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Mercury 200 Verado FourStroke, Operation And Maintenance Manual

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Mercury 200 Verado FourStroke Operation And Maintenance Manual Download Page 9

Maintenance

Cleaning Care Recommendations.................................................................... 66

EPA Emissions Regulations............................................................................. 68

Inspection and Maintenance Schedule............................................................. 69

Flushing the Cooling System............................................................................ 70

Cowl Removal and Installation......................................................................... 71

Battery Inspection ............................................................................................ 72

Verado Engine Battery Specifications.............................................................. 72

Air Filter (200–300)........................................................................................... 74

Air Filter (350, 350 Pro).................................................................................... 75

Fuel System...................................................................................................... 75

Corrosion Control Anodes................................................................................ 78

Trim Wear Pad Replacement........................................................................... 79

Propeller Replacement..................................................................................... 80

Spark Plug Inspection and Replacement..........................................................83

Fuses................................................................................................................ 85

DTS Wiring System.......................................................................................... 87

Accessory Drive Belt Inspection....................................................................... 87

Checking Power Trim Fluid...............................................................................88

Checking Power Steering Fluid........................................................................ 88

Changing Engine Oil ........................................................................................ 89

Gearcase Lubrication........................................................................................92

Storage

Storage Preparation..........................................................................................98

Protecting External Outboard Components...................................................... 98

Protecting Internal Engine Components........................................................... 98

Gearcase.......................................................................................................... 99

Positioning Outboard for Storage..................................................................... 99

Battery Storage................................................................................................. 99

Troubleshooting

Starter Motor Will Not Crank the Engine.........................................................100

Engine Will Not Start.......................................................................................100

Engine Starts But Will Not Shift Into Gear...................................................... 100

Engine Runs Erratically.................................................................................. 100

Performance Loss...........................................................................................101

Battery Will Not Hold Charge.......................................................................... 101

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Summary of Contents for 200 Verado FourStroke

Page 1: ...Operation and Maintenance Manual 2016 Mercury Marine 200 350 Including Pro Series Verado FourStroke 8M0125708 1216 eng...

Page 2: ...eng...

Page 3: ...nual 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 Throug...

Page 4: ...ne whose policies are based on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warran...

Page 5: ...le information Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Hull Identification Number HIN Purchase Date Boat Manufacturer Boat Model Length Exh...

Page 6: ...eng iv...

Page 7: ...Deck Boats 7 Wave and Wake Jumping 9 Impact with Underwater Hazards 9 Selecting Accessories for Your Outboard 11 Safe Boating Recommendations 11 Specifications 14 Recording Serial Number 15 Component...

Page 8: ...Power Trim and Tilt 51 Operation Important Daily Inspection Before Each Use 55 Prestarting Check List 55 Operating in Freezing Temperatures 56 Operating in Saltwater or Polluted Water 56 Operating at...

Page 9: ...ion and Replacement 83 Fuses 85 DTS Wiring System 87 Accessory Drive Belt Inspection 87 Checking Power Trim Fluid 88 Checking Power Steering Fluid 88 Changing Engine Oil 89 Gearcase Lubrication 92 Sto...

Page 10: ...104 Installation Information Mercury Marine Validated Engine Mounting Hardware 106 Fastening Hardware Specification Not Factory Supplied 106 Accessories Mounted to the Transom Clamp Bracket 108 Faste...

Page 11: ...g 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...

Page 12: ...ination 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 outboard must be equippe...

Page 13: ...d 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 w...

Page 14: ...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...

Page 15: ...oat 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 the outboard into neutral an...

Page 16: ...orm dragging teak body surfing This dangerous practice not only places a person in an area of high engine exhaust concentration but also subjects them to the possibility of injury from the boat propel...

Page 17: ...serve the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plungin...

Page 18: ...jury 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...

Page 19: ...er 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 while airborne upon water contact it may penetrate under the water...

Page 20: ...pipes bridge supports wing dams trees stumps and rocks Striking a floating or underwater object could result in any of an infinite number of situations Some of these situations could yield the follow...

