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Mercury 250 XS OptiMax, Operation, Maintenance & Installation Manual, Page: 9 / 131

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Mercury 250 XS OptiMax Operation, Maintenance & Installation Manual Download Page 9

Maintenance

Cleaning Care Recommendations.................................................................... 45

Power Package Care........................................................................................ 47

Replacement Parts for Your Power Package................................................... 47

EPA Emissions Regulations............................................................................. 47

Inspection and Maintenance Schedule............................................................. 48

Flushing the Cooling System (Powerhead)...................................................... 50

Flushing the Cooling System (Lower Unit)....................................................... 51

Top Cowl Removal and Installation.................................................................. 52

Fuel System...................................................................................................... 52

Steering Link Rod Fasteners............................................................................ 55

Fuses ............................................................................................................... 56

Corrosion Control Anodes................................................................................ 57

Spark Plug Inspection and Replacement..........................................................58

Battery Inspection ............................................................................................ 60

Charging System Fusible Link.......................................................................... 60

Replacing the Propeller.................................................................................... 61

Lubrication Points............................................................................................. 63

Single‑Ram Trim System.................................................................................. 64

Three‑Ram Trim System.................................................................................. 67

Gearcase Lubricant.......................................................................................... 70

Submerged Power Package............................................................................. 71

Storage

Storage Preparation..........................................................................................72

Protecting Internal Engine Components........................................................... 73

Protecting External Outboard Components...................................................... 74

Gearcase.......................................................................................................... 74

Positioning Outboard for Storage..................................................................... 74

Battery Storage................................................................................................. 74

Troubleshooting

Starter Motor Will Not Crank the Engine...........................................................75

Engine Will Not Start.........................................................................................75

Engine Runs Erratically.................................................................................... 75

Performance Loss.............................................................................................76

Warning Horn Activates (With Power Loss)......................................................76

Warning Horn Activates (No Power Loss)........................................................ 76

Battery Will Not Hold Charge............................................................................ 77

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Summary of Contents for 250 XS OptiMax

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 250 and 300 XS OptiMax 8M0133624 617 eng...

Page 2: ...eng...

Page 3: ...nual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throug...

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

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

Page 6: ...eng iv...

Page 7: ...board 12 Safe Boating Recommendations 12 Recording Serial Number 14 Specifications 250 XS OptiMax 15 Specifications 300XS OptiMax 16 Special Tools and Kits 18 Component Identification 18 Propeller Sel...

Page 8: ...Operation 33 Operation Important Information 35 Engine Break in 35 Engine Break in Fuel Mixture 36 Prestarting Check List 36 Operating in Freezing Temperatures 36 Operating in Saltwater or Polluted W...

Page 9: ...Inspection 60 Charging System Fusible Link 60 Replacing the Propeller 61 Lubrication Points 63 Single Ram Trim System 64 Three Ram Trim System 67 Gearcase Lubricant 70 Submerged Power Package 71 Stor...

Page 10: ...ecifications 89 Lifting the Outboard 89 Steering Cable Starboard Side Routed Cable 90 Steering Link Rod Fasteners 91 Rear Mounted Steering Rams or Tie Bars 92 Determining Outboard Mounting Height 93 D...

Page 11: ...outboard properly If you have any questions contact your dealer This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety ins...

Page 12: ...it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat outboard combination F...

Page 13: ...r out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine wh...

Page 14: ...d stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves w...

Page 15: ...the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could...

Page 16: ...ne immediately whenever anyone in the water is near your boat Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Ponto...

Page 17: ...jury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats...

Page 18: ...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 th...

Page 19: ...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 a...

Page 20: ...s drowsiness and nausea WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning which can lead to unconsciousness brain damage or death Avoid exposure to carbon monoxide Stay cle...

Page 21: ...e is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of...

Page 22: ...ourself 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 a...

Page 23: ...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 operati...

Page 24: ...e 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 t...

Page 25: ...spark plug NGK IZFR6J 11 factory installed NGK IZFR6J service Spark plug gap 1 1 mm 0 042 in Firing order 1 2 3 4 5 6 Maximum timing Controlled by PCM Idle timing Controlled by PCM Fuel line pressure...

