Mercury 135 OptiMax Manual
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Mercury 135 OptiMax Manual

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See also: Service Manual , Operation & Maintenance 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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  • 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 Operation Pre‑Starting Check List......................... 27 Operating In Freezing Temperatures....................27 Operating In Salt Water Or Polluted Water................... 27 Operating at High Elevations........................ 27 Setting Trim Angle While Running Engine at Idle Speed..............28 Engine Break‑in Procedure........................28 Starting The Engine..........................
  • Page 7 OWNER SERVICE ASSISTANCE Local Repair Service..........................53 Service Away From Home........................53 Parts And Accessories Inquiries......................53 Service Assistance..........................53 Mercury Marine Service Offices......................53 OUTBOARD INSTALLATION Important Information..........................55 Avoiding Fuel Flow Restriction......................55 Electric Fuel Pump..........................55 Boat Horsepower Capacity........................55 Start in Gear Protection........................
  • 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

    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 16 RPM range when under normal full throttle operation. 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 17: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death.
  • Page 18 GENERAL INFORMATION The lanyard is a cord usually 122 - 152 cm (4 - 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. The lanyard is coiled to make its at-rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.

  • 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 Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.

  • Page 21: Impact With Underwater Hazards

    WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
  • Page 22 GENERAL INFORMATION WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide. 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) 135/150/175 OptiMax Specifications Models Horsepower...

  • Page 25: Component Identification

    GENERAL INFORMATION Component Identification 3403 Top cowl Auxiliary tilt switch Bottom cowl Transom brackets Water pump indicator hole Gearcase Driveshaft housing Cooling water intake holes Anti-ventilation plate...

  • Page 26: 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 27: 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 28: Fuel Additives

    Fuel Additives To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickleen Engine Treatment additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container.

  • Page 29: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800...
  • Page 31 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following. Warning Horn Function Sound...

  • Page 32: Power Trim And Tilt

    FEATURES AND CONTROLS 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 33 FEATURES AND CONTROLS • In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction (called bow steering or over-steering) if any turn is attempted, or if a significant wave is encountered.

  • Page 34: Shallow Water Operation

    FEATURES AND CONTROLS Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 22362 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 35: 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 36: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full-in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs.
  • Page 37 OPERATION NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Provide a sufficient supply of water at the water inlets during operation. Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged.
  • Page 38 OPERATION Shift outboard to neutral (N) position. 26838 For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should be filled as follows: a. Squeeze the fuel line primer bulb until it feels firm. b.

  • Page 39: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle. • Do not shift outboard into reverse when the engine is not running. • Your outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R).

  • Page 40: 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. EPA Emissions...

  • Page 41: Flushing The Cooling System

    MAINTENANCE AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in salt water.

  • Page 42: Top Cowl Removal And Installation

    MAINTENANCE Remove the plug from fitting in the bottom cowl. 28428 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. 28430 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. 27816 Lift up the rear cowl latch.

  • Page 43: Flywheel Cover Removal And Installation

    MAINTENANCE CLEANING AND WAXING PROCEDURE Before washing, rinse the top cowl with clean water to remove dirt and dust that may scratch the surface. Wash the top cowl with clean water and a mild non-abrasive soap. Use a soft clean cloth when washing.

  • Page 44: Steering Link Rod Fasteners

    MAINTENANCE WATER SEPARATING FUEL FILTER NOTE: The warning system will turn on when water in the fuel filter reaches the full level. See Features & Controls - Warning System. The water separating fuel filter removes moisture and also debris from the fuel. If the filter becomes filled with water, the water can be removed.

  • Page 45: Fuse Replacement

    MAINTENANCE WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

  • Page 46: Corrosion Control Anode

    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. 28552 Good fuse Ignition system circuit - 20 amp fuse Blown fuse Electric fuel pump/ECM driver power/ injectors/oil pump circuit - 20 amp fuse...

  • Page 47: Battery Information

    MAINTENANCE Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.

  • Page 48: Propeller Replacement

    MAINTENANCE Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Shift outboard to neutral (N) position.
  • Page 49 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 50: Spark Plug Inspection And Replacement

    MAINTENANCE 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. 26941 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications.

  • Page 51: Compressor Air Intake Filter

    MAINTENANCE Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 26946 Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.80 mm (0.031 in.) Before installing spark plugs, clean off any dirt on the spark plug seats.

  • Page 52: Alternator Belt Inspection

    Cracks or deterioration in the rubber portion of the belt. b. Belt surfaces rough or uneven. c. Signs of wear on edges or outer surfaces of belt. 29398 Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 53 Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 26902 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 54 MAINTENANCE • Alternator Belt Tensioner Pivot Shaft - Lubricate through fitting. 29399 • Swivel Bracket - Lubricate through fitting. • Tilt Support Lever - Lubricate through fitting. 27873 Swivel bracket Tilt support lever • Tilt Tube - Lubricate through fitting. 27874 WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of...

  • Page 55: Gearcase Lubrication

    Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml (22.5 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 56: Submerged Outboard

    MAINTENANCE Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. 3400 Vent plug Fill/drain plug Vent hole IMPORTANT: Replace sealing washers if damaged. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

  • Page 57: Storage

    Precision fuel Stabilizer and Mercury Precision Quickleen products as described on their 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 58: 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 59: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 60: Performance Loss

    TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged propeller or improper propeller size. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •...