Page 21: ...ation and maintenance manuals for all your selected accessories Refer to Outboard Installation Accessories Mounted to the Transom Clamp Bracket for important information on mounting accessories to the...

Page 22: ...lotation devices Federal law requires that there be a U S Coast Guard approved life jacket personal flotation device correctly sized and readily accessible for every person onboard plus a throwable cu...

Page 23: ...block the operator s view when the boat is above idle or planing transition speed Watch out for others the water and your wake Never drive your boat directly behind a water skier Your boat traveling a...

Page 24: ...and Oil Gearcase capacity Refer to Maintenance Gearcase Lubrication Engine oil capacity with oil filter replacement 7 0 Liter 7 4 US qt Required battery type 12 volt AGM absorbed glass mat battery USA...

Page 25: ...h oil filter replacement 7 0 Liter 7 4 US qt Required battery type 12 volt AGM absorbed glass mat battery USA SAE battery type 800 minimum marine cranking amps MCA with a minimum reserve capacity of 1...

Page 26: ...300 a Rear cowl b Lower cowl chaps c Antiventilation plate d Gearcase e Cooling water intake holes f Spray plate g Pedestal h Engine flush i Auxiliary tilt switch j Top cowl j i h g f e d c b a 28919...

Page 27: ...fect 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...

Page 28: ...esents the pitch For example 14x19 represents a propeller with a 14 inch diameter and 19 inches of pitch a Diameter b Pitch Travel during one revolution The following are some propeller basics that wi...

Page 29: ...pellers manufactured by Mercury Marine are made from either aluminum or stainless steel Aluminum is suitable for general purpose use and is standard equipment on many new boats Stainless steel is over...

Page 30: ...e the outboard may be tilted down to the vertical operating position with no additional support required 28780 2 If additional ground clearance is required the outboard should be tilted up and support...

Page 31: ...m support device 28779 Additional clearance may be required for railroad crossings driveways and trailer bouncing See your local dealer for recommendations IMPORTANT Do not rely on the power trim tilt...

Page 32: ...e however performance losses may occur Do not use leaded gasoline Outside USA and Canada A posted pump octane rating of 95 RON is required for best performance A posted pump octane rating of 91 RON mi...

Page 33: ...ethanol you must increase the frequency of inspection for leaks and abnormalities IMPORTANT When operating a Mercury Marine engine on gasoline containing methanol or ethanol do not store the gasoline...

Page 34: ...d FC W Catalyst Compatible Synthetic Blend Marine Engine Oil is the preferred choice for general all temperature use in all 200 350 HP Verado engines 57244 In lieu of the preferred grade oil the follo...

Page 35: ...val and Installation 4 Pull out the dipstick Wipe the dipstick end with a clean rag or towel and push it back in all the way 5 Pull the dipstick back out again and observe the oil level Oil should be...

Page 36: ...ing position and check the dipstick 9 Repeat the process until oil level is on the operating range crosshatched region Do not try to fill to the upper end of the operating range crosshatched region IM...

Page 37: ...ward to increase speed Pull the control handle back from neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3413 2 Shift lock Pressing the shift lock allows the...

Page 38: ...tle to increase engine RPM To disengage return the control handle to the neutral position Engine RPM is limited to prevent engine damage 3416 5 Stop start button Allows the boat operator to start or s...

Page 39: ...ositions cover must be removed Turning the screw clockwise will increase tension Adjust to tension desired a Detent tension adjustment screw b Control handle tension adjustment screw Slim Binnacle Con...

Page 40: ...dle out of detent positions Turning screw clockwise will increase tension Adjust to tension desired 4 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the ten...

Page 41: ...h must be in the run position for the start stop switch to function c Transfer Allows boat control to be transferred to a different helm d Throttle only Allows the boat operator to increase engine RPM...

Page 42: ...rs at the helms are moved to neutral and transfer is requested again Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer procedure...

Page 43: ...3 When the helm transfer is complete another beep sounds and the transfer button light turns off NOTE If the helm transfer is not completed in 10 seconds the request is automatically cancelled a doubl...

