Mercury 200 User Manual

Mercury marine 200/225/250/275 outboard motor

Hide thumbs Also See for 200:

Manual (124 pages)

User manual (118 pages)

Operation and maintenance manual (60 pages)

Table Of Contents

Table of Contents

Quick Links

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)

registered

for

warranty

2003/44/EC amending 94/25/EC

purpose?

Please

ISO 10240

ISO 8665

ISO 11547

ISO 13591; ISO 8469

ABYC P‑17

ISO 8178

ISO 8665

ISO 14509

94/25/EC

ISO 10240

ISO 8665

ISO 11547

ISO 13591; ISO 8469

check

Table of Contents

Need help?

Do you have a question about the 200 and is the answer not in the manual?

Questions and answers

Fred Ellwood

April 6, 2025

I have a mercury 200 hp EFI 2,5 l XRI think it's a 1990 model need fuel injecters I can't find them

Summary of Contents for Mercury 200

Page 1: Declaration Of Conformity
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
Wave And Wake Jumping........................11 Impact With Underwater Hazards......................11 Exhaust Emissions..........................12 Selecting Accessories For Your Outboard.................... 13 Safe Boating Suggestions........................14 Recording Serial Number........................14 200/225/250/275 Specifications - International..................15 Component Identification........................16 Installation Installing Outboard..........................17 Propeller Selection..........................18 Transporting Trailering Boat/Outboard ........................
Page 4 TABLE OF CONTENTS Power Trim and Tilt..........................34 Operation Pre-Starting Check List......................... 37 Operating In Freezing Temperatures....................37 Operating In Salt Water Or Polluted Water................... 37 Engine Break-in Procedure........................37 Starting The Engine..........................37 Gear Shifting............................49 Dual Helm Station Transfer........................50 Synchronizing Dual Engines.........................
Page 5 TABLE OF CONTENTS Battery Will Not Hold Charge........................ 79 Owner Service Assistance Local Repair Service..........................80 Service Away From Home........................80 Parts And Accessories Inquiries......................80 Service Assistance..........................80 Mercury Marine Service Offices......................80...
Page 7: Warranty Information
Outside United States and Canada ‑ Check with your local distributor. 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 8: Fourstroke Outboard Limited Warranty United States, Canada, Europe, Confederation Of Independent States, Middle-East And Africa
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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
Page 9: Year Limited Warranty Against Corrosion
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 10 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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
Page 11: Warranty Coverage And Exclusions
All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. 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 WARRANTY INFORMATION 10. Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit. 11. Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty.
Page 13: 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 on board 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 14: High-Speed And High-Performance Boat Operation
Operation booklet from your dealer, distributor, or Mercury Marine. ob00307 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 remote control system. 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 Read the following Safety Information before proceeding. Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.
Page 16: Passenger Safety Message - Pontoon Boats And Deck Boats
GENERAL INFORMATION Whenever a boat is moving (coasting) and the outboard gear shift is in neutral position, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury. WHILE BOAT IS STATIONARY WARNING Stop your engine immediately whenever anyone in the water is near your boat.
Page 17: Wave And Wake Jumping
GENERAL INFORMATION ob00313 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 18: Exhaust Emissions
GENERAL INFORMATION ob00315 WARNING To avoid serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater obstacle maintain a top speed no greater than minimum planing speed. Striking a floating or underwater object could result in an infinite number of situations. Some of these situations could result in the following: •...
Page 19: Selecting Accessories For Your Outboard
Running the boat with no forward the bow too high hatches open Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.
Page 20: Safe Boating Suggestions
Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft.) in front of you in 5 seconds.
Page 21: 200/225/250/275 Specifications - International
