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Mercury 200 Optimax DTS Owner's 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 nearest dealer can be found on 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

This outboard motor's serial number plate contains in the lower corner left hand corner either the CE mark
alone or the CE mark accompanied by a notified body number. This outboard motor manufactured by Mercury
Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park Industriel, de Petit‑Rechain, Belgium
complies with the requirements of the following directives by meeting the associated standards, as amended:
If the CE mark is accompanied by a notified body number, the following Recreational Craft Directive applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
General steering system
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
The notified body responsible for surveillance of the quality system under Full Quality
Assurance Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
If the CE mark is not accompanied by a notified body number, the following Recreational Craft Directive
language applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
2003/44/EC amending 94/25/EC
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
i
94/25/EC

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  • Page 1: Welcome Aboard

    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 EN 61000‑6‑2; EN 61000‑4‑2; EN Electrostatic discharge testing 61000‑4‑3 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 European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 3: 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................1 Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle-East and Africa............................2 3 Year Limited Warranty Against Corrosion......................
  • Page 4 TABLE OF CONTENTS Features and Controls Warning System..............................23 Remote Control Features............................. 25 Power Trim and Tilt.............................. 31 Operation Pre-Starting Check List............................35 Operating In Freezing Temperatures........................35 Operating In Salt Water Or Polluted Water......................35 Operating at High Elevations..........................35 Setting Trim Angle While Running Engine at Idle Speed..................
  • Page 5 Engine Starts But Will Not Shift Into Gear......................74 Engine Runs Erratically............................74 Performance Loss..............................75 Battery Will Not Hold Charge..........................75 Owner Service Assistance Local Repair Service............................76 Service Away From Home............................ 76 Parts And Accessories Inquiries........................... 76 Service Assistance............................... 76 Mercury Marine Service Offices........................... 76...

  • Page 7: Warranty Information

    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. Your dealer can also process this change of information.

  • Page 8: Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation Of Independent States, Middle-East And Africa

    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. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Year Limited Warranty Against Corrosion WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M 2 Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
  • Page 10 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. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 11: Warranty Coverage And Exclusions

    Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 12: 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.

  • Page 13: High-Speed And High-Performance Boat Operation

    Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start in gear protection is provided by the control system. This prevents the engine from starting when the shift is actuated in any position other than neutral.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob01514 Self‑locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.

  • Page 15: Protecting People In The Water

    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 16: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. 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.

  • Page 17: Impact With Underwater Hazards

    GENERAL INFORMATION ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

  • Page 18: Exhaust Emissions

    GENERAL INFORMATION • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat. • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. •...

  • Page 19: 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. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.

  • Page 20: Recording Serial Number

    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 21 GENERAL INFORMATION Models Kilowatts Full Throttle RPM Range 5000‑5750 Idle Speed in Forward Gear 575 ± 25 RPM Number of Cylinders Piston Displacement 3048 cc (186 cu. in.) Cylinder Bore 92.1 mm (3.626 in.) Piston Stroke 76.2 mm (3.000 in.) Recommended Spark Plug NGK IZFR5G Spark Plug Gap...

  • Page 22: Component Identification

    GENERAL INFORMATION Component Identification ob01582 Top cowl Anode plate Bottom cowl Auxiliary tilt switch Water pump indicator hole Transom brackets Driveshaft housing Gearcase Anti‑ventilation plate Cooling water intake holes...

  • Page 23: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.
  • Page 24 INSTALLATION ob00323 If changing conditions cause the RPM to drop below the recommended range, such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a propeller change or cleaning may be required to maintain performance and ensure the outboards durability. Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.

  • Page 25: 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 26: 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 27: Fuel Requirements

    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 28 FUEL AND OIL 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. Re‑tighten the fill cap.

  • Page 29: Features And Controls

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn is located under the dash within the wiring harness. WARNING HORN SIGNALS When the key switch is turned to the "ON" position, the horn will turn on for a moment as a test to show the horn is working.
  • Page 30 FEATURES AND CONTROLS Warning Horn Function Sound Description Oil level is critically low Continuous Engine Guardian System is activated. Power will be limited. The oil level is critically low in the engine mounted oil reservoir. Refill the engine mounted oil reservoir along with the remote oil tank.

