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Mercury Verado FOURSTROKE 200 Installation Manual

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200-350 VERADO FOURSTROKE
INSTALLATION MANUAL

Table of Contents

Important Steering Installation Guidelines ............................... 4
Notice to Installer ..................................................................... 4
Bracket .............................................................................. 6
Unacceptable Accessory Mounting ................................... 6
Avoiding Loss of Throttle and Shift Control ............................. 7
Boat Horsepower Capacity ...................................................... 8
Selecting Accessories for Your Outboard ............................... 8
Routing Connections Through the Cowl .................................. 8
Procedure .......................................................................... 8
Fuel Hose Connection ............................................................. 9
Fuel Hose Size .................................................................. 9
Accessory Electric Fuel Pump ................................................. 9
Avoiding Fuel Flow Restriction ................................................ 9
Low Permeation Fuel Hose Requirement ............................ 10
Fuel Demand Valve ............................................................... 11
Fuel Supply Module Priming Procedure ................................ 11
Priming the FSM with a Purge Tool ................................. 11
Installing Outboard ................................................................ 12
Multiple Engine Steering Requirements........................... 12
Multiple Steering Cylinders............................................... 12
Installation Specifications................................................. 14
Maximum Static Waterline................................................ 14
Maximum Outboard Mounting Height............................... 14
Drilling Outboard Mounting Holes..................................... 15
Checking Boat Transom Construction.............................. 17
Lifting the Outboard (200-300)......................................... 17
Page 1 / 44
© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is
prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K-planes,
Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury
Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore,
Skyhook, SmartCraft, Sport-Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're
Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
Battery ................................................................................... 25
Wiring and Installation ........................................................... 32
Wire Harness Diagrams ........................................................ 36
System Wiring Installation Checklist ..................................... 43
© 2016 Mercury Marine
Lifting the Outboard (350)................................................. 18
Fastening the Outboard.................................................... 21
Battery Requirements....................................................... 25
Battery Connections......................................................... 29
Verado Engine Battery Specifications.............................. 30
Wire Color Code Abbreviations........................................ 32
DTS Wiring Guidelines..................................................... 32
Data Harness Pulling Procedure...................................... 33
Switch............................................................................... 33
Wiring Accessories........................................................... 34
.......................................................................................... 36
.......................................................................................... 38
.......................................................................................... 40
.......................................................................................... 42
Data Cable ....................................................................... 43
Junction Box (if equipped) ............................................... 43
Electronic Remote Control ............................................... 43
DTS Command Module Harness ..................................... 43
Battery ............................................................................. 44
Lanyard Stop Switch ........................................................ 44
90-8M0118154
eng APRIL 2016

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  • Page 1: Table Of Contents

    © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K-planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury...

  • Page 2: Notice To Users Of This Manual

    NOTE: Indicates information that helps in the understanding of a particular step or action. This manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual without prior notification.

  • Page 3: Copyright And Trademark Information

    Cleanliness and Care of Product A Mercury Marine power product is a combination of many machined, honed, polished, and lapped surfaces with tolerances measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important.

  • Page 4: Important Steering Installation Guidelines

    Installation of this product will require electronic calibration. This calibration must not be attempted by anyone other than the original equipment manufacturer (OEM) or a Mercury technician trained in digital throttle and shift (DTS) systems at an authorized Mercury dealership. Improper installation and calibration of the DTS product will result in a system that is inoperable or unsafe for use.

  • Page 5: Mercury Marine Validated Engine Mounting Hardware

    Fastening Hardware Specification (Not Factory Supplied) IMPORTANT: Mercury Marine has designed and tested the engine when it is directly mounted to the transom using the mounting hardware included with the engine. Torque requirements have been established using the hardware included with the engine.

