Mercury 200 Verado FourStroke Operation, Maintenance & Warranty Manual
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Mercury 200 Verado FourStroke Operation, Maintenance & Warranty Manual

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  • Page 1 Outboard Operation Maintenance Warranty Manual...
  • Page 3 Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC Name of engine manufacturer: Mercury Marine Address: W6250 Pioneer Road, P.O. Box 1939 Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA Name of authorized representative: Brunswick Marine in EMEA Inc.
  • Page 4 Identification of Engines Covered by This Declaration of Conformity Unique engine EC Module H Name of engine family identification number: certificate number starting serial number Verado 6 cylinder 200, 225, 0P401000 or RCD‑H‑2 Rev 4 250, 275, 300, 350, 400R hp 1B227000 Verado 4 cylinder 135, 150, 0P401000 or...
  • Page 5 Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.
  • Page 6 Please review this important information. The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, to change specifications, designs, methods, or procedures without notice and without incurring obligation.

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration United States and Canada..........1 Transfer of Warranty United States and Canada..........1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada.................. 2 3 Year Limited Warranty Against Corrosion............2 Warranty Coverage and Exclusions..............4 U.S.
  • Page 8 Low Permeation Fuel Hose Requirement ............42 EPA Pressurized Portable Fuel Tank Requirements........43 Fuel Demand Valve (FDV) Requirement............43 Mercury Marine's Pressurized Portable Fuel Tank........... 43 Filling Fuel Tank....................44 Engine Oil Recommendations................45 Checking and Adding Engine Oil..............45 Features and Controls Panel Mount Control Features and Operation..........
  • Page 9 Maintenance Outboard Care....................83 EPA Emissions Regulations................83 Inspection and Maintenance Schedule............. 84 Flushing the Cooling System................86 Cowl Removal and Installation................. 87 Cleaning Care for Top and Bottom Cowls............89 Cleaning Care for the Powerhead (Saltwater Use)........... 89 Battery Inspection .................... 89 Verado Engine Battery Specifications..............
  • Page 10 Troubleshooting Starter Motor Will Not Crank the Engine............120 Engine Will Not Start..................120 Engine Starts But Will Not Shift Into Gear............120 Engine Runs Erratically.................. 120 Performance Loss................... 121 Battery Will Not Hold Charge................121 Owner Service Assistance Local Repair Service..................122 Service Away from Home................

  • Page 11: Warranty Information

    Federal Safety Act be required. You may change your registered 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 12: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.
  • Page 13 COVERAGE: Warranty coverage is available only to retail customers that purchase from a 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 predelivery inspection process is completed and documented.

  • Page 14: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
  • Page 15 9. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 10. 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 16: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use warranty, whichever occurs first, to the retail customer, that the engine is designed, built,...

  • Page 17: California Emissions Limited Warranty

    Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved).
  • Page 18 Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.

  • Page 19: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 20: Emission Certification Star Label

    As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

  • Page 21: Warranty Policy-Australia And New Zealand

    What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.
  • Page 22 Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a 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 predelivery inspection process is completed and documented.
  • Page 23 The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au.
  • Page 24 Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this...

  • Page 25: Global Warranty Charts Outboard And Jets

    You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.
  • Page 26 WARRANTY INFORMATION Standard Limited Standard Limited Product Corrosion Warranty Warranty OptiMax jet drive (200 and 250 hp) 1 year 3 years Racing Product Standard Limited Standard Limited (Recreation use only) Warranty Corrosion Warranty OptiMax (250 XS) 2 years 3 years OptiMax (225 Sport XS) 2 years 3 years OptiMax (300 XS)
  • Page 27 WARRANTY INFORMATION Outside of South Pacific For product purchased outside of the South Pacific region, contact the distributor in your country, or the Marine Power Service Center closest to you. ASIA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion...
  • Page 28 WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Contact the Marine Verado 400R 2 years 3 years Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 29 WARRANTY INFORMATION SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 years 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years closest to you Verado...

  • Page 30: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard.

  • Page 31: High-Speed And High-Performance Boat Operation

    Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. 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 remote control system.
  • Page 32 GENERAL INFORMATION The lanyard cord is 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 clip on the other end for attaching to the operator's PFD or wrist. 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 33 GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 34: 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 35 GENERAL INFORMATION WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide.

