Mercury 200 Optimax Operation, Maintenance And Installation Manual Download

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The electrical wiring circuits 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 before replacing the fuse. 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

the band is broken, replace the fuse.

2. Replace the fuse with a new fuse with the same rating.

The fuses and circuits are identified as follows:

Fuse location and identification

a -

Good fuse

b -

Blown fuse

c -

Power‑on circuit – 15‑amp fuse

d -

Ignition coil circuit – 20‑amp fuse

e -

Spare fuse slot

f -

Fuel injector/direct injector/PCM and electric fuel pump circuits –

20‑amp fuse

g -

Diagnostic circuit – 2‑amp fuse

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.

51464

MAINTENANCE

eng

Summary of Contents for 200 Optimax

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 200 250 OptiMax Including Pro XS 8M0133618 617 eng ...

Page 2: ...eng ...

Page 3: ...anual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Manual included with the product The Warranty Manual contains a description...

Page 5: ...Skyhook SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine ...

Page 6: ...eng iv ...

Page 7: ...Your Outboard 14 Safe Boating Recommendations 14 Recording Serial Number 16 200 200 Pro XS OptiMax Specifications 17 225 250 Pro XS Specifications 17 250 OptiMax Specifications 18 Component Identification 20 Transporting Trailering Boat Outboard 21 Fuel and Oil Fuel Requirements 22 Oil Recommendation 23 Fuel Additives 23 Fuel Requirements 23 Avoiding Fuel Flow Restriction 24 Low Permeation Fuel Ho...

Page 8: ...hallow Water 38 Starting the Engine 39 Gear Shifting 42 Stopping the Engine 42 Maintenance Cleaning Care Recommendations 43 EPA Emissions Regulations 45 Inspection and Maintenance Schedule 46 Flushing the Cooling System 47 Top Cowl Removal and Installation 47 Alternator Belt Inspection 48 Fuel System 48 Steering Link Rod Fasteners 50 Fuses 51 Corrosion Control Anode 52 Battery Inspection 53 Batter...

Page 9: ...ard for Storage 69 Battery Storage 70 Troubleshooting Starter Motor Will Not Crank the Engine 71 Engine Will Not Start 71 Engine Runs Erratically 71 Performance Loss 72 Warning Horn Activates With Power Loss 72 Warning Horn Activates No Power Loss 72 Battery Will Not Hold Charge 73 Owner Service Assistance Service Assistance 74 Ordering Literature 76 eng vii ...

Page 10: ... Your Outboard 83 Fuel System 83 Installation Specifications 85 Lifting the Outboard 85 Steering Cable Starboard Side Routed Cable 86 Steering Link Rod Fasteners 87 Recommended Mounting Height 89 Drilling Outboard Mounting Holes 92 Fastening the Outboard to the Transom 93 Electrical Hoses Control Cables and Front Clamp 98 Oil Injection Set Up 109 Trim In Pin 111 Maintenance Log Maintenance Log 113...

Page 11: ...ng 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 WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

Page 12: ... it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat outboard combination For additional information obtain a copy of our Hi Performance Boat Operation booklet from your dealer distributor or Mercury Marine Outboard Remote Control Models The remote control connected to your...

Page 13: ...hin the specified full throttle operating range When operating the boat at full throttle under normal load conditions the engine RPM should be in the upper half of the recommended full throttle RPM range Refer to Specifications If engine RPM is above that range select a propeller of increased pitch in order to reduce engine RPM If engine RPM is below the recommended range select a propeller of red...

Page 14: ...peller Adding 1 inch of 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 that allows the engine to exceed the recommended full throttle RPM range whe...

Page 15: ...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 the operator s position to activate the switch Tiller handle outboards and some remote control units ...

Page 16: ...rd stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boat...

Page 17: ... the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the b...

Page 18: ... Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats and Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated f...

Page 19: ...njury 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 reduction in boat speed could...

Page 20: ...hange 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 boat pitches down far enough w...

Page 21: ... can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed Boat speed should be kept to a minimum planing speed when...

Page 22: ...ss drowsiness and nausea WARNING Inhaling engine exhaust gases can 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 co co co co co co co co co co co co co co co co co co co co Engi...

