Mercury Optimax 150 Manual Download

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Optimax 1.5 L Fond du Lac,

Wisconsin USA

75, 90,115

1B227000

RCD-H-2

Optimax 2.5 L Fond du Lac,

Wisconsin USA

135, 150

1B227000

RCD-H-2

Optimax 3.0 L Fond du Lac,

Wisconsin USA

200

1B227000

RCD-H-2

If the CE mark is not accompanied by the notified body number, the following Recreational Craft

Directive language applies only to product entering the EU prior to January 1, 2007:

Recreational Craft Directive:

94/25/EC

Applicable Requirement

Standards Applied

Owner's manual (A.2.5)

ISO 10240

Handling characteristics (A.4)

ISO 8665

Outboard engine starting (A.5.1.4)

ISO 11547

Fuel tanks (A.5.2.2)

ISO 13591; ISO 8469

General steering system (A.5.4.1)

ABYC P-17

The following applies to all products covered by this manual:

Safety of Machinery Directive

98/37/EC

Principles of safety integration (1.1.2)

ISO 12100-1; ISO 12100-2; EN 1050

Noise (1.5.8)

ICOMIA 39/94

Vibration (1.5.9)

ICOMIA 38/94

Electromagnetic Compatibility Directive 89/336/EC

Generic emission standard

EN 61000-6-3

Generic immunity standard

EN 61000-6-1

Vehicles, boats and internal combustion engine driven

devices - radio disturbance characteristics

SAE J551 (CISPR 12)
CISPR 12; EN 55012:2002/A1:2005

Electrostatic discharge testing

EN 61000-6-2; EN 61000-4-2; EN 61000-4-3

This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe.

Summary of Contents for Optimax 150

Page 1: ...y number the following Recreational Craft Directive applies Recreational Craft Directive 2003 44 EC amending 94 25 EC Applicable Requirement Standards Applied Owner s manual A 2 5 EN ISO 10240 2004 Handling characteristics A 4 EN ISO 8665 1995 Outboard engines starting A 5 1 4 EN ISO 11547 1995 General steering system A 5 4 1 ABYC P 17 EN ISO 10592 1995 Exhaust emission requirements B 2 EN ISO 817...

Page 2: ...ISO 11547 Fuel tanks A 5 2 2 ISO 13591 ISO 8469 General steering system A 5 4 1 ABYC P 17 The following applies to all products covered by this manual Safety of Machinery Directive 98 37 EC Principles of safety integration 1 1 2 ISO 12100 1 ISO 12100 2 EN 1050 Noise 1 5 8 ICOMIA 39 94 Vibration 1 5 9 ICOMIA 38 94 Electromagnetic Compatibility Directive 89 336 EC Generic emission standard EN 61000 ...

Page 3: ...iii Patrick C Mackey President Mercury Marine Fond du Lac WI USA on May 1 2006 European Regulations Contact Regulations and Product Safety Department Mercury Marine Fond du Lac WI USA ...

Page 4: ...iv ...

Page 5: ...d Remote Control Models 9 Remote Steering Notice 9 Lanyard Stop Switch 9 Protecting People In The Water 11 Passenger Safety Message Pontoon Boats And Deck Boats 11 Wave And Wake Jumping 12 Impact With Underwater Hazards 13 Exhaust Emissions 13 Selecting Accessories For Your Outboard 15 Safe Boating Suggestions 15 Recording Serial Number 16 135 150 175 OptiMax Specifications 16 Component Identifica...

Page 6: ...l Cover Removal and Installation 35 Fuel System 35 Steering Link Rod Fasteners 36 Fuse Replacement 37 Corrosion Control Anode 38 Battery Inspection 38 Battery Information 39 Propeller Replacement 40 Spark Plug Inspection And Replacement 42 Compressor Air Intake Filter 43 Alternator Belt Inspection 44 Lubrication Points 44 Gearcase Lubrication 47 Submerged Outboard 48 Storage Storage Preparation 49...

Page 7: ... in Gear Protection 56 Selecting Accessories For Your Outboard 56 Fuel Tanks 56 Installation Specifications 57 Lifting the Outboard 57 Steering Cable Starboard Side Routed Cable 58 Steering Link Rod Fasteners 59 Determining Recommended Outboard Mounting Height 61 Drilling Outboard Mounting Holes 61 Fastening the Outboard to the Transom 63 Electrical Hoses and Control Cables 65 Shift and Throttle C...