Page 26: ...equivalent MCA do not meet Mercury Marine battery requirements Specifications 300XS OptiMax Specifications Propshaft horsepower 300 HP 221 kw Engine displacement 3160 cc 193 cid Engine weight 20 in T...

Page 27: ...lled by PCM Fuel pressure 655 13 8 kPa 95 2 psi Air pressure 758 13 8 kPa 110 2 psi Gear ratio Torque Master 1 62 1 1 75 1 Sport Master 1 62 1 1 75 1 Fleet Master 1 75 1 Required fuel Premium unleaded...

Page 28: ...for Sport Master gearcase 848998A1 Dual Water Pick Up Flush Seal Kit Fleet Torque Master gearcase 881150K1 Component Identification 1 Top cowl 2 Side cowl latches both sides 3 Front cowl latch 4 Auxi...

Page 29: ...peed performance Boat weight and hull design influence the effectiveness of this increased engine speed and may decrease top boat speed If full throttle operation is below the recommended full throttl...

Page 30: ...al dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 2722 IMPORTANT Do not rely on the power trim tilt system or tilt support lever...

Page 31: ...ntly in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel ra...

Page 32: ...ne oil Premium Plus 2 Cycle Outboard Oil Mercury Racing 2 Stroke Oil is recommended for OptiMax engines that are used in applications of extreme loads associated with commercial work or extended perio...

Page 33: ...Fuel Tank Requirements The Environmental Protection Agency EPA requires portable fuel systems that are produced after January 1 2011 for use with outboard engines to remain fully sealed pressurized up...

Page 34: ...sible fuel spillage When installing the fuel tank cap turn the cap to the right until you hear a click This signals that the fuel cap is fully seated A built in device prevents overtightening The fuel...

Page 35: ...te Oil Tank Remove the filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 gallons Replace the filler cap and tighten securely IMPORTANT Always make sure the oil tank caps ar...

Page 36: ...filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tanks from the boat to refill them Always stop the engine before filling the tanks Do not...

Page 37: ...f equipped Refer to Features and Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Refer to General Information Lanyard Stop Switch f Thrott...

Page 38: ...attention You may continue using your boat however depending on the nature of the problem the engine s power may be limited by the Engine Guardian system see Engine Guardian System following to protec...

Page 39: ...dian 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 engine is operated at an...

Page 40: ...stment of the outboard within the first 20 range of travel The term tilt generally refers to adjusting the outboard further up out of the water With the engine turned off the outboard can be tilted ou...

Page 41: ...Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer resulting in the operator losing control of the boat Install the trim limit pin in a position...

Page 42: ...ke holes are above the water line Power Tilt Operation Single Ram Systems To tilt the outboard shut off the engine and press the trim tilt switch or the auxiliary tilt switch to the up position The ou...

Page 43: ...tilt support lever by raising the outboard off the support lever and rotating the lever until it locks Lower the outboard Auxiliary Tilt Switch This switch can be used to tilt the outboard up or down...

Page 44: ...ilting of the outboard 2728 2 Tilt the outboard to the desired position and tighten the manual tilt release valve NOTE The manual tilt release valve must be tightened before operating the outboard to...

Page 45: ...on pump on new or rebuilt engines or after performing maintenance on the oiling system Refer to Outboard Installation Priming the Oil Injection Pump for instructions FUEL REQUIREMENTS Do not use premi...

Page 46: ...Hours Change engine speed every 10 minutes Engine Break in Fuel Mixture The propulsion control module PCM controls oil and fuel mixture during engine break in Prestarting Check List Engine lowered to...

Page 47: ...not spray on corrosion control anodes as this will reduce the effectiveness of the anodes Operating at High Elevations Your engine automatically compensates for high elevation changes A different pit...

Page 48: ...plugs If this condition exists trim outboard up until exhaust relief hole is out of the water a Relief hole submerged wrong b Relief hole above waterline correct Operating in Shallow Water When operat...

