Mercury 200 OptiMax DTS Manual Download Page 152

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TROUBLESHOOTING

140

eng

• Spark plugs fouled or defective. Refer to

Maintenance

section.

Engine Starts But Will Not Shift Into Gear

• Shift actuator failure. "Gear Shift Diff" error message shown

on System View. Refer to

Maintenance

section.

Engine Runs Erratically

POSSIBLE CAUSES

• Spark plugs fouled or defective. Refer to

Maintenance

section.

• Incorrect setup and adjustments.
• Fuel is being restricted to the engine.

a. Engine fuel filter is obstructed. Refer to

Maintenance

section.

b. Fuel tank filter obstructed.
c. Stuck antisiphon valve on built‑in fuel tank.
d. Fuel line is kinked or pinched.
e. Injector plugged.

• 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.
• Excessive water in bilge.
• Boat bottom is dirty or damaged.

Battery Will Not Hold Charge

POSSIBLE CAUSES

• Battery connections are loose or corroded.

Summary of Contents for 200 OptiMax DTS

Page 1: ... for your confidence in Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason ...

Page 2: ...ation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2010 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort M with Waves logo Mercury with Waves logo and SmartCraft logo are all registere...

Page 3: ...54936 1939 Country USA Name of Authorized Representative Brunswick Marine in EMEA Inc Address Parc Industriel de Petit Rechain Town Verviers Post Code 4800 Country Belgium Name of Notified Body for exhaust emission assessment Det Norske Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Name of Notified Body for noise emission assessment Det Norske Veritas AS...

Page 4: ...RCD H 2 Essential requirements standards other normative document method technical file Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 engine identification B 2 exhaust emission requirements EN ISO 8178 1 1996 B 3 durability B 4 owner s manual ISO 8665 1995 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s manual This decl...

Page 5: ...eng v Name function Mark D Schwabero President Mercury Outboard Date and place of issue July 24 2008 Fond du Lac Wisconsin USA ...

Page 6: ...vi eng ...

Page 7: ... Control Warranty Statement 18 Emission Certification Star Label 19 General Information Boater s Responsibilities 21 Before Operating Your Outboard 21 Boat Horsepower Capacity 22 High Speed and High Performance Boat Operation 22 Outboard Remote Control Models 23 Propeller Selection 23 Remote Steering Notice 26 Lanyard Stop Switch 27 Protecting People in the Water 30 Passenger Safety Message Pontoo...

Page 8: ...tives 48 Fuel Requirements 48 Avoiding Fuel Flow Restriction 48 Low Permeation Fuel Hose Requirement 48 EPA Pressurized Portable Fuel Tank Requirements 48 Fuel Demand Valve FDV Requirement 49 Mercury Marine s Pressurized Portable Fuel Tank 49 Filling Fuel Tank 51 Oil Recommendation 51 Filling Remote Oil Tank 51 Filling Engine Mounted Oil Reservoir Tank 52 ...

Page 9: ...atures and Operation 70 Shadow Mode Control Features and Operation 75 Shadow Mode Control with CAN Trackpad Features and Operation 83 Warning System 92 Power Trim and Tilt 95 Operation Pre Starting Check List 100 Operating in Freezing Temperatures 100 Operating in Saltwater or Polluted Water 101 Operating at High Elevations 101 Setting Trim Angle While Running Engine at Idle Speed 101 Engine Break...

Page 10: ...18 DTS Wiring System 119 Corrosion Control Anode 119 Battery Inspection 120 Battery Information 121 Propeller Replacement 122 Spark Plug Inspection and Replacement 125 Compressor Air Intake Filter 126 Lubrication Points 128 Checking Power Trim Fluid 132 Gearcase Lubrication 133 Submerged Outboard 134 Storage Storage Preparation 135 Fuel System 135 Protecting Internal Engine Components 137 Protecti...

Page 11: ...ll Not Shift Into Gear 140 Engine Runs Erratically 140 Performance Loss 140 Battery Will Not Hold Charge 140 Owner Service Assistance Local Repair Service 142 Service Away from Home 142 Parts and Accessories Inquiries 142 Service Assistance 142 Mercury Marine Service Offices 143 Maintenance Log Maintenance Log 145 ...

