Mercury 200 OptiMax Manual
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Mercury 200 OptiMax Manual

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

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  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
  • Page 2 Name of Notified Body for exhaust emission assessment and noise emission assessment: Det Norske Veritas AS Veritasveien 1 1322 Hovik Norway Notified Body Number: 0575 Brands: Combustion cycle: 2 Engine type: Fuel type: Mercury, Outboard Gasoline stroke, direct injection Mariner Module H Starting Engine Manufacture Noise and Horsepower...
  • Page 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006. European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer of Warranty..............1 Warranty Registration United States And Canada......1 Warranty Registration Outside the United States and Canada. . .2 Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle‑East and Africa....................3 3 Year Limited Warranty Against Corrosion........6 Warranty Coverage and Exclusions..........
  • Page 6 TABLE OF CONTENTS Fuel and Oil Fuel Recommendations.............33 Oil Recommendation..............34 Fuel Additives................35 Fuel Requirements..............35 Avoiding Fuel Flow Restriction..........35 Filling Remote Oil Tank.............35 Filling Engine Mounted Oil Reservoir Tank.......36 Filling Fuel Tank................36 Features and Controls Remote Control Features............37 Warning System................38 Power Trim and Tilt..............41 Operation Pre‑Starting Check List..............45 Operating in Freezing Temperatures.........45...
  • Page 7 TABLE OF CONTENTS Maintenance Outboard Care................52 EPA Emissions................52 Inspection And Maintenance Schedule........53 Flushing The Cooling System............54 Top Cowl Removal And Installation...........55 Cleaning Care for Top Cowl............55 Alternator Belt Inspection............56 Fuel System................56 Steering Link Rod Fasteners.............59 Fuse Replacement ‑ 200 and 225 hp Models......60 Fuse Replacement ‑...
  • Page 8 Battery Will Not Hold Charge.............83 Owner Service Assistance Local Repair Service..............84 Service Away from Home............84 Parts and Accessories Inquiries..........84 Service Assistance..............84 Mercury Marine Service Offices..........85 Outboard Installation Important Information..............87 Avoiding Fuel Flow Restriction..........87 Boat Horsepower Capacity............88 Start in Gear Protection.............88 Selecting Accessories for Your Outboard........88...

  • Page 9: Warranty Information

    1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 10: Warranty Registration Outside The United States And Canada

    2. To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail.

  • Page 11: Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation Of Independent States, Middle-East And Africa

    Outside the United States, Canada, Europe, Confederation of Independent States, Middle‑East and Africa ‑ check with your local distributor. WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below.
  • Page 12 WARRANTY 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 pre–delivery inspection process is completed and documented.
  • Page 13 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.

  • Page 14: Year Limited Warranty Against Corrosion

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by 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.
  • Page 15 WARRANTY 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 pre‑delivery inspection process is completed and documented.
  • Page 16 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 17 Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty.

  • Page 18: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
  • Page 19 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants or fluids changed as a matter of normal...
  • Page 20 WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product.

  • Page 21: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 22: Boat Horsepower Capacity

    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 23: 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...
  • Page 24 GENERAL INFORMATION 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. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub.

  • Page 25: Remote Steering Notice

    RPM range when under normal full throttle operation. PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats.

  • Page 26: Lanyard Stop Switch

    GENERAL INFORMATION 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.
  • Page 27 GENERAL INFORMATION The lanyard is a cord usually 122 ‑ 152 cm (4 ‑ 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
  • Page 28 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. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

  • Page 29: 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 30: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 31: Wave And Wake Jumping

    GENERAL INFORMATION Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 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 re‑enters the water.

  • Page 32: Impact With Underwater Hazards

    GENERAL INFORMATION There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward.

  • Page 33: 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 34 GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 35: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of non‑approved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
  • Page 36 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) The Red Cross and 4) your state boating law enforcement agency.