Page 49: ...he vent cap may damage the threads in the oil reservoir tank Damaged threads may result in future oil leakage 2 Check the oil level in the engine mounted oil reservoir tank The tank must contain at le...

Page 50: ...ose IMPORTANT Fill the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel pump will run without fuel during the priming process and may be damaged Prime the oil inje...

Page 51: ...ump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation INITIAL STARTING PROCEDURE NOTE For initial start up of a new engine...

Page 52: ...6837 2 Open fuel tank filler cap vent screw manual venting fuel tanks 19748 3 Squeeze the fuel line primer bulb several times until it feels firm 19779 4 Set the lanyard stop switch to the RUN positio...

Page 53: ...key to the START position Release the key when the engine starts If the engine fails to start in ten seconds return the key to the OFF position wait one second and try again 19804 8 Check for water co...

Page 54: ...is greater than a no wake speed Shifting into reverse at higher boat speeds could cause the engine to stall and in some situations this could cause water to be drawn into the cylinders resulting in se...

Page 55: ...lure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning...

Page 56: ...mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remo...

Page 57: ...med in the Maintenance Log at the back of this book Save all maintenance work orders and receipts Replacement Parts for Your Power Package Mercury recommends using original Mercury Precision replaceme...

Page 58: ...not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule DAILY CHECKS C...

Page 59: ...ers on the suction side of the fuel system dealer item Lubricate the driveshaft splines dealer item Check the tightness on all the fasteners dealer item Check the torque of the outboard mounting hardw...

Page 60: ...ogging the internal water passages a Plug located on fitting b Water hose 1 Remove the plug from fitting in the bottom cowl 2 Attach a water hose to the fitting Turn on the water and flush for three t...

Page 61: ...er Flush Seal over the nose inlets 3 Sport Master gearcases Install the appropriate flushing attachment so the nose cone cup fits tightly over the intake holes 4 Attach a water hose to the flushing at...

Page 62: ...exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately IMPORTANT Use an approved container to collect and store fuel Wipe up any spill...

Page 63: ...aches the full level Refer to Warning System in Features and Controls Refer to the Inspection and Maintenance Schedule for the proper maintenance interval Removal a O ring seals b Filter c Raised boss...

Page 64: ...condition drain the water from the fuel filter chamber a Drain hose b Aft hose fitting c Filter drain screw 1 Remove the drain hose from the aft hose fitting right side of the chamber Hold the unatta...

Page 65: ...instructions and torque procedures WARNING Worn loose or seized steering components can lead to loss of boat control Inspect all steering attachment components for wear lubricate all attachment hardw...

Page 66: ...ses The electrical wiring circuits on the engine are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload before replacing the fuse If...

Page 67: ...cuits 20 amp fuse g Diagnostic circuit 2 amp fuse Corrosion Control Anodes NOTICE Anodes made of insufficiently pure aluminum alloys may not adequately protect critical drive components from corrosion...

Page 68: ...g on an anode as effectiveness of the anode will be reduced Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl res...

Page 69: ...nt is necessary do not pry or apply any force on the center electrode This is critical with any type of spark plug that has a wear surface such as platinum or iridium added to either the ground electr...

Page 70: ...e the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals Charging System Fusible Link This model has a 100 amp fusible link between the alternator and...

Page 71: ...nition and engage the safety stop switch 3 Straighten the bent tabs on the propeller nut retainer if applicable 4 Place a block of wood between the gearcase and the propeller to hold the propeller and...

Page 72: ...bly propeller washer Belleville washer washer and propeller nut onto the propeller shaft a Propeller hub assembly b Propeller c Washer d Belleville washer e Washer f Propeller nut Tube Ref No Descript...

Page 73: ...95 Tube Ref No Description Where Used Part No Extreme Grease Trim rod ball ends propeller shaft 8M0071842 95 2 4 C with PTFE Swivel bracket tilt support lever tilt tube 92 802859A 1 NOTE Turn the bal...

Page 74: ...The single ram heavy duty trim pump is installed in a remote location usually inside the engine motor well It is available on all offshore models The heavy duty trim system Is intended for offshore ap...