Page 23: ...ce 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 close to another boat that has its engine operating 2 Examples of poor vent...

Page 24: ...yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and your state or provincial boating law enforcement agency provide c...

Page 25: ...e driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat s capacity plate Know your boat s operating and loading limitations Know if your boat will float if it is full of water When in doubt contact your authorized Mercury Marine dealer or the boat manufacturer Ensure that everyone in the boat is...

Page 26: ...he 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 involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is p...

Page 27: ...earcase lubricant High Performance Gear Lubricant Gearcase lubricant capacity 970 ml 32 8 fl oz Battery rating 1000 marine cranking amps MCA or 800 cold cranking amps CCA Charging system output maximum 60 A Emission control system Electronic engine control EC Battery manufacturers may rate and test their batteries to different standards MCA CCA Ah and reserve capacity RC are the ratings recognized...

Page 28: ...acity Standard gearcase 970 ml 32 8 fl oz Gen II Torque Master 1040 ml 35 1 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 250 OptiMax Specifications Models 250 Cylinder configuration 60 V6 Kilowatts horsepower 184 250 Number of cylinders 6 Idle RPM 575 RPM Full throttle RPM...

Page 29: ...arcase lubricant capacity 970 ml 32 8 fl oz Battery rating 1000 marine cranking amps MCA or 800 cold cranking amps CCA Charging system output maximum 60 A Emission control system Electronic engine control EC Battery manufacturers may rate and test their batteries to different standards MCA CCA Ah and reserve capacity RC are the ratings recognized by Mercury Marine Manufacturers that use standards ...

Page 30: ...h 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 2 4 5 6 7 8 9 10 11 12 13 3 51577 GENERAL INFORMATION 20 eng ...

Page 31: ...cal dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 28284 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 Shift the outboard to forward gear This prevents the propell...

Page 32: ...ently in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittin...

Page 33: ...3 Outboard 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 Oil is not available we recommend using Mercury or Quicksilver TC W3 Premium Plus 2 Cycle Oil Severe engine damage may result from use of an inferior oil Mercury Racing 2 Stroke Oil is recommended for OptiMax engines that are used in appli...

Page 34: ...al Protection Agency EPA requires portable fuel systems that are produced after January 1 2011 for use with outboard engines to remain fully sealed pressurized up to 34 4 kPa 5 0 psi These tanks may contain the following An air inlet that opens to allow air to enter as the fuel is drawn out of the tank An air outlet that opens vents to the atmosphere if pressure exceeds 34 4 kPa 5 0 psi Fuel Deman...

Page 35: ...ssible fuel spillage When installing the fuel tank cap turn the cap to the right until you hear a click This signals that the fuel cap is fully seated A built in device prevents overtightening The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal Since sealed fuel tanks are not vented they will expand and contract as the fuel expands...

Page 36: ...ote Oil Tank Remove the filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 gallons Replace the filler cap and tighten securely IMPORTANT Always make sure the oil tank caps are threaded on tight An air leak will prevent oil flow to the engine 2723 Filling Engine Mounted Oil Reservoir Tank NOTE Filling this tank is only necessary if the oil level should ever drop and the l...

Page 37: ... filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tanks from the boat to refill them Always stop the engine before filling the tanks Do not completely fill the fuel tanks Leave 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 FUE...

Page 38: ...ard 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 Throttle only button Refer to Operation Starting the Engine Warning System WARNING HORN SIGNALS When the key switch is turned to the ON position the horn will turn on f...

Page 39: ...le conditions are as follows Water in the engine mounted fuel filter Refer to Maintenance Water Separating Fuel Filter Cooling system water pressure or engine temperature problem Stop the engine and check the water intake holes in the lower unit for obstruction Low engine oil level Refer to Fuel and Oil Filling Engine Mounted Oil Reservoir Tank ENGINE GUARDIAN SYSTEM The Engine Guardian system mon...

Page 40: ...the cylinders There is no audible warning while Engine Guardian overspeed limit is active To reset the Engine Guardian protection 1 Completely reduce the throttle for three seconds 2 Engage the throttle If the engine does not respond repeat step one SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard A few of the functions the instrument package wil...

