Mercury 225 OptiMax Operation, Maintenance & Warranty Manual Download

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Starter Motor Will Not Crank the Engine

POSSIBLE CAUSES

•

Lanyard stop switch not in RUN position.

•

Blown 5‑amp fuse. Check DTS power harness circuit fuse. Refer to

Maintenance

section.

•

Outboard is not shifted to neutral position.

•

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

VesselView.

•

Weak battery or battery connections are loose or corroded.

•

Ignition key switch failure.

•

Wiring or electrical connection 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 filter obstructed.

•

Ignition system component failure.

•

Spark plugs fouled or defective. Refer to

Maintenance

section.

Engine Starts But Will Not Shift Into Gear

•

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

VesselView.

Engine Runs Erratically

POSSIBLE CAUSES

•

Overheating ‑ Warning horn not working.

•

Low oil pressure. Check oil level.

•

Spark plugs fouled or defective. Refer to

Maintenance

section.

•

Incorrect setup and adjustments.

•

Fuel is being restricted to the engine.

a. Engine fuel filter is obstructed. Refer to

Maintenance

section.

TROUBLESHOOTING

120

eng

Summary of Contents for 225 OptiMax

Page 1: ...Outboard Operation Maintenance Warranty Manual 2015 Mercury Marine 200 350 Including Pro Series Verado FourStroke 8M0089146 1214 eng ...

Page 2: ...eng ...

Page 3: ... emission assessment Det Norske Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Name of notified body for noise emission assessment Det Norske Veritas AS Address Veritasveien 1 Town Hovik Post Code 1322 Country Norway ID Number 0575 Conformity assessment module used for exhaust emissions B C B D B E B F G H Conformity assessment module used for noise emiss...

Page 4: ...4 Essential requirements Standards Other normative document method Technical file Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 engine identification B 2 exhaust emission requirements EN ISO 8178 1 1996 B 3 durability EN ISO 8178 1 1996 B 4 owner s manual ISO 8665 2006 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s man...

Page 5: ...ill be pleasant Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the fact...

Page 6: ...a Mercury Premier Service rating means a dealer Achieves a high 12 month service Customer Satisfaction Index CSI score for warranty service Possesses all of the necessary service tools test equipment manuals and parts books Employs at least one certified or master technician Provides timely service for all Mercury Marine customers Offers extended service hours and mobile service when appropriate U...

Page 7: ...abel 10 Warranty Policy Australia and New Zealand 11 Global Warranty Charts Outboard and Jets 15 General Information Boater s Responsibilities 20 Before Operating Your Outboard 20 Boat Horsepower Capacity 20 High Speed and High Performance Boat Operation 21 Outboard Remote Control Models 21 Lanyard Stop Switch 21 Protecting People in the Water 24 Exhaust Emissions 24 Passenger Safety Message Ponto...

Page 8: ...on 50 Dual Handle Console Control Features and Operation 56 Shadow Mode Control with CAN Trackpad Features and Operation 64 Warning System 67 Power Trim and Tilt 69 Operation Important Daily Inspection Before Each Use 73 Prestarting Check List 73 Operating in Freezing Temperatures 74 Operating in Saltwater or Polluted Water 74 Operating at High Elevations 74 Propeller Selection 74 Effects of Eleva...

Page 9: ...sion Control Anodes 350 HP 97 Trim Wear Pad Replacement 97 Propeller Replacement 25 4 mm 1 0 in Diameter Propeller Shaft 98 Propeller Replacement 31 75 mm 1 1 4 in Diameter Propeller Shaft 101 Spark Plug Inspection and Replacement 102 Fuses 105 DTS Wiring System 106 Accessory Drive Belt Inspection 107 Checking Power Trim Fluid 107 Checking Power Steering Fluid 109 Changing Engine Oil 109 Gearcase ...

Page 10: ... 120 Engine Runs Erratically 120 Performance Loss 121 Battery Will Not Hold Charge 121 Owner Service Assistance Local Repair Service 122 Service Away from Home 122 Parts and Accessories Inquiries 122 Service Assistance 122 Ordering Literature 125 Installation Outboard Installation 127 Maintenance Log Maintenance Log 134 viii eng ...

Page 11: ... s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 OUTSIDE UNITED STATES AND CANADA For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Cent...