Page 12: ...xii eng ...

Page 13: ...ealer on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required 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 proce...

Page 14: ...d du Lac WI 54936 1939 920 929 5054 Fax 1 920 929 5893 Upon processing the transfer of warranty Mercury Marine will record the new owner s information There is no charge for this service OUTSIDE THE UNITED STATES AND CANADA For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Transfer of Mercury Produc...

Page 15: ...rage is not transferable from one product to another product or for non eligible applications The Certified Pre Owned engine plans are not transferable For help or assistance contact Mercury Product Protection Department at 1 888 427 5373 from 7 30 a m to 4 30 p m CST Monday Friday or email mpp_support mercmarine com Outboard Limited Warranty UNITED STATES CANADA EUROPE MIDDLE EAST AFRICA AND THE ...

Page 16: ...on proper reregistration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer Warranty coverage may be terminated for used repossessed product or product purchased at auction from a salvage yard or from an insurance company CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers...

Page 17: ...or warranty service Warranty claims shall be made by delivering the product for inspection to a 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 t...

Page 18: ...ake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point eve...

Page 19: ...FIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY 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 M2 Jet Drive Tracker by Mercury Marine Outboard Mercury MerCruiser Inboard or Sterndrive Engine Product will not be rendered inoperative as a direct re...

Page 20: ...routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s s...

Page 21: ...chaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage...

Page 22: ...ween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 23: ...ion is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connecti...

Page 24: ...intenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 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 conditio...

Page 25: ...the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations This emission related warranty covers all the components listed in the Emission Control System Components Emission Control System Components The EPA and Califormia emission rel...

Page 26: ...ty The California Air Resources Board has promulgated air emission regulations for outboard engines The regulations apply to all outboard engines sold to retail consumers in California and which were manufactured for the 2001 model year and later Mercury Marine in compliance with those regulations provides this limited warranty for the emission control systems see the components listed in the Emis...

Page 27: ... a warranted part will also be repaired under warranty DURATION OF COVERAGE This limited warranty provides coverage for the components of the emissions control systems of new 2001 model year and later outboards sold to retail customers in California for four 4 years from either the date the product is first sold or first put into service whichever occurs first or the accumulation of 250 hours of e...

Page 28: ...is warranty is limited to at our expense and at our option repairing or replacing defective parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured WHAT IS NOT COVERED This limited warrant...

Page 29: ... Regulations or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim at the discretion of Mercury Marine Failures of warranted parts caused by the use of a nonexempted add on or modified part will not be covered DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLA...

Page 30: ...ssemblies Where a warrantable condition exists Mercury Marine will repair your outboard engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission control parts from model year 2001 and later outboard engines are warranted for four 4 years or for 250 hours of use whichever occurs first However warranty coverage based on the hourly period is only p...

Page 31: ...The symbol for a cleaner marine engine means Cleaner air and water for a healthier lifestyle and environment Better fuel economy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources Longer emission warranty protects consumer for worry free operation 22531 One Star Low Emission The One Star label identifies engines that meet the Air R...

Page 32: ...xhaust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines 42539 Four Stars Super Ultra Low Emission The Four Star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meet...

Page 33: ...utboard properly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed DANGER Indicates a hazardous ...

Page 34: ...l guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 High Speed and High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capabil...

Page 35: ...our outboard are available through Mercury Marine To view the entire product offering and find the correct propeller that is best suited for your application visit www mercmarinepropellers com or see your local authorized Mercury dealer SELECTING THE CORRECT PROPELLER An accurate tachometer for measuring engine speed is important in choosing the correct propeller Choose a propeller for your boatin...

Page 36: ...itch For example 14x19 represents a propeller with a 14 inch diameter and 19 inches of pitch a Diameter b Pitch Travel during one revolution The following are some propeller basics that will help you determine the correct propeller for your boating application Diameter The diameter is the distance across the imaginary circle that is made when the propeller rotates The correct diameter for each pro...

