: a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant. b. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer.

  • Page 89: Protecting External Outboard Components

    Lubricate all outboard components listed in Maintenance - Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch-up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No.

  • Page 90: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 5 Amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. •...

  • Page 91: Performance Loss

    TROUBLESHOOTING • Threaded connection of an air hose is loose. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged propeller or improper propeller size. • Boat overloaded or load improperly distributed. •...

  • Page 92: Owner Service Assistance

    Should you have a question, concern, or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
  • Page 93 Telephone (954) 744-3500 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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