Page 12: ...0 00 per engine to cover the transfer fee Plan coverage is not transferable from one product to another product or for noneligible applications The certified preowned engine plans are not transferable For help or assistance contact Mercury Product Protection Department at 1 888 427 5373 from 7 30 a m to 4 30 p m CST Monday Friday or e mail mpp_support mercmarine com 3 Year Limited Warranty Against...

Page 13: ...with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any co...

Page 14: ...e 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 EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SO...

Page 15: ...to the product for warranty service Customer must deliver product to an authorized dealer 6 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 7 Labor performed by other than an authorized dealer may be covered only under the following circumstances when performed on emergency basis providing there are no authorized dealers in the area who ca...

Page 16: ... 40 CFR Part 1045 Subpart B Mercury Marine provides a five year or 175 hours of engine use warranty whichever occurs first to the retail customer that the engine is designed built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine is free from defects in materials and workmanship that cause the engine to fail to ...

Page 17: ...that the outboard engine was designed built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code For information regarding the limited warranty for the nonemission related components of the outboard please see the limited warranty statement for your outboa...

Page 18: ...Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury WHAT MERCURY WILL DO Mercury Marine s...

Page 19: ...DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHT...

Page 20: ...er be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days...

Page 21: ...sources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines Warranty Policy Australia and New Zealand MERCURY MARINER OUTBOARD LIMITED WARRANTY AUSTRALIA AND NEW ZEALAND POLICY This limited warranty ...

Page 22: ...nexpired warranty coverage cannot be transferred either to or from a commercial use customer Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty 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 spe...

Page 23: ... tear faded paint 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 installat...

Page 24: ... 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 EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY TRANSFER OF WARRANTY AUSTRALIA AND NEW ZEALAND POLICY The limited warranty is transferable to a subsequent purchaser but only for the...

Page 25: ... and 250 hp 1 year 3 years Racing Product Recreation use only Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax 250 XS 2 years 3 years OptiMax 300 XS 2 years 3 years Verado 400R 2 years 3 years Outside the United States For product purchased outside the United States contact the distributor in your country or the authorized Marine Power Service Center closest to you CANADA WARR...

Page 26: ...or dealer closest to you AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS OUTBOARD AND JET Products Standard Limited Warranty Standard Limited Corrosion Warranty Light Commercial All outboard 3 years 3 years Contact the Marine Power Service Center closest to you Outside of Australia and New Zealand For product purchased outside of Australia and New Zealand contact the distributor in your country or the M...

Page 27: ...ional only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application Verado 400R 1 year 3 years None Outside of Asia For product purchased outside of the Asian region contact the distributor in your country or the Marine Power Service Center closest to you EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES CIS WARRANTY CHARTS OUTBOARD AND JET Product Recreational only St...

Page 28: ...AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2 Stroke 1 year 3 years Contact the Marine Power Service Center closest to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Ve...

Page 29: ...to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Verado 400R 2 years 3 years Outside South Africa For products purchased outside of the South Africa region contact the distributor in your country or the Marine Power Service Center closest to ...

Page 30: ...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 31: ...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 equipped with a Mercury remote control designed for digital throttle and shift Start in gear protection is provided by the remote control system Lanyard Stop Switch The purpose of a lanyard stop switch is to...

Page 32: ...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 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 boats...

Page 33: ...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 bo...

Page 34: ...boat or any solid device attached to the boat can cause serious injury or death to swimmers Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide CO is a deadly gas that is present in th...

Page 35: ...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 propeller GOOD VENTILATION Ventilate the passenger area open side curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATION Under certain running and or...

Page 36: ...bserve 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 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 wil...

Page 37: ...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 38: ...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 39: ... 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 40: ... Clamp Bracket for important information on mounting accessories to the transom clamp bracket Safe Boating Recommendations To safely enjoy the waterways familiarize 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 ...

Page 41: ...in the boat Prepare other boat operators Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the 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 bo...

Page 42: ...is 61 m 200 ft in front of you in five seconds Watch fallen skiers When using your boat for waterskiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to 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 ...

Page 43: ...oline Refer to Fuel and Oil Recommended oil Refer to Fuel 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 SAE battery type 800 minimum marine cranking amps MCA with a minimum reserve capacity of 135 minutes RC25 rating International EN battery typ...