Page 41: ...ater 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 trim range will give satisfactory results However to take full advantage of the trimming capability there may be times when you choose to trim y...

Page 42: ...h speeds with the outboard trimmed too far under can create excessive bow steer resulting in the operator losing control of the boat Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner In rare circumstances the owner may decide to limit the trim in This can be accomplished by purchasing a stainless steel tilt pin from your dealer and in...

Page 43: ...oard cannot be tilted using the power trim tilt switch the outboard can be manually tilted NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation Turn out the manual tilt release valve three turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tigh...

Page 44: ...ed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range 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 FEATURES AND CONTROLS 34 eng ...

Page 45: ...he oil injection pump on new or rebuilt engines or after performing maintenance on the oiling system Refer to Outboard Installation Priming the Oil Injection Pump for instructions FUEL REQUIREMENTS Do not use premixed gas and oil in this engine The engine automatically receives extra oil during engine break in Use a fresh supply of the recommended gasoline during engine break in and after engine b...

Page 46: ...conds Do not idle for more than five minutes Run the engine the majority of the time between 4000 5400 RPM approximately three quarter throttle Short bursts of wide open throttle for 10 seconds or less are acceptable Change the engine speed approximately every two minutes Avoid trimming the outboard out up beyond a vertical trim position during operation Avoid using a hydraulic jack plate to raise...

Page 47: ...s tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use Each month spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces Do not spray on corrosion control anodes as this will reduce the effective...

Page 48: ...lity and durability of the engine Setting Trim Angle While Running Engine at Idle Speed Submerging the exhaust relief hole on the outboard can happen on some boats if you trim full in while running at idle speed resulting in exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim outboard up until exhaust relief hole is out of the water a Relief hole sub...

Page 49: ...he fuel system should be filled according to the following 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 un...

Page 50: ...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 OPERATION 40 eng ...

Page 51: ... 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 failure or blockag...

Page 52: ...nders resulting in severe engine damage Do not shift the outboard into reverse when the engine is not running Damage to the shift linkage could occur The outboard has three gear shift positions forward F neutral N and reverse R When shifting always stop at the neutral position and allow the engine idle speed to stabilize before shifting into another gear Always shift the outboard into gear with a ...

Page 53: ...ilure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product CLEANING GAUGES IMPORTANT Never use high pressure water to clean gauges Routine cleaning of the gauges is recommended to prevent a buildup of salt and other environmental debris Crystalized s...

Page 54: ...a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth 5 To remove minor scratches use Mercury Marine Cowl Finishing Compound 92 859026K 1 CLEANING CARE FOR THE POWERHEAD SALTWATER USE If the outboard i...

Page 55: ...IFICATION 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 US EPA engine family name g Regulated emission limit for the engine family h Regulated emission limit for the engine ...

Page 56: ... ANNUALLY OR 100 HOURS Grease the engine if applicable Change the engine oil and filter if equipped Inspect the thermostat saltwater or brackish water only Add Quickleen to the fuel tank once per year per engine Apply antiseize to the spark plug threads Replace the gear lubricant Inspect the corrosion control anodes Lubricate the propeller shaft splines Replace all filters on the suction side of t...

Page 57: ...r after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages NOTE Engine can be stopped or running at idle speed when flushing the cooling system Do not flush engine using a water system that exceeds 310 26 kPa 45 psi 1 Remove the plug from fitting in the bottom cowl 29444 2 Attach a water hose to the fitting Turn on the wa...

Page 58: ...le 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 Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Mater...

Page 59: ...eaches 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 O ring seals with oil 2 Install the fuel filter and tig...

Page 60: ...in screw and drain the fuel filter chamber 3 Tighten the drain screw and attach the hose a Drain hose b Side fitting c Drain screw IMPORTANT Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm forcing fuel into the chamber Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using a sp...

Page 61: ...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 back nut off 1 4 turn Assemble steering link r...

Page 62: ...he same rating The fuses and circuits are identified as follows Fuse location and identification a Good fuse b Blown fuse c Power on circuit 15 amp fuse d Ignition coil circuit 20 amp fuse e Spare fuse slot f Fuel injector direct injector PCM and electric fuel pump circuits 20 amp fuse g Diagnostic circuit 2 amp fuse Corrosion Control Anode Your outboard has corrosion control anodes at different l...

