Mercury 200 Optimax Page 95 Manual Download

Page: 95 / 155

MAINTENANCE

eng

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,

or blistered, or if the precious metal is not visible on the

plug's electrode.

IMPORTANT: The color of the plug may not accurately reflect

its condition. To accurately diagnose a faulty plug, inspect the

precious metal on the plug's electrode. If no precious metal is

visible, replace the plug.

a -

Precious metal

3. Set the spark plug gap to specifications.

27848

9381

Summary of Contents for 200 Optimax

Page 1: ... 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 the ...

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: ...r California Emission Control Warranty Statement 18 Emission Certification Star Label 19 General Information Boater s Responsibilities 21 Before Operating Your Outboard 21 Boat Horsepower Capacity 21 Intended Boat Application 22 Propeller Selection 22 Outboard Remote Control Models 25 Remote Steering Notice 26 Lanyard Stop Switch 26 Protecting People in the Water 30 Exhaust Emissions 30 Passenger ...

Page 8: ... Features 49 Zero Effort Control Features 50 Warning System 50 Overspeed Rev Limit 53 Power Trim and Tilt 54 Operation Engine Break in 59 Engine Break in Fuel Mixture 59 Pre Starting Check List 59 Operating in Freezing Temperatures 60 Operating in Saltwater or Polluted Water 60 Operating at High Elevations 61 Effects of Elevation and Weather on Performance 61 Setting Trim Angle While Running Engin...

Page 9: ...eering Link Rod Fasteners 78 Fuses 80 Corrosion Control Anode 81 Spark Plug Inspection and Replacement 82 Battery Inspection 84 Charging System Fusible Link 85 Propeller Replacement 25 4 mm 1 0 in Diameter Propeller Shaft 85 Propeller Replacement 31 75 mm 1 1 4 in Diameter Propeller Shaft 88 Lubrication Points 90 Checking Power Trim Fluid 92 Gearcase Lubrication 93 Storage Storage Preparation 95 P...

Page 10: ...mance Loss 100 Warning Horn Activates With Power Loss 100 Warning Horn Activates No Power Loss 101 Battery Will Not Hold Charge 101 Owner Service Assistance Local Repair Service 103 Service Away from Home 103 Parts and Accessories Inquiries 103 Service Assistance 103 Mercury Marine Service Offices 104 Ordering Literature 105 ...

Page 11: ...illing the Fuel System 108 Installation Specifications 109 Lifting the Outboard 109 Steering Cable Starboard Side Routed Cable 110 Steering Link Rod Fasteners 111 Determining Recommended Outboard Mounting Height 114 Drilling Outboard Mounting Holes 115 Fastening the Outboard to the Transom 116 Electrical Hoses Control Cables and Front Clamp 120 Filling the Fuel System 137 Oil Injection Set Up 138 ...

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: ... Learn how to operate your outboard properly If you have any questions contact your dealer 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 WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situatio...

Page 34: ...ur Propeller Selection The propeller on your outboard is one of the most important components in the propulsion system An improper propeller choice can significantly affect the performance of your boat and could result in damage to the outboard engine When choosing a propeller a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through ...

Page 35: ...reduced pitch to increase engine RPM IMPORTANT To ensure proper fit and performance Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware Propellers are designated by the diameter pitch number of blades and material The diameter and pitch are stamped cast into the side or the end of the propeller hub The first number represents the diameter of the pro...

Page 36: ...er pitch propeller will accelerate quickly but top end speed will be reduced The higher the propeller pitch the faster the boat will usually go though typically slowing acceleration Determining the Correct Pitch size First check the full throttle RPM under normal load condition If the full throttle RPM is within the recommended range select a replacement or upgrade propeller with the same pitch as...

Page 37: ...n many sizes of both aluminum and stainless 3 and 4 blade propellers have unique performance characteristics In general 3 blade propellers offer good all around performance and higher top speed than 4 blade propellers However 4 blade propellers are usually faster to plane and more efficient at cruising speeds but lack the top end speed of a 3 blade propeller Outboard Remote Control Models The remo...

