Mercury 200 VERADO Manual Download

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MAINTENANCE

110

Tube Ref No.

Description

Where Used

Part No.

110

4 Stroke 10W30
Outboard Oil

Air filter element

92-802833A1

AIR FILTER INSTALLATION

1. Install Fuel System Module (FSM) purge valve hose to air filter

assembly.

3665

2. Install crankcase ventilation hose.
3. Install air filter assembly and tighten clamp screw securely.

3664

a -

Crankcase ventilation
hose

b -

Fuel System Module
(FSM) purge valve
hose

c -

Filter assembly

d -

Clamp screw

Summary of Contents for 200 VERADO

Page 1: ...the lower corner left hand corner either the CE mark alone or the CE mark accompanied by a notified body number This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industriel de Petit Rechain Belgium complies with the requirements of the following directives by meeting the associated standards as amended If the CE mark is accompanied by a notified ...

Page 2: ...2 ISO 13591 ISO 8469 General steering system ABYC P 17 The following applies to all product covered by this manual Safety of Machinery Directive 98 37 EC Principles of safety integration 1 1 2 EN 292 1 EN 292 2 EN 1050 Noise 1 5 8 ICOMIA 39 94 Vibration ICOMIA 38 94 Electromagnetic Compatibility Directive 89 336 EC Generic emission standard EN 61000 6 3 Generic immunity standard EN 61000 6 1 Vehic...

Page 3: ...iii Patrick C Mackey President Mercury Marine Fond du Lac WI USA European Regulations Contact Regulations and Product Safety Department Mercury Marine Fond du Lac WI USA ...

Page 4: ...iv ...

Page 5: ...Boater s Responsibilities 13 Before Operating Your Outboard 13 Boat Horsepower Capacity 14 High Speed And High Performance Boat Operation 14 Outboard Remote Control Models 15 Lanyard Stop Switch 15 Protecting People In The Water 17 Passenger Safety Message Pontoon Boats And Deck Boats 18 Wave And Wake Jumping 19 Impact With Underwater Hazards 20 Exhaust Emissions 22 Selecting Accessories For Your ...

Page 6: ... Control Features and Operation 48 Dual Handle Console Control Features and Operation 53 Dual Handle Console Control with CAN Trackpad Features and Operation 58 Shadow Mode Control Features and Operation 63 Shadow Mode Control with CAN Trackpad Features and Operation 72 Warning System 83 Power Trim and Tilt 87 Operation Pre Starting Check List 92 Operating In Freezing Temperatures 92 Operating In ...

Page 7: ...de 114 Propeller Replacement 115 Spark Plug Inspection and Replacement 116 Fuses 118 DTS Wiring System 120 Accessory Drive Belt Inspection 120 Checking Power Trim Fluid 121 Checking Power Steering Fluid 122 Changing Engine Oil 122 Gearcase Lubrication 126 Storage Storage Preparation 129 Protecting External Outboard Components 130 Protecting Internal Engine Components 130 Gearcase 130 Positioning O...

Page 8: ...ratically 133 Performance Loss 133 Battery Will Not Hold Charge 133 Owner Service Assistance Local Repair Service 135 Service Away From Home 135 Parts And Accessories Inquiries 135 Service Assistance 135 Mercury Marine Service Offices 136 ...

Page 9: ...nd du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Warranty Registration United...

Page 10: ...he warranty registration Mercury Marine will send registration verification by mail to the purchaser of the product If this registration verification is not received within 30 days please contact your selling dealer immediately Warranty coverage is not effective until your product is registered with Mercury Marine Warranty Registration Outside The United States And Canada 1 It is important that yo...

Page 11: ... received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you IMPORTANT Registrationlistsmustbemaintainedbythefactory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warrantyregi...

Page 12: ...roduct Unexpired warrant coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre d...

Page 13: ...wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installation ...

Page 14: ...verage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE...

Page 15: ...pection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sac...

Page 16: ...aser 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 a...

Page 17: ...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 18: ... 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 connection ...

Page 19: ...nance 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 condition wh...

Page 20: ...r products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product ...

Page 21: ...erly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed DANGER DANGER indicates an imminently haz...

Page 22: ...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 CAPACITY XXX ob00306 High Speed And High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you...

Page 23: ...dashboard or side adjacent to the operator s position The lanyard is a cord usually between 122 and 152 cm 4 and 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with n...