Page 44: ... 1 1 75 1 1 75 1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel 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 SAE battery type 800 minimum marine cranking amps MCA with a minimum reserve capacity of 135 minutes RC25 rat...

Page 45: ...wn a Model number b Serial number c Year manufactured Component Identification 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 XXXXXXXXX XXXXX XXXX a b c 57237 j i h g f e d c b a 28919 GENERAL INFORMATION eng 35 ...

Page 46: ...ffect the performance of your boat and could result in damage to the outboard engine When choosing a propeller a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine To view the entire product offering and find the correct propeller that is best suited for your application visit www mercmarinepropellers com or see yo...

Page 47: ...resents 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 will help you determine the correct propeller for your boating application Diameter The diameter is the distance across the imaginary circle that is made when the propeller rotates The correct diameter...

Page 48: ...opellers 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 five times more durable than aluminum and typically provides performance gains in acceleration and top end speed due to design efficiencies Stainless steel propellers also come in a larger variety o...

Page 49: ...ce 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 supported using the outboard s tilt support bracket trailering position in addition to using an accessory transom support device Refer to Features and Controls Power Trim and Tilt 28924 TRANSPORTING eng 39 ...

Page 50: ...om 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 system to maintain proper ground clearance for trailering The power trim tilt system is not intended to support the outboard for trailering TRANSPORTING 40 eng ...

Page 51: ...9 R M 2 minimum is acceptable however performance losses may occur Do not use leaded gasoline Outside USA and Canada Having a posted pump Octane Rating of 95 RON is required for best performance Having a posted pump Octane Rating of 93 RON minimum is acceptable however performance losses may occur If unleaded gasoline is not available use a major brand of leaded gasoline MODELS 200 PRO 225 AND 250...

Page 52: ...softening hardening swelling or corrosion particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection fr...

Page 53: ...gine The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage The fuel demand valve has a manual release The manual release can be used pushed in to open bypass the valve in case of a fuel blockage in the valve a Fuel demand valve installed in the fuel hose between the fuel tank and the engine b Manual release c Vent wate...

Page 54: ...b lock 3 Press down on the tab lock Rotate the fuel cap 1 4 turn to relieve the pressure 4 Press down on the tab lock again and remove the cap DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1 When installing the fuel tank cap 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 2 Open the manual vent scre...

Page 55: ...or Quicksilver NMMA FC W certified 25W 40 Mineral Marine 4 Stroke Engine Oil may be used If the recommended Mercury or Quicksilver NMMA FC W certified oils are not available a major outboard manufacturer s brand of NMMA FC W certified 4 Stroke Outboard Oil of similar viscosity may be used IMPORTANT The use of nondetergent oils multiviscosity oils other than Mercury or Quicksilver NMMA FC W certifi...

Page 56: ...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 in the operating range cross hatched region IMPORTANT Do not try to fill the oil level to the top of the operating range cross hatched region Oil level is correct as long as it appears in the operatin...

Page 57: ...s on the operating range cross hatched region Do not try to fill to the upper end of the operation range cross hatched region 28761 IMPORTANT Inspect oil for signs of contamination Oil contaminated 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 th...

Page 58: ...rward 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 3 Trim switch if equipped Pressing the trim switch will trim the engine up or do...

Page 59: ...ttle 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 stop the engine without using the ignition key The ignition key must be in the ON position to start the engine 3414 6 Lanyard stop switch Turns the ignition off whenever the operator when attached to ...

Page 60: ...positions 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 Control Features and Operation DTS SLIM BINNACLE SINGLE HANDLE CONSOLE FEATURES AND OPERATION 1 Operation of shift and throttle is controlled by the movement of the control handle Push the control handl...

Page 61: ...ndle 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 tension on the control handle This will help prevent unwanted motion of the remote control handle in rough water Turn screw clockwise to increase tension and counterclockwise to decrease tension Adjust ...

Page 62: ...t or stop the engine without the use of the key switch The key switch 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 for warm up without shifting the transmission into gear e Increases brightness settings for CAN pad VesselView and SmartCraft gauge...

Page 63: ...neutral a beep will sound and the helm transfer will not succeed until the levers 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 is started To remove the fault codes it may be necessary to cycle the key switch off and on and then restart the helm tra...

