Mercury 200 Pro XS Operation, Maintenance And Installation Manual
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Mercury 200 Pro XS Operation, Maintenance And Installation Manual

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  • Page 1 Operation Maintenance Installation Manual...

  • Page 3: Read This Manual Thoroughly

    Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Name / function: John Pfeifer, President, Mercury Marine...
  • Page 4 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is...
  • Page 5 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...

  • Page 7: Table Of Contents

    Impact with Underwater Hazards..............11 Exhaust Emissions................... 12 Selecting Accessories for Your Outboard............14 Safe Boating Recommendations..............14 Recording Serial Number................. 16 200/200 Pro XS OptiMax Specifications............17 225/250 Pro XS Specifications................. 17 250 OptiMax Specifications................18 Component Identification.................. 20 Transporting Trailering Boat/Outboard .................
  • Page 8 Features and Controls Remote Control Features................. 28 Warning System....................28 Power Trim and Tilt................... 31 Operation Important Information..................35 Engine Break‑in....................36 Engine Break‑in Fuel Mixture................36 Prestarting Check List..................36 Operating in Freezing Temperatures..............37 Operating in Saltwater or Polluted Water............37 Operating at High Elevations................
  • Page 9 Storage Storage Preparation..................67 Fuel System...................... 67 Protecting Internal Engine Components............69 Protecting External Outboard Components............69 Gearcase......................69 Positioning Outboard for Storage..............69 Battery Storage....................70 Troubleshooting Starter Motor Will Not Crank the Engine............71 Engine Will Not Start..................71 Engine Runs Erratically..................
  • Page 10 Outboard Installation Mercury Marine Validated Engine Mounting Hardware........78 Accessories Mounted to the Transom Clamp Bracket........78 Boat Horsepower Capacity................82 Start in Gear Protection..................82 Selecting Accessories for Your Outboard............83 Fuel System...................... 83 Installation Specifications................. 85 Lifting the Outboard..................85 Steering Cable ‑...

  • Page 11: 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 12: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 13: Propeller Selection

    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 14 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 15: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 16 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 17 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 18: 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 19 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 20: 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 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. 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 22: Exhaust Emissions

    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. Exhaust Emissions...
  • Page 23 GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 24: 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. Read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 25 (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 26: Recording Serial Number

    GENERAL INFORMATION Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.

  • Page 27: 200/200 Pro Xs Optimax Specifications

    *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

  • Page 28: 250 Optimax Specifications

    GENERAL INFORMATION Models Idle RPM 575 RPM Full throttle RPM range 5500–6000 RPM Overspeed Rev Limit 6300 RPM Neutral Rev Limit 2250 RPM Engine displacement 3032 cc (185 in³) Cylinder bore 92.075 mm (3.625 in.) Stroke 76.2 mm (3.0 in.) NGK IZFR6J‑11 Recommended spark plugs NGK IZFR6J...
  • Page 29 *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

  • Page 30: Component Identification

    GENERAL INFORMATION Component Identification Top cowl Front cowl latch Auxiliary tilt switch Clamp/swivel bracket Gearcase Cooling water intake Skeg Anti‑ventilation plate Anodes (one per side) 10 - Driveshaft housing 11 - Bottom cowl 12 - Water pump indicator (tell‑tale) 13 - Side cowl latches (both sides) 51577...

  • Page 31: 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.

  • Page 32: Fuel And Oil

    USA is alcohol (ethanol, methanol, or butanol). GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 33: Oil Recommendation

    Outboard 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 34: Avoiding Fuel Flow Restriction

    FUEL AND OIL Avoiding Fuel Flow Restriction IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.

  • Page 35: Mercury Marine's Pressurized Portable Fuel Tank

    FUEL AND OIL 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 36: Filling Remote Oil Tank

    FUEL AND OIL DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. 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.

  • Page 37: 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. Fill the fuel tanks outdoors away from heat, sparks, and open flames.