Numb OTXXXXXX 20XX XXXX ob01322 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation 200/225/250/275 Specifications ‑ International Models 200/225/250/275 Horsepower 200/225/250/275 Kilowatts 149/168/186/205 Full Throttle RPM Range 5800‑6400 550 RPM Idle Speed in Neutral Gear...
Page 22: Component Identification
GENERAL INFORMATION Models 200/225/250/275 Engine Oil Capacity With Oil 7.0 liters (7.4 qt) Filter Replacement 1000 Marine Cranking Amps (MCA), 800 Cold Battery Rating Cranking AMPS (CCA) or 180 Ampere Hour (Ah) Sound at Drivers Ear (ICOMIA 39‑94) 4‑Stroke 79.6...
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. IMPORTANT: For optimum boat performance and detailed engine installation instructions, refer to the outboard installation manual, supplied with the outboard.
Page 24: Propeller Selection
INSTALLATION ob01312 Maximum Static Waterline The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE" mark on the idle relief grommet (located at the rear of the outboard) when the outboard is fully tilted in/down. If waterline is above "MAX STATIC WATERLINE"...
Page 25 INSTALLATION 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 26: Transporting
TRANSPORTING Trailering Boat/Outboard When transporting the boat on a trailer, the outboard should be positioned and/or supported in one of the following ways: If the boat trailer provides sufficient ground clearance, the outboard may be tilted down to the vertical operating position with no additional support required. ob01268 If additional ground clearance is required, the outboard should be tilted up and supported using the outboard's tilt support bracket (trailering position) and/or an accessory transom support...
Page 27 TRANSPORTING ob01267 Additional clearance may be required for railroad crossings, driveways and trailer bouncing. Refer to your local dealer for recommendations. IMPORTANT: Do not rely on the power trim/tilt system to maintain proper ground clearance for trailering. The power trim/tilt system is not intended to support the outboard for trailering. Shift the outboard to forward gear.
Page 28: Fuel And Oil
If unleaded gasoline is not available, use a major brand of leaded gasoline. USA and Canada ‑ Models 200/225/250: Having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline [92 (R+M)/2 Octane] is also acceptable. Do NOT use leaded gasoline.
Page 29: Filling Fuel Tank
Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 multi‑viscosity 4‑Stroke Outboard Oil is recommended for general, all‑temperature use. If the recommended Mercury or Quicksilver NMMA FC‑W certified oil is not available, a major brand of NMMA FC‑W certified 4‑Stroke Outboard Oil of similar viscosity may be used.
Page 30 FUEL AND OIL Remove the top cowl. Refer to Maintenance ‑ Cowl Removal And Installation. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region).
Page 31: Features And Controls
FEATURES AND CONTROLS Remote Control Features PANEL MOUNT FEATURES 3409 Lanyard/lanyard stop switch ‑ Refer to Throttle only button ‑ Allows the boat General Information ‑ Lanyard Stop operator to increase engine RPM for Switch. warm‑up, without shifting the engine into gear.
Page 32 FEATURES AND CONTROLS CONSOLE MOUNT FEATURES - SINGLE ENGINE 3410 Control handle ‑ Forward (F), Neutral Arrow trackpad ‑ Used to scroll through (N), Reverse (R). System View displays, if equipped. Refer to System View Operation Manual for Trim/tilt switch ‑ Refer to Power Trim screen 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 Arrow trackpad ‑ Used to scroll through and Tilt. System View displays, if equipped. Refer to System View Operation Manual for Control handles ‑...
Page 34 FEATURES AND CONTROLS SLIM BINNACLE CONSOLE MOUNT FEATURES - SINGLE ENGINE START STOP 14637 Control handle ‑ Forward (F), Neutral Start/stop button ‑ Allows the boat (N), Reverse (R). operator to 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 Arrow trackpad ‑ Used to scroll through and Tilt. System View displays, if equipped. Refer to System View Operation Manual for 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: Warning System
FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Starboard engine throttle and shift = Running controlled by starboard control handle Center engine throttle and shift = Off (ignition key Off (ignition key Running neutral/idle unless switch turned on) switch turned on) both control handles are in the same gear...
Page 38 FEATURES AND CONTROLS Warning Horn Function Sound Description Low battery Four beeps every 2 Battery charging unable to minutes keep up with demand. Raise engine speed, to increase charge, or shut down accessories, to reduce demand. Cooling system problem Continuous Engine Guardian System is activated.
Page 39 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, oil pressure, water pressure, battery voltage, fuel consumption and engine operating hours.
Page 40: Power Trim And Tilt
FEATURES AND CONTROLS Power Trim and Tilt The 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 trimming down.
Page 41: Tilt Support Lever