Page 64: ... 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 double beep sounds and control will remain at the existing active helm Press the transfer button again to start the helm transfer 4 The helm where the transfer request was initiated is now active and cont...

Page 65: ...ngage 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 neutral lights stop flashing and remain illuminated DOCK Dock mode reduces throttle capacity to approximately 50 of normal throttle demand allowing finer control of engine power in close quarter situati...

Page 66: ... 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 handles through the detents is adjustable to help prevent unwanted motion Adjustment NOTE The control handle tension and detent tension may require periodic maintenance using the adjustment screws To...

Page 67: ...needs 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 screw b Handle tension adjustment screw a b 51901 FEATURES AND CONTROLS eng 57 ...

Page 68: ...trailering etc b NEUTRAL lights Illuminate 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 d DOCK Control lever operation reduces throttle capacity to approximately 50 of normal control lever throttle demand e Increases brightness settings for CAN pad...

Page 69: ...e capacity to approximately 50 of normal throttle demand allowing finer 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 only mode will avoid unintended gear engagement The engines will turn using the steering wheel and the RPM of the engines can be inc...

Page 70: ...ERC levers into neutral Throttle only will not disengage unless 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 with a single lever on a dual engine application This feature simplifies engine management during rough sea conditions by allowing you to use...

Page 71: ...nc cannot engage until the engines 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 turns red when the engines are synchronized 51857 SYNC button The RPM display of VesselView also shows an orange icon under the RPM numbers if the engines RPMs differ more t...

Page 72: ...ransfer 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 ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position NOTE If you attempt to transfer helm control when the ERC levers are not in neutral a beep will ...

Page 73: ...e 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 TRANSFER button NOTE If the ERC levers at the helms are not in neutral the neutral lights will flash Move all the ERC levers to neutral and the neutral light will stop flashing 2 With the TRANSFER button l...

Page 74: ...ort 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 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 t...

Page 75: ...the remote control allows the boat operator to control the 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 vessel personality for shadow operation IMPORTANT Quad engine vessel personalities may vary on which engines are configured to be the master e...

Page 76: ...ion key switch turned off Running Running Running Port inner engine throttle and shift controlled by starboard control handle Running Running Running Off ignition key 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 co...

Page 77: ...s the port outer engine into forced neutral idle condition the inner port engine will also be forced to neutral idle Operation to the inner engine can be restored by moving the port control handle back into neutral and then into gear Warning System WARNING HORN SIGNALS When the key switch is turned to the ON position the horn will turn on for a moment as a test to indicate the horn is working Ther...

Page 78: ...e Guardian system If the Engine Guardian system has determined the reset has not corrected the problem Engine Guardian will 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 rev limit is set at an RPM greater than the operating range In the event that the...

Page 79: ...ilt 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 RPM and below the outboard can also be tilted up past the trim range to permit shallow water operation a Trim switch b Tilt range of travel c Trim range of travel POWER TRIM OP...

Page 80: ...w higher out of the water Generally increase top 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 above the waterline TILTING TO FULL UP POSITION Tilt at Helm NOTE The trim tilt switch will remain active for 15 minutes after the ignition key switch...

Page 81: ... 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 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 tighten the manual tilt release valve a ...

Page 82: ...ent hitting bottom 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only 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 al...

Page 83: ... 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 boat capacity plate Fuel supply OK Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where you are going and when you expe...

Page 84: ...em 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 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 corrosio...

Page 85: ...e engine which in turn lowers the following Boost pressure on supercharged engines Horsepower and torque throughout the RPM range Peak RPM Cranking compression EXAMPLE An engine running at an elevation of 8 000 feet will have over a 30 power loss while a loss of engine power on a hot and humid day could be as much as 14 These losses apply to normally aspirated and supercharged engines Compensating...

Page 86: ...up 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 more than five minutes at a time Fuel Supply Module Priming Procedure The fuel supply module FSM is not vented to the ambient air The air trapped in the FSM fuel lines and fuel rail will be slightly c...

Page 87: ...rged 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 is found the fuel supply system to the outboard may be too restrictive Correct the condition and try again 7 Remove the fuel pressure gauge 8 Turn the ignition key ON When the fuel pumps stop running...