  • Page 38: 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 Control handle –...
  • Page 39 FEATURES AND CONTROLS 1. Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian system may engage and protect the engine by limiting power. You should return to port immediately and contact your servicing dealer. 2.
  • Page 40 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 consumption, and engine operating hours.

  • Page 41: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt Your 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 42 FEATURES AND CONTROLS WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully.
  • Page 43 FEATURES AND CONTROLS TILTING OPERATION To tilt the outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position. 1.
  • Page 44 FEATURES AND CONTROLS 3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range. AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system.

  • Page 45: Operation

    OPERATION Important Information 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 46: Engine Break-In

    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 47: 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 48: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION EXAMPLE: An engine running at an elevation of 8,000 feet will have over a 30% power loss while a loss of engine power on a hot and humid day could be as much as 14%. These losses apply to normally aspirated and supercharged engines.

  • Page 49: Starting The Engine

    OPERATION Models with a three‑ram trim system: If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range. Models with a single‑ram trim system: The outboard will remain at the selected tilt position, regardless of engine RPM. Starting the Engine NOTICE Without sufficient cooling water, the engine, the water pump, and other...
  • Page 50 OPERATION 2. Open the fuel tank filler cap vent screw (manual venting fuel tanks). 19748 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm.
  • Page 51 No obstruction may indicate a water pump failure or blockage in the cooling system, which can overheat the engine. Have an authorized Mercury Marine dealer check the system.

  • Page 52: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift the outboard into or out of gear unless the engine speed is at idle. Shifting at higher than engine idle speed could cause damage to the gearcase. • Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake speed.

  • Page 53: 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. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package.
  • Page 54 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. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 55: Epa Emissions Regulations

    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 56: Inspection And Maintenance Schedule

    MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Inspection and Maintenance Schedule DAILY CHECKS • Check the engine oil level • Check the lanyard stop switch •...

  • Page 57: Flushing The Cooling System

    MAINTENANCE • Check the remote control cable adjustment, if equipped—dealer item • Replace the high‑pressure fuel filter, if equipped—dealer item • Replace the accessory drive belt, if equipped—dealer item • Check the power trim fluid level, if equipped—dealer item • Inspect the engine motor mounts—dealer item Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each...

  • Page 58: Alternator Belt Inspection

    MAINTENANCE INSTALLATION 1. Position the top cowl over the engine. 2. Ensure the bottom rubber seal fits properly and lock the front and side latches. Alternator Belt Inspection 1. Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found.
  • Page 59 MAINTENANCE WATER SEPARATING FUEL FILTER This filter removes moisture and debris from the fuel. If the filter becomes filled with water, the water can be removed. If the filter becomes plugged with debris, replace the filter. The warning system engages when water in the fuel filter reaches the full level.

  • Page 60: Steering Link Rod Fasteners

    MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm, forcing fuel into the filter. DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on.

  • Page 61: Fuses

    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 in 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 62: Corrosion Control Anode

    MAINTENANCE The electrical wiring circuits on the engine are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload before replacing the fuse. If the cause is not found, the fuse may blow again.

  • Page 63: Battery Inspection

    MAINTENANCE Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode, as this will reduce effectiveness of the anode. The gearcase has three anodes.

  • Page 64: Propeller Replacement

    MAINTENANCE • When connecting the engine battery, use hex nuts to secure the battery leads to the battery posts. Tighten the nuts to the specified torque. Description lb‑in. lb‑ft Hex nuts 13.5 – A decal advising against using deep cycle batteries and wing nuts should be placed on or near the battery box for future service reference.
  • Page 65 MAINTENANCE 1. Shift the outboard to neutral (N) position. 26838 IMPORTANT: Refer to Spark Plug Inspection and Replacement for removing the spark plug leads. 2. Remove the spark plug leads to prevent engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900...
  • Page 66 5. Pull the propeller straight off the shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902...
  • Page 67 MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install forward thrust washer, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c Propeller nut Propeller nut retainer Rear thrust hub Continuity washer Propeller Forward thrust washer 26908...