  • Page 6: Accessories Mounted To The Transom Clamp Bracket

    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 7: Avoiding Loss Of Throttle And Shift Control

    200–350 VERADO FOURSTROKE Do not mount an accessory to the transom clamp bracket in an unsupported condition. Refer to Figure 2. 54625 Figure 2 Do not attach an accessory to the boat by use of the engine mounting hardware. Refer to Figure 3. Figure 3 Engine supplied mounting fasteners Transom clamp bracket...

  • Page 8: Boat Horsepower Capacity

    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 9: Fuel Hose Connection

    200–350 VERADO FOURSTROKE Fuel Hose Connection IMPORTANT: A boat mounted fuel filter is required for this engine. A decal on the fuel hose is a visual reminder to ensure that a boat mounted fuel filter is installed. Refer to the instruction sheet included with the fuel filter kit. 58159 Fuel Hose Size IMPORTANT: The fuel line inside diameter must be 10 mm (3/8 in.) with a separate fuel line and fuel tank pickup for each...

  • Page 10: Low Permeation Fuel Hose Requirement

    200–350 VERADO FOURSTROKE Fuel Level (Distance from Half Full) Vacuum 40.6 cm (16 in.) 8.5 kPa (2.52 in. Hg) (1.24 psi) 35.6 cm (14 in.) 8.9 kPa (2.63 in. Hg) (1.29 psi) 30.5 cm (12 in.) 9.3 kPa (2.74 in. Hg) (1.35 psi) 25.4 cm (10 in.) 9.7 kPa (2.85 in.

  • Page 11: Fuel Demand Valve

    200–350 VERADO FOURSTROKE Fuel Demand Valve Some boat fuel systems incorporate a fuel demand valve between the fuel tank and the engine and others do not. This engine can be operated with or without a fuel demand valve. The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve.

  • Page 12: Installing Outboard

    Applications with multiple engines of 350 hp or higher require two of the engines to be equipped with a power steering cylinder along with the use of a 50 cc or greater displacement helm. Address concerns to your Mercury product application engineer.

  • Page 13: Determining Recommended Outboard Mounting Height

    200–350 VERADO FOURSTROKE Determining Recommended Outboard Mounting Height 66.0 cm (26 in.) 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.) 29215 Add 12.7 cm (5 in.) for XL models and 25.4 cm (10 in.) for XXL models to listed outboard mounting height.

  • Page 14: Installation Specifications

    200–350 VERADO FOURSTROKE Installation Specifications NOTICE Care must be taken to prevent water from entering the cowl. Mounting height and location will affect how water is deflected between engines (multiple applications) and between the engine and transom under hard acceleration or deceleration forces.

  • Page 15: Drilling Outboard Mounting Holes

    200–350 VERADO FOURSTROKE Model Maximum Mounting Height L models 63.5 cm (25 in.) XL models 76.2 cm (30 in.) XXL models 88.9 cm (35 in.) 28929 Mounting the outboard higher than the specified maximum may cause damage to the gearcase components. Drilling Outboard Mounting Holes IMPORTANT: Before drilling any mounting holes, carefully read Determining Recommended Outboard Mounting Height.
  • Page 16 200–350 VERADO FOURSTROKE Recommended Mounting Installation (300 and 350) The outboard should be secured to the boat transom with the six 12.7 mm (1/2 in.) diameter mounting screws with two nuts on each screw. The two top screws must have one vacant transom mounting bracket hole between the screws. Only one locknut per screw is allowed.

  • Page 17: Checking Boat Transom Construction

    200–350 VERADO FOURSTROKE 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. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.