  • Page 36: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION 1. Examples of poor ventilation while the boat is stationary: 21626 Operating the engine when the boat is moored in a confined space Mooring close to another boat that has its engine operating 2. Examples of poor ventilation while the boat is moving: 21628 Operating the boat with the trim angle of the bow too high Operating the boat with no forward hatches open (station wagon effect)
  • Page 37 GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 38: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.

  • Page 39: 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. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 40: Selecting Accessories For Your Outboard

    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. Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard.
  • Page 41 (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.
  • Page 42 GENERAL INFORMATION Never operate a boat while under the influence of alcohol or drugs. It is the law. • Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert.

  • Page 43: Specifications

    GENERAL INFORMATION Specifications Models Horsepower Kilowatts Full throttle RPM 5800–6400 range Idle RPM in neutral gear* Number of cylinders Displacement 2,598 cc (158.5 cid) Cylinder bore 82 mm (3.23 in.) Stroke 82 mm (3.23 in.) Spark plug NGK ILFR6G‑E Spark plug gap 0.8 mm (0.0315 in.) Spark plug hex size 16 mm...
  • Page 44 GENERAL INFORMATION Models 300 Pro 350 Pro Kilowatts Full throttle RPM range 5800–6400 Idle RPM in neutral gear* Number of cylinders Displacement 2,598 cc (158.5 cid) Cylinder bore 82 mm (3.23 in.) Stroke 82 mm (3.23 in.) Spark plug NGK ILFR6G‑E Spark plug gap 0.8 mm (0.0315 in.) Spark plug hex size...

  • Page 45: 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. XXXXXXXXX XXXXX XXXX 57237 Model number Serial number Year manufactured Component Identification Rear cowl Lower cowl chaps Anti‑ventilation plate Gearcase Cooling water intake...

  • Page 46: 350 Hp Component Identification

    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 47 RPM. IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material.
  • Page 48 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 49: Transporting

    TRANSPORTING Trailering Boat/Outboard When transporting the boat on a trailer, the outboard should be positioned and supported in one of the following ways: 1. If the boat trailer provides sufficient ground clearance, the outboard may be tilted down to the vertical operating position with no additional support required.
  • Page 50 TRANSPORTING 3. For maximum ground clearance, the outboard can be tilted to the full tilt position and supported using the outboard tilt support bracket or an accessory transom support device. 28779 Additional clearance may be required for railroad crossings, driveways, and trailer bouncing.

  • Page 51: Fuel Recommendations

    Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: MODELS 350, 350 PRO, 400R USA and Canada ‑...

  • Page 52: 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.

  • Page 53: Epa Pressurized Portable Fuel Tank Requirements

    Vent/water drain holes 46273 Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 54: Filling Fuel Tank

    FUEL AND OIL • When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening. • The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal.

  • Page 55: Engine Oil Recommendations

    IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives is not recommended.
  • Page 56 FUEL AND OIL 1. Before starting (cold engine) tilt outboard out/up past vertical to allow trapped oil to drain back to the oil sump. Allow outboard to remain tilted for approximately one minute. 2. Tilt the outboard to a vertical operating position. 3.
  • Page 57 FUEL AND OIL 6. If the oil level is below the operating range (cross hatched region), remove the oil filler cap and add approximately 500 ml (16 oz) of specified outboard motor oil. Allow a few minutes for the added oil to drain to the oil sump and check the dipstick.

  • Page 58: Features And Controls

    FEATURES AND CONTROLS Panel Mount Control Features and Operation 1. Operation of the 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. Pull the control handle back from neutral to the first detent for reverse gear.
  • Page 59 FEATURES AND CONTROLS 4. 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 60: Slim Binnacle Control Features And Operation

    FEATURES AND CONTROLS 7. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water.
  • Page 61 FEATURES AND CONTROLS 2. Trim Switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM.
  • Page 62 FEATURES AND CONTROLS Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. STOP/ START DOCK TRANSFER THROTTLE - ONLY 52365 Slim binnacle ERC Item Control Function Trim control Raises and lowers the engine for best efficiency, or (handle) for conditions such as shallow water, trailering, etc.
  • Page 63 FEATURES AND CONTROLS Item Control Function Illuminates when the drive is in the neutral gear Neutral light position. The lights flash when the engine is in throttle only mode. HELM TRANSFER Some boats are designed to allow control of the vessel from more than one location.
  • Page 64 FEATURES AND CONTROLS 1. At the helm you are requesting be made active and with the ERC levers in neutral, press the transfer button one time. After the transfer button is pressed, the transfer button light turns on and one beep will sound confirming the impending transfer.
  • Page 65 FEATURES AND CONTROLS 3. Place either ERC lever into gear. The warning horn will beep each time the lever is moved in and out of gear while in throttle only, but will remain in neutral. 4. The RPM of the engines can be increased. NOTE: Pressing the "Throttle‑Only"...