Page 37: ...f pitch will reduce the full throttle RPM by 150 to 200 Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200 Upgrading from a 3 blade propeller to a 4 blade propeller will generally decrease full throttle RPM by 50 to 100 IMPORTANT Avoid damage to the engine Never use a propeller which allows the engine to exceed the recommended full throttle RPM range when under normal full t...

Page 38: ... steering link rod that connects the steering cable to the engine must be fastened utilizing self locking nuts These self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can c...

Page 39: ...52 cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should...

Page 40: ...ting at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel or tiller handle that is pulling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers 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 ...

Page 41: ...sengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use check to ensure the lanyard stop switch works properly Start the engine and stop it ...

Page 42: ...r 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 A spinning propeller a moving boat or any solid device attached to the boat can cause serious injury or death to swimmers Stop the engine imme...

Page 43: ...the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a w...

Page 44: ...at 26783 Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done with sufficient speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat reenters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such case t...

Page 45: ...so steer sharply to one side Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control ...

Page 46: ...er striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures or water leaks Operating a damaged outboard could cause additional damage to othe...

Page 47: ...an result in carbon monoxide poisoning which can lead to unconsciousness brain damage or death Avoid exposure to carbon monoxide Stay clear from exhaust areas when engine is running Keep the boat well ventilated while at rest or underway STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide Avoid areas of concentrated engine exhaust gases When engines are running k...

Page 48: ...cient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a Operating the engine whe...

Page 49: ... 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 Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions Use flotation devic...

Page 50: ...the boat Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly Prepare other boat operators Instruct at least one other person onboard in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Stop ...

Page 51: ...s A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record this number fo...

Page 52: ...ecommended spark plug NGK IZFR5G Spark plug gap 0 8 mm 0 031 in Standard gearcase ratio 1 75 1 High altitude gearcase ratio 1 87 1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity 798 ml 27 fl oz Battery rating 1000 marine cranking amps MCA or 800 cold cranking amps CCA Charging system output 60 A Emission control system Electronic engine...

Page 53: ... Identification a Top cowl b Bottom cowl c Water pump indicator hole d Driveshaft housing e Anti ventilation plate f Anode plate g Auxiliary tilt switch h Transom brackets i Gearcase j Cooling water intake holes a b c d e f g h i j 29423 ...

Page 54: ...nderwater obstacles if the outboard is not attached to the transom correctly We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the transom with the four ...

Page 55: ... a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded refer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher el...

Page 56: ...ION 44 eng 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 57: ...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 2722 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering...

Page 58: ... brand of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are alcohol ethanol or ether MTBE or ETBE If ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol These reformulated gasolines are acceptable for use in your Mercury...

Page 59: ...ion particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is...

Page 60: ...talling at low speed and or a lean fuel condition at high RPM that could cause engine damage Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or offered for sale in the United States The Environmental Protection Agency EPA requires that any outboard manufactured after January 1 2009 must use low permeation fuel hose for the primary fuel hose connecting the fue...

Page 61: ...valve installed in the fuel hose between the fuel tank and primer bulb b Manual release c Vent water drain holes Mercury Marine s Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements These fuel tanks are available as an accessory or are provided with certain portable outboard models SPECIAL FEATURES OF THE PORTABLE...

Page 62: ...ssure Rotate the fuel cap 1 4 turn to relieve pressure before opening 1 Open the manual vent screw on top of the fuel cap 2 Turn the fuel cap until it contacts the tab lock 3 Press down on the tab lock Rotate the fuel cap 1 4 turn to relieve the pressure 4 Press down on the tab lock again and remove the cap DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1 When installing the fuel tank cap...

Page 63: ...e approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled Oil Recommendation Recommended Oil Mercury OptiMax DFI or Quicksilver DFI 2 Cycle Engine Oil Mercury OptiMax DFI or Quicksilver DFI 2 Cycle Engine Oil is recommended for your engine If Mercury OptiMax DFI or Quicksilver DFI 2 Cycle Engine O...

Page 64: ...ling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated 1 Remove the top cowl 2 Loosen the fill cap on the engine oil reservoir tank Run the engine until all the air has been vented out of the oil reservoir tank and tank is filled with oil to the point of overflow 3 Retighten the fill cap Stop the engine and replace the top cowl 29424 ...