  • Page 37: Recording Serial Number

    GENERAL INFORMATION Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is...
  • Page 38 GENERAL INFORMATION Models Piston stroke 76.2 mm (3.000 in.) Recommended spark NGK IZFR6J or NGK IZFR5G plug NGK PZFR6H Spark plug gap 0.8 mm (0.031 in.) Standard gearcase 1.75:1 ratio High altitude gearcase 1.87:1 ratio Recommended Refer to Fuel and Oil gasoline Recommended oil Refer to Fuel and Oil...

  • Page 39: Component Identification

    GENERAL INFORMATION Component Identification 29423 Top cowl Anode plate Bottom cowl Auxiliary tilt switch Water pump indicator Transom brackets hole Gearcase Driveshaft housing Cooling water intake Anti‑ventilation plate holes...

  • Page 40: Transporting

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

  • Page 41: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R +M)/2 minimum.

  • Page 42: Oil Recommendation

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

  • Page 43: Fuel Additives

    FUEL AND 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 44: Filling Engine Mounted Oil Reservoir Tank

    FUEL AND OIL Filling Engine Mounted Oil Reservoir Tank NOTE: Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated. 1. Remove the top cowl. 2. Loosen the fill cap on the engine oil reservoir tank. Run the engine until all the air has been vented out of the oil reservoir tank and tank is filled with oil to the point of overflow.

  • Page 45: 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 46: Warning System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch. 27755 Horn inside remote Horn connected to control ignition key switch WARNING HORN SIGNALS...
  • Page 47 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling System Continuous Engine Guardian System is activated. Problem Power limit will vary with level of overheat. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
  • Page 48 Moving the throttle lever back to the idle position will reset the system. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption, and engine operating hours.

  • Page 49: 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 50 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 51 FEATURES AND CONTROLS • Increase clearance over submerged objects or a shallow bottom. • Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). • In excess, can cause boat porpoising (bouncing) or propeller ventilation.
  • Page 52 FEATURES AND CONTROLS 1. Turn manual tilt release valve turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 22362 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 53: Operation

    OPERATION Pre‑Starting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 54: Operating In Saltwater Or Polluted Water

    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 55: Engine Break-In Procedure

    OPERATION Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. GASOLINE/OIL BREAK-IN MIXTURE NOTE: Do not use pre‑mixed gas and oil during break‑in. Use straight gasoline during engine break‑in and after engine break‑in.

  • Page 56: Starting The Engine

    OPERATION Starting the Engine Before starting, read the pre‑starting check list, special operating instructions, and engine break‑in procedure in the Operation section. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
  • Page 57 OPERATION 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to the neutral ("N") position. 26838 6. For the initial start of a new engine, or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: a.

  • Page 58: Gear Shifting

    OPERATION 8. Turn the ignition key to "START" position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to "OFF" position, wait one second and try again. 19804 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting.

  • Page 59: Stopping The Engine

    OPERATION • After shifting outboard into gear, advance the lever further to increase speed. 27237 Stopping The Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843...

  • Page 60: Maintenance

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA Emissions EMISSION CERTIFICATION LABEL...

  • Page 61: Inspection And Maintenance Schedule

    MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.

  • Page 62: Flushing The Cooling System

    MAINTENANCE • Inspect the alternator belt. See Alternator Belt Inspection. • Check the corrosion control anodes. Check more frequently when used in saltwater. See Corrosion Control Anodes. • Drain and replace the gearcase lubricant. See Gearcase Lubrication. • Check the power trim fluid. See Checking Power Trim Fluid. •...

  • Page 63: Top Cowl Removal And Installation

    MAINTENANCE NOTE: Engine can be stopped or running at idle speed when flushing the cooling system. Do not flush engine using a water system that exceeds 310.26 kPa (45 psi). 1. Remove the plug from fitting in the bottom cowl. 29444 2.