  • Page 66: Dual-Handle Console Control Features And Operation

    FEATURES AND CONTROLS Dual‑Handle Console Control Features and Operation DUAL-HANDLE ELECTRONIC REMOTE CONTROL (ERC)— OPERATION AND ADJUSTMENT Operation The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear.
  • Page 67 FEATURES AND CONTROLS To adjust handle tension: 1. Remove the side cover plugs of the handle that needs adjustment. 2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension. 3. Adjust to the tension desired. Detent tension adjustment screw Handle tension...
  • Page 68 FEATURES AND CONTROLS SPECIAL DIGITAL THROTTLE AND SHIFT (DTS) FEATURES The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously. 55232 Dual engine ERC Item Control Function Trim control Raises and lowers the engines for best efficiency, or (handle)
  • Page 69 FEATURES AND CONTROLS Item Control Function Decreases brightness settings for CAN pad, – VesselView and SmartCraft gauges. Enables the throttle and shift functions of both 1 LEVER engines to be controlled by the port lever. Turns off or on the auto‑synchronization feature. SYNC Refer to Sync.
  • Page 70 FEATURES AND CONTROLS To engage throttle only mode: 1. Place both ERC levers in neutral. 2. Press the THROTTLE ONLY button. The button light will turn on and the neutral lights will blink. 3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in throttle only, but will remain in neutral.
  • Page 71 FEATURES AND CONTROLS 2. Press the 1 LEVER button. The button light turns off. Sync Sync is an automatic engine synchronization feature that is always on unless it is turned off. Sync monitors the position of both ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM.
  • Page 72 FEATURES AND CONTROLS Transfer (Boats equipped with dual helms) The TRANSFER button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer. 51858 TRANSFER button HELM TRANSFER...
  • Page 73 FEATURES AND CONTROLS NOTICE The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects nearby resulting in damage. Keep an adequate look out while performing the helm transfer. To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items or when near other vessels.

  • Page 74: Shadow Mode Control With Can Trackpad Features And Operation

    FEATURES AND CONTROLS Shadow Mode Control with CAN Trackpad Features and Operation TRIPLE ENGINE THROTTLE AND SHIFT OPERATION Movement of the handles on the remote control allows the boat operator to control the engine throttle speed and gear shift positions of all three engines. The throttle and shift function is dependant on what engines are running.
  • Page 75 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 engaging.
  • Page 76 FEATURES AND CONTROLS Port Starboard Starboard Port Outer Control Handle Inner Inner Outer Engine Function Engine Engine Engine Starboard inner and outer engines throttle Running Running and shift = controlled by starboard control handle Port inner engine Off (ignition throttle and shift = key switch Running Running...

  • Page 77: Warning System

    FEATURES AND CONTROLS Turning off the starboard outer engine while underway will cause the starboard inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then into gear.
  • Page 78 2. Engage the throttle. If the engine does not respond, repeat step one. 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, oil pressure, water pressure, battery voltage, fuel...

  • Page 79: Power Trim And Tilt

    FEATURES AND CONTROLS The SmartCraft instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems. 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.
  • Page 80 FEATURES AND CONTROLS • Lower the bow. • Result in quicker planing off, especially with a heavy load or a stern heavy boat. • Generally improve the ride in choppy water. • 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.
  • Page 81 FEATURES AND CONTROLS 3. Disengage the tilt support bracket, by raising the outboard up and rotating the tilt support lever up. Lower the outboard. Tilt support lever Tilt support bracket 28922 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
  • Page 82 FEATURES AND CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. 28927 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 83: Operation

    OPERATION Important Daily Inspection Before Each Use Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

  • Page 84: Operating In Freezing Temperatures

    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 85: Effects Of Elevation And Weather On Performance

    OPERATION If changing conditions cause the RPM to drop below the recommended range, such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a propeller change or cleaning may be required to maintain performance and ensure the outboards durability.