Page 65: ...d from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3413 2 Shift lock Pressing the shift lock allows the engine to shift The shift lock must always be pressed when moving the control handle out of the neutral position 3428 ...

Page 66: ...arm up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button while moving the control handle ahead to the forward detent The horn indicates throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position Engine RPM is limited to prevent engine damage 3416...

Page 67: ...erator when attached to the lanyard moves far enough away from the operator s position to activate the switch a Lanyard stop switch 7 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn screw clockwise to increase tension and counte...

Page 68: ...ent tension adjustment screw b Control handle tension adjustment screw Single Handle Console Control Features and Operation 1 Operation of shift and throttle is controlled by the movement of the control handle Push the control handle forward from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first detent for...

Page 69: ...in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to the desired tension 4 Detent tension adjustment screw This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions cover must be removed Turning the screw clockwise will increase tension Adjust to the desired tension a Detent tension adjustm...

Page 70: ...e LED illuminates to show the remote control is active and ready for use 9 Throttle only station select button Allows the boat operator to increase engine RPM for warm up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button while moving the control handle ahead to the forward detent The horn will sound once a...

Page 71: ... transfer function allows the boat operator to select which helm is in control of engine operation Pressing the throttle only station select button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm Adjust the control handles...

Page 72: ... the control handle setting at the new station with the handle setting that is at the old to be inactive station If the handle is not matched the neutral light will flash The light blinks faster as the handle is nearing match position Once the light stays on continuously the handle is matched and the throttle only station select button can be pressed again to complete the transfer This completes t...

Page 73: ...sh the control handle forward from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first detent for reverse gear Continue pushing back to increase speed F N R 12871 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up or down a Trim switch 12874 a ...

Page 74: ...ntrol handle out of detent positions cover must be removed Turning the screw clockwise will increase tension Adjust to the desired tension a Detent tension adjustment screw b Control handle tension adjustment screw 5 Start stop button Allows the boat operator to start or stop the engine without using the ignition key 6 Neutral LED The neutral LED illuminates when engine is in neutral gear position...

Page 75: ...engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer a Start stop button b Throttle only station select button c Neutral LED d Active LED HELM TRANSFER 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 ...

Page 76: ...d position remote control lever to the idle position 3 Press throttle only station select button two times The ACTIVE light will illuminate to indicate the remote control is in control of the engine a Active light b Throttle only station select button 4 The ACTIVE light will switch off at the original helm Synchronizing Helms Prior to Helm Transfer Pressing the throttle only station select button ...

Page 77: ...om neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3417 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up or down 5269 3 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rou...

Page 78: ...rn will sound once and the neutral light will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer 6 ...

Page 79: ...he active LED illuminates to show the remote control is active and ready for use 10 Sync LED The sync LED illuminates when the RPM of the two engines are being synchronized by the DTS system a Neutral LEDS b Select button c Arrow trackpad d Sync LED e Throttle only station select button f Active LED SYNCHRONIZING ENGINES The auto synchronizing feature when engaged will automatically adjust all eng...

Page 80: ...elm transfer should only be attempted while both stations are manned One person helm transfer should only be performed while engine is in neutral NOTE Idle position is preferred when doing a helm transfer If conditions do not allow the remote control to be placed at idle position a helm transfer can be done while in gear NOTE The active light on the remote control will be illuminated at the helm t...

Page 81: ...VE light will switch off at the original helm Synchronizing Helms Prior to Helm Transfer Pressing the throttle only station select button one time allows the boat operator 10 seconds to match up the control handle setting at the new station with the handle setting that is at the old to be inactive station If the handle is not matched the neutral light will flash The light blinks faster as the hand...

Page 82: ...peed Pull the control handle back from neutral to the first detent for reverse gear Continue pulling the handle back to increase speed F N R 3417 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up and down NEUTRAL SY NC TH RO TT LE ON LY TR OL L TR AN SF ER DO CK 1 LE VE R 22132 3 Neutral lights The neutral lights illuminate when the engine is in neutral gear position ...