Page 38: ...cted loss of boat control resulting in serious injury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from t...

Page 39: ... 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 the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard a Lanyard cord...

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: ...tion 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 immediately whenever anyone in the water is near your boat Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat Exhaust Emissions BE ALERT TO CA...

Page 43: ...erway STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide Avoid areas of concentrated engine exhaust gases When engines are running keep swimmers away from the boat and do not sit lie or stand on swim platforms or boarding ladders While underway do not allow passengers to be positioned immediately behind the boat platform dragging teak body surfing This dangerous...

Page 44: ...all 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 when the boat is moored in a confined space b Mooring...

Page 45: ...rs to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of the boat Falling over the front of the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN ...

Page 46: ...ve idle can cause serious injury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden re...

Page 47: ...new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your bo...

Page 48: ...g or underwater object could result in an infinite number of situations Some of these situations could result in the following Part of the outboard or the entire outboard could break loose and fly into the boat The boat could move suddenly in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will ...

Page 49: ...pact have an authorized Mercury Marine dealer inspect and repair the vessel or power package 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 IMPORTANT Check with your dealer before installing accessories The misuse of approved accesso...

Page 50: ...oat U S Foundation information number 1 800 336 BOAT Make sure everyone in the boat is properly seated Do not allow anyone to sit or ride on any part of the boat that was not intended for such use This includes the back of seats gunwales transom bow decks raised fishing seats any rotating fishing seat or anywhere that an unexpected acceleration sudden stopping unexpected loss of boat control or su...

Page 51: ...ing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is invol...

Page 52: ...ifications Models 200 225 250 Cylinder configuration 60 V6 60 V6 60 V6 Propeller shaft horsepower 200 225 250 Propeller shaft kilowatts 147 165 184 Number of cylinders 6 Idle RPM 575 RPM Full throttle RPM range 5000 5750 RPM 5500 6000 RPM Engine displacement 3032 cc 185 in Cylinder bore 92 075 mm 3 625 in Stroke 76 2 mm 3 0 in Recommended spark plugs NGK IZFR5G NGK lZFR6J or NGK IZFR6J 11 if these...

Page 53: ... 4 mm 1 0 in diameter propeller shaft gearcase Right hand rotation 970 ml 32 8 fl oz Left hand rotation 900 ml 30 4 fl oz Gearcase lubricant 31 75 mm 1 1 4 in diameter propeller shaft gearcase 760 ml 25 7 fl oz Battery rating 1000 marine cranking amps MCA or 800 cold cranking amps CCA 1 Charging system output maximum 60 A Emission control system Electronic engine control EC Sound at driver s ear I...

Page 54: ...latch 3 Auxiliary tilt switch 4 Clamp swivel bracket 5 Gearcase 6 Cooling water intake 7 Skeg 8 Anti ventilation plate 9 Anodes one per side 10 Driveshaft housing 11 Bottom cowl 12 Water pump indicator tell tale 13 Side cowl latches both sides 1 7493 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 55: ...e the engine is not operating rotate the propeller shaft in the appropriate direction during shifting Trailer your boat with the outboard tilted down in a vertical operating position If additional ground clearance is required the outboard should be tilted up using an accessory outboard support device Refer to your local dealer for recommendations Additional clearance may be required for railroad c...

Page 56: ... considered engine misuse and is not covered under the limited warranty Use only the recommended fuel in the engine OCTANE REQUIREMENTS U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium1 87 R M 2 OCTANE REQUIREMENTS OUTSIDE THE U S CANADA FUEL TYPE MINIMUM POSTED OCTANE Unleaded premium2 92 RON 1 Mercury Marine does not recommend using leaded gasoline Read the information in the Fuel Con...

Page 57: ...ts are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank The fuel system components on your Mercury engine will withstand up to 10 alcohol content in...

Page 58: ...bnormalities is required 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 fuel tank to the outboard Low permeation hose is USCG Type B1 15 or Typ...

Page 59: ...ir Tank Remove the top cowl 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 Retighten the fill cap Stop the engine and replace the top cowl 2724 NOTE Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated...