FEATURES AND CONTROLS • Lift the bow higher out of the water. • Generally increase top speed. • Increase clearance over submerged objects or a shallow bottom. • In excess can cause boat porpoising (bouncing) or propeller ventilation. • Cause engine overheating if any cooling water intake holes are above the water line. TILTING TO FULL UP POSITION Tilt At Helm NOTE: The trim/tilt switch will remain active for 15 minutes after the ignition key switch has been turned...
Page 42: Auxiliary Tilt Switch
FEATURES AND CONTROLS ob01143 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard.
Page 43: 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 44 OPERATION 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. Make sure the cooling water intake is submerged. ob01310 Check the engine oil level.
Page 45: Warming Up Engine
OPERATION 3413 NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote control handle. Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting.
Page 46 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. Advance the control handle to increase engine RPM. Engine RPM is limited to prevent engine damage.
Page 47 OPERATION 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. 3417 Turn the ignition key to "START"...
Page 48 OPERATION ACTIVE THROTTLE ONLY STATION SELECT 3418 Warming up engine Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. ACTIVE THROTTLE ONLY STATION SELECT 3419 Move the control handle into neutral position. Press and hold the throttle only/station select button while moving the control handle ahead to the forward detent.
Page 49 OPERATION ob01310 Check the engine oil level. ob00667 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.
Page 50 OPERATION Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking. Return the key to "START" position and try again. Repeat the procedure for the second engine. 3485 The "ACTIVE"...
Page 51 OPERATION SLIM BINNACLE - SINGLE ENGINE 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 52 OPERATION 3417 NOTE: The engine can be started by using the ignition key or the start/stop button located on the remote control panel. Ignition key starting ‑ Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting.
Page 53 OPERATION Warming up engine Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. 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.
Page 54 OPERATION ob00667 Open fuel tank vent on manual venting type tanks. ob00348 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.
Page 55: Gear Shifting
OPERATION NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT 14657 Warming up engines Throttle Only/Station Select Button ‑ This feature allows the boat operator to increase engine RPM for warm‑up, without shifting the engines into gear. NEUTRAL SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT...
Page 56: Dual Helm Station Transfer
OPERATION 3427 • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position. 3428 •...
Page 57: Synchronizing Dual Engines
OPERATION The active light is illuminated at the remote control station that is in control of the engine. WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One person helm transfer should only be performed while engine is in neutral.
Page 58: Stopping The Engine
OPERATION SYNC ACTIVE THROTTLE ONLY STATION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%. Stopping The Engine IMPORTANT: Turning key to the "START" position while the engine is running will result in engine shut down, while leaving the DTS system active.
Page 59 OPERATION Turn screw towards "+" to increase friction or towards "–" to decrease friction. Reinstall cover.
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. 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 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. Inspection And Maintenance Schedule BEFORE EACH USE • Check engine oil level. See Fuel & Oil ‑ Checking and Adding Engine Oil. •...
Page 62: Flushing The Cooling System
MAINTENANCE • Check power trim fluid. See Checking Power Trim Fluid. • Replace high pressure in‑line fuel filter • Replace spark plugs at first 300 hours or three years. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and Replacement.
Page 63 MAINTENANCE Pull up on the top cowl lock latch. ob01324 Pull top cowl forward and lift off. Pull lower cowl release latch up. Remove rear cowl towards aft of outboard. ob01257 COWL INSTALLATION Position lower cowl from aft side of outboard. Make sure it fits properly in the rubber seal. Lock cowl in place by pulling lower cowl latch down.
Page 64: Cleaning Care For Top And Bottom Cowls
Wax the surface using a non‑abrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by hand using a clean soft cloth. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1). Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability.
Page 65: Dts Battery Specifications
MAINTENANCE DTS Battery Specifications IMPORTANT: Do not use deep cycle batteries for the main engine starting battery. IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations.
Page 66: Air Filter
MAINTENANCE NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating. 13.5Nm (120 lbs. in.) DO NOT USE WING NUTS.