Page 83: ...de Docking mode reduces throttle capacity to approximately 50 of normal throttle To turn off docking mode shift the engine into neutral and press the DOCK button 7 Throttle only button Allows the boat operator to increase engine RPM for warm up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button and move the...

Page 84: ...r button g Sync button 10 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to tension desired NEUTRAL 22133 SYNC 1 LEVER NEUTRAL TROLL THROTT...

Page 85: ...o match the speed of the starboard engine Press the SYNC button on the CAN trackpad to turn auto synchronization on or off When the sync LED is yellow the SYNC button has been pressed but the conditions are not right for auto synchronization to engage When the sync LED turns red engine synchronization has been engaged The engines will remain synchronized as long as engine speed is over 900 RPM for...

Page 86: ...SFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm Adjust the control handles to the desired throttle and gear position Once the TRANSFER button is pressed the transfer LED will light up and one beep will sound Pr...

Page 87: ...eatures and Operation TRIPLE ENGINE THROTTLE AND SHIFT OPERATION Movement of the handles on the remote control allows the boat operator to control the engine throttle speed and gear shift positions of all three engines The throttle and shift function is dependant on what engines are running Refer to the following table Port Engine Center Engine Starboard Engine Control Handle Function Running Runn...

Page 88: ...ngine can be restored by moving the control handle of the functioning outer engine back into neutral position and then reengaging The center engine speed and gear shift will then be controlled by the functioning outer engine Turning off the center engine while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes one of the outer e...

Page 89: ...f Off Running Running Starboard inner and outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Running Port inner engine throttle and shift controlled by port control handle Running Running Running Off ignition key switch turned on Starboard inner engine throttle and shift controlled by starboard control handle Off ignition key sw...

Page 90: ...ine to go into forced neutral idle Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then reengaging The inner engine speed and gear shift will then be controlled by the starboard control handle Turning off the port outer engine while underway will cause the port...

Page 91: ...ging If a failure should occur while underway which causes the port outer engines into forced neutral idle condition the inner port engine will also be forced to neutral idle Operation to the inner engine can be restored by moving the port control handle back into neutral and then reengaging TRIM SWITCH AND KEY PAD FEATURES 1 Trim switch if equipped Operates the trim for all engines An accessory t...

Page 92: ... inactive helm initiates a helm transfer Refer to Helm Transfer 3 Arrow trackpad Navigates through System View on screen function messages 4 Select button Selects System View on screen options and confirm data entries Holding the select button for two seconds will pause the slide show if selected in Favorites Holding the select button for three seconds will activate the reset data function except ...

Page 93: ...tarboard engine Engine auto synchronization will automatically engage when engine speed is over 900 RPM for two seconds and remote control handles are positioned within 10 of each other The SYNC light will turn on when the engines are synchronized Auto synchronization will stay engaged up to 95 throttle opening To disengage move one or both control handles until they are more than 10 apart reduce ...

Page 94: ... transfer function allows the boat operator to select which helm is in control of engine operation Pressing the throttle only station select button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm Adjust the control handles...

Page 95: ... blinks faster as the handle is nearing match position Once the light stays on continuously the handle is matched and the throttle only station select button can be pressed again to complete the transfer This completes the transfer process and give control to the new station If the helm transfer is not completed within 10 seconds the helm transfer is cancelled Shadow Mode Control with CAN Trackpad...

Page 96: ...arboard engine throttle and shift controlled by starboard control handle Running Off Off Port engine throttle and shift controlled by port control handle Off Off Running Starboard engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Off ignition key switch turned on Center engine throttle and shift neutral idle unless both control handles are i...

Page 97: ... the following table Port Outer Engine Port Inner Engine Starboard Inner Engine Starboard Outer Engine Control Handle Function Running Running Running Running Port inner and outer engines throttle and shift controlled by port control handle Starboard inner and outer engines throttle and shift controlled by starboard control handle Running Running Off Off Port inner and outer engine throttle and sh...

Page 98: ...ngine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Off ignition key switch turned on Port inner engine throttle and shift controlled by port control handle Starboard inner engine throttle and shift controlled by starboard control handle Turning off the starboard outer engine while underway will cause the starboard inner engine to go in...