  • Page 86: 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 can become submerged on some boats if the engine is trimmed full in while running at idle speed. This may result in exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim outboard up until exhaust relief hole is out of the water.
  • Page 87 OPERATION PRIMING THE FSM WITH A PURGE TOOL The use of a purge tool for priming the FSM is the preferred method, but is not always practical. The objective is to purge the air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port. During the key "ON,"...

  • Page 88: Starting The Engine

    OPERATION 3. Turn the ignition key "ON." The fuel pumps will run for approximately five seconds. 4. Turn the ignition key to the "START" position and release the key. The ECM controls the activation of the starter. The starter may continue cranking for up to eight seconds.
  • Page 89 OPERATION 2. Check the engine oil level. 27780 3. Open the fuel tank vent on manual venting type tanks. 19748 4. Set the lanyard stop switch to the RUN position. Refer to General Information ‑ Lanyard Stop Switch. NOTE: The engine will not start unless the lanyard is set to the RUN position. 19791...
  • Page 90 OPERATION 5. Shift the outboard to neutral (N) position. 51902 Forward Neutral Reverse NOTE: For initial start of a new engine or for an engine that ran out of fuel, refer to Fuel Supply Module Priming Procedure . 6. Ignition key starting ‑ Turn the ignition key to the START position and release the key.

  • Page 91: Gear Shifting

    OPERATION Gear Shifting DTS PANEL MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R).

  • Page 92: Stopping The Engine

    OPERATION • The outboard has three gear shift positions to provide operation: forward, neutral, and reverse. 51902 Forward Neutral Reverse • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Advance the control lever to further increase speed. Stopping the Engine IMPORTANT: Turning key to the "START"...

  • Page 93: Outboard Care

    Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments set to factory standards.

  • Page 94: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...
  • Page 95 MAINTENANCE • Visually check power steering fittings and hoses for leaks or signs of damage. Check tie bar fasteners (multiple outboard rigs) for proper tightness. • Check propeller blades for damage. AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water.

  • Page 96: Flushing The Cooling System

    MAINTENANCE Tube Ref Description Where Used Part No. Anti-Seize Spark plug threads 92-898101385 Compound • Check wiring and connectors. • Check tightness of bolts, nuts, and other fasteners. • Check cowl seals to make sure seals are intact and not damaged. •...

  • Page 97: Cowl Removal And Installation

    MAINTENANCE 2. Disconnect the flush connector from the fitting on the bottom cowl. 28726 3. Thread a water hose into the flush fitting. 28727 4. Turn on the water tap (1/2 maximum) and let the water flush through the cooling system for about 15 minutes. 5.
  • Page 98 MAINTENANCE 2. Pull top cowl forward and lift off. 3. Pull lower cowl release latch up. 4. Remove rear cowl towards aft of outboard. 28770 COWL INSTALLATION 1. Position lower cowl from aft side of outboard. Make sure it fits properly in the rubber seal.

  • Page 99: Cleaning Care For Top And Bottom Cowls

    Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components.

  • Page 100: Verado Engine Battery Specifications

    IMPORTANT: Verado engines require a 12‑volt absorbed glass mat (AGM) marine starting battery that meets the minimum ratings. For best performance, Mercury Marine does not recommend using the more common flooded (wet cell) or gel cell type lead acid batteries for starting Verado engines.

  • Page 101: Air Filter (200-300)

    MAINTENANCE WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.

  • Page 102: Air Filter (350, 350 Pro)

    MAINTENANCE 2. Remove crankcase ventilation hose. Crankcase ventilation hose Filter assembly Clamp screw 57401 3. Wash air filter assembly in warm soapy water. 4. Dry filter assembly with compressed air. 5. Apply 4 Stroke 10W30 Outboard Oil on a rag or towel and lightly pad air filter element.

  • Page 103: Fuel System

    MAINTENANCE Fuel System WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors.
  • Page 104 MAINTENANCE 1. If equipped, disassemble the rigging tube to access the fuel line with the in‑line fuel filter sleeve. 57275 In-line fuel filter sleeve location 2. Remove the clamp securing the vessel fuel line to the adapter and remove the fuel line from the adapter. 3.
  • Page 105 MAINTENANCE WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors.

  • Page 106: Corrosion Control Anodes

    MAINTENANCE Water‑In‑Fuel Warning—Draining the Filter 1. Close the fuel valve, if equipped. 2. Place a container under the fuel filter. 3. Remove the water‑in‑fuel sensor and allow the filter to drain into the container. The liquid that has drained from the filter must be disposed of according to applicable regulations and law.