Page 63: ...dic 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 a n...

Page 64: ...and 3 8 hex nuts to be used for battery terminal wing nut replacement Metric hex nuts must be obtained locally 8M0085862 Refer to the outboard owner s manual for battery requirements Battery cable size and length is critical Refer to engine installation manual for size requirements NOTICE IMPORTANT DO NOT USE DEEP CYCLE BATTERIES 13 5Nm 120 lb in DO NOT USE WINGNUTS Propeller Replacement WARNING R...

Page 65: ...26838 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing the spark plug leads 2 Remove the spark plug leads to prevent engine from starting 26899 3 Straighten the bent tabs on the propeller nut retainer 26900 MAINTENANCE eng 55 ...

Page 66: ...icksilver or Mercury Precision Lubricants Extreme Grease or 2 4 C with PTFE 26902 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Propeller shaft 92 802859A 1 Extreme Grease Propeller shaft 8M0071842 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply a coat of the recommended lubricant to the entire propeller ...

Page 67: ...st washer 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 washer 9 Place a block of wood between the gearcase and the propeller and torque the propeller nut to specifications Description Nm lb in lb ft Propeller nut 75 55 10 Secure...

Page 68: ... plug leads by twisting the rubber boots while pulling them off the spark plugs 26899 2 Remove the spark plugs Replace the spark plug if the electrode is worn the insulator is rough cracked broken or blistered or if the precious metal is not visible on the spark plug electrode IMPORTANT The color of the plug may not accurately reflect its condition To accurately diagnose a faulty plug inspect the ...

Page 69: ...on the ground electrode without touching the center electrode the porcelain or the wear portion of the ground electrode e When it is necessary to close the gap gently tap the plug ground electrode on a hard surface 4 Before installing spark plugs clean off any dirt on the spark plug seats Install the plugs finger tight and then tighten an additional 1 4 turn or tighten to the specified torque Desc...

Page 70: ...le tie INSTALLATION 1 Place the nylon washer and rubber washer onto the air filter and insert the filter into the housing Rotate the filter 1 4 turn to the lock position 2 Position the filter housing so the inlet hose is facing towards the back of the engine Install the hose and secure with a cable tie a b c 28732 d e f MAINTENANCE 60 eng ...

Page 71: ...Lubricate the following with Extreme Grease Tube Ref No Description Where Used Part No Extreme Grease Trim rod ball ends 8M0071842 Trim rod ball ends Turn the ball ends to work the lubricant into the ball sockets 28458 2 Lubricate the following with Extreme Grease or 2 4 C with PTFE a b c 28738 d MAINTENANCE eng 61 ...

Page 72: ...and seizing to the shaft 26902 3 Lubricate the following with 2 4 C with PTFE or Extreme Grease Tube Ref No Description Where Used Part No Extreme Grease Alternator belt tensioner pivot shaft swivel bracket tilt support lever tilt tube steering cable 8M0071842 95 2 4 C with PTFE Alternator belt tensioner pivot shaft swivel bracket tilt support lever tilt tube steering cable 92 802859A 1 Alternator...

Page 73: ...c lock leading to serious injury or death from 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 a b 27873 a b 27875 MAINTENANCE eng 63 ...

Page 74: ...e the fill cap and check the 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 MAINTENANCE 64 eng ...

Page 75: ...s 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 the outboard in a vertical operating position 2 Remove the propeller Refer to Propeller Replacement 3 Place the drain pan below the outboard 4 Remove the vent plug and fill drain plug and drain lubricant ...

Page 76: ...ng washer before removing the lubricant tube 5 Remove the lubricant tube and install 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 is necessary once the engine is exposed to the atmosphere to minimize inter...

Page 77: ... 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 gum in the gasoline The Mercury Precision Quickleen product will...

Page 78: ...owing in a container a 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Quickleen lubricant b 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Fuel Stabilizer 10 Remove the fuel filter See Maintenance Fuel System for procedure 11 Pour this mixture into the fuel filter opening Install the fuel filter 12 Prime the fuel system See Operation Starting The Engine 13 Place the outboard in water or use th...