Page 44: ...gage throttle only mode 1 Place the ERC lever into neutral Throttle only will not disengage unless the ERC lever is in neutral 2 Press the Throttle Only button The button light will turn off 3 The neu...

Page 45: ...neutral to the first detent for reverse gear Continue pulling the handle back to increase speed in reverse a Forward b Neutral c Reverse The amount of force needed to move the handles and to move the...

Page 46: ...eeds adjustment 2 Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension 3 Adjust to the tension desired a Detent tension adjustment scr...

Page 47: ...ate when the drive is in the neutral gear position The lights flash when the engine is in throttle only mode c TRANSFER Allows boat control to be transferred to a different helm Refer to Helm Transfer...

Page 48: ...control of engine power in close quarter situations 51854 DOCK button Throttle Only NOTE Throttle only mode should be used if the captain is not in command at the helm Placing the ERC in throttle onl...

Page 49: ...ess the ERC levers are in neutral 2 Press the THROTTLE ONLY button The button light will turn off 3 The neutral lights stop flashing and remain illuminated 1 Lever This feature commands both engines w...

Page 50: ...ngines are at a minimum speed The indicator light on the SYNC button is on when both engines are on The light is yellow at idle and 95 of throttle and when the engines are not synchronized The light t...

Page 51: ...ansfer should only be performed while engine is in neutral The helm transfer function allows the boat operator to select which helm is in control of the vessel Before a transfer can be initiated the E...

Page 52: ...ERC levers in neutral press the TRANSFER button one time After the TRANSFER button is pressed the transfer button light turns on and one beep will sound confirming the impending transfer 51858 TRANSF...

Page 53: ...rt and starboard engines Center engine shift neutral unless both engines are in the same gear Running Running Off Port and center engine throttle and shift controlled by port control handle Off Runnin...

Page 54: ...engine throttle speed and gear shift positions of all four engines The throttle and shift function is dependent on what engines are running The following table represents the most common quad engine v...

Page 55: ...d on Running Running Off ignition key switch turned on Port inner engine throttle and shift controlled by port control handle Starboard inner engine throttle and shift controlled by starboard control...

Page 56: ...ine into forced neutral idle condition the inner port engine will also be forced to neutral idle Operation to the inner engine can be restored by moving the port control handle back into neutral and t...

Page 57: ...trol Operation with Hand Throttle On Off Switch 1 Engine speed is controlled from idle to WOT by either the foot throttle or the panel mount control handle 2 The default setting when the engine is sta...

Page 58: ...throttle on off switch button c A single horn beep will sound d The hand throttle indicator light is off e Throttle control at the foot throttle NOTE If the transfer fails a double horn beep will sou...

Page 59: ...d contact your servicing dealer 2 Intermittent short beeps for six seconds Indicates a noncritical engine condition This condition does not require immediate attention You may continue using your boat...

Page 60: ...ill remain activated limiting the throttle The problem must be identified and corrected before Engine Guardian will allow the engine to reach a normal operating RPM OVERSPEED REV LIMIT The overspeed r...

Page 61: ...ning and the key switch in the ON position the outboard can be tilted out of the water At speeds below 4300 RPM the outboard can be tilted up past the normal trim range a Trim switch b Tilt range of t...

Page 62: ...speed Increase clearance over submerged objects or a shallow bottom In excess can cause boat porpoising bouncing or propeller ventilation Cause engine overheating if any cooling water intake holes are...

Page 63: ...tilt switch the outboard can be manually tilted 28497 NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operatio...

Page 64: ...nt hitting bottom 1 Reduce engine speed below 4300 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only With the outboard til...

Page 65: ...for each person aboard and readily accessible it is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know your boats maximum load capacity Look at the bo...

Page 66: ...m If you keep your boat moored in the water always 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...

Page 67: ...sity to the engine which may lower the following Boost pressure on supercharged engines Horsepower and torque throughout the RPM range Peak RPM Cranking compression EXAMPLE An engine running at an ele...