Page 24: ...hallow 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 at shut down However the bo...

Page 25: ...nt 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 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even...

Page 26: ...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 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 ...

Page 27: ...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 result in the elevated passenger falling over the front of the boat ob00313 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done with sufficient speed to...

Page 28: ...at 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 surface and submarine for an instant This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward The boat may also steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whene...

Page 29: ...nt 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 driving in waters known to have underwater obstacles After striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the outboard should be taken to an aut...

Page 30: ...ion of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas...

Page 31: ... Precision or Quicksilver Accessories have been specifically designed and tested for your outboard These accessories are available from Mercury Marine dealers WARNING Checkwithyourdealerbeforeinstallingaccessories Themisuse ofapprovedaccessoriesortheuseofnon approvedaccessories can result in product failure serious injury or death Some accessories not manufactured or sold by Mercury Marine are not...

Page 32: ...ing law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat 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...

Page 33: ...g 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 involve...

Page 34: ...rtified Europe Insignia as applicable 200 225 250 275 Specifications International Models 200 225 250 275 Horsepower 200 225 250 275 Kilowatts 149 168 186 205 Full Throttle RPM Range 5800 6400 Idle Speed in Neutral Gear1 550 RPM Number of Cylinders 6 Piston Displacement 2 598 cc 158 5 cid Cylinder Bore 82 mm 3 23 in Stroke 82 mm 3 23 in Recommended Spark Plug NGK ILFR6G Spark Plug Gap 0 8 mm 0 031...

Page 35: ... Lubricant Capacity 970 ml 32 8 fl oz Left Hand Rotation Gearcase Lubricant Capacity 900 ml 30 4 fl oz Engine Oil Capacity With Oil Filter Replacement 7 0 liters 7 4 qt Battery Rating 1000 Marine Cranking Amps MCA 800 Cold Cranking AMPS CCA or 180 Ampere Hour Ah Sound at Drivers Ear ICOMIA 39 94 4 Stroke 79 6 ...

Page 36: ... Component Identification ob01302 j a b c d e g h i f a Rear cowl b Lower cowl chaps c Anti ventilation plate d Gearcase e Cooling water intake holes f Spray plate g Pedestal h Engine flush i Auxiliary tilt switch j Top cowl ...

Page 37: ...tboard installation manual supplied with the outboard We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the boat transom with the four 12 7 mm 1 2 in dia...

Page 38: ...age to the gearcase components ob01312 Maximum Static Waterline The static waterline with boat at rest must be below the MAX STATIC WATERLINE mark on the idle relief grommet located at the rear of the outboard when the outboard is fully tilted in down If waterline is above MAX STATIC WATERLINE mark adjust boat load forward or increase raise outboard mounting height to correctly place mark above wa...

Page 39: ...while maintaining maximum boat speed 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboards durability Check full throttle RPM using an accurate tachometer with th...

Page 40: ... sufficient ground clearance the outboard may be tilted down to the vertical operating position with no additional support required ob01268 2 If additional ground clearance is required the outboard should be tilted up and supported using the outboard s tilt support bracket trailering position and or an accessory transom support device Refer to Features and Controls Tilting Operation ob01307 ...

Page 41: ...clearance may be required for railroad crossings driveways and trailer bouncing Refer to your local dealer for recommendations IMPORTANT Do not rely on the power trim tilt system to maintain proper ground clearance for trailering The power trim tilt system is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propeller from spinning freely when...

Page 42: ...s required for best performance Having a posted pump Octane Rating of 90 RON minimum is acceptable however performance losses may occur EU Models 200 225 Having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable USA and Canada Models 200 225 250 Having a posted pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable Do NOT us...

Page 43: ...or specific recommendations on the boat s fuel system components fuel tanks fuel lines and fittings Be aware that gasolines containing alcohol may cause increased Corrosion of metal parts Deterioration of rubber or plastic parts Fuel permeation through rubber fuel lines Starting and operating difficulties WARNING FIRE AND EXPLOSION HAZARD Fuel leakage from any part of the fuel system can be a fire...

Page 44: ...ea while filling fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them Always stop engine before refilling 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 PORTABLE FUEL...

Page 45: ...pped oil to drain back to the oilsump Tiltoutboardtovertical nottilted positionwhenchecking engine oil For accurate readings check oil only when engine is cold or after engine has not run for at least an hour 1 Before starting cold engine tilt outboard out up past vertical to allow trapped oil to drain back to the oil sump Allow outboard to remain tilted for approximately one minute 2 Tilt outboar...