Page 79: ... flywheel manually several times to distribute the oil or storage seal in the cylinders 3 Install the spark plugs Protecting External Outboard Components Lubricate all outboard components listed in Maintenance Inspection and Maintenance Schedule Touch up any paint nicks See your dealer for touch up paint Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces e...

Page 80: ...let in the gearcase can freeze Store the outboard in the full down position Battery Storage Follow the battery manufacturer s instructions for storage and charging Remove the battery from the boat and check water level Charge if necessary Store the battery in a cool dry place Periodically check the water level and charge the battery during storage STORAGE 70 eng ...

Page 81: ...pty 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 filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose Ignition system component failure Spark plugs fouled or defe...

Page 82: ...sition sensor failure Continuous horn sound The oil level in the engine mounted oil reservoir tank is critically low Refill the reservoir tank and the remote oil tank Refer to Fuel and Oil for details The oil pump has failed halting the oil supply to the engine Engine speed exceeds the maximum allowable RPM The system limits the engine to within the allowable range If the overspeed condition conti...

Page 83: ...er Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded 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 TROUBLESHOOTING eng 73 ...

Page 84: ...rs in the recovery of stolen power packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer is required to reduce the possibility of serious engine damage REPLACEMENT SERVICE PARTS WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine produ...

Page 85: ...erial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geographic office in your area Please include your daytime telephone number with mail and fax correspondence United States Canada Telephone English 1 920 929 5040 Français 1 905 636 4751 Mercury Marine ...

Page 86: ...e Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O ...

Page 87: ...s Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Quantity Item Stock Number Price Total Total Due OWNER SERVICE ASSISTANCE eng 77 ...

Page 88: ... utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have the following decal on the transom clamp 51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories such as emergency boa...

Page 89: ...ESSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 1 The following list provides additional guidelines for mounting accessories to the transom clamp bracket The ...

Page 90: ...amp bracket Refer to Figure 1 Figure 1 a Minimum clearance 3 175 mm 0 125 in b Edge of accessory bracket c Transom clamp bracket wall d Radius e Engine supplied mounting fasteners f Fasteners supplied by the accessory manufacturer installed through unused engine mounting bracket holes b c d a f 54624 e OUTBOARD INSTALLATION 80 eng ...

Page 91: ...ecuring the engine to the boat 1 Do not mount an accessory to the transom clamp bracket in an unsupported condition Refer to Figure 2 54625 Figure 2 2 Do not attach an accessory to the boat by use of the engine mounting hardware Refer to Figure 3 Figure 3 a Engine supplied mounting fasteners b Transom clamp bracket c Accessory 53523 a b c OUTBOARD INSTALLATION eng 81 ...

Page 92: ...ds the boat s maximum power rating Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain 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 CAP...

Page 93: ...ressure must not exceed 28 kPa 4 psi If necessary install a pressure regulator 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 ...

Page 94: ... line length limitations and secure the tank in place Permanent Fuel Tank Permanent fuel tanks should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding antisiphon protection ventilation etc FILLING THE FUEL SYSTEM For the initial start of a new engine or for an engine that ran out of fuel or was drained of fuel the fuel syst...

Page 95: ...ng 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 2 Thread the lifting eye into the flywheel hub for a minimum of five turns a Lif...

Page 96: ...bly from the driveshaft housing or to lift entire engine for removal installation Steering Cable Starboard Side Routed Cable 1 Lubricate the O ring seal and the 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 2 Insert the steering cable into the tilt tube 3725 OUTBOARD INSTALLATION 86 eng ...

Page 97: ...13 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 due to occupants being thrown within or out of the...

Page 98: ...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 the locknut to specifications Descripti...

Page 99: ...eight dimension 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 piercing the water surface is usually preferred f Maximum boat speed anticipated ...

Page 100: ...rictions will result in poor performance at idle 2 Add 12 7 cm 5 in for XL models to the listed outboard mounting heights 3 The mounting height of the outboard 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 boa...

Page 101: ...sion 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 piercing the water surface is usually preferred NOTE For 63 5 cm 25 in XL models add 12 7 cm...