Page 99: ...causes the starboard outer engines into forced neutral idle condition the inner starboard engine will also be forced to neutral idle Operation to the inner engine can be restored by moving the starboard control handle back into neutral and then reengaging If a failure should occur while underway which causes the port outer engines into forced neutral idle condition the inner port engine will also ...

Page 100: ...s the TROLL button move the throttle to a different speed or shift the engine into neutral 4 Transfer button Pressing the TRANSFER button allows engine operation to be transferred to a different helm Refer to Helm Transfer 5 Dock button Pressing the DOCK button initiates docking mode Docking mode reduces throttle capacity to approximately 50 of normal throttle To turn off docking mode shift the en...

Page 101: ...synchronization feature Refer to Synchronizing Engines a Neutral LEDS b Troll button c Transfer button d Dock button e Throttle only f 1 lever button g Sync button 9 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn the screw cloc...

Page 102: ...o match the speed of the starboard engine Press the SYNC button on the CAN trackpad to turn auto synchronization on or off When the sync LED is yellow the SYNC button has been pressed but the conditions are not right for auto synchronization to engage When the sync LED turns red engine synchronization has been engaged The engines will remain synchronized as long as engine speed is over 900 RPM for...

Page 103: ...SFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm Adjust the control handles to the desired throttle and gear position Once the TRANSFER button is pressed the transfer LED will light up and one beep will sound Pr...

Page 104: ...he 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 The warning horn will emit either a continuous beep or intermittent short beeps This will alert the operator and help identify the following listed situations For visual display of the spec...

Page 105: ... allow a fast idle The warning horn is activated if the oil pump should ever stop functioning electrically No lubricating oil is being supplied to the engine Engine overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum allowable RPM The system will limit the engine speed to within the allowable range Engine overspeed indicates a condition that should be corre...

Page 106: ...corrected if possible The system must be reset before the engine will operate at higher speeds Moving the throttle lever back to the idle position will reset the system SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard A few of the functions the instrument package will display are engine RPM coolant temperature battery voltage fuel consumption and...

Page 107: ...referring to adjusting the outboard further up out of the water With the engine turned off and ignition switch turned on the outboard can be tilted out of the water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation a Trim switch b Trim range of travel c Tilt range of travel POWER TRIM OPERATION With most boats operating around th...

Page 108: ...sult in quicker planing off especially with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering torque or pull to the right with the normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called ...

Page 109: ...f any cooling water intake holes are above the waterline TRIM WITHOUT KEY Trim without key is a method of allowing trim operation after the ignition key switch is turned off The command module and PCM remain powered and are able to process trim requests for up to 15 minutes after the key switch is turned off The command module does not process any requests other than trim during this period Once t...

Page 110: ...tilt switch can be used to tilt the outboard with the key switch in the OFF position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the tilt support lever down Lower the outboard a Tilt support lever b Knob MANUAL TILTI...

Page 111: ...outboard up or down using the power trim system a Auxiliary tilt switch SHALLOW WATER OPERATION When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exc...

Page 112: ...perate a boat while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Maintenance Schedule Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at...

Page 113: ...y 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 Operating at High Elevations Your engine automatically compensates for high elevation changes A different pitch propeller may help reduce some normal performance loss resulting from reduced oxygen in the air Consult your dealer Setting T...

Page 114: ...aters this extra oil mode will be complete in about ten hours BREAK IN PROCEDURE 1 For the first hour of operation allow the engine to warm up for 30 60 seconds a Run the engine at varied throttle settings the majority of the time between 3000 and 4500 RPM or three quarter throttle b Change engine speed approximately every two minutes and avoid continuous operation at idle speed for more than ten ...

Page 115: ...ar Shifting in the Operation section and the remote control features and operation in the Features and Controls section NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 1 Make sure the cooling water intake is submerged 27811 2 Open the fuel tank vent on ma...

Page 116: ...ess the lanyard is set to the RUN position 4 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch 19791 5 Shift the outboard to the neutral N position F N R 3413 F N R 3417 6 For the initial start of a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled as follows a Squeeze the fuel line primer bulb un...