Page 46: ...range 6 If the oil level is below the operating range cross hatched region remove the oil filler cap and add approximately 500 ml 16 oz of specified outboard motor oil Allow a few minutes for the added oil to drain to the oil sump and recheck the dipstick Repeat the process until oil level is on the operating range cross hatched region Do not try to fill to the upper end of the operation range cro...

Page 47: ...minated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 7 Push the dipstick back in all the way 8 Reinstall the oil fill cap hand tight 9 Reinstall top cowl ...

Page 48: ...from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3413 2 Shift lock Pressing the shift lock allows the engine to shift The shift lock must always be pressed when moving the control handle out of the neutral position 3428 ...

Page 49: ...m up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button while moving the control handle ahead to the forward detent The horn indicates throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position Engine RPM is limited to prevent engine damage 3416 ...

Page 50: ...er the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch a 22964 7 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn screw clockwise to increase tension and countercloc...

Page 51: ...b a Detent tension adjustment screw b Control handle tension adjustment screw Single Handle Console Control Features and Operation 1 Operation of shift and throttle is controlled by the movement of the control handle Push the control handle forward from neutral to the first detent for forward gear Continue pushing forward to increase speed Pull the control handle back from neutral to the first det...

Page 52: ...rough water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to the desired tension 4 Detent tension adjustment screw This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions cover must be removed Turning the screw clockwise will increase tension Adjust to the desired tension a b ob01170 a Detent tensio...

Page 53: ...tion except when in the slide show function Holding the select button for five seconds or more will bring up the Home page 7 Neutral LED The neutral LED illuminates when engine is in neutral gear position It also flashes when throttle only is activated NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the control handle 8 Active LED Th...

Page 54: ... throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer d b a c e 5187 a Neutral LED b Select button c Arrow trackpad d Throttle only station select button e Active LED HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control The boat operator should never leave...

Page 55: ...throttle and gear position NOTE There is a 10 second time frame to complete a helm transfer If the helm transfer is not completed the action will be cancelled and a double beep will sound Pressing the throttle only station select button again will re initiate a helm transfer 1 Place active remote control lever to idle position 2 Proceed to the inactive helm and position remote control lever to the...

Page 56: ...andle is matched and the throttle only station select button can be pressed again to complete the transfer This completes the transfer process and give control to the new station If the helm transfer is not completed within 10 seconds the helm transfer is cancelled Slim Binnacle Control Features and Operation 1 Operation of shift and throttle is controlled by the movement of the control handle Pus...

Page 57: ...trol handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the remote control handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to the desired tension ...

Page 58: ...t screw b Control handle tension adjustment screw 5 Start stop button Allows the boat operator to start or stop the engine without using the ignition key 6 Neutral LED The neutral LED illuminates when engine is in neutral gear position It also flashes when throttle only is activated NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the...

Page 59: ...e throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer START STOP 22970 d c a b a Start stop button b Throttle only station select button c Neutral LED d Active LED HELM TRANSFER WARNING Avoid serious injury or death from loss of boat control The boat operator should never leave t...

Page 60: ...er to idle position 2 Proceed to the inactive helm and position remote control lever to the idle position 3 Press throttle only station select button two times The ACTIVE light will illuminate to indicate the remote control is in control of the engine START STOP 22608 a b a Active light b Throttle only station select button 4 The ACTIVE light will switch off at the original helm Synchronizing Helm...

Page 61: ... neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3417 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up or down 5269 3 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough...

Page 62: ...nt The horn will sound once and the neutral light will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Tr...

Page 63: ... active LED illuminates to show the remote control is active and ready for use 10 SYNC LED The SYNC LED illuminates when the RPM of the two engines are being synchronized by the DTS system 5270 ACTIVE SYNC THROTTLE ONLY STATION SELECT a b c d e f a Neutral LEDS b Select button c Arrow trackpad d SYNC LED e Throttle only station select button f Active LED SYNCHRONIZING ENGINES The auto synchronizin...

Page 64: ...e is in neutral NOTE Idle position is preferred when doing a helm transfer If conditions do not allow the remote control to be placed at idle position a helm transfer can be done while in gear NOTE The active light on the remote control will be illuminated at the helm that is in control of the engine The helm transfer function allows the boat operator to select which helm is in control of engine o...