Page 75: ...l steering condition The outboard can be operated beyond the 20 trim limit if operating outboard in shallow water as long as the engine RPM is kept below 1200 RPM WARNING Operating a boat in a trim up...

Page 76: ...ing Fluid until the level in the reservoir reaches the MIN level mark It is acceptable to fill the reservoir beyond the MIN level mark but do not overfill past the MAX level mark 114 15033 Tube Ref No...

Page 77: ...y stop the outward trim travel at 20 when engine RPM is approximately 2000 RPM or higher outboard also has to be in water and in gear The outboard can be operated beyond the 20 trim limit for operatin...

Page 78: ...Some boats particularly some bass boats are built with a greater than normal transom angle which will allow the outboard to be trimmed further in or under This greater trim under capability is desira...

Page 79: ...he tilt support lock a Tilt support lock Tube Ref No Description Where Used Part Number 114 Power Trim and Steering Fluid Fill hole 92 802880A1 2 Remove fill cap and check fluid level The fluid level...

Page 80: ...rain plug lower plug 4 Quickly place lubricant tube into the fill hole 5 Slowly add lubricant until it flows from the upper vent hole 6 Stop adding lubricant Install the upper vent plug and sealing wa...

Page 81: ...and sealing ring e Drain pan 1 Place the outboard in a vertical operating position 2 Place a drain pan below the outboard gearcase 3 Remove the vent plug upper plug and sealing ring 4 Remove the fill...

Page 82: ...fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on their resp...

Page 83: ...of Mercury Precision Quickleen lubricant 8 cc 0 3 oz or 2 teaspoons of Mercury Precision Fuel Stabilizer 9 Remove the fuel filter Refer to Fuel System in the Maintenance section of this manual 10 Pour...

Page 84: ...sion Guard External metal surfaces 92 802878 55 Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubricant Positioning Outboard for Storage Store outboard in an upright vertical posi...

Page 85: ...ty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump...

Page 86: ...efer to Fuel and Oil for details Battery voltage is out of limits Throttle position sensor failure Continuous horn sound The oil level in the engine mounted oil reservoir tank is critically low Refill...

Page 87: ...ions are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator Open circuit in...

Page 88: ...s in the recovery of stolen power packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer...

Page 89: ...rial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geo...

Page 90: ...Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Ma...

Page 91: ...Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Q...

Page 92: ...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 ha...

Page 93: ...SSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to...

Page 94: ...mp 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...

Page 95: ...curing 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 t...

Page 96: ...s the boat s maximum power rating Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufactu...

Page 97: ...ary fuel hose connecting the fuel tank to the outboard Low permeation hose is USCG Type B1 15 or Type A1 15 defined as not exceeding 15 g m 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 mari...

Page 98: ...fety standards which include recommendations applicable to grounding antisiphon protection ventilation etc FILLING THE FUEL SYSTEM For the initial start of a new engine or for an engine that ran out o...

Page 99: ...g lifting can result in the engine falling causing serious injury or death Before lifting the engine verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the...

Page 100: ...ly from the driveshaft housing or to lift entire engine for removal installation Steering Cable Starboard Side Routed Cable 1 Lubricate the O ring seal and the entire cable end 3724 95 Tube Ref No Des...

Page 101: ...3 Never replace locknuts with common nuts nonlocking as they will work loose and vibrate off freeing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result...

Page 102: ...sert locknut d Tighten the locknut until it seats then loosen turn 2 Assemble the steering link rod to the engine with the special washer head bolt a and self locking nylon insert locknut b 3 Torque t...

Page 103: ...avitation particularly noticeable when planing off or when operating with a heavy load Observe the following Monitor water pressure and engine temperature at all times Improper mounting height may res...

Page 104: ...erside of transom bracket hooks and the bottom of the boat measurement c in the diagram below falls between the recommended mounting height range Ensure that this measurement is to the actual bottom o...

Page 105: ...an 25 mm 1 in from the top of the boat transom not including any shims used to increase transom mounting height Never install the upper mounting bolts through these shims Install the outboard to a hei...