Page 117: ...ll automatically crank the engine for starting If the engine fails to start the engine will stop cranking Turn the key to START position again until engine starts S T A R T OFF ACC ON S T A R T OFF ACC ON 3485 8 After the engine starts check for a steady stream of water flowing out of the water pump indicator hole 19805 IMPORTANT If no water is coming out of the water pump indicator hole stop engi...

Page 118: ...t running The outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R 3427 F N R 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 Advance the control lever to further increase sp...

Page 119: ... shifting always stop at neutral position and allow the engine speed to return to idle Advance the control lever to further increase speed 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 This will allow the use of the power trim tilt from the remote control handle Reduce engine speed and...

Page 120: ...l Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory ...

Page 121: ...nance performed to maintain emission levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule BEFORE EACH USE Check that lanyard stop switch stops the engine Visually inspect the fuel system for deteri...

Page 122: ...CCURS FIRST Retorque the outboard mounting fasteners that fasten the outboard to the transom Torque to 75 Nm 55 lb ft 1 Lubricate all lubrication points Lubricate more frequently when used in saltwater See Lubrication Points Replace spark plugs at first 100 hours or first year After that inspect spark plugs every 100 hours or once yearly Replace spark plugs as needed See Spark Plug Inspection and ...

Page 123: ...ating occurs or reduced water pressure is noted 1 Inspect the poppet valve assembly for deterioration of the rubber diaphragm Replace the rubber diaphragm if necessary 1 Replace the two in line oil filters located in the air compressor oil return lines 1 BEFORE PERIODS OF STORAGE Refer to storage procedure See Storage section Flushing the Cooling System Flush the internal water passages of the out...

Page 124: ...perly and lock the front and side latches Cleaning Care for Top Cowl IMPORTANT Dry wiping wiping the plastic surface when it is dry will result in minor surface scratches Always wet the surface before cleaning Follow the cleaning and waxing procedure CLEANING AND WAXING PROCEDURE 1 Before washing rinse the top cowl with clean water to remove the dirt and dust that may scratch the surface 2 Wash th...

Page 125: ...rioration in the rubber portion of the belt b Belt surfaces rough or uneven c Signs of wear on edges or outer surfaces of belt 29448 Fuel System WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and...

Page 126: ...nspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced FUEL FILTER REPLACEMENT Removal 1 Use the fuel filter removal installation tool or the shaft of a screwdriver bet...

Page 127: ...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 Draining the water from the fuel filter chamber is required 1 Pull the drain hose off the right side fitting Hold the open end of the hose over a container 2 Use a 1 8 in hex wrench and loosen the drain screw a...

Page 128: ...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 a special washer head bolt a Part Number 10 849838 and self locking nylon insert locknuts c and d Part Number 11 826709113 These locknuts must never be replaced with common nuts nonlocking as they will work loose and vibrate off freeing the link ro...

Page 129: ... bolt 10 849838 b Flat washer 2 c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighten until it seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and self locking nylon insert locknut Tighten locknut until it seats then...

Page 130: ...the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same rating a Good fuse b Blown fuse c Power on circuit 20 amp fuse d Ignition system circuit 20 amp fuse e Spare fuse slot f Fuel injector direct injector starter slave solenoid PCM and electric fuel pumps circuit 20 amp fuse g Diagnostic circuit 2 amp fuse ...

Page 131: ...all unused connectors and receptacles are covered with a weather cap Verify the harnesses are fastened along the routing path Corrosion Control Anode Your outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals Each anode requires periodic inspection esp...

Page 132: ...control anode transom bracket Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Ensure the battery is secure against movement 3 Battery cable terminals should be clean tight and correctly installe...

Page 133: ...attery cable size and length is critical Refer to engine installation manual for size requirements The decal needs to be placed on or near the battery box for future service reference One 5 16 in and one 3 8 in hex nut is supplied per battery for wing nut replacement Metric hex nuts are not supplied NOTICE DTS OptiMax Engines DO NOT USE DEEP CYCLE BATTERIES DTS Digital Throttle and Shift applicati...

Page 134: ...ng a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Shift outboard to neutral N position F N R 28926 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing spark plug leads 2 Remove spark plug leads to prevent engine from starting 26899...