Page 65: ...ginal helm Synchronizing Helms Prior To Helm Transfer Pressing the throttle only station select button one time allows the boat operator 10 seconds to match up the control handle setting at the new station with the handle setting that is at the old to be inactive station If the handle is not matched the neutral light will flash The light blinks faster as the handle is nearing match position Once t...

Page 66: ...om neutral to the first detent for reverse gear Continue pulling the handle back to increase speed F N R 3417 2 Trim switch if equipped Pressing the trim switch allows the engine to trim up and down NEUTRAL SY NC TH RO TT LE ON LY TR OL L TR AN SF ER DOCK 1 LE VE R 22132 3 Neutral lights The neutral lights illuminate when the engine is in neutral gear position The lights will flash when the engine...

Page 67: ... Docking mode reduces throttle capacity to approximately 50 of normal throttle To turn off docking mode shift the engine into neutral and press the DOCK button 7 Throttle only button Allows the boat operator to increase engine RPM for warm up without shifting the engine into gear To engage throttle only move the control handle into the neutral position Press the throttle only button and move the c...

Page 68: ...tral LEDS b Troll button c Transfer button d Dock button e Throttle only f 1 lever button g Sync button 10 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease ...

Page 69: ...onizing feature when engaged will automatically adjust all engine speeds to match the speed of the starboard engine Press the SYNC button on the CAN trackpad to turn auto synchronization on or off When the sync LED is yellow the SYNC button has been pressed but the conditions are not right for auto synchronization to engage When the sync LED turns red engine synchronization has been engaged The en...

Page 70: ...to be placed in the neutral position a helm transfer can be done while in gear The helm transfer function allows the boat operator to select which helm is in control of engine operation Pressing the TRANSFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to match th...

Page 71: ...he handles are not matched the neutral lights will flash The light blinks faster as the handles are nearing match position Once the light stays on continuously the handles are matched and the button can be pressed again to complete the transfer This completes the transfer process and gives control to the new station If the helm transfer is not completed within 10 seconds the action will be cancell...

Page 72: ...nes 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 Running Running Starboard and center engine throttle and shift controlled by starboard control handle Running Off Running Port engine throttle and shift controlled by port control handle Starboard engine throttle and shift cont...

Page 73: ...ngaging The center engine speed and gear shift will then be controlled by the functioning outer engine Turning off the center engine while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes one of the outer engines into forced neutral idle condition the center engine will also be forced to neutral idle Operation to the center en...

Page 74: ... starboard control handle Running Running Off Off Port inner and outer engine throttle and shift controlled by port control handle Off Off Running Running Starboard inner and outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Running Port inner engine throttle and shift controlled by port control handle Running Running Running O...

Page 75: ...y switch turned off Starboard inner engine throttle and shift controlled by port control handle Running Off Off Running Port outer engine throttle and shift controlled by port control handle Starboard outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Off ignition key switch turned on Port inner engine throttle and shift control...

Page 76: ...nd moving the port control handle back into neutral position and then re engaging The inner engine speed and gear shift will then be controlled by the port control handle Turning off one of the inner engines while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes the starboard outer engines into forced neutral idle condition th...

Page 77: ...ght will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage Pressing the station select button at an inactive helm initiates a helm transfer Refer to Helm Transfer 3 Arrow trackpad Navigates through Syst...

Page 78: ...e LED illuminates to show the remote control is active and ready for use 7 Sync LED The SYNC LED illuminates when the RPM of the engines are being synchronized by the DTS system ACTIVE SYNC THROTTLE ONLY STATION SELECT a b c d e f NEUTRAL SELECT 13854 a Neutral LEDS b Select button c Arrow trackpad d Sync LED e Throttle only station select button f Active LED SYNCHRONIZING ENGINES The auto synchro...

Page 79: ...e is in neutral NOTE Idle position is preferred when doing a helm transfer If conditions do not allow the remote control to be placed at idle position a helm transfer can be done while in gear NOTE The active light on the remote control will be illuminated at the helm that is in control of the engine The helm transfer function allows the boat operator to select which helm is in control of engine o...

Page 80: ...e setting at the new station with the handle setting that is at the old to be inactive station If the handle is not matched the neutral light will flash The light blinks faster as the handle is nearing match position Once the light stays on continuously the handle is matched and the throttle only station select button can be pressed again to complete the transfer This completes the transfer proces...