  • Page 31: Remote Control Features

    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 32 FEATURES AND CONTROLS CONSOLE MOUNT FEATURES - SINGLE ENGINE 3410 Control handle ‑ Forward (F), Neutral (N), Arrow trackpad ‑ Used to scroll through Reverse (R). System View displays, if equipped. Refer to System View Operation Manual for screen Trim/tilt switch ‑ Refer to Power Trim and options.
  • Page 33 FEATURES AND CONTROLS CONSOLE MOUNT FEATURES - DUAL ENGINE SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch ‑ Refer to Power Trim and Arrow trackpad ‑ Used to scroll through Tilt. System View displays, if equipped. Refer to System View Operation Manual for screen Control handles ‑...
  • Page 34 FEATURES AND CONTROLS SLIM BINNACLE CONSOLE MOUNT FEATURES - SINGLE ENGINE START STOP 14637 Control handle ‑ Forward (F), Neutral (N), Start/stop button ‑ Allows the boat operator to Reverse (R). start or stop the engine without using the ignition key. Trim/tilt switch ‑...
  • Page 35 FEATURES AND CONTROLS SHADOW MODE REMOTE CONTROL FEATURES NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT 14642 Trim/tilt switch ‑ Refer to Power Trim and Arrow trackpad ‑ Used to scroll through Tilt. System View displays, if equipped. Refer to System View Operation Manual for screen Control handle ‑...
  • Page 36 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Port engine throttle and shift = controlled by port control handle Starboard engine throttle and shift = controlled by starboard control handle Running Running Running Center engine throttle = average of port and starboard engines Center engine shift =...

  • Page 37: Power Trim And Tilt

    FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Center engine throttle and shift = neutral/idle Off (ignition key Off (ignition key switch Running unless both control switch turned on) turned on) handles are in the same gear Turning off one of the outer engines while underway will cause the center engine to go into forced neutral/idle.
  • Page 38 FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface.
  • Page 39 FEATURES AND CONTROLS Disengage the tilt support lever, by raising the outboard off the support lever and rotating the tilt support lever down. Lower the outboard. ob00664 Tilt support lever Knob MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.
  • Page 40 FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. Reduce engine speed below 2000 RPM. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only.

  • Page 41: Operation

    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 42: Engine Break-In Procedure

    OPERATION or35-1 Relief hole submerged (wrong) Relief hole above water line (correct) Engine Break‑in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break‑in Procedure. 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 43 OPERATION Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged. ob00668 Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. ob00348 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 NOTE: The engine will not start unless the lanyard is set to the "RUN"...
  • Page 44 OPERATION NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote control handle. For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should be filled as follows: a.
  • Page 45 OPERATION 3416 Move the control handle into neutral position. Depress shift lock button, press and hold the throttle only button while moving the control handle ahead to the forward detent. The horn sound indicates that throttle only is engaged. Hold in the button until the horn sounds twice. The horn sound indicates that throttle only is engaged. Advance the control handle to increase engine RPM.
  • Page 46 OPERATION ob00349 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position. 3417 For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should be filled as follows:...
  • Page 47 OPERATION ACTIVE THROTTLE ONLY STATION SELECT 3418 Check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for obstruction.
  • Page 48 OPERATION CONSOLE MOUNT - DUAL ENGINE/DUAL HELM STARTING PROCEDURE Before starting, read the Pre‑Starting Check List, Special Operating Instructions, and Engine Break‑in Procedure in the Operation Section. CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine.
  • Page 49 OPERATION 3417 For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should be filled as follows: a. Squeeze the fuel line primer bulb until it feels firm. b.
  • Page 50 OPERATION ob00331 Warming Up Engine Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engines into gear. SYNC ACTIVE THROTTLE ONLY STATION SELECT 3425 Move the control handles into neutral position. Press and hold the throttle only button while moving the control handles ahead to the forward detent.
  • Page 51 OPERATION Open fuel tank vent on manual venting type tanks. ob00348 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.
  • Page 52 OPERATION NEUTRAL START STOP 11774 The "ACTIVE" light located on the remote control panel will become illuminated once the engine is started and communicating with the remote control. NEUTRAL START STOP 11776 After engine starts, check for a steady stream of water flowing out of the water pump indicator hole. ob00331 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check the cooling water intake for obstruction.
  • Page 53 OPERATION NEUTRAL START STOP 12204 Move the control handle into neutral position. Depress shift lock button, press and hold the throttle only/station select button while moving the control handle ahead to the forward detent. Hold in the button until the horn sounds twice and the neutral light starts flashing. The flashing light indicates that the throttle only is engaged.
  • Page 54 OPERATION ob00349 NOTE: The engines will not start unless the lanyard is set to the "RUN" position. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboards to neutral (N) position. 3417 For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should be filled as follows:...
  • Page 55 OPERATION NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT 14657 After engine starts, check for a steady stream of water flowing out of the water pump indicator hole. ob00331 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check the cooling water intake for obstruction.