Page 88: ...m 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 prime within 10 full eight second cranking events use the previous procedure Priming the FSM with a Purge Tool to prime the fuel system Starting the Engine Before starting read the Prestarting Check Lis...

Page 89: ...fuel 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 is set to the RUN position 19791 OPERATION eng 79 ...

Page 90: ...g 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 pump indicator hole IMPORTANT If no water is coming out of the water pump indicator hole stop the engine and check the cooling water intake for obstruction No obstruction may indicate a water pump fai...

Page 91: ...F N R When shifting always stop at neutral position and allow the engine speed to return to idle Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position 3428 Advance the control lever to further increase speed DTS CONSOLE MOUNT REMOTE CONTROL IMPORTANT Never shift the outboard into gear unless the engine speed is at id...

Page 92: ...ever to further increase speed Stopping the Engine IMPORTANT Turning key to the START position while the engine is running will result in engine shut down while leaving the DTS system active This will allow the use of the power trim tilt from the remote control handle Reduce engine speed and 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...

Page 93: ...or Quicksilver replacement parts and Genuine Lubricants EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory standards For this r...

Page 94: ...wer or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule BEFORE EACH USE Check engine oil level Refer to Fuel and Oil Checking and Adding Engine Oil Check that the lanyard stop switch stops the engine Check the outboard for tightness to the boat transom If any looseness of the outboard or mounting fasteners exists tighten the outboard mo...

Page 95: ... mounting fasteners to 75 Nm 55 lb ft This item should be serviced by an authorized dealer Remove the in line fuel filter sleeve Refer to In line Fuel Filter Sleeve Removal Check the accessory drive belt Inspect the front engine mounts 350 only This item should be serviced by an authorized dealer Inspect the thermostat for corrosion and for a broken spring Verify the thermostat closes completely a...

Page 96: ...ed by an authorized dealer Check power trim fluid Refer to Checking Power Trim Fluid Replace high pressure in line fuel filter This item should be serviced by an authorized dealer Replace spark plugs at first 300 hours or three years After that inspect spark plugs every 300 hours or three years Replace spark plugs as needed Refer to Spark Plug Inspection and Replacement Replace the front engine mo...

Page 97: ... the cooling system for about 15 minutes 5 When flushing is complete turn off water and disconnect the water hose 6 Install the flushing connector to the fitting on the bottom cowl Tighten the connector securely Cowl Removal and Installation COWL REMOVAL IMPORTANT Most maintenance points are accessible by removing the top cowl only 1 Pull up on the top cowl lock latch 28946 MAINTENANCE eng 87 ...

Page 98: ...d Make sure it fits properly in the rubber seal 2 Lock cowl in place by pulling lower cowl latch down 29591 3 Place top cowl into position over engine front first Ensure cowl fits properly into the rubber seal 4 The top cowl will lock into place when downward pressure is applied to the back side of cowl Ensure cowl is securely fastened by pulling up on back of cowl MAINTENANCE 88 eng ...

Page 99: ...ff any salt build up from the powerhead and powerhead components with fresh water Keep water spray out of the air filter intake and alternator After washing allow the powerhead and components to dry Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components Do not allow the Corrosion Guard spray to come in contac...

Page 100: ...m marine cranking amps with a minimum reserve capacity of 135 minutes RC25 rating International EN Verado Starting Battery Rating Required Verado starting battery 12 volt absorbed glass mat AGM battery Required cold cranking amps CCA and amp hours Ah 975 minimum cold cranking amps with a minimum of 65 amp hours NOTE Do not use an engine starting battery that does not meet the specified ratings If ...

Page 101: ... 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 5 16 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 b...

Page 102: ... be moist to the touch Tube Ref No Description Where Used Part No 110 4 Stroke 10W30 Outboard Oil Air filter element 92 858045K01 AIR FILTER INSTALLATION 1 Install crankcase ventilation hose 2 Install air filter assembly and tighten clamp screw securely Air Filter 350 350 Pro The air filter is an integral component of the flywheel guard It should be inspected for debris whenever the top cowl is re...

Page 103: ...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 IN LINE FUEL FILTER SLEEVE REMOVAL This engine is equipped with an in line fuel filter sleeve installed in the fuel delivery line near the engine cowl inlet The filter captures debris that may be...