Page 81: ...nes 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 Running Running Starboard and center engine throttle and shift controlled by starboard control handle Running Off Running Port engine throttle and shift controlled by port control handle Starboard engine throttle and shift cont...

Page 82: ...ngaging The center engine speed and gear shift will then be controlled by the functioning outer engine Turning off the center engine while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes one of the outer engines into forced neutral idle condition the center engine will also be forced to neutral idle Operation to the center en...

Page 83: ... starboard control handle Running Running Off Off Port inner and outer engine throttle and shift controlled by port control handle Off Off Running Running Starboard inner and outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Running Port inner engine throttle and shift controlled by port control handle Running Running Running O...

Page 84: ...y switch turned off Starboard inner engine throttle and shift controlled by port control handle Running Off Off Running Port outer engine throttle and shift controlled by port control handle Starboard outer engine throttle and shift controlled by starboard control handle Off ignition key switch turned on Running Running Off ignition key switch turned on Port inner engine throttle and shift control...

Page 85: ...nd moving the port control handle back into neutral position and then re engaging The inner engine speed and gear shift will then be controlled by the port control handle Turning off one of the inner engines while underway will have no effect on the operation of the outer engines If a failure should occur while underway which causes the starboard outer engines into forced neutral idle condition th...

Page 86: ...Troll button Pressing the TROLL button activates troll control The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering To activate move the control handles into forward detent and press the button Use the or buttons to decrease or increase speed up to the maximum calibrated set point If troll control is set at a desired speed and then shut ...

Page 87: ...ttle only button while moving the control handle ahead to the forward detent The horn will sound once and the neutral light will start flashing The horn will sound twice when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine damage 7 1 lever button Pressi...

Page 88: ...utral LEDS b Troll button c Transfer button d Dock button e Throttle only f 1 lever button g Sync button 9 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed This will help prevent unwanted motion of the handle in rough water Turn the screw clockwise to increase tension and counterclockwise to decrease ...

Page 89: ...onizing feature when engaged will automatically adjust all engine speeds to match the speed of the starboard engine Press the SYNC button on the CAN trackpad to turn auto synchronization on or off When the sync LED is yellow the SYNC button has been pressed but the conditions are not right for auto synchronization to engage When the sync LED turns red engine synchronization has been engaged The en...

Page 90: ...to be placed in the neutral position a helm transfer can be done while in gear The helm transfer function allows the boat operator to select which helm is in control of engine operation Pressing the TRANSFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to match th...

Page 91: ...osition Once the light stays on continuously the handles are matched and the button can be pressed again to complete the transfer This completes the transfer process and gives control to the new station If the helm transfer is not completed within 10 seconds the action will be cancelled Warning System WARNING HORN SIGNALS When the key switch is turned to the ON position the horn located on the com...

Page 92: ...blem Continuous Engine Guardian System is activated Power limit will vary with level of overheat Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole If no water is coming out of the water pump indicator hole or flow is intermittent stop engine and check water intake holes for obstruction Oil pressure low Continuous Engine Guardian System i...

Page 93: ...or out of range Single beep engine running May be a problem with one of the engine functions Have your dealer check the engine soon Continuous Engine Guardian System is activated Power limit will restrict engine speed to either idle or 75 depending on fault ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems The system...

Page 94: ...nctions the instrument package will display are engine RPM coolant temperature oil pressure water pressure battery voltage fuel consumption and engine operating hours The SmartCraft Instrument package will also aid in Engine Guardian diagnostics The SmartCraft Instrument package will display critical engine alarm data and potential problems ...

Page 95: ...ming up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating the boat on plane The term tilt is generally used when referring to adjusting the outboard further up out of the water With the engine not running and the key switch in the ON position the outboard can be tilted out of the water At low idle speed 2000 ...

Page 96: ...r 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 bow steering or over steering if any turn is attempted or if a significant wave is encountered WARNING Avoid possible serious injury or death Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid poss...

Page 97: ...The outboard will tilt up until the switch is released or it reaches its maximum tilt position Tilt At Engine The cowl mounted auxiliary tilt switch can be used to tilt the outboard with the key switch in the OFF position Tilt Support Lever 1 Rotate the tilt support lever down 2 Lower outboard until tilt support bracket rests on the pedestal 3 Disengage the tilt support bracket by raising the outb...

Page 98: ...e operating the outboard to prevent the outboard from tilting up during reverse operation 1 Turn out the manual tilt release valve 3 turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim syst...