  • Page 18: Lifting The Outboard (350)

    200–350 VERADO FOURSTROKE NOTE: Avoid interference by placing the lower mounting bolts into the lower mounting slots before placing the outboard against the transom. Flywheel puller/lifting ring Lower mounting bolts 52414 Flywheel Puller/Lifting Ring 91‑895343T02 Lifting the Outboard (350) Remove the top cowl. Loosen the clamp securing the induction assembly to the attenuator.
  • Page 19 200–350 VERADO FOURSTROKE Disconnect the crankcase vent hose at the coupling. Cable tie at the coupling Mounting post 57736 Lift the flywheel cover off the mounting posts (3) and attenuator. Install the attenuator debris cap onto the attenuator to prevent debris entering the air induction system. 58385 Install the flywheel puller/lifting ring onto the flywheel.
  • Page 20 200–350 VERADO FOURSTROKE Install the outboard to the nearest determined height. Flywheel puller/lifting ring Transom mounting bolts 52414 Flywheel Puller/Lifting Ring 91‑895343T02 10. Fasten the outboard with the mounting hardware provided with the engine. Refer to Fastening the Outboard. 11. Remove the attenuator debris cap. 12.

  • Page 21: Fastening The Outboard

    57307 Fastening the Outboard IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability issues that can lead to safety concerns. Follow all of the instructions relating to the outboard installation.
  • Page 22 The outboard must be secured to the boat transom with the four 12.7 mm (0.5 in.) diameter mounting screws, locknuts, and washers provided. If the mounting screws are not appropriate, purchase alternate length screw kits. Mercury Marine screw kit part numbers are provided in Transom Mounting Hardware, following.
  • Page 23 Fastening Hardware Specification (Not Factory Supplied) IMPORTANT: Mercury Marine has designed and tested the engine when it is mounted directly to the transom using the mounting hardware included with the engine. Torque requirements have been established using the hardware included with the engine.
  • Page 24 As a result, for boats that make use of such products, it is particularly important to use proper fasteners, to follow recommended inspection protocol, and to maintain the proper mounting screw clamp load. • Use a Mercury transom screw kit that is appropriate for mounting the metal lift plate (jack plate) or setback bracket to the boat transom. •...

  • Page 25: Battery

    The requirements are to be used for all engine installations. Standards The following Mercury requirements are considered to be supplemental to existing ABYC Standard E‑11 requirements. Refer to the most current standards and recommended practices published by the American Boat and Yacht Council (ABYC).
  • Page 26 ISO sizes. IMPORTANT: SAE wire size is not the same as AWG. The number in parentheses is the American Wire Gauge (AWG) cable recommended by Mercury for the indicated cranking circuit length.

  • Page 27: Battery Switches

    200–350 VERADO FOURSTROKE Tube Ref No. Description Where Used Part No. Corrosion Guard Battery terminals 92-802878 55 IMPORTANT: Locking hex nuts are required on battery posts. If the battery is equipped with wing nuts, remove the wing nuts and install hex nuts. Do not use wing nuts on battery post connections. Tighten the battery terminal nuts to the specified torque.
  • Page 28 Control, Isolation, and Charging Components Diode/semiconductor isolation is the isolation method supported and recommended by Mercury Marine. Other (nonsupported) isolation methods include low‑voltage disconnects (LVDs), voltage sensing relays (VSRs), and automatic closing/charging relays (ACRs). Consult with the device manufacturer for proper use and installation.

  • Page 29: Battery Connections

    Trim pumps must be connected to the switched side of the battery if a battery switch is used. Isolated Battery Architecture The isolated Mercury battery architecture specification is designed for powering the cranking system and specified critical vessel loads only. If any auxiliary vessel components (loads or other power sources) are connected to the engine power source, they must be connected in a way such that they are not allowed to degrade the propulsion power source to less than 11.5 VDC.

  • Page 30: 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 flooded (wet cell), gel cell type lead acid batteries, or lithium ion batteries for starting Verado engines.

  • Page 31: Connecting Battery Cables And Dts Power Harness

    NOTE: Do not extend the lead length of the DTS power harness. Install the DTS power harness directly to the starting battery. NOTE: The DTS power harness is provided with the 20 in. L models. For XL and XXL models, refer to the Mercury for the required DTS power harness kit.