Page 104: ... 3 Remove the in line fuel filter sleeve from the adapter and discard 57228 4 Install the vessel fuel line onto the adapter and secure with a clamp 5 Verify the fuel line connection does not have a fuel leak 6 Assemble the rigging tube if equipped VESSEL MOUNTED WATER SEPARATING FUEL FILTER This engine requires a vessel mounted water separating fuel filter The filter should be replaced annually or...

Page 105: ... of according to applicable regulations and law a Water separating fuel filter b Water in fuel sensor 4 Remove the filter by turning it counterclockwise Dispose of the filter according to applicable regulations and law 5 Lubricate the new filter seal with oil Do not use grease 6 Install the filter and tighten securely 7 Install the water in fuel sensor and tighten securely Do not overtighten this ...

Page 106: ...w minutes Allow the trapped air to be purged from the fuel system before operating the engine above idle in gear Corrosion Control Anodes The outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals Each anode requires periodic inspection especially in salt...

Page 107: ...control anode on the bottom of the antiventilation plate b One control anode on the bottom of the trim manifold c Two control anodes on the bottom of each power trim ram d One control anode on the bottom of the pedestal Trim Wear Pad Replacement The 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 ...

Page 108: ...atch 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 25 4 mm 1 0 in Diameter Propeller Shaft 1 Shift the outboard into neutral position 2 Straighten the bent tabs on the propeller nut retainer 26900 a b c 36869 MAINTENANCE 98 eng ...

Page 109: ...peller shaft splines 8M0071842 95 2 4 C with PTFE Propeller shaft splines 92 802859A 1 FLO TORQ III AND IV PROPELLERS 1 Lubricate the propeller shaft with one of the following 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 2 Install the propeller onto the shaft as shown If the components supplied w...

Page 110: ...e adapter e Locknut retainer f Locknut g Raised pins h Tabs bent against the locknut Flo Torq lV fastened with a locknut a Forward thrust washer b Drive sleeve c Propeller d Drive sleeve adapter e Locknut retainer f Locknut g Raised pins h Tabs bent against the locknut Description Nm lb in lb ft Locknut 75 55 3 c d e f a b 51612 h g a b c d e f 51613 h g MAINTENANCE 100 eng ...

Page 111: ...f wood between the gearcase and the propeller to hold the propeller and remove the propeller nut 29592 3 Pull the propeller straight off the shaft If the propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 4 To aid in future removal of the propeller liberally coat the propeller shaft splines with one of the following Mercury Quicksilver product...

Page 112: ...b 6 Place a block of wood between the gearcase and the propeller Tighten the propeller nut to the specified torque 2691 Description Nm lb in lb ft Propeller nut 75 55 Spark Plug Inspection and Replacement 1 Remove top and rear cowls Refer to Cowl Removal and Installation 2 Disconnect the wiring harness from the pencil coil connections 3 Remove screws securing the coils a b c d e f 44856 MAINTENANC...

Page 113: ...orn 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 precious metal on the plug s electrode If no precious metal is visible replace the plug a Precious metal a b c 57247 a 9381 MAINTENANCE eng 103 ...

Page 114: ...e 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 7 Saltwater use Apply Anti Seize Compound only onto the threads of the spark plugs Tube Ref No Description Where Used Part No 81 Anti Seize Compound Spark plug threads 92 898101385 8 Before ...

Page 115: ...ications Marine applications are exposed to environments that may have the potential to accumulate explosive vapors ATO fuses have exposed elements and should never be used in marine applications The electrical wiring circuits on the outboard are protected from overload with fuses If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow aga...

Page 116: ...h Spare fuses 3 i Thrust vector module 20 amp Joystick Piloting models only j Diagnostics terminal 2 amp k Fuel injectors 20 amp DTS Wiring System WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring Water intrusion may lead to wiring failure and loss of throttle and shift control To avoid the possibility of serious injury or death from loss of boat contro...

Page 117: ...ve an authorized dealer replace the belt a Tensioner arrow b Red target window replace the belt 2 Inspect the condition of the drive belt If any of the following conditions are found have an authorized dealer replace the belt Cracks in the back of the belt or in the base of V grooves Excessive wear at the roots of the grooves Rubber portion swollen by oil Belt surfaces roughened Signs of wear on e...