Page 99: ...peed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only With the outboard tilted past 20 trim limit the warning horn will sound and engine speed will be automatically limited to approximately 2000 RPM The outboard must be tilted trimmed down below the maximum trim range to allow operation above 2000 RPM ...

Page 100: ...t while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Maintenance Schedule Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at all times s...

Page 101: ...ilver Corrosion Guard on external metal surfaces Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes Engine Break in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break in Procedure 1 For the first two hours of operation run the engine at varied throttle settings up to 4500 RPM or at three quarter throttle and at ...

Page 102: ...ntake holes in the gearcase to prevent damage to the water pump running dry or overheating of the engine 1 Make sure the cooling water intake is submerged ob01310 2 Check the engine oil level ob00667 3 Open fuel tank vent on manual venting type tanks 19748 NOTE The engine will not start unless the lanyard is set to the RUN position ...

Page 103: ...hat ran out of fuel or was drained of fuel the fuel system should be filled as follows Turn the ignition key switch to the ON position for approximately one minute This operates the fuel lift pump Turn the ignition key switch back to the OFF position and then return the ignition key switch to the ON position again for an additional minute Turn the ignition key switch back to the OFF position The f...

Page 104: ...f no water is coming out of the water pump indicator hole stop engine and check the cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operatingtheenginewhileoverheatedwillcauseenginedamage Gear Shifting DTS PANEL MOUNT REMOTE CONTROL IMPO...

Page 105: ...lever to further increase speed DTS CONSOLE MOUNT REMOTE CONTROL IMPORTANT Never shift outboard into gear unless engine speed is at idle Do not shift outboard into forward or reverse when the engine is not running The outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R F N R 3417 When shifting always stop at neutral position and allow the engine speed to ...

Page 106: ...gine is running will result in engine shut down while leaving the DTSsystemactive Thiswillallowtheuseofthepowertrim tiltfrom the remote control handle Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position S T A R T OFF ACC ON S T A R T OFF ACC ON 3482 ...

Page 107: ...e of your outboard orattemptingtoperformmaintenanceorrepaironyouroutboard if you are not familiar with the correct service and safety procedurescouldcausepersonalinjury death orproductfailure Record maintenance performed in the Maintenance Log at the back of this book Save all maintenance work orders and receipts SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Pre...

Page 108: ...ecommended spark plug and gap OWNER RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Inspection and Maintenance Sche...

Page 109: ...under adverse conditions such as extended trolling See Changing Engine Oil Inspect thermostat visually for corrosion and or for a broken spring Make sure thermostat closes completely at room temperature 1 Check engine water separating fuel filter for contaminants Clean and or replace filter See Fuel System Check corrosion control anodes Check more frequently when used in salt water See Corrosion C...

Page 110: ...avoid oil spillage Perform scheduled water pump replacement in combination with an engine oil change Replace water pump impeller more often if overheating occurs or reduced water pressure is noted 1 Check power trim fluid See Checking Power Trim Fluid Replace high pressure in line fuel filter 1 Replace spark plugs at first 300 hours or three years After that inspect spark plugs every 300 hours or ...

Page 111: ...ttom cowl ob01236 3 Thread a water hose into the flush fitting ob01237 4 Turn on the water tap 1 2 maximum and let the water flush through the cooling system for about 15 minutes 5 When flushing is complete turn off water and disconnect the water hose 6 Reinstall the flushing connector to the fitting on the bottom cowl Tighten the connector securely Cowl Removal and Installation COWL REMOVAL IMPOR...

Page 112: ...latch ob01324 2 Pull top cowl forward and lift off 3 Pull lower cowl release latch up 4 Remove rear cowl towards aft of outboard ob01257 COWL INSTALLATION 1 Position lower cowl from aft side of outboard Make sure it fits properly in the rubber seal ...

Page 113: ...surfacewhenitisdry will result in minor surface scratches Always wet the surface before cleaning Do not use detergents containing hydrochloric acid Follow the cleaning and waxing procedure CLEANING AND WAXING PROCEDURE 1 Before washing rinse the cowls with clean water to remove dirt and dust that may scratch the surface 2 Wash the cowls with clean water and a mild non abrasive soap Use a soft clea...