Page 60: ...me unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled WARNING Avoid serious injury or death from a gasoline fire or explosion Use caution when filling fuel tanks Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks ...

Page 61: ...ase lever c Trim tilt switch if equipped Refer to Features and Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON START h Fast idle lever Refer to Operation Starting the Engine i...

Page 62: ...ning horn inside the boat The warning horn may be located inside the remote control or under the dash connected to the ignition key switch a Inside the remote control b Under the dashboard 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 tell you the horn is working a b c 4090 a b 27755 ...

Page 63: ...ng engine power in order to provide engine protection If Guardian System is activated the system must be reset before the engine will operate at higher speeds Moving throttle lever back to idle or to the required reduced throttle position resets the system Problem Horn Monitor Display Guardian Activated Percentage of Full Engine Power Available Power Up System Check Single Beep Yes N A N A During ...

Page 64: ...n Engages Yes Yes 10 v 0 11 5 v 50 No No 11 5 16 v 100 Yes Yes 16 v 50 17 v 0 Horn Failure No Yes Yes 95 Water In Fuel 4 Beeps 2 Minutes Off Yes No N A MAP Sensor Failure No Yes Yes 95 Air Temperature Sensor Failure No Yes No N A Ignition Coil Failure No Yes No N A Injector Failure No Yes No N A SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this power packa...

Page 65: ...be displayed during the engine break in period Overspeed Rev Limit The overspeed rev limit is set at an RPM greater than the operating range In the event that the engine is operated at an RPM greater than or equal to the overspeed limit the PCM does not allow the engine to maintain the power required Refer to Specifications to determine this engine s RPM limit Upon reaching the rev limit the Guard...

Page 66: ...ally used when referring to adjusting the outboard further up out of the water With the engine turned off 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 Tilt range of travel c Trim range of travel POWER TRIM OPERATION With most boats operating around the middle of the...

Page 67: ...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 68: ...at a normal installation height with the normal right hand rotation propeller In excess can cause boat porpoising bouncing or propeller ventilation Cause engine overheating if any cooling water intake holes are above the waterline TILTING OPERATION To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the swi...

Page 69: ...clockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 22362 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 a...

Page 70: ...FEATURES AND CONTROLS 58 eng AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system a Auxiliary tilt switch a 2745 ...

Page 71: ...e Always vary throttle settings during Break in 1st Hour Allow engine to warm up for 30 60 seconds Do not idle for more than five 5 minutes Run the engine the majority of the time between 4000 5400 RPM approximately three quarter throttle Change engine speed approximately every two 2 minutes Avoid trimming the outboard out up beyond a vertical trim position during operation Avoid using hydraulic j...

Page 72: ...pletely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possible damage Operating in Saltwater or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passage...

Page 73: ...harged engines Horsepower and torque throughout the RPM range Peak RPM Cranking compression EXAMPLE An engine run at an elevation of 8 000 feet will have over a 30 power loss while a loss of engine power on a hot and humid day could be as much as 14 These losses apply to normally aspirated and supercharged engines Compensating for power robbing conditions Switch to lower pitch propeller Change gea...

Page 74: ... Relief hole above waterline correct Operating in Shallow Water When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom NOTICE Operating the engine with the outboard in the tilt range can damage the engine or the transom If operating the engine in the tilt range such as in shallow water do not exceed 2000 RPM 1 Reduce engine speed...

Page 75: ...owing procedure 1 Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb until it feels firm 2 Turn the ignition key switch to the ON position for three seconds to operate the electric fuel pump 3 Turn the ignition key switch back to the OFF position and squeeze the primer bulb until it feels firm Turn the ignition key switch to the...

Page 76: ... so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm 27348 4 Set the lanyard stop switch to the RUN position Read the lanyard stop switch safety explanation and warning in the General Information section 19791 5 Shift the outboard to the neutral position N 26838 ...

Page 77: ...ter coming out of the water pump indicator hole 2746 NOTE The electronic starting system will automatically prime choke the engine and increase idle speed for starting NOTICE Operating the engine while overheated can cause engine damage If no water exits the water pump indicator hole stop the engine and check the cooling water intake holes for obstruction No obstruction may indicate a water pump f...