Page 135: ...Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C with PTFE Propeller shaft 92 802859A 1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply a coat of the ...

Page 136: ...ub propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 9 Place a block of wood between gearcase and propeller and torque to specifications Description Nm lb in lb ft Propeller nut 75 55 10 Secu...

Page 137: ... avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark p...

Page 138: ...ons Description Nm lb in lb ft Spark plug 27 20 Compressor Air Intake Filter The filter should be changed every 100 hours of operation or once a season IMPORTANT Never run the engine without the compressor air intake filter REMOVAL 1 Open the clamp and lift out the filter housing Rotate the filter housing 1 4 turn clockwise to the unlock position and remove the air filter ...

Page 139: ...MAINTENANCE eng 127 2 Remove the hose cable tie and and pull the air filter off the hose a Air filter b Nylon washer c Rubber washer d Clamp e Filter housing f Cable tie a b c 28732 d e f ...

Page 140: ...he lock position 2 Position the filter housing so that the inlet hose is facing towards the back of the engine Reinstall the hose and secure with a cable tie 3 Secure the filter housing with the clamp Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101 Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Trim rod ball ends 92 8028...

Page 141: ...E Propeller shaft 92 802859A 1 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 26902 3 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with PTFE or Special Lubricant 101 Tube Ref No Description Where Used Par...

Page 142: ...t tensioner pivot shaft swivel bracket tilt support lever tilt tube steering cable 92 802859A 1 Alternator belt tensioner pivot shaft Lubricate through fitting 2884 Swivel bracket Lubricate through fitting Tilt support lever Lubricate through fitting a Swivel bracket b Tilt support lever a b 27873 ...

Page 143: ...loss of boat control Completely retract the end of the steering cable before applying lubricant Steering cable Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting a Fitting b Cable end 4 Lubricate the following with lightweight oil Steering link rod pivot points Lubricate pivot points 27876 a b 27875 ...

Page 144: ...p and check fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Precision Lubricant Power Trim and Steering Fluid If not available use automotive automatic transmission fluid ATF 28460 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim system 92 858074K01 ...

Page 145: ...gearcase Examine the drained gearcase lubricant for metal particles A small amount of metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEARCASE 1 Place outboard in a vertical operating position 2 Remove propeller Refer to Propeller Replacement 3 Place drai...

Page 146: ...g washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer i...

Page 147: ...ing gasoline as possible from the fuel tank remote fuel line and engine fuel system 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 ...

Page 148: ...h the hose 6 Pull the drain hose off the left side fitting Hold the open end of the hose over a container 7 Loosen the drain screw and drain the float chamber a Left side fitting b Drain screw c Drain hose 8 Retighten the drain screw and reattach the hose 9 Premix the following in a container a 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Quickleen lubricant b 8 cc 0 27 oz or 2 teaspoons of Me...

Page 149: ...h water connection when flushing the cooling system or operating the engine Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceding IMPORTANT Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark plug leads 1 Remove the spark plugs Add approximately 30 ml 1 oz of engine oil or inject a five ...

Page 150: ...ge Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze Store the outboard in the full down position Battery Storage Follow the battery manufacturer s instructions for ...

Page 151: ...ion faulty Starter motor solenoid or slave solenoid failure Engine Will Not Start POSSIBLE CAUSES Lanyard stop switch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Prime...

Page 152: ... the engine a Engine fuel filter is obstructed Refer to Maintenance section b Fuel tank filter obstructed c Stuck antisiphon valve on built in fuel tank d Fuel line is kinked or pinched e Injector plugged 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 si...

Page 153: ...eng 141 Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator Open circuit in the alternator output wire fused link ...

Page 154: ... local authorized dealer The dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts 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 produc...

Page 155: ...4936 1939 Fax English 920 929 5893 Français 905 636 1704 Website www mercurymarine com Australia Pacific Telephone 61 3 9791 5822 Brunswick Asia Pacific Group 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Cen...

Page 156: ...OWNER SERVICE ASSISTANCE 144 eng Asia Singapore Telephone 65 65466160 Brunswick Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789 ...

Page 157: ...MAINTENANCE LOG eng 145 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

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