Page 114: ...ator drive belt belt pulleys or the outboard motor mounts IMPORTANT Do not allow lubricant or Corrosion Guard spray to come in contact with the alternator drive belt or the belt pulleys The alternator drive belt could slip and be damaged if it becomes coated with any lubricant or Corrosion Guard spray Tube Ref No Description Where Used Part No 120 Corrosion Guard External metal surfaces of the pow...

Page 115: ...tarting Battery Requirements BCI GRP 24 MCA 1000 CCA 800 Ah 180 International Rating NOTE Due to the wide variety of battery manufacturers throughout the world ratings and physical battery sizes will vary Check with the manufacturer for a starting battery with a MCA CCA or Ah specification that will be equal to or greater than the SAE Standard J537 specified previously IMPORTANT For DTS products e...

Page 116: ... 16 and 3 8 hex nuts supplied for wing nut replacement Metric hex nuts not supplied NOTICE DTS Optimax Engines 37 895387 IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements DO NOT USE WING NUTS DO NOT USE DEEP CYCLE BATTERIES 13 5Nm 120 lbs in DTS Digital Throttle and Shift applications and Optimax engines must use a marine starting battery...

Page 117: ...ove air filter assembly and disconnect Fuel System Module FSM purge valve hose by rotating the air filter assembly and pulling on hose 3665 4 Wash air filter assembly in warm soap water 5 Dry filter assembly with compressed air 6 Apply 4 Cycle Outboard Oil on rag or towel and lightly pad air filter element Wipe off excess oil Air filter element should be moist to the touch ...

Page 118: ...1 AIR FILTER INSTALLATION 1 Install Fuel System Module FSM purge valve hose to air filter assembly 3665 2 Install crankcase ventilation hose 3 Install air filter assembly and tighten clamp screw securely 3664 a b c d a Crankcase ventilation hose b Fuel System Module FSM purge valve hose c Filter assembly d Clamp screw ...

Page 119: ...ell ventilated area 3 Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line must be replaced WATER SEPARATING FUEL FILTER NOTE The warning system will turn on when water in the fuel filter reaches the full level Re...

Page 120: ...located aft of starter motor 3470 CAUTION Fuel vapor vent system is under pressure Cover valve assembly with a rag or towel to prevent fuel or fuel vapor spray Relieve pressure slowly 3 Place rag or towel around valve release pressure by pushing core of valve end in 3472 ...

Page 121: ...om bracket Hoses and wire harness can remain attached to filter holder 2 Tip the filter holder to drain any fluid into an approved container ob01263 Filter Installation 1 Position filter holder onto bracket and secure filter holder in place 2 Lubricate the sealing ring on the filter with oil 3 Install the filter and tighten securely by hand ...

Page 122: ...tal to be slowly eroded instead of the outboard metals Each anode requires periodic inspection especially in salt water which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode Two anodes are located on each side of the gearcas...

Page 123: ...propeller straight off shaft If 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 TubeRefNo Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft splines 92 802867A1 95 2 4 C Marine Lu...

Page 124: ...ropeller e Replaceable drive sleeve f Forward thrust hub 7 Place a block of wood between gearcase and propeller and torque to specifications Description Nm lb in lb ft Propeller nut 75 55 8 Secure propeller nut by bending three of the tabs into the thrust hub grooves ob00422 Spark Plug Inspection and Replacement 1 Remove top and rear cowlings Refer to Cowl Removal and Installation 2 Disconnect the...

Page 125: ...rode is worn threads of seal area are corroded or the insulator is rough cracked broken blistered or fouled ob01092 5 Set the spark plug gap to specifications ob00680 Spark Plug Spark Plug Gap 0 8 mm 0 0315 in 6 Saltwater use Apply a thin coating of Anti Seize Compound only on threads of spark plugs TubeRefNo Description Where Used Part No 81 Anti Seize Compound Spark plug threads 92 881091K1 7 Cl...

Page 126: ...ion 10 Secure coils with retained bolts Torque to specifications Description Nm lb in lb ft Bolts 8 71 11 Connect the six wiring harness connectors to pencil coil connections a b c 3658 a Wiring harness connector b Pencil coil c Bolt 12 Reinstall rear and top cowls Fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to loca...

Page 127: ...board side of engine ob01516 2 Remove the plastic cover from the fuse holder 3 Remove fuse puller from fuse holder 4 Remove suspected blown fuse to determine if the silver colored band is broken 5 Replace fuse with a new fuse of the same amperage rating ob01252 ...