Page 78: ...s not operating rotate the propeller shaft in the appropriate direction during shifting Your outboard has three gear shift positions to provide operation forward neutral out of gear and reverse N R F 27237 When shifting always stop at neutral position and allow the engine speed to return to idle Always shift into gear with a quick motion After shifting into gear advance the lever further to increa...

Page 79: ...e best operating condition by performing the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule Record maintenance performed in the Maintenance Log at the back of this book Save all maintenance work orders and receipts Submerged Power Package A submerged power package requires prompt service by an authorized dealer after recovery This immediate attention is nece...

Page 80: ...blishment or individual EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at the time of manufacture a Idle speed b Engine horsepower c Piston displacement d Engine power kilowatts e Date of manufacture f Family number g Regulated emission limit for the engine family h Regulated emiss...

Page 81: ...ue the outboard mounting fasteners to the specified torque When looking for signs of looseness look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard transom brackets Also look for signs of movement between the outboard transom brackets and the boat transom lift plate setback bracket Description Nm lb in lb ft Outboar...

Page 82: ...25 HOURS OR EVERY 30 DAYS WHICHEVER OCCURS FIRST Visually inspect the front and side cowl latches for tightness Tighten if necessary Visually inspect the fuel and oil systems for deterioration or leaks Visually check steering link rod fasteners for wear Lubricate all components refer to the Installation Manual for lubrication specifications Check all attachment hardware for proper torque tightness...

Page 83: ...with Power Tune Engine Cleaner Tube Ref No Description Where Used Part No 151 Power Tune Engine Cleaner Use to remove engine deposits 92 858080K03 EVERY 100 HOURS OR ONCE A YEAR WHICHEVER OCCURS FIRST Retorque the outboard mounting fasteners that fasten the outboard to the boat transom Tighten the fasteners to the specified torque 1 Description Nm lb in lb ft Outboard mounting locknuts and bolts s...

Page 84: ...ipped is in place Check that the idle relief muffler if equipped is in place Check for loose hose clamps and rubber boots if equipped on the air intake assembly EVERY 100 HOURS OF OPERATION Inspect carbon fiber reeds for chipping or cracks BEFORE PERIODS OF STORAGE Refer to Storage section Flushing the Cooling System Powerhead Flush the internal water passages of the engine with fresh water after ...

Page 85: ... 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 a Fleet Master and Torque Master gearcase b Sport Master gearcase c Water hose d Flushing attachments 1 Remove the propeller Refer to Propeller Replacement 2 Fleet Master and Torque Master gearcases Install the appr...

Page 86: ...oming out of the water pump indicator hole Continue flushing for three to five minutes carefully monitoring water supply at all times 8 Stop the engine turn off the water and remove the flushing attachment Reinstall the propeller Top Cowl Removal and Installation REMOVAL Release the front and side cowl latches Lift the top cowl from the outboard 2732 INSTALLATION Position the top cowl over the eng...

Page 87: ...es of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately IMPORTANT Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved recept...

Page 88: ... warning system engages when water in the fuel filter reaches the full level Refer to Warning System in Features and Controls Refer to the Inspection and Maintenance Schedule for the proper maintenance interval Removal a O ring seals b Filter c Raised bosses 1 Disconnect the link rod 2 Use the shaft of a screwdriver between the filter cap bosses and unscrew the filter Installation 1 Lubricate the ...

Page 89: ...nt 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 open end of the hose over a container 2 Loosen drain screw and drain the fuel filter chamber NOTE If little or no liquid drains from the hose loosen the red filter to vent the chamber 3 Retigh...

Page 90: ...self locking nylon insert locknuts P N 11 826709113 Never replace locknuts with common nuts nonlocking 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 cause a sudden unexpected loss of boat control resulting in serious injury or death d...