  • Page 64: Alternator Belt Inspection

    MAINTENANCE CLEANING AND WAXING PROCEDURE 1. Before washing, rinse the top cowl with clean water to remove dirt and dust that may scratch the surface. 2. Wash the top cowl with clean water and a mild non‑abrasive soap. Use a soft clean cloth when washing. 3.
  • Page 65 MAINTENANCE Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle.
  • Page 66 MAINTENANCE Installation 1. Lubricate the O‑ring seals with oil. 29599 Filter Link rod O‑ring seals 2. Install the fuel filter and tighten securely. 3. Reconnect the link rod. 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 67: Steering Link Rod Fasteners

    MAINTENANCE 3. Retighten the drain screw and reattach hose. 24607 Drain hose Drain screw Side fitting IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a"...

  • Page 68: Fuse Replacement - 200 And 225 Hp Models

    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.

  • Page 69: Fuse Replacement - 250 Hp Model

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

  • Page 70: Corrosion Control Anode

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

  • Page 71: Battery Inspection

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

  • Page 72: Battery Information

    MAINTENANCE Battery Information 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 73: Propeller Replacement

    MAINTENANCE Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
  • Page 74 5. Pull propeller straight off 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 Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref No.
  • Page 75 MAINTENANCE 7. Flo‑Torq I Drive Hub Propellers ‑ Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c 26908 Propeller nut Continuity washer Propeller nut retainer Propeller Rear thrust hub Forward thrust washer 8.

  • Page 76: Spark Plug Inspection And Replacement

    MAINTENANCE 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion.

  • Page 77: Compressor Air Intake Filter For 200 And 225 Hp Models

    MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.80 mm (0.030 in.) 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten 1/4 turn or torque to specifications.
  • Page 78 MAINTENANCE 2. Remove the hose cable tie and pull the air filter off the hose. 28732 Air filter Clamp Nylon washer Filter housing Rubber washer Cable tie INSTALLATION 1. Place the nylon washer and rubber washer onto the air filter and insert the filter into the housing.

  • Page 79: Lubrication Points

    3. Secure the filter housing with the clamp. 28738 Air filter Clamp Filter housing Inlet hose Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Ref No. Description Where Used Part No. 92-802865Q0 Special Lubricant 101 Trim rod ball ends •...
  • Page 80 Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 26902 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 81 MAINTENANCE • Alternator Belt Tensioner Pivot Shaft ‑ Lubricate through fitting. 2884 • Swivel Bracket ‑ Lubricate through fitting. • Tilt Support Lever ‑ Lubricate through fitting. 27873 Swivel bracket Tilt support lever • Tilt Tube ‑ Lubricate through fitting. 27874 WARNING Incorrect cable lubrication can cause hydraulic lock, leading to...

  • Page 82: Checking Power Trim Fluid

    MAINTENANCE • Steering Cable ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 27875 Fitting Cable end 4. Lubricate the following with Light Weight Oil. • Steering Link Rod Pivot Points ‑ Lubricate pivot points. 27876 Checking Power Trim Fluid 1.

  • Page 83: Gearcase Lubrication

    2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 84 970 (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. 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.

  • Page 85: Submerged Outboard

    MAINTENANCE 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 86: Storage

    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 87 7. Loosen the drain screw and drain the float chamber. 23752 Left side fitting Drain hose Drain screw 8. Retighten the drain screw and reattach the hose. 9. Premix the following in a container: a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant.

  • Page 88: Protecting Internal Engine Components

    STORAGE 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. Reinstall the fuel filter. 12. Prime the fuel system. See Operation - Starting The Engine.

  • Page 89: Protecting External Outboard Components

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

  • Page 90: Troubleshooting

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

  • Page 91: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c.

  • Page 92: Owner Service Assistance

    Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

  • Page 93: Mercury Marine Service Offices

    Model and serial number of your outboard • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone (920) 929‑5040...
  • Page 94 OWNER SERVICE ASSISTANCE Japan Telephone 81‑053‑423‑2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81‑053‑423‑2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 5467789 Singapore, 508762...

  • Page 95: Outboard Installation

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

  • Page 96: Boat Horsepower Capacity

    The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting in gear. Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.

  • Page 97: Fuel Tanks

    OUTBOARD INSTALLATION 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. Fuel Tanks...

  • Page 98: 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 99: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. 28495 Lifting eye 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...