Page 118: ...op of the fill neck Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid 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 fill cap Tighten fill cap 1 4 turn Cap will snap in place Do not tighten beyond this point a c d b 29312...

Page 119: ...NT Tilt 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 that the outboard is upright not tilted and the engine is cold or has not run for at least one hour IMPORTANT The pump method is preferred to remove engine oil from XXL models If the drain metho...

Page 120: ...A 5 11591 Aids in the removal of engine oil without draining the crankcase DRAIN METHOD 1 Tilt the outboard out up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump 2 Place the outboard in a vertical position 3 Place an appropriate container under the engine oil sump plug The drain plug seal washer is located beneath the splash plate on the port side...

Page 121: ... 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 tool by turning the filter counterclockwise a Oil filter Oil Filter Wrench 91 889277 5221 Aids in the removal of the oil filter 4 Clean the oil filter mounting base 5 Lubricate the new filter gasket wi...

Page 122: ...er 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 gearcase Examine the drained gearcase lubricant for...

Page 123: ...ricant 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 Vent hole b Fill hole IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before rem...

Page 124: ... 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 completely drain a 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 Allow a few minutes for the lubricant ...

Page 125: ...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 gearcase before installing the lubricant level plug Install the lubricant level plug 6 Remove the lubricant tube and install the fill drain plug and sealing washer 7 Tighten the plugs to the specified t...

Page 126: ...nt 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 500 mL 17 oz of the specified gear lubricant IMPORTANT Replace the sealing washers if damaged 3 Allow a few minutes for the lubricant level to stabilize in the gearcase before installing the lubricant level plug Install the lubricant level plug 4 Remove the...

Page 127: ...ant 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 gearcase before installing the lubricant level plug Install the lubricant level plug 6 Remove the lubricant tube and install the fill drain plug and sealing washer 7 Tighten the plugs to the specified torq...

Page 128: ...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 fuel to help prevent formation of varnish and gum Proceed with the following instructions Portable fuel tank Pour the required amount of Fuel System Treatment and Stabilizer follow instructions on contai...

Page 129: ...s and pencil coils Gearcase Drain and refill the gearcase lubricant refer to 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 damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gear...

Page 130: ...ated 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 filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Starts But Will Not Shift Into Gear Shift actuator failure...

Page 131: ...propeller size Incorrect engine timing adjustment or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Air filter or intake screen that is partially blocked with debris 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 el...

Page 132: ...it to your authorized dealer Only authorized dealers specialize in Mercury products and have factory trained mechanics special tools and equipment and genuine Quicksilver parts and accessories to properly service your engine NOTE Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package SERVICE AWAY FROM HOME If you are away from your local de...

Page 133: ...ssories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring about parts and accessories the dealer requires the engine model and serial numbers to order the correct parts RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us If you ever have a problem question or concern about your power package contact...

Page 134: ...ic Group 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 ...

Page 135: ...blications Department P O Box 1939 Fond du Lac WI 54936 1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To...

Page 136: ...Quantity Item Stock Number Price Total Total Due OWNER SERVICE ASSISTANCE 126 eng ...

Page 137: ...he mounting hardware 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 to the transom Outboards that require validated mounting hardware will have the following decal on the transom clamp 51965 FASTENING HARDWARE SPECIFICATION NOT FACTORY SUPPLIED IMP...

Page 138: ...cations 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 stress This corresponds to a F467F mechanical marking per ASTM Washer specifications This washer is for use on the transom bracket side of the application 0 88 x 0 53 x 0 104 inch flat washer 630...

Page 139: ...d safety 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 control the boat Always ensure that the engine fasteners are tightened to the specified torque Acceptable Accessory Mounting to the Transom Clamp Bracket After the engine is mounted to the transom o...

Page 140: ...m clamp 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 INSTALLATION 130 eng ...

Page 141: ...an securing 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 INSTALLATION eng 131 ...

Page 142: ...injury 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 the outboard 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 ...

Page 143: ...e boat transom with the four 12 7 mm 1 2 in diameter mounting bolts locknuts and washers provided Install two bolts through the upper set of mounting holes and two bolts through the lower set of mounting slots 28923 INSTALLATION eng 133 ...

Page 144: ...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 134 eng ...

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Mercury 225 OptiMax, Operation, Maintenance & Warranty Manual

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