Page 67 MAINTENANCE 3665 Wash air filter assembly in warm soap water. Dry filter assembly with compressed air. Apply 4‑Cycle Outboard Oil on rag or towel and lightly pad air filter element. Wipe off excess oil. Air filter element should be moist to the touch. Tube Ref No.
Page 68: Fuel System
MAINTENANCE 3664 Crankcase ventilation hose Filter assembly Fuel System Module (FSM) purge Clamp screw valve hose Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system.
Page 69 MAINTENANCE 3470 CAUTION Fuel vapor vent system is under pressure. Cover valve assembly with a rag or towel to prevent fuel or fuel vapor spray. Relieve pressure slowly. Place rag or towel around valve, release pressure by pushing core of valve end in. 3472 Unscrew the filter in a counterclockwise direction to remove.
Page 70 MAINTENANCE ob01253 Filter Draining Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter holder. Tip the filter holder to drain any fluid into an approved container. ob01263 Filter Installation Position filter holder onto bracket and secure filter holder in place. Lubricate the sealing ring on the filter with oil.
Page 71: Corrosion Control Anode
MAINTENANCE ob01258 Corrosion Control Anode The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded.
Page 72 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Tube Ref No. Description Where Used Part No.
Page 73: Spark Plug Inspection And Replacement
MAINTENANCE ob00422 Spark Plug Inspection and Replacement Remove top and rear cowlings. Refer to Cowl Removal and Installation. Disconnect the six wiring harness connectors from pencil coil connections. Remove mounting bolts, using a twisting motion, and pull pencil coils from spark plugs. 3658 Wiring harness connector Bolt...
Page 74: Fuses
MAINTENANCE Tube Ref No. Description Where Used Part No. Anti-Seize Spark plug threads 92-881091K1 Compound Clean area of spark plug seat. 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. Description lb.
Page 75: Dts Wiring System
MAINTENANCE Remove the plastic cover from the fuse holder. Remove fuse puller from fuse holder. Remove suspected blown fuse to determine if the silver colored band is broken. Replace fuse with a new fuse of the same amperage rating. ob01252 ob01259 Electronic Control Module and purge Spare fuses ‑...
Page 76: Checking Power Trim Fluid
Pedestal The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive automatic transmission fluid (ATF). Tube Ref No.
Page 77: Changing Engine Oil
MAINTENANCE ob01527 Power steering cover Fill/full level Fill cap Tube Ref No. Description Where Used Part No. Synthetic Power Steering Fluid SAE Power steering system 92-858002K01 0W-30 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 7.0 liters (7.4 quarts). PUMP METHOD IMPORTANT: Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump.
Page 78 MAINTENANCE Crankcase Oil Pump 91‑90265A 5 Aids in the removal of engine oil without draining the crankcase. 11591 DRAIN METHOD Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump. Place the outboard in a vertical position.
Page 79 MAINTENANCE CHANGING OIL FILTER IMPORTANT: To reduce or prevent oil spillage when removing the oil filter ensure that the outboard is upright (not tilted) and the engine is cold or has not run for at least one hour. Remove the top cowl. Place a rag or towel below the oil filter to absorb any spilled oil.
Page 80: Gearcase Lubrication
MAINTENANCE ob01250 Reinstall oil fill cap. With outboard in water or cooling water flush hose connected, idle engine for five minutes to check for leaks at the oil filter. Stop engine and check oil level. Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
Page 81 MAINTENANCE 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/sealing washer. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
Page 82: Storage
Stabilizer Protecting External Outboard Components • 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 83: Gearcase
STORAGE Tube Ref No. Description Where Used Part No. Storage Seal Rust 92-802878Q5 Spark plug holes Inhibitor • Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal throughout the cylinders. •...
Page 84: 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 85: Performance Loss
TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Overheating ‑ Warning horn not working. • Low oil pressure. Check oil level. • Throttle not opening fully. • Damaged propeller or improper propeller size. • Incorrect engine timing, adjustment, or setup. • Boat overloaded or load improperly distributed. •...
Page 86: Owner Service Assistance
Should you have a question, concern, or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
Page 87 Telephone (954) 744‑3500 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...

This manual is also suitable for:

225 250 275

Mercury 200 User Manual

Quick Links

Declaration of Conformity

Need help?

Questions and answers

Related Manuals for Mercury 200

Summary of Contents for Mercury 200

This manual is also suitable for:

Table of Contents