  • Page 100: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 2. Insert steering cable into tilt tube. 3725 3. Torque nut to specification. 3727 Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 101 OUTBOARD INSTALLATION 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.
  • Page 102 OUTBOARD INSTALLATION 3. Torque the head bolt, then the locknut to specifications. Description lb. in. lb. ft. Tighten locknut until it seats, then Cable Coupler Nylon Locknut "d" loosen ¼ turn. Head Bolt Nylon Locknut "b" Special washer head bolt...

  • Page 103: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 24305 The solid line is recommended to determine the outboard mounting height.

  • Page 104: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION 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 105 OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. 2757 Drill guide holes Transom centerline Transom drilling fixture Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 106: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 10‑67755‑1 Transom bolt 1/2‑20 x 4.50 in. long (2.25 in. thread) 11‑826711‑17 Nylon insert locknut 1/2‑20 12‑28421 Washer ‑...
  • Page 107 OUTBOARD INSTALLATION When first determining transom strength, use a dial torque wrench. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate.
  • Page 108 OUTBOARD INSTALLATION NOTE: For more accurate torque, whenever possible turn/tighten the mounting locknuts rather than turning the mounting bolts. 3729 Flat washer (4) Locknut (4) 1/2 in. diameter bolt Flat washer (4) Shank of bolt Description lb. in. lb. ft. Outboard mounting locknuts and bolts...

  • Page 109: Electrical, Hoses, Control Cables And Front Clamp

    OUTBOARD INSTALLATION 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. Connect remote harness to the 14 pin connector on the engine harness. 28742 14 pin connector BATTERY INFORMATION...
  • Page 110 OUTBOARD INSTALLATION Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. NOTICE - DTS & OptiMax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and OptiMax engines must use a marine starting...
  • Page 111 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Ground cable Black sleeve ‑ Negative Cranking battery (–) 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.
  • Page 112 OUTBOARD INSTALLATION This outboard has a speedometer water pick‑up located in the leading edge of the gearcase. If you want to use this water pickup for the speedometer, disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl. Install the coupler provided with the outboard on the end of the tubing.
  • Page 113 OUTBOARD INSTALLATION Locating the Center Point of the Shift Cable IMPORTANT: Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustment of the shift cable. 1. Mark the forward position as follows: a.
  • Page 114 OUTBOARD INSTALLATION 3. Mark the center on the shift cable midway between the forward and reverse marks. 4361 Center mark 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.
  • Page 115 OUTBOARD INSTALLATION 2. Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder. 3. Secure the shift cable to the anchor pin with the retainer clip. 28749 Cable barrel Retainer clip...
  • Page 116 OUTBOARD INSTALLATION 2. Attach the throttle cable to the throttle lever. Secure with a washer and locknut. Tighten the locknut to the specified value. or107 Nylon washer Locknut Description lb. in. lb. ft. Throttle cable locknut "b" Tighten then loosen 1/4 turn. 3.
  • Page 117 OUTBOARD INSTALLATION c. Place a thin piece of paper between the idle adjustment screw and the idle stop. The adjustment is correct when the paper can be removed without tearing, but has some drag on it. IMPORTANT: The idle stop screw must be touching the stop. or109 Idle stop screw Idle stop...
  • Page 118 OUTBOARD INSTALLATION 2. Place the neoprene wrap around the wiring, hoses, and control cables, and place into the lower half of the front clamp. 29073 Neoprene wrap Lower half of the front clamp 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties.

  • Page 119: Filling The Fuel System

    OUTBOARD INSTALLATION 5. Reinstall the cowl seal. 29075 Retainer Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: 1.

  • Page 120: Oil Injection Set-Up

    OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten fill cap. 2683 Fill cap 2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
  • Page 121 OUTBOARD INSTALLATION PRIMING 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 122 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 123: Trim In Pin

    OUTBOARD INSTALLATION Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 124 OUTBOARD INSTALLATION The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired. A non‑stainless steel shipping bolt should not be used in this application other than on a temporary basis.

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