Page 102: ...st not exceed 66 04 cm 26 in for L models 78 9 cm 31 in for XL models Mounting the outboard higher will cause gearhousing damage Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause the propeller to break loose during planing Drilling Outboard Mounting Holes IMPORTANT Before drilling any mounting holes carefully read Determining Recomm...

Page 103: ...5 00 in long 3 25 in thread 826711 17 Nylon insert locknut 20 28421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in thread 67755 1 20 x 4 50 in long 2 25 in thread 8M0071543 20 x 5 00 in long 3 25 in thread 8...

Page 104: ...the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom strength If the bolt or nut continues to turn without the torque reading on the dial increasing it is an indication that the transom is yielding The load ...

Page 105: ... be flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between transom clamp and boat transom not allowed a b 51817 OUTBOARD INSTALLATION eng 95 ...

Page 106: ... ensure proper clearance of the transom bracket relief radius area 51867 Installation 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 that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be drawn t...

Page 107: ...875 in flat washer 4 c Nylon insert locknut 4 d 1 500 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 OUTBOARD INSTALLATION eng 97 ...

Page 108: ... use 51985 Decal on the transom bracket Electrical Hoses Control Cables and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl Connect remote harness to the 14 pin connector on the engine harness a 14 pin connector a 28742 OUTBOARD INSTALLATION 98 eng ...

Page 109: ...n lb ft Hex nuts 13 5 120 A decal advising against using deep cycle batteries and wing nuts should 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 54395 Place decal on or near battery box for future service reference Included with the engine rigging components are ...

Page 110: ...Cranking battery Dual Outboards Connect a common ground cable wire size same as engine battery cables between negative terminals on starting batteries a Red sleeve positive b Black sleeve negative c Ground cable d Cranking battery b a c 15496 a a b b c d d 15497 OUTBOARD INSTALLATION 100 eng ...

Page 111: ...s Fasten hose connections with cable ties Water Pressure and Speedometer Hose or Tubing NOTE This applies to models without SmartCraft 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 coup...

Page 112: ...se without blue stripe l Cable tie INSTALLING THE SHIFT CABLE IMPORTANT The shift cable is the 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 th...

Page 113: ...position mark 2 Mark the reverse position as follows a Move the remote control handle into reverse 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 Reverse position mark 3 Mark the center ...

Page 114: ...n toward the rear until resistance is felt 7 Center the anchor pin between these resistance points a Anchor pin Adjusting 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 a 28...

Page 115: ...ontrol into reverse while turning the propeller shaft If the propeller shaft does not lock solidly in gear adjust the barrel away from the cable end guide Repeat steps a through c d Return the remote control handle to neutral If the propeller shaft does not turn freely without drag adjust the barrel closer to the cable end guide Repeat steps a through d INSTALLING THE THROTTLE CABLE IMPORTANT Atta...

Page 116: ...d 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 adjustment 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 scr...

Page 117: ... 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 2 Place the neoprene wrap around the wiring hoses and control cables and place into the lower half of the front clamp a Neoprene wrap b Lower half of the front clamp a b 29073 OUTBOARD INSTALLATION eng 107 ...

Page 118: ... 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 5 Install the cowl seal a Retainer a b 29074 a 29075 OUTBOARD INSTALLATION 108 eng ...

Page 119: ...l tank with the recommended oil listed in the Operation and Maintenance Manual Tighten the fill cap a Fill cap 2 Remove the cap and fill the engine oil tank with oil Install the fill cap a Engine oil tank b Fill cap a 2683 a b 7745 OUTBOARD INSTALLATION eng 109 ...

Page 120: ...ll 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 primer bulb until it feels f...

Page 121: ... Operate the engine until all the air has vented out and oil starts to flow out of the tank 4 Tighten the fill cap Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer resulting in the operator losing control of the boat Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe ...

Page 122: ...9930A 1 2749 Limits the down trim angle of the power trim equipped engines or aids in determining the trim out angle on non power trim engines The owner may decide to limit the trim 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 i...

Page 123: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 113 ...

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Mercury 200 Optimax, Operation, Maintenance And Installation Manual

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