  • Page 61: 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 62 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...

  • Page 63: Outboard Installation

    IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2-Cycle Outboard Oil is not available, substitute another brand of 2-Cycle outboard oil that is NMMA Certified TC-W3.

  • Page 64: Start In Gear Protection

    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 65: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine center line for dual engine - 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33-3/8 in.) Dual engine 151.8 cm (59-3/4 in.) Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death.

  • Page 66: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION Lift the outboard and place it on the boat transom. Lifting Eye 91-90455--1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine for removal/ installation. 2756 Steering Cable - Starboard Side Routed Cable Lubricate O-ring seal and entire cable end.

  • Page 67: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION Torque nut to specification. 3727 Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10-849838) and self-locking nylon insert locknuts (P/N 11-826709113).
  • Page 68 OUTBOARD INSTALLATION WARNING Worn, loose, or seized steering components can lead to loss of boat control. Inspect all steering attachment components for wear, lubricate all attachment hardware, and check all fasteners for proper tightness in accordance with the inspection and maintenance schedule. or79 Special washer head bolt (P/N Flat washer (2)

  • Page 69: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION 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.) 24305 The solid line is recommended to This line may be preferred to determine determine the outboard mounting outboard mounting height dimension for...
  • Page 70 OUTBOARD INSTALLATION Mark four mounting holes on the transom using the transom drilling fixture. or69-1 Drill guide holes Transom centerline Transom drilling fixture Transom Drilling Fixture 91-98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 Drill four 13.5 mm (17/32 in.) mounting holes.

  • Page 71: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware - Supplied with Outboard Part Number Part Name Description 10-67755-1 Transom bolt 1/2-20 x 4.50 in. long (2.25 in. thread) 11-826711-17 Nylon insert locknut 1/2-20 12-28421 Washer - Inner 0.516 in.
  • Page 72 OUTBOARD INSTALLATION NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. 20860 Large transom washer Transom reinforcement plate Description Part Number Large transom washer 67-896392 Transom reinforcement plate 67-896305...

  • Page 73: Electrical, Hoses, And Control Cables

    OUTBOARD INSTALLATION Electrical, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove screws and open the front clamp assembly. 7644 Screw (2) Front clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp. Connect remote harness to the 14 pin connector on the engine harness.

  • Page 74: Single Outboard

    OUTBOARD INSTALLATION • Do not use deep cycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA or 180 Ah. • When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.
  • Page 75 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve - positive (+) Ground cable Black sleeve - negative (–) Cranking battery FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel Hose Size - Minimum fuel line inside diameter (I.D.) is 8mm (5/16 in.), with separate fuel line/fuel tank pickup for each engine.
  • Page 76 OUTBOARD INSTALLATION 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 SPEEDOMETER AND WATER PRESSURE TUBING CONNECTIONS NOTE: This applies to models without SmartCraft gauges.

  • Page 77: Shift And Throttle Cable

    OUTBOARD INSTALLATION Shift and Throttle Cable COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gearcases can be identified by a "L" stamped into the end of the propeller shaft. The Quicksilver Dual Engine Console Mount Control is required to shift the counter rotation outboard. The installation instructions shipped with the control explain the procedure required to connect this control to a counter rotation outboard.
  • Page 78 OUTBOARD INSTALLATION c. Place a mark on the shift cable against the cable end guide. 4355 Forward position mark Mark the reverse position as follows: a. Move the remote control handle into reverse and advance the handle to the full speed position.
  • Page 79 OUTBOARD INSTALLATION Center the anchor pin between these resistance points. 4363 Anchor pin Shift cable retainer Adjusting the Shift Cable To adjust the shift cable: Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable.

  • Page 80: Throttle Cable Installation

    OUTBOARD INSTALLATION b. Shift the remote control into neutral. If the propeller shaft does not turn freely without drag, adjust the barrel away from the cable end guide. Repeat steps a and b. c. Shift the remote control into reverse while turning the propeller shaft. If the propeller shaft does not lock solidly in gear, adjust the barrel away from the cable end guide.

  • Page 81: Front Clamp Reassembly

    OUTBOARD INSTALLATION Adjust the throttle cable barrel so that the installed throttle cable will hold the idle stop screw against the stop. 4366 Throttle cable barrel Idle stop screw Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse.

  • Page 82: Filling The Fuel System

    OUTBOARD INSTALLATION Place the neoprene wrap over the wiring, hoses, and control cables. 3766 Fasten clamp together with two screws. 7644 Screw (2) Front clamp 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 83: Oil Injection Set-Up

    OUTBOARD INSTALLATION Oil Injection Set-up FILLING OIL SYSTEM Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten fill cap. 2683 Fill cap Remove cap and fill engine oil tank with oil. Reinstall the fill cap. 7745 Engine oil tank Fill cap...

  • Page 84: Priming The Oil Injection Pump

    OUTBOARD INSTALLATION PRIMING THE OIL INJECTION PUMP Before starting engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. 7747 Oil injection pump Oil supply hose IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump.

  • Page 85: Propeller Installation

    OUTBOARD INSTALLATION Propeller Installation WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. 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.

  • Page 86: Trim In Pin

    OUTBOARD INSTALLATION Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.

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