Page 68: ...p to 4500 RPM or at three quarter throttle and at full throttle for approximately one minute every ten minutes 2 For the next eight hours of operation avoid continuous operation at full throttle for m...

Page 69: ...ged fuel is relatively clear of air bubbles NOTE If the outboard fuel system does not prime within 15 key ON events check for leaks in the fuel supply line to the outboard Repair as needed If no leak...

Page 70: ...of 10 full eight second cranking events 6 Once the engine starts it may run rough at idle for up to two minutes while the residual air is purged from the fuel system 7 If the fuel system will not pri...

Page 71: ...tank vent on manual venting type tanks 19748 4 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch NOTE The engine will not start unless the lanyard switch...

Page 72: ...Turn the key to the START position again until the engine starts S T A R T OFF ACC ON S T A R T OFF ACC ON 3485 7 After the engine starts check for a steady stream of water flowing out of the water p...

Page 73: ...o 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 stabi...

Page 74: ...r shift the outboard into gear unless the engine speed is at idle Do not shift the outboard into forward or reverse when the engine is not running The outboard has three gear shift positions to provid...

Page 75: ...evers at the idle position Stopping the Engine IMPORTANT Turning key to the START position while the engine is running will result in engine shut down while leaving the DTS system active This will all...

Page 76: ...lure 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...

Page 77: ...e 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 w...

Page 78: ...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 Regu...

Page 79: ...o the spark plug threads Replace the gear lubricant Inspect the corrosion control anodes Inspect the condition of the accessory drive belt Inspect the thermostat if used in saltwater or brackish water...

Page 80: ...erating position during flushing 1 With the engine turned off place the outboard in either the operating position vertical or in a tilted position 2 Disconnect the flush connector from the fitting on...

Page 81: ...top cowl only 1 Pull up on the top cowl lock latch 28946 2 Pull top cowl forward and lift off 3 Pull lower cowl release latch up 4 Remove rear cowl towards aft of outboard 28770 COWL INSTALLATION 1 Po...

Page 82: ...e 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 nonconductive shield to...

Page 83: ...ndards and Coast Guard regulations must be adhered to when installing the battery Ensure that the battery cable installation meets the pull test requirements and that the positive battery terminal is...

Page 84: ...irements 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 Air F...

Page 85: ...key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and...

Page 86: ...fuel line after the vessel mounted fuel filtration system This filter must be removed after 100 hours of operation and may be either discarded or replaced with a new filter 58120 Fuel inlet hose loca...

Page 87: ...iately Filter Replacement 1 Close the fuel valve if equipped 2 Place a container under the fuel filter 3 Remove the water in fuel sensor and allow the filter to drain into the container The liquid tha...

Page 88: ...to the specified torque Description Nm lb in lb ft Water in fuel sensor 2 5 22 1 6 Open the fuel valve 7 Start the engine and inspect the area for fuel leaks Repair as required NOTE After draining the...

Page 89: ...he Verado engine utilizes thrust guide plates on either side of the driveshaft housing to improve stability of the engine As the engine is trimmed up or down the thrust guide plates will rub against t...

Page 90: ...x 20 screw with patch lock pad 8 b Trim wear pad 2 c Trim manifold Description Nm lb in lb ft M6 x 20 screw 8 6 53 Propeller Replacement 1 Shift the outboard into the neutral position 2 Straighten the...

Page 91: ...oducts Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft splines 8M0071842 95 2 4 C with PTFE Propeller shaft splines 92 802859A 1 6 Flo Torq II solid hub 200 300 non HD a Inst...

Page 92: ...lace a block of wood between the gearcase and the propeller Tighten the propeller nut to the specified torque Description Nm lb in lb ft Propeller nut propellers without a hub bushing 75 55 3 Propelle...

Page 93: ...ten the propeller nut to the specified torque Description Nm lb in lb ft Propeller nut 75 55 3 Spark Plug Inspection and Replacement 1 Remove top and rear cowls Refer to Cowl Removal and Installation...

