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Mercury 225 HP Installation Manual

4-stroke
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NOTICE TO INSTALLER: After completing assembly, these instructions should be
placed with the product for the owner's future use.
IMPORTANT: If the boat is to be water tested, the operator should be familiar with the
operation procedures in the Operation and Maintenance Manual.
Electric Fuel Pump
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Boat Horsepower Capacity

Start in Gear Protection
Warning Horn Requirement
Selecting Accessories For The Outboard
Dual Engine Center Line Dimension
Lifting Outboard
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Steering Cable
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Steering Link Rod
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Installing Outboard
. . . . . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If
necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1.
cause loss of boat control 2. place too much weight at the transom, altering the de-
signed flotation characteristics of the boat or 3. cause the boat to break apart, par-
ticularly around the transom area. Overpowering a boat can result in serious injury,
death, or boat damage.
90-10232040 MARCH 2003
INSTALLATION MANUAL
225 HP (4-Stroke)
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U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER
MAXIMUM PERSON
CAPACITY (POUNDS)
MAXIMUM WEIGHT
CAPACITY
Printed in U.S.A. -
1
Front Cable Clamp Assembly
1
Remote Wiring Harness
2
Battery Cable Connections to the Engine
2
Battery Cable Connections to the Battery
2
Fuel Hose Connection
2
Shift Cable Installation
3
Throttle Cable Installation
3
Propeller Installation
4
Trim Tab Adjustment
5
XXX
XXX
XXX
WARNING
2003, Mercury Marine
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Summary of Contents for Mercury 225 HP

  • Page 1: Boat Horsepower Capacity

    INSTALLATION MANUAL 225 HP (4-Stroke) NOTICE TO INSTALLER: After completing assembly, these instructions should be placed with the product for the owner’s future use. IMPORTANT: If the boat is to be water tested, the operator should be familiar with the operation procedures in the Operation and Maintenance Manual.

  • Page 2: Start-In-Gear Protection

    225 (4-STROKE) INSTALLATION MANUAL Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protec- tion device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine.

  • Page 3: Lifting Outboard

    225 (4-STROKE) INSTALLATION MANUAL Lifting Outboard Use 3 point lift strap 91-883705T. Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate entire cable end. Quicksilver 2-4-C Marine Lubricant with Teflon 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 N·m). Page 3 of 16...

  • Page 4: Steering Cable Seal

    225 (4-STROKE) INSTALLATION MANUAL Steering Cable Seal Install O-Ring seal and cap. O-Ring Seal Steering Link Rod 1. Install steering link rod to rear hole (f) on steering arm per illustration. Special Bolt (10-856680) Torque to 20 lb. ft. (27.1 N·m) Nylon Insert Locknut (11-34932) Torque to 20 lb.

  • Page 5: Installing Outboard

    225 (4-STROKE) INSTALLATION MANUAL Installing Outboard 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (located in this manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line with the bottom of the boat. Anti-Ventilation Plate Page 5 of 16...
  • Page 6 225 (4-STROKE) INSTALLATION MANUAL 4. Fasten outboard with provided mounting hardware shown. 1/2 in. Diameter Bolts (4) Flat Washers(4) Locknuts (4) Flat Washers(4) Marine Sealer - Apply to Shanks of Bolts, Not Threads Page 6 of 16...

  • Page 7: Front Cable Clamp Assembly

    225 (4-STROKE) INSTALLATION MANUAL Front Cable Clamp Assembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, and fuel hose routed between cable clamp and engine attachment point, to relieve stress. 1. Bundle the fuel line, battery cables and wiring together and wrap with the piece of foam (provided) as shown.

  • Page 8: Remote Wiring Harness

    225 (4-STROKE) INSTALLATION MANUAL 4. Install the top half of the cable clamp and reinstall the cowl bracket. 5. Slide the rigging tube onto the cable clamp and fasten with collar and hose clamp. Top Half Cable Clamp Cowl Bracket Rigging Tube Collar Hose Clamp...

  • Page 9: Battery Cable Connections To The Engine

    225 (4-STROKE) INSTALLATION MANUAL Battery Cable Connections to the Engine Route battery cables through the front cable clamp. Connect the battery cables to the termi- nals on the engine as shown. NOTE: Bolts for fastening the battery cables terminals are located in the same packaging kit that contains the front cable clamp.

  • Page 10: Dual Outboards

    225 (4-STROKE) INSTALLATION MANUAL DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between nega- tive (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between Negative (–) Terminals Page 10 of 16...

  • Page 11: Fuel Hose Connection

    225 (4-STROKE) INSTALLATION MANUAL Fuel Hose Connection PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.

  • Page 12: Shift Cable Installation

    225 (4-STROKE) INSTALLATION MANUAL Shift Cable Installation Install cables into the remote control following the instructions provided with the remote con- trol. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.
  • Page 13 225 (4-STROKE) INSTALLATION MANUAL 4. Place shift cable on the shift pin. Adjust cable barrel so it slips freely into the barrel hold- 5. Fasten cable to the shift pin with hairpin cotter. Cable Barrel Hair Pin Cotter 6. Check shift cable adjustments as follows: a.

  • Page 14: Throttle Cable Installation

    225 (4-STROKE) INSTALLATION MANUAL Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control. 1. Position remote control into neutral. 2. Install throttle cable to the throttle arm with hairpin cotter. 3. Adjust the cable barrel until the alignment mark on the cam lines up with center of the roller.

  • Page 15: Propeller Installation

    225 (4-STROKE) INSTALLATION MANUAL Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine start- ing and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.

  • Page 16: Trim Tab Adjustment

    225 (4-STROKE) INSTALLATION MANUAL Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2.

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