Page 91: ...Flat washer 2 d Nylon insert locknut P N 11 826709113 used on cable coupler 1 Assemble steering link rod to steering cable coupler with two flat washers c and a self locking nylon insert locknut d Tighten the locknut until it seats then loosen turn 2 Assemble the steering link rod to the engine with the special washer head bolt a and self locking nylon insert locknut b 3 Torque the head bolt then ...

Page 92: ...ircuits on the engine are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse 2 Replace fuse with a new fuse with the same rating ...

Page 93: ...0 amp fuse g Accessories cowl mounted tilt switch wake power to ECM 20 amp fuse h Electric fuel pump ECM driver power oil pump circuit injectors 20 amp fuse Corrosion Control Anode NOTICE Anodes made of insufficiently pure aluminum alloys may not adequately protect critical drive components from corrosion We recommend using anodes sold through Mercury Precision Parts only a b 5 2 20 20 20 c e d f ...

Page 94: ... on clamp swivel bracket All anodes require periodic inspection especially in saltwater refer to the Inspection and Maintenance Schedule Replace any anodes before they are 50 corroded Never paint or apply protective coating on the anode as effectiveness of the anode will be reduced Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors u...

Page 95: ...lator is rough cracked broken or blistered or if the precious metal is not visible on the plug s electrode IMPORTANT The color of the plug may not accurately reflect its condition To accurately diagnose a faulty plug inspect the precious metal on the plug s electrode If no precious metal is visible replace the plug a Precious metal 3 Set the spark plug gap to specifications 27848 a 9381 ...

Page 96: ...eriodic 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 installed Positive to positive and negative to negative 4 Ensure the battery is equipped with...

Page 97: ...s limited because the alternator is not charging the boat battery If the fusible link circuit becomes open contact your authorized Mercury Marine dealer 3797 Propeller Replacement 25 4 mm 1 0 in Diameter Propeller Shaft WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the...

Page 98: ...f the shaft If the propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 5 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 94 Anti Corrosion Grease Propeller shaft splines 92 802867Q 1 95 2 4 C with PTFE Propeller...

Page 99: ...r f Forward thrust hub 7 Flo Torq II drive hub propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 8 Place a block of wood between the gearcase and propeller and torque to specifications Description...

Page 100: ...he 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 position 2 Place a block of wood between the gearcase and propeller to hold the propeller and remove the propeller nut 29592 3 Pull propeller straight off the shaft If the propeller is seized to the shaft and cannot be removed have ...

Page 101: ...splines 92 802859A 1 NOTE Propellers used on the 31 75 mm 1 1 4 in diameter propeller shaft require the heavy duty propeller hub kit 5 Heavy duty propeller hub Install the propeller hub propeller washer Belleville washer washer and propeller nut onto the shaft a Propeller nut b Washer c Belleville washer d Washer e Propeller f Propeller hub a b c d e f 44856 ...

Page 102: ...CE 90 eng 6 Place a block of wood between the gearcase and propeller and tighten the propeller nut to the specified torque 2691 Description Nm lb in lb ft Propeller nut 75 55 Lubrication Points 7723 95 95 34 3 4 ...

Page 103: ... the ball sockets Lubricate through fittings WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant 7727 95 95 95 110 110 Tube Ref No Description Where Used Part No 95 2 4 C Marine Lubricant with PTFE Steering cable and grease fitting on belt tensioner pulle...

Page 104: ...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 105: ...amage the 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 ...

Page 106: ...ard in a vertical operating position 2 Remove vent plug sealing washer 3 Remove fill drain plug Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole a Vent hole b Fill hole IMPORTANT Replace sealing 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 clean...

Page 107: ...ine and engine fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on their containers to the fuel tank before the last operation of the boat Adding Fuel Stabilizer will help prevent the formation of varnish and gum in the gasoline The Mercury Precision Quickleen pr...

Page 108: ...n hose off the left side fitting Hold the open end of the hose over a container and loosen drain screw and drain the float chamber Retighten drain screw and reattach hose a Left side fitting b Drain screw c Drain hose 6 Premix the following in a container 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Quickleen lubricant 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Fuel Stabilizer a b c 2895...