Page 128: ...mage the wire insulation allowing water to enter the wiring Water intrusion may lead to wiring failure and loss of throttle and shift control Verify the harnesses are not routed near sharp edges hot surfaces or moving parts Verify that all unused connectors and receptacles are covered with a weather cap Verify that the harnesses are fastened along the routing path Accessory Drive Belt Inspection I...

Page 129: ...ob01526 a d b c a Tilt support lever b Power trim fill cap c Tilt support bracket d Pedestal 5 The fluid level should be approximately 25 mm 1 in from the top of the fill neck Add Quicksilver or Mercury Precision Lubricants Power Trim Steering Fluid If not available use automotive automatic transmission fluid ATF TubeRefNo Description Where Used Part No 114 Power Trim and Steering Fluid Power trim...

Page 130: ...iption Where Used Part No 138 Synthetic Power Steering Fluid SAE 0W 30 Power steering system 92 858002K01 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 7 0 liters 7 4 quarts PUMP METHOD IMPORTANT Tilt outboard out up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump IMPORTANT Toreduceorpreventoilspillagewhenremovingthe oil ...

Page 131: ...emove dipstick and slide adaptor tube of crankcase oil pump through oil dipstick hole to bottom of engine oil sump 4 Pump out the engine oil into an appropriate container Crankcase Oil Pump 91 90265A 5 11591 Aids in the removal of engine oil without draining the crankcase DRAIN METHOD 1 Tilt outboard out up past vertical for approximately one minute to allow trapped oil to drain back to the oil su...

Page 132: ...ing engine oil from contacting the anti splash and anti cavitation plates 5 Remove drain plug seal washer and drain engine oil into container 6 Reinstall drain plug seal washer CHANGING OIL FILTER IMPORTANT Toreduceorpreventoilspillagewhenremovingthe oil filter ensure that the outboard is upright not tilted and the engine is cold or has not run for at least one hour 1 Remove the top cowl 2 Place a...

Page 133: ...g the filter counterclockwise ob01251 Oil Filter Wrench 91 802653Q02 5221 Assists in removal of oil filter 4 Clean the oil filter mounting base 5 Apply film of clean oil to filter gasket Do not use grease 6 Screw new filter on until gasket contacts base then tighten 3 4 to 1 turn ...

Page 134: ...he presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcas...

Page 135: ...rcase lubricant capacity is approximately 970 ml 32 8 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant 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 hole and add lubricant until it appears at the vent hole a ...

Page 136: ...RTANT 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 cleaned fill drain plug and sealing washer ...

Page 137: ...rain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system IMPORTANT Thisoutboardisequippedwithaclosedfuelsystem whentheengineisnotrunning Withthisclosedsystem fuelwithin theengine sfuelsystem otherthanthefueltank willremainstable during normal storage periods without the addition of fuel treatment stabilizers Fill the fuel tank and engine fuel sy...

Page 138: ...rk Plug Inspection and Replacement for correct procedure for removing spark plugs Remove pencil coils and spark plugs Spray approximately 30 ml 1 fl oz of Storage Seal Rust Inhibitor into each spark plug hole TubeRefNo Description Where Used Part No 119 Storage Seal Rust Inhibitor Spark plug holes 92 802878 5 6 Actuate key push button start switch to crank the engine through one start cycle which ...

Page 139: ...aust outlet in the gearcase could freeze and cause damage to the outboard Battery Storage Follow the battery manufacturer s instructions for storage and recharging Remove the battery from the boat and check water level Recharge if necessary Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage ...

Page 140: ...onnection faulty Starter motor solenoid or slave solenoid failure Engine Will Not Start POSSIBLE CAUSES Incorrect starting procedure Refer to Operation section 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 Maintenance section Fuel pump failure Fuel tank fil...

Page 141: ...ermanently built in type fuel tanks d Fuel line is kinked or pinched Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Overheating Warning horn not working Low oil pressure Check oil level Throttle not opening fully Damaged propeller or improper propeller size Incorrect engine timing adjustment or setup Boat overloaded or load improperly distributed Excessive wat...

Page 142: ...TROUBLESHOOTING 134 Excessive use of electrical accessories Defective rectifier alternator or voltage regulator Open circuit in the alternator output wire fused link ...

Page 143: ...he 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 product contact your dealer or a...

Page 144: ...ebsite www mercurymarine com Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9793 5880 Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Recha...

Page 145: ...pan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Singapore 508762 Fax 5467789 ...

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