  • Page 107: Corrosion Control Anodes (350 Hp)

    MAINTENANCE Corrosion Control Anodes (350 HP) The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion.

  • Page 108: Propeller Replacement - 25.4 Mm (1.0 In.) Diameter Propeller Shaft

    MAINTENANCE IMPORTANT: Always use new mounting screws when installing trim wear pads. 36869 M6 x 20 screw with patch lock pad (8) Trim wear pad (2) Trim manifold Description lb‑in. lb‑ft M6 x 20 screw (8) – Propeller Replacement ‑ 25.4 mm (1.0 in.) Diameter Propeller Shaft 1.
  • Page 109 4. Pull propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Tube Ref Description Where Used Part No.
  • Page 110 MAINTENANCE 5. Secure the locknut by bending the tabs up against the flats on the nut. 51612 Flo-Torq lll fastened with a locknut Forward thrust washer Drive sleeve Propeller Drive sleeve adapter Locknut retainer Locknut Raised pins Tabs bent against the locknut 51613 Flo-Torq lV fastened with a locknut Forward thrust washer...

  • Page 111: Propeller Replacement - 31.75 Mm (1-1/4 In.) Diameter Propeller Shaft

    4. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Tube Ref Description Where Used Part No.

  • Page 112: Spark Plug Inspection And Replacement

    MAINTENANCE 5. Heavy‑duty propeller hub ‑ Install the propeller hub, propeller, washer, Belleville washer, washer, and propeller nut onto the shaft. b c d 44856 Propeller nut Washer Belleville washer Washer Propeller Propeller hub 6. Place a block of wood between the gearcase and the propeller. Tighten the propeller nut to the specified torque.
  • Page 113 MAINTENANCE 4. Use a twisting motion, remove the pencil coils from the spark plugs. 57247 Wiring harness connector Pencil coil Screw 5. Remove the spark plugs. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal is not visible on the spark plug electrode.
  • Page 114 MAINTENANCE 6. Set the spark plug gap. Refer to General Information ‑ Specifications. 27848 a. All of the spark plugs should have the gap checked and corrected as necessary before installation. b. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap.

  • Page 115: Fuses

    MAINTENANCE 11. Connect the wire harness to the pencil coil. 57247 Wiring harness connector Pencil coil Screw 12. Install the rear and top cowls. Fuses IMPORTANT: An ATC fuse has the fuse element enclosed or sealed inside the plastic housing. This type of fuse must be used for marine applications. Marine applications are exposed to environments that may have the potential to accumulate explosive vapors.

  • Page 116: Dts Wiring System

    MAINTENANCE Remove the cover from the fuse holder. Remove the suspected blown fuse and look at the silver band inside the fuse. If band is broken, replace the fuse. Replace the fuse with a new fuse with the same amp rating. 57250 Fuse puller Fuse holder...

  • Page 117: Accessory Drive Belt Inspection

    MAINTENANCE • Verify the harnesses are not routed near sharp edges, hot surfaces, or moving parts. • Verify all unused connectors and receptacles are covered with a weather cap. • Verify the harnesses are fastened along the routing path. Accessory Drive Belt Inspection 1.
  • Page 118 Pedestal 29312 5. The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 119: Checking Power Steering Fluid

    MAINTENANCE Checking Power Steering Fluid Remove power steering cover and fill cap to check fluid level. The fluid level should be slightly below the bottom of the fill hole. Use SAE 0W‑30 synthetic power steering fluid, if needed. 29315 Power steering cover Fill cap Fill/full level Tube Ref...
  • Page 120 3. Remove the dipstick. 4. Install the oil extraction tube to the crankcase oil pump. NOTE: The oil extraction tube can be purchased from a Mercury Marine outboard or MerCruiser service dealership. 5. Insert the oil extraction tube into the oil dipstick hole until the tube is at the bottom of the engine oil sump.
  • Page 121 MAINTENANCE Oil Drain Funnel 91‑892866A01 Diverts draining engine oil from contacting the antisplash and anticavitation plates. 4993 5. Remove drain plug/seal washer and drain the engine oil into a container. 6. Install the drain plug/seal washer. CHANGING OIL FILTER IMPORTANT: To reduce or prevent oil spillage when removing the oil filter, ensure the outboard is upright (not tilted) and the engine is cold or has not run for at least one hour.