Page 94: ...p checked and corrected as necessary before installation b Measure the gap with a feeler gauge or pin gauge Never use a wedge type gap checking tool to inspect or to adjust the gap c If an adjustment...

Page 95: ...spark plugs using a twisting motion 10 Secure coil with the screw Tighten the screw to the specified torque Description Nm lb in lb ft Screw 8 71 11 Connect the wire harness to the pencil coil a Wiri...

Page 96: ...e suspected blown fuse and look at the silver band inside the fuse If band is broken replace the fuse Replace the fuse with a new fuse with the same amp rating a Fuse puller b Fuse holder c Good fuse...

Page 97: ...ather cap Verify the harnesses are fastened along the routing path Accessory Drive Belt Inspection 1 Inspect the accessory drive belt tensioner to ensure the tensioner is within the recommended range...

Page 98: ...If not available use automotive automatic transmission fluid ATF Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim system 92 858074K01 6 Install the power trim fi...

Page 99: ...the outboard out up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump IMPORTANT To reduce or prevent oil spillage when removing the oil filter ensure th...

Page 100: ...l drain funnel must be used to divert oil from the lower splash plate and into the container 1 Tilt the outboard out up past vertical for approximately one minute to allow any trapped oil to drain bac...

Page 101: ...d the engine is cold or has not run for at least one hour 1 Remove the top cowl 2 Place a rag or towel below the oil filter to absorb any spilled oil 3 Remove the old filter with an oil filter wrench...

Page 102: ...r in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water i...

Page 103: ...icant Checking Lubricant Level and Refilling Gearcase 1 Place outboard in a vertical operating position 2 Remove vent plug sealing washer 3 Remove fill drain plug Place lubricant tube into the fill ho...

Page 104: ...Remove the lubricant level plug and fill drain plug Allow a sufficient amount of time for the gearcase to drain Depending on the ambient air temperature it may take 30 minutes for the gearcase to com...

Page 105: ...ricant level hole remove the fill drain plug and add lubricant until it appears at the lubricant level hole 4 Stop adding lubricant 5 Allow a few minutes for the lubricant level to stabilize in the ge...

Page 106: ...Lubricant level plug b Fill drain plug Filling the Gearcase 1 After the gearcase has been drained fill the gearcase through the fill drain hole 2 Add the specified gear lubricant IMPORTANT Replace th...

Page 107: ...the sealing washers if damaged 3 If lubricant is not visible at the lubricant level hole remove the fill drain plug and add lubricant until it appears at the lubricant level hole 4 Stop adding lubric...

Page 108: ...ystem other than the fuel tank will remain stable during normal storage periods without the addition of fuel treatment stabilizers Fill the fuel tank and engine fuel system with treated stabilized fue...

Page 109: ...Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can da...

Page 110: ...ction Old or contaminated gasoline Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Maint...

Page 111: ...improper propeller size Low water pressure Low battery voltage Worn stretched or broken accessory belt Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or...

Page 112: ...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...

Page 113: ...rial 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 geo...

Page 114: ...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 Ma...

Page 115: ...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 Q...

Page 116: ...e included with the outboard Installing other products onto the boat that utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard...

Page 117: ...ons Nut to be a prevailing torque full height nut nylon 6 6 or equivalent insert Thread size 0 50 20 inch UNF thread Material Brass Grade Cu 613 per ASTM Minimum mechanical properties 80 000 psi proof...

Page 118: ...y issues WARNING Avoid serious injury or death resulting from a loss of boat control Loose engine fasteners could cause the transom bracket to fail resulting in a loss of the driver s ability to contr...

Page 119: ...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...

Page 120: ...ring 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...

Page 121: ...y or death Before operation the outboard must be correctly installed with the required mounting hardware IMPORTANT For optimum boat performance and detailed engine installation instructions refer to t...

Page 122: ...through the lower set of mounting slots 28923 RECOMMENDED MOUNTING INSTALLATION 300 350 HP The outboard should be secured to the boat transom with the six 12 7 mm 1 2 in diameter mounting screws with...

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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