Page 109: ...efer 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 second spray of storage seal into each spark plug hole 2 Rotate the flywheel manually several times to distribute the oil or storage seal in the cylinders 3 Reinstall spark plu...

Page 110: ... 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 storage and recharging Remove the battery from the boat and check water level Recharge if nec...

Page 111: ...witch 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 Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank ...

Page 112: ... Injector plugged Threaded connection of an air hose is loose Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not opening fully Damaged propeller or improper propeller size Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Warning horn failure Engine block pressure sensor or coolant temperature sens...

Page 113: ...the allowable range If the overspeed condition continues Guardian places the engine into power reduction Overspeed may be caused by incorrect propeller pitch engine height trim angle etc High engine temperature or low block water pressure Cooling system clogged Incorrect transom height water pickups not getting adequate water supply Warning Horn Activates No Power Loss POSSIBLE CAUSES Warning horn...

Page 114: ...TROUBLESHOOTING 102 eng Defective rectifier alternator or voltage regulator ...

Page 115: ... 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 116: ...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 117: ...CANADA For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact MERCURY MARINE Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest dealer o...

Page 118: ... or Premium Plus TC W3 is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or varying grades of gasoline IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Periodically consult with your dealer to get the latest gasoline and oil recommendations If Mercury Precision or Quicksilver 2 Cycle Outboard Oil is not available substitute a...

Page 119: ...ertain federal 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 Start in Gear Protection WARNING Starting the engine with the drive in gear can cause serious injury or death Never operate a boat that does not have a neutral safety protection device The remote cont...

Page 120: ... 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 fuel tank to the outboard Low permeation hose is USCG Type B1 15 or Type A1 15 defined as not exceeding 15 gm 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fuel hose Fi...

Page 121: ...cm 59 3 4 in Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling causing serious injury or death Before lifting the engine verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight To lift the outboard 1 Remove the cowl from the outboard 18...

Page 122: ...the boat transom Lifting Eye 91 90455 1 2756 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing or to lift entire engine for removal installation Steering Cable Starboard Side Routed Cable 1 Lubricate O ring seal and entire cable end 3724 95 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE O ring seal and entire cable end 92 802859A 1 a 28495 ...

Page 123: ...teering 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 P N 10 849838 and self locking nylon insert locknuts P N 11 826709113 Never replace locknuts with common nuts nonlocking as they will work loose and vibrate off freeing the link rod to disengage ...

Page 124: ...ized steering components can lead to loss of boat control Inspect all steering attachment components for wear lubricate all attachment hardware and check all fasteners for proper tightness in accordance with the inspection and maintenance schedule a Special washer head bolt P N 10 849838 b Nylon insert locknut P N 11 826709113 used on head bolt c Flat washer 2 d Nylon insert locknut P N 11 8267091...

Page 125: ...asher head bolt a and self locking nylon insert locknut b 3 Torque the head bolt then the locknut to specifications Description Nm lb in lb ft Cable coupler nylon insert locknut d Tighten locknut until it seats then loosen turn Head bolt nylon insert locknut b 27 20 Special washer head bolt 27 20 ...

Page 126: ...ion if maximum speed is the only objective d This line may be preferred to determine outboard mounting height dimension for dual outboard installation e Outboard mounting height height of outboard mounting brackets from bottom of boat transom For heights over 56 0 cm 22 in a propeller that is designed for surfacing operation is usually preferred f Maximum boat speed MPH anticipated 20 in 21 in 22 ...

Page 127: ...tboard must not exceed 63 5 cm 25 in for L models 76 cm 30 in for XL models Mounting the outboard higher may cause damage to the gearcase components Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause propeller to break loose during planing Drilling Outboard Mounting Holes IMPORTANT Before drilling any mounting holes carefully read De...

Page 128: ...Hardware Supplied with Outboard Part Number Part Name Description 10 67755 1 Outboard mounting bolt 20 x 4 50 in long 2 25 in thread 11 826711 17 Nylon insert locknut 20 12 28421 Flat washer 1 1 2 in diameter 12 54012 Flat washer 7 8 in diameter Available Outboard Mounting Bolts Part Number Description 10 67755005 20 x 2 50 in long 1 25 in thread 10 67755006 20 x 3 50 in long 1 25 in thread 10 814...