  • Page 122: Gearcase Lubrication

    MAINTENANCE OIL FILLING 1. Remove the oil fill cap and add the recommended oil to the midpoint of the operating range (midpoint of crosshatched region on the dipstick). Adding approximately 7 Liter (7.4 US qt) will bring the oil level to midpoint of the crosshatched region on the dipstick.
  • Page 123 Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 970 ml (32.8 fl oz). Gearcase Lubricant Recommendation Mercury or Quicksilver High Performance Gear Lubricant. Checking Lubricant Level and Refilling Gearcase 1. Place outboard in a vertical operating position. 2. Remove vent plug/sealing washer.
  • Page 124 Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 850 ml (28.7 fl oz). Gearcase Lubricant Recommendation Mercury or Quicksilver High Performance Gear Lubricant. Draining Gearcase 1. Place the outboard in a vertical operating position. 2. Remove the propeller. Refer to Propeller Replacement.
  • Page 125 7. Tighten the plugs to the specified torque. Description lb‑in. lb‑ft Plugs 22.6 – 16.6 HEAVY DUTY 137 MM (5.4 IN.) DIAMETER GEARCASE Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 510 ml (17.2 fl oz). Gearcase Lubricant Requirement Mercury or Quicksilver High Performance Gear Lubricant.
  • Page 126 MAINTENANCE Tube Ref Description Where Used Part No. High Performance Gearcase 92-858064K01 Gear Lubricant Draining Gearcase 1. Place the outboard in a vertical operating position. 2. Remove the propeller. Refer to Propeller Replacement. 3. Place a pan below the gear housing to capture the lubricant. 4.
  • Page 127 MAINTENANCE 2. Remove the lubricant level plug. Verify the sealing washer is not adhered to the bearing carrier. The lubricant should be level with the hole or slowly leak from the hole. IMPORTANT: Replace the sealing washers if damaged. 3. If lubricant is not visible at the lubricant level hole, remove the fill/drain plug and add lubricant until it appears at the lubricant level hole.

  • Page 128: Storage

    Stabilizer Protecting External Outboard Components • 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 Description Where Used Part No.

  • Page 129: Protecting Internal Engine Components

    STORAGE Protecting Internal Engine Components IMPORTANT: Refer to Maintenance ‑ Spark Plug Inspection and Replacement for correct procedure for removing spark plugs. • Remove pencil coils and spark plugs. • Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole.

  • Page 130: 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 131: Performance Loss

    TROUBLESHOOTING b. Fuel tank filter obstructed. c. Stuck anti‑siphon valve located on permanently built‑in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel pump failure. • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Overheating ‑ Warning horn not working. •...

  • Page 132: Owner Service Assistance

    STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.
  • Page 133 RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.
  • Page 134 OWNER SERVICE ASSISTANCE CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English +1 920 929 5040...

  • Page 135: Ordering Literature

    Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 136 OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total Total Due...

  • Page 137: Installation

    51965 FASTENING HARDWARE SPECIFICATION (NOT FACTORY SUPPLIED) IMPORTANT: Mercury Marine has designed and tested the engine when it is directly mounted to the transom, jack plate, or setback plate using the mounting hardware included with the engine. Torque requirements have been established using the hardware included with the engine.
  • Page 138 INSTALLATION Must be a hex head bolt with an unthreaded shank length of not less than 1 inch Thread size 0.50‑20 inch UNF ‑ 2A thread Material Austenitic stainless steel grade 304 or 316 90,000 psi ultimate tensile strength/50,000 psi Minimum mechanical yield strength.
  • Page 139 INSTALLATION ACCESSORIES MOUNTED TO THE TRANSOM CLAMP BRACKET Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the same fasteners that secure the outboard to the transom or jack plate.
  • Page 140 INSTALLATION • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners...
  • Page 141 INSTALLATION Unacceptable Accessory Mounting IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition.
  • Page 142 INSTALLATION 3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4. Figure 4 Boat transom or jack plate Transom clamp bracket Wedge/plate 54058 INSTALLING OUTBOARD WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death.
  • Page 143 INSTALLATION The outboard must be secured to the boat transom with the four 12.7 mm (1/2 in.) diameter mounting bolts, locknuts and washers provided. Install two bolts through the upper set of mounting holes and two bolts through the lower set of mounting slots.

  • Page 144: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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