Page 106: ...t as this gearcase is designed for surfacing applications a Underside of transom bracket hooks b Bottom of the boat c Distance between a and b d Propeller shaft centerline Item Model1 Recommended Moun...

Page 107: ...Drill guide holes b Transom drilling fixture c Transom centerline Transom Drilling Fixture 91 98234A2 5489 Aids in engine installation by acting as a template for engine mounting holes 2 Drill four 1...

Page 108: ...washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in...

Page 109: ...The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom streng...

Page 110: ...e flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between...

Page 111: ...nsure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting...

Page 112: ...75 in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts st...

Page 113: ...se 51985 Decal on the transom bracket Electrical Hoses Control Cables and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl Conn...

Page 114: ...lb ft Hex nuts 13 5 120 A decal advising against using deep cycle batteries and wing nuts should be placed on or near the battery box for future service reference One 5 16 in and one 3 8 in hex nut is...

Page 115: ...ranking battery Dual Outboards Connect a common ground cable wire size same as engine battery cables between negative terminals on starting batteries a Red sleeve positive b Black sleeve negative c Gr...

Page 116: ...Fasten hose connections with cable ties Water Pressure and Speedometer Hose or Tubing NOTE This applies to models without SmartCraft gauges This outboard has a speedometer water pickup located in the...

Page 117: ...e without blue stripe l Cable tie INSTALLING THE SHIFT CABLE IMPORTANT The shift cable is the first cable to move when the remote control handle is moved out of neutral so install connect it to the en...

Page 118: ...osition mark 2 Mark the reverse position as follows a Move the remote control handle into reverse and advance the handle to the full speed position Ensure the throttle control lever is touching the th...

Page 119: ...toward the rear until resistance is felt 7 Center the anchor pin between these resistance points a Anchor pin Adjusting the Shift Cable 1 Align the shift cable end guide with the center mark as instr...

Page 120: ...ntrol into reverse while turning the propeller shaft If the propeller shaft does not lock solidly in gear adjust the barrel away from the cable end guide Repeat steps a through c d Return the remote c...

Page 121: ...into gear a few times to activate the throttle linkage Rotate the propeller shaft while shifting into reverse b Return the remote control to neutral c Place a thin piece of paper between the idle adj...

Page 122: ...oil hoses between clamp and engine attachment point to relieve stress and prevent hoses from being kinked or pinched 1 Place the lower half of the front clamp into the bottom cowl opening 2 Place the...

Page 123: ...half Secure both halves together with cables ties a Top half of the front clamp b Cable ties 4 Secure the front clamp into the bottom cowl with the retainer and two screws 5 Install the cowl seal a Re...

Page 124: ...tank with the recommended oil listed in the Operation and Maintenance Manual Tighten the fill cap a Fill cap 2 Remove the cap and fill the engine oil tank with oil Install the fill cap a Engine oil t...

Page 125: ...l the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel pump will run without fuel during the priming process and may be damaged 1 Fill the fuel system a Connect fu...

Page 126: ...neutral into forward This will automatically start the priming process PURGING AIR FROM THE ENGINE OIL TANK 1 Loosen the fill cap on the engine oil tank 2 Start the engine 3 Operate the engine until a...

Page 127: ...ses must be able to extend to the rear edge of the transom to connect to the engine 2 Make hydraulic connections to the remote pump assembly according to the instructions included with the pump 3 Usin...

Page 128: ...e Gasket 5 Route the trim pump harness end through the cover and cowl and attach the harness to the pump and the main engine harness 6 Install the grommet to protect the harness 7 Route the trim hoses...

Page 129: ...ents excessive trim under and operate the boat in a safe manner Some boats particularly some bass boats are built with a greater than normal transom angle which will allow the outboard to be trimmed f...

Page 130: ...930A 1 2749 Limits the down trim angle of the power trim equipped engines or aids in determining the trim out angle on non power trim engines The owner may decide to limit the trim in This can be acco...

Page 131: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 121...

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