  • Page 56: Gear Shifting

    OPERATION The warm up mode can be re‑activated by turning off and re‑starting the engines. Gear Shifting DTS PANEL MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running.

  • Page 57: Dual Helm Station Transfer

    OPERATION 3417 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Advance the control lever to further increase speed. Dual Helm Station Transfer The throttle only/station select button allows the boat operator to select which remote control is in control of the engine operation.

  • Page 58: Synchronizing Dual Engines

    OPERATION The active light will switch off at the original remote control station. SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER Pressing the station select button and holding it in allows the boat operator ten seconds to match up the control handle settings at the new station with the handle settings that are at the old (to be inactive) station.

  • Page 59: Remote Control Adjustments

    OPERATION Remote Control Adjustments 5176 ob01170 Detent tension adjustment Control handle friction adjustment screw Remove cover to gain access to screws. Detent tension adjustment ‑ The detent screw can be adjusted to increase or decrease the effort needed to move the control handle into or out of detent position. Control handle friction adjustment ‑...

  • Page 60: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 61: Inspection And Maintenance Schedule

    MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •...

  • Page 62: 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). Remove the plug from fitting in the bottom cowl. ob01584 Attach a water hose to the fitting.

  • Page 63: Alternator Belt Inspection

    MAINTENANCE Alternator Belt Inspection Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found. a. Cracks or deterioration in the rubber portion of the belt. b. Belt surfaces rough or uneven. c.
  • Page 64 MAINTENANCE 3388 Filter O‑ring seals Install the fuel filter and tighten securely. 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 65: Steering Link Rod Fasteners

    MAINTENANCE 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 66: Dts Wiring System

    MAINTENANCE 3328 Good fuse Fuel injector/direct injector/starter slave solenoid/PCM and electric fuel pumps circuit ‑ Blown fuse 20 AMP fuse Depth finder and accessories circuit ‑ 2 Ignition system circuit ‑ 20 AMP fuse AMP fuse DTS power harness circuit (fuse holder located near starting battery) ‑...

  • Page 67: 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.

  • Page 68: Propeller Replacement

    MAINTENANCE IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements. 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.
  • Page 69 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon.
  • Page 70 MAINTENANCE ob00382 Propeller nut Continuity washer Propeller nut retainer Propeller Rear thrust hub Forward thrust hub Flo‑Torq II Drive Hub Propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft. ob00421 Propeller nut Propeller...

  • Page 71: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc.

  • Page 72: Lubrication Points

    Special Lubricant 101 Trim rod ball ends 92-802865Q1 • Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets. ob01093 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon.
  • Page 73 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. ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No.
  • Page 74 MAINTENANCE • Tilt Support Lever ‑ Lubricate through fitting. ob00683 Swivel bracket Tilt support lever • Tilt Tube ‑ Lubricate through fitting. ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked.

  • Page 75: Checking Power Trim Fluid

    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 76: Submerged Outboard

    Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 798 ml (27 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug.

  • Page 77: Storage

    The most effective method of storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on the containers to the fuel tank before the last operation of the boat. 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: Protecting Internal Engine Components

    Retighten drain screw and reattach hose. Premix the following in a container: a. 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.

  • Page 79: 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 80: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 5 Amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. •...

  • Page 81: Performance Loss

    TROUBLESHOOTING • 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. • Boat overloaded or load improperly distributed. •...

  • Page 82: Owner Service Assistance

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 83 Telephone (954) 744‑3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3535 U.S.A. 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...

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