  • Page 32: Wiring And Installation

    NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than 12.2 m (40 ft), contact Mercury Marine for more information. DTS Wiring Guidelines WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring.

  • Page 33: Data Harness Pulling Procedure

    Secure the data harness with mounting clips or cable ties within 25 cm (10 in.) of the connections at either end. Wiring Instructions for Non‑Mercury Marine Ignition Key Switch CAUTION Ignition switches not sold by Mercury Marine can exceed acceptable current flow and voltage drop specifications, causing the engine to start unexpectedly. Only install switches sold through Mercury Marine. 90-8M0118154...

  • Page 34: Wiring Accessories

    If a boatbuilder or dealer chooses to disregard this recommendation, any non‑Mercury Marine components connected to a SmartCraft or DTS system must adhere to all specifications provided. Documentation exhibiting compliance with these specifications must be submitted and approved by Mercury Marine before releasing the finished product for sale.
  • Page 35 200–350 VERADO FOURSTROKE Remove the cowling and open the cover on the electrical box. Route the battery cables and other connections through the front cowl opening. Fasten the negative battery cable to the ground on the side of the engine and positive battery cable to the stud in the electrical box.

  • Page 36: Wire Harness Diagrams

    200–350 VERADO FOURSTROKE Wire Harness Diagrams Single‑Engine Electrical Connections (50‑Amp MAXI Fuse) Page 36 / 44 90-8M0118154...
  • Page 37 200–350 VERADO FOURSTROKE Engine Alternator wire Positive battery cable Power steering signal harness Negative battery cable DTS power harness Fused harness Battery isolator Battery switch 10 - Alternate connection option 11 - Auxiliary battery 12 - Starting battery 13 - 50‑amp MAXI fuse 14 - Power steering pump...

  • Page 38: Dual-Engine Electrical Connections (50-Amp Maxi Fuse)

    200–350 VERADO FOURSTROKE Dual‑Engine Electrical Connections (50‑Amp MAXI Fuse) Page 38 / 44 90-8M0118154...
  • Page 39 200–350 VERADO FOURSTROKE Port engine Starboard engine Alternator wire Positive battery cable Power steering signal harness Battery isolator Dual‑engine power steering signal harness adapter Negative battery cable DTS power harness 10 - Fused harness 11 - Battery switch 12 - Alternate connection option 13 - Port engine starting battery...

  • Page 40: Triple-Engine Electrical Connections (50-Amp Maxi Fuse)

    200–350 VERADO FOURSTROKE Triple‑Engine Electrical Connections (50‑Amp MAXI Fuse) Page 40 / 44 90-8M0118154...
  • Page 41 200–350 VERADO FOURSTROKE Port engine Center engine Starboard engine Alternator wire Positive battery cable Power steering signal harness Triple‑engine power steering signal harness adapter Battery isolator Negative battery cable 10 - DTS power harness 11 - Fused harness 12 - Battery switch 13 - Alternate connection option...

  • Page 42: Quad-Engine Electrical Connections (50-Amp Maxi Fuse)

    200–350 VERADO FOURSTROKE Quad‑Engine Electrical Connections (50‑Amp MAXI Fuse) Page 42 / 44 90-8M0118154...

  • Page 43: System Wiring Installation Checklist

    Verify that all unused receptacles are covered with a weather cap. Non‑Mercury Marine Supplied Ignition Key Switch If a non‑Mercury Marine ignition key is used, verify that it passes the ingress protection testing per IEC IP66 specification minimum. Ignition switches must pass this specification.

  • Page 44: Battery

    200–350 VERADO FOURSTROKE Verify that while moving the remote control handle (full forward and full reverse) the harness has unobstructed movement (moves freely). Verify that the lanyard stop switch is wired into the system correctly. Verify that the harness is fastened along the routing path. Verify that all unused connectors have weather caps to prevent corrosion.

This manual is also suitable for:

Verado fourstroke 350Verado 350Verado 350 proVerado 400r

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