Page 129: ...2 75 in thread CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT Determine the strength of the boat transom The outboard mounting locknuts and bolts should be able to hold 75 Nm 55 lb ft of torque without the boat transom yielding or cracking If the boat transom yields or cracks under this torque the construction of the transom may not be adequate The boat transom must be strengthened or the load carry...

Page 130: ...transom reinforcement plate a Large transom washer b Transom reinforcement plate 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting hardware Tighten the locknuts to the specified torque IMPORTANT Ensure a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be drawn tight while...

Page 131: ...oard mounting bolt 4 b 7 8 in flat washer 4 c Nylon insert locknut 4 d 1 1 2 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 a c d c a d 40952 b e ...

Page 132: ...e the battery leads can result in a loss of power to the Digital Throttle and Shift DTS system leading to serious injury or death due to loss of boat control Secure the battery leads to the battery posts with hex nuts to avoid loose connections Do not use deep cycle batteries Engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah When connecting the engine battery hex nuts must...

Page 133: ... 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 IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements DO NOT USE WING NUTS 37 895387 3486 13 5Nm 120 lbs in Place decal on or near battery box for future service reference 5 16 and 3 8 hex ...

Page 134: ...sleeve Negative c Ground cable d Cranking battery HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter I D is 8 mm 5 16 in with a separate fuel line fuel tank pickup for each engine Fasten the remote fuel hose to the fitting with a hose clamp Oil Hoses Connect the remote oil hoses to the engine hose connections Fasten hose connections with cable ties a a b b c d d 15497 ...

Page 135: ...t gauges This outboard has a speedometer water pickup located in the leading edge of the gearcase If you want to use this water pickup for the speedometer disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl Install the coupler provided with the outboard on the end of the tubing ...

Page 136: ...hown a Water pressure tube b Speedometer water pickup tube if required c Coupler d Plug e Barb hose fitting f Speedometer hose or tubing g Water pressure tube h Remote fuel hose i Hose clamp j Oil hose with blue stripe k Oil hose without blue stripe l Cable tie c e d g f b a h i j k l j k 29069 ...

Page 137: ...ard position as follows a Move the remote control handle from neutral into forward and advance the handle to the full speed position Ensure the throttle control lever is touching the throttle control lever stop screw b Slowly return the handle back to the neutral detent position c Place a mark on the shift cable against the cable end guide a Forward position mark 2 Mark the reverse position as fol...

Page 138: ... marks a Center mark 4 Align the cable end guide against this center mark when installing the cable to the engine 5 Position the remote control and outboard into neutral position 6 Slide the anchor pin forward until resistance is felt then slide the anchor pin toward the rear until resistance is felt 7 Center the anchor pin between these resistance points a Anchor pin a 29077 4361 a a 28746 ...

Page 139: ... 3 Secure the shift cable to the anchor pin with the retainer clip a Cable barrel b Cable latch c Retainer clip 4 Check the shift cable adjustments as follows a Shift the remote control to forward while turning the propeller shaft If the propeller shaft does not lock in gear adjust the cable barrel closer to the cable end guide b Shift the remote control into neutral If the propeller shaft does no...

Page 140: ...first cable to move when the remote control handle is moved out of neutral so install connect it to the engine first Locating the Center Point of the Shift Cable IMPORTANT Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustment of the shift cable 1 Mark the forward position as follows a Move the remote control handle from neutral into forward and ad...

Page 141: ... cable against the cable end guide a Reverse position mark 3 Mark the center on the shift cable midway between the forward and reverse marks a Center mark standard and counter rotation outboards 4 Align the cable end guide against this center mark when installing the cable to the engine 5 Position the remote control and outboard into neutral position 6 Slide the shift cable retainer forward until ...

Page 142: ...he Shift Cable To adjust the shift cable 1 Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable a Center mark 2 Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder 2675 a 4362 a ...