  • Page 68: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.

  • Page 69: Air Compressor Filter

    MAINTENANCE 3. Set the spark plug gap. Refer to 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 70 MAINTENANCE 2. Remove the hose cable tie and pull the air filter off the hose. 28732 Air filter Nylon washer Rubber washer Clamp Filter housing Cable tie INSTALLATION 1. Place the nylon washer and rubber washer onto the air filter and insert the filter into the housing.

  • Page 71: Lubrication Points

    MAINTENANCE 3. Secure the filter housing with the clamp. 28738 Air filter Filter housing Clamp Inlet hose Lubrication Points 1. Lubricate the following with Extreme Grease. Tube Ref Description Where Used Part No. Extreme Grease Trim rod ball ends 8M0071842 •...
  • Page 72 MAINTENANCE Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
  • Page 73 MAINTENANCE • Tilt support lever ‑ Lubricate through fitting. Swivel bracket Tilt support lever 27873 • Tilt tube ‑ Lubricate through fitting. 27874 WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant.

  • Page 74: Checking Power Trim Fluid

    27877 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricant Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 75: Gearcase Lubrication

    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 the outboard in a vertical operating position. 2. Remove the vent plug/sealing washer.

  • Page 76: Submerged Outboard

    MAINTENANCE 3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole. 22693 Vent hole Fill hole IMPORTANT: Replace the sealing washers if damaged. 4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube.

  • Page 77: Storage Preparation

    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 78 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. 10. Remove the fuel filter. See Maintenance ‑ Fuel System for procedure. 11. Pour this mixture into the fuel filter opening. Install the fuel filter.

  • Page 79: Protecting Internal Engine 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 Description Where Used Part No.

  • Page 80: Battery Storage

    STORAGE NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.

  • Page 81: 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. • Ignition key switch failure.

  • Page 82: Performance Loss

    TROUBLESHOOTING d. Fuel line is kinked or pinched. e. Injector plugged. • 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. •...

  • Page 83: Battery Will Not Hold Charge

    TROUBLESHOOTING • Water is detected in the water‑separating fuel filter. Refer to Maintenance for procedures on removing water from the filter. Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. •...

  • Page 84: 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 85 OWNER SERVICE ASSISTANCE 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 86: 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 87 OWNER SERVICE ASSISTANCE Mercury Marine Submit the following Attn: Publications Department order form with payment W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Copy this form and print or type–This is your shipping label) Name...

  • Page 88: Outboard Installation

    51965 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 89 OUTBOARD INSTALLATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
  • Page 90 OUTBOARD 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 91 OUTBOARD 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 92: Boat Horsepower Capacity

    OUTBOARD 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 Boat Horsepower Capacity WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death.

  • Page 93: Selecting Accessories For Your Outboard

    Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.
  • Page 94 OUTBOARD INSTALLATION FUEL DEMAND VALVE (FDV) REQUIREMENT Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and primer bulb. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

  • Page 95: Installation Specifications

    OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine centerline 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 96: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 3. Connect a hoist to the lifting eye. 4. 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.

  • Page 97: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 3. Tighten the nut to the specified torque. 3727 Description lb‑in. lb‑ft 47.5 – Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 98 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. 2767 Special washer head bolt (P/N 10‑849838) Nylon insert locknut (P/N 11‑826709113) ‑...

  • Page 99: Recommended Mounting Height

    OUTBOARD INSTALLATION Recommended Mounting Height DETERMINING OUTBOARD MOUNTING HEIGHT FOR A STANDARD GEAR HOUSING 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 Standard 20-inch (L) mounting bracket graph...
  • Page 100 OUTBOARD INSTALLATION NOTICE 1. The outboard should be mounted high enough on the transom so that the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions.
  • Page 101 OUTBOARD INSTALLATION DETERMINING OUTBOARD MOUNTING HEIGHT FOR A TORQUE MASTER II GEAR HOUSING The following mounting height information is a general guideline for most applications. Every boat has a unique characteristic that may require the mounting height to be changed from the guidelines explained here. Installing a set‑back bracket or jackplate is the responsibility of the installer to verify the installation is the right combination for the boat.

