Mercury optimax 115 Installation Manual
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Mercury optimax 115 Installation Manual

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NOTICE TO INSTALLER: After completing assembly, these instructions should be
placed with the product for the owner's future use.
IMPORTANT: If the boat is to be water tested, the operator should be familiar with the
operation procedures in the Operation and Maintenance Manual.

Important Information

Before Starting Engine
Before starting engine for the first time, prime the oil injection pump. Procedure on page 16.
Prevent possible engine damage, Prime the oil injection pump before starting en-
gine for the first time.
Required Fuel
Do not use pre-mixed gas and oil in this engine. Use a clean and fresh recommended
gasoline during engine break-in and after engine break-in.
Recommended Oil
Mercury or Quicksilver Optimax/DFI 2-Cycle engine oil is recommended for your engine. If Opti-
max/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.

Avoiding Fuel Flow Restrictions

IMPORTANT: Adding components to the fuel supply system as in filters, valves, fit-
tings, etc. may restrict the fuel flow and could cause engine stalling at low speed, and/
or a lean fuel condition at high RPM, that could cause engine damage.

Electric Fuel Pump

If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If
necessary, install a pressure regulator to regulate the pressure.
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INSTALLATION MANUAL
75/90/115 OPTIMAX
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CAUTION
2004, Mercury Marine
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April 13, 2025

What are the two small polyurethane tubes one is gray one is black that run along the fuel lines and go up into the motor?

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Summary of Contents for Mercury optimax 115

  • Page 1: Table Of Contents

    Recommended Oil Mercury or Quicksilver Optimax/DFI 2-Cycle engine oil is recommended for your engine. If Opti- max/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 2: Boat Horsepower Capacity

    75/90/115 OPTIMAX Boat Horsepower Capacity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY Do not overpower or overload the boat. Most boats will carry a required capacity plate indi- cating the maximum acceptable power and load as determined by the manufacturer follow- ing certain federal guidelines.

  • Page 3: Installation Specifications

    75/90/115 OPTIMAX Installation Specifications a – Transom Opening – Minimum Single Engine (Remote) – 33-3/8 in. (848 mm) Dual Engines – 59-3/4 in. (1518 mm) b – Engine Center Line For Dual Engine 26 in. (660mm) Minimum Lifting Outboard Use Flywheel Puller/Lifting Eye (91-83164M). Page 3 of 18...

  • Page 4: Steering Cable

    75/90/115 OPTIMAX Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate O-ring seal and entire cable end. 2-4-C With Teflon (92-825407A12) 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 N·m). Page 4 of 18...

  • Page 5: Steering Link Rod

    75/90/115 OPTIMAX Steering Link Rod 1. Install steering link rod per illustration. Special Bolt (10-849838) Torque to 20 lb. ft. (27 N·m) Nylon Insert Locknut (11-34863) Torque to 20 lb. ft. (27 N·m) Flat Washer (2) Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a”...

  • Page 6: Determining Recommended Outboard Mounting Height

    75/90/115 OPTIMAX Determining Recommended Outboard Mounting Height 26 in. (660mm) 25 in. (635mm) 24 in. (609mm) 23 in. Outboard (584mm) Mounting Height (See 22 in. NOTE Below) (560mm) 21 in. (533mm) 20 in. (508mm) 19 in. (482mm) NOTE: Add 5 in. (127mm) for XL mod- els to the listed outboard mounting Maximum Boat Speed Anticipated height.

  • Page 7: Installing Outboard

    75/90/115 OPTIMAX Installing Outboard 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (lo- cated in this manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Refer to “Determining Recommended Outboard Motor Mounting Height,” preceding and install outboard to the nearest recommended mounting height.

  • Page 8: Electrical, Fuel Hose And Control Cables

    75/90/115 OPTIMAX Electrical, Fuel Hose, and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch assem- bly must be wired with a warning horn. This warning horn is used with the engine warning system. Front Cover Assembly REMOVAL Pull up the cowl seal and remove the cover from the bottom cowl.

  • Page 9: Remote Wiring Harness

    75/90/115 OPTIMAX Remote Wiring Harness 1. Connect wiring. Push the retainer over the ends of the connectors. This will hold the con- nectors together. Place the harness connection and retainer into the cable holder lo- cated in the bottom cowl has shown. BLU/WHT BLU/WHT GRN/WHT...

  • Page 10: Battery Cable Connections

    75/90/115 OPTIMAX Battery Cable Connections SINGLE OUTBOARD (–) Red Sleeve (Positive) Black Sleeve (Negative) Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between nega- tive (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) –...

  • Page 11: Fuel Hose Connection

    75/90/115 OPTIMAX Fuel Hose Connection PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.

  • Page 12: Shift Cable Installation

    75/90/115 OPTIMAX Shift Cable Installation Install cables into the remote control following the instructions provided with the remote con- trol. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. 1.
  • Page 13 75/90/115 OPTIMAX 4. Push in on the shift cable end (d) until resistance is felt. Adjust the cable barrel (e) to attain distance (a) taken in Step 3. Shift Cable End Cable Barrel 5. Place cable barrel into pocket. Fasten cable with locknut and flat washer. Place Barrel Into Barrel Pocket Locknut –...

  • Page 14: Throttle Cable Installation

    75/90/115 OPTIMAX Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote con- trol. 1. Position remote control into neutral. 2. Install throttle cable to the throttle arm with washer and locknut. 3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.

  • Page 15: Filling Fuel System

    75/90/115 OPTIMAX Filling Fuel System NOTE: 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 to be filled as follows: Squeeze the fuel line primer bulb until it feels firm. Turn the ignition key switch to the ON position for three seconds.

  • Page 16: Priming The Oil Injection Pump

    75/90/115 OPTIMAX 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. Oil Injection Pump Oil Supply Hose CAUTION To prevent damage to the fuel pumps, fill the engine fuel system with fuel.

  • Page 17: Propeller Installation

    IMPORTANT: Propellers used on this product require the Mercury Marine Flo-Torq lll type hub 835257A9 or equivalent. Flo-Torq lll Drive Hub Propellers...

  • Page 18: Trim-In Stop Adjustment

    75/90/115 OPTIMAX Trim-In Stop Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This great- er trim “under” capability is desirable to improve acceleration, reduce the angle and time spend in a bow high boat attitude during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations.

This manual is also suitable for:

Optimax 75Optimax 90

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