Page 143: ... not lock in gear adjust the cable barrel closer to the cable end guide b Shift the remote control into neutral If the propeller shaft does not turn freely without drag adjust the barrel away from the cable end guide Repeat steps a and b c Shift the remote control into reverse while turning the propeller shaft If the propeller shaft does not lock solidly in gear adjust the barrel away from the cab...

Page 144: ...Attach the throttle cable to the throttle lever Secure with a washer and locknut Tighten the locknut to the specified value a Nylon washer b Locknut Description Nm lb in lb ft Throttle cable locknut b Tighten then loosen 1 4 turn 3 Adjust the cable barrel so the installed throttle cable will hold the idle stop screw against the stop a Barrel sleeve b Cable barrel c Idle stop screw 4 Check the thro...

Page 145: ... is correct when the paper can be removed without tearing but has some drag on it IMPORTANT The idle stop screw must be touching the stop a Idle stop screw b Idle stop d Adjust the cable barrel if necessary 5 Lock the barrel holder in place with the cable latch 2682 INSTALLING THE THROTTLE CABLE MODELS WITH 31 75 MM 1 1 4 IN DIAMETER PROPELLER SHAFT IMPORTANT Attach the shift cable to the engine p...

Page 146: ...hrottle cable will hold the idle stop screw against the stop a Cable barrel b Idle stop screw 4 Check the throttle cable adjustment as follows a Shift the outboard into gear a few times to activate the throttle linkage Rotate the propeller shaft while shifting into reverse b Return the remote control to neutral c Place a thin piece of paper between the idle adjustment screw and the idle stop The a...

Page 147: ...l holder in place with the cable latch 2682 FRONT CLAMP ASSEMBLY INSTALLATION IMPORTANT There must be sufficient slack in the engine wiring harness battery cables fuel hose and oil hoses between clamp and engine attachment point to relieve stress and prevent hoses from being kinked or pinched 1 Place the lower half of the front clamp into the bottom cowl opening 2680 a b ...

Page 148: ...wer half of the front clamp a Neoprene wrap b Lower half of the front clamp 3 Join the top half of the front clamp with the bottom half Secure both halves together with cables ties a Top half of the front clamp b Cable ties 4 Secure the front clamp into the bottom cowl with the retainer and two screws a b 29073 a b 29074 ...

Page 149: ... To fill and prime the fuel system 1 Squeeze the fuel line primer bulb until it feels firm 2 Turn the key switch to the ON position for three seconds This operates the electric fuel pump 3 Turn the key switch back to the OFF position and squeeze the primer bulb again until it feels firm 4 Turn the key switch to the ON position again for three seconds 5 Continue this procedure until the fuel line p...

Page 150: ...LLING OIL SYSTEM 1 Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual Tighten fill cap a Fill cap 2 Remove cap and fill engine oil tank with oil Reinstall the fill cap a Engine oil tank b Fill cap a 2683 a b 7745 ...

Page 151: ... injection pump IMPORTANT Fill the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel pump will run without fuel during the priming process and may be damaged 1 Fill the fuel system a Connect fuel hose b Fill the fuel system by squeezing the primer bulb c Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line ...

Page 152: ...ree seconds g Continue this procedure until the fuel primer bulb stays firm 2 Turn the ignition key switch to the ON position 3 Within the first 10 seconds after the key switch has been turned on move the remote control handle from neutral into forward This will automatically start the priming process PURGING AIR FROM THE ENGINE OIL TANK 1 Loosen the fill cap on the engine oil tank 2 Start the eng...

Page 153: ...bility is desirable to improve acceleration reduce the angle and time spent in a bow high boat during planing off and in some cases may be necessary to plane off a boat with aft livewells given the variety of available propellers and height range of engine installations However once on plane the engine should be trimmed to a more intermediate position to avoid a bow down planing condition called p...

Page 154: ... in This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired A nonstainless steel shipping bolt should not be used in this application other than on a temporary basis ...

Page 155: ...MAINTENANCE LOG eng 143 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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Mercury 200 Optimax, Manual

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