  • Page 102: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION Maximum boat speed anticipated NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions.

  • Page 103: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description...
  • Page 104 OUTBOARD INSTALLATION Available Outboard Mounting Bolts Part Number Description 8M0032860 ½‑20 x 8.00 in. long (2.75 in. thread) CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking.
  • Page 105 OUTBOARD INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 106 Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area.
  • Page 107 OUTBOARD INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 108: Electrical, Hoses, Control Cables, And Front Clamp

    OUTBOARD INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Electrical, Hoses, Control Cables, and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl.
  • Page 109 OUTBOARD INSTALLATION BATTERY INFORMATION (ALL BATTERIES INCLUDING DTS) 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 110 OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard Red sleeve ‑ positive Black sleeve ‑ negative (–) Cranking battery (-) (-) 15496 Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑...
  • Page 111 OUTBOARD INSTALLATION HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate fuel line/fuel tank pickup for each engine. Fasten the remote fuel hose to the fitting with a hose clamp. Oil Hoses Connect the remote oil hoses to the engine hose connections.
  • Page 112 OUTBOARD INSTALLATION Make the water pressure gauge hose connection to the tubing as shown. 29069 Water pressure tube Speedometer water pickup tube (if required) Coupler Plug Barb hose fitting Speedometer hose or tubing Water pressure tube Remote fuel hose Hose clamp Oil hose with blue stripe Oil hose without blue stripe Cable tie...
  • Page 113 OUTBOARD INSTALLATION a. Move the remote control handle from neutral into forward and advance the handle to the full speed position. Ensure the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the handle back to the neutral detent position. c.
  • Page 114 OUTBOARD INSTALLATION 4. Align the cable end guide against this center mark when installing the cable to the engine. 5. Position the remote control and outboard into neutral position. 6. Slide the anchor pin forward until resistance is felt, then slide the anchor pin toward the rear until resistance is felt.
  • Page 115 OUTBOARD INSTALLATION 3. Secure the shift cable to the anchor pin with the retainer clip. 28749 Cable barrel Shift cable retainer Retainer clip 4. Check the shift cable adjustments as follows: a. Shift the remote control to forward while turning the propeller shaft. If the propeller shaft does not lock in gear, adjust the cable barrel closer to the cable end guide.
  • Page 116 OUTBOARD INSTALLATION Description lb‑in. lb‑ft Throttle cable locknut "b" Tighten, then loosen 1/4 turn 3. Adjust the cable barrel so the installed throttle cable will hold the idle stop screw against the stop. 28751 Barrel sleeve Cable barrel Idle stop screw 4.
  • Page 117 OUTBOARD INSTALLATION 5. Lock the barrel holder in place with the cable latch. 2682 FRONT CLAMP ASSEMBLY INSTALLATION IMPORTANT: There must be sufficient slack in the engine wiring harness, battery cables, fuel hose, and oil hoses, between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.
  • Page 118 OUTBOARD INSTALLATION 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties. 29074 Top half of the front clamp Cable ties 4. Secure the front clamp into the bottom cowl with the retainer and two screws.

  • Page 119: Oil Injection Set-Up

    OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1. Fill the remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten the fill cap. Fill cap 2683 2. Remove the cap and fill the engine oil tank with oil. Install the fill cap. Engine oil tank Fill cap 7745...
  • Page 120 OUTBOARD INSTALLATION PRIMING THE OIL INJECTION PUMP Before starting the 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. 3768 Oil supply hose Oil injection pump IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump.

  • Page 121: Trim In Pin

    OUTBOARD INSTALLATION d. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. 26846 e. Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm. f.
  • Page 122 OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow‑down planing condition called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower. Tilt pin (not included with engine) 2688 Stainless Steel Tilt Pin 17‑49930A 1...

  • Page 123: 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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