Page 8: ...viii ...

Page 9: ...ury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required 2 To be eligible for warranty coverage the product must be regi...

Page 10: ...ited Warranty provides coverage for three 3 years from the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial users of these products receive warranty coverage of one 1 year from the date of first retail sale or one 1 year from the date in which the product was first put into service whi...

Page 11: ... at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal and or replacement of boat partitions or mate...

Page 12: ...ty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage abuse or improper service corrosion to accessories instruments steering systems corrosion to factory installed jet drive unit damage due to marine growth product sold with less than a one year limited Product warranty replacement parts parts purchased by customer products use...

Page 13: ...o an authorized dealer 5 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 6 Labor performed by other than an authorized dealer may be covered only under following circumstances When performed on emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out etc and p...

Page 14: ...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 Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result...

Page 15: ...choice can significantly affect 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 mercmari...

Page 16: ...mining the Correct Pitch size First check the full throttle RPM under normal load condition If the full throttle RPM is within the recommended range select a replacement or upgrade propeller with the same pitch as the current propeller Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200 Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200 Upgrading from a 3 ...

Page 17: ...brate off freeing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected loss of boat control resulting serious injury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures a a ...

Page 18: ... planing speeds in shallow 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...

Page 19: ... your boat Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats And Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed ...

Page 20: ...t speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such case the landing may cause the boat to veer violently in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or ou...

Page 21: ...peed 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 authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull f...

Page 22: ...nclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide WHILE BOAT IS STATIONARY 21626 a b a Runnin...

Page 23: ...w decks raised fishing seats any rotating fishing seat or anywhere that an unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly...

Page 24: ...atts 100 7 111 9 130 5 Full Throttle RPM Speed 5000 5500 RPM 5250 5750 RPM Idle Speed in Forward Gear 550 25 RPM Number of Cylinders 6 Piston Displacement 2508 cc 153 cu in Cylinder Bore 88 4 mm 3 500 in Piston Stroke 67 3 mm 2 650 in Recommended Spark Plug NGK IZFR5G Spark Plug Gap 0 8 mm 0 031 in Standard Gearcase Gear Ratio 2 00 1 1 87 1 High Altitude Gearcase Gear Ratio 2 30 1 2 00 1 Recommend...

Page 25: ...mponent Identification a b c d e f g h i 3403 a Top cowl b Bottom cowl c Water pump indicator hole d Driveshaft housing e Anti ventilation plate f Auxiliary tilt switch g Transom brackets h Gearcase i Cooling water intake holes ...

Page 26: ...e Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 28419 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This pr...

Page 27: ...ration of the water alcohol from the gasoline in the fuel tank The fuel system components on your Mercury Marine engine will withstand up to 10 alcohol content in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specific recommendations on the boat s fuel system components fuel tanks fuel lines and fittings Be aware that gasoline...

Page 28: ...ine break in Avoiding Fuel Flow Restriction IMPORTANT Adding components to the fuel supply system filters valves fittings etc may restrict the fuel flow This may cause engine stalling at low speed and or a lean fuel condition at high RPM that could cause engine damage Filling Remote Oil Tank Remove filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 gallons Replace filler...

Page 29: ...or sparks in the area 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 f...

Page 30: ... e Lanyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON START h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer to Operation Starting the Engine Warning System The outboard warning system incorporates a warning horn inside the boat The warning ho...

Page 31: ...at higher speeds Moving throttle lever back to idle resets the system Oil Level is Critically Low Continuous Engine Guardian System is activated Power will be limited The oil level is critically low in the engine mounted oil reservoir Refill the engine mounted oil reservoir along with the remote oil tank Oil Pump Failure Continuous Engine Guardian System is activated Power will be limited The warn...

Page 32: ... the outboard can also be tilted up past the trim range to permit for example shallow water operation a b c 27761 a Trim switch b Tilt range of travel c Trim range of travel POWER TRIM OPERATION With most boats operating around the middle of the trim range will give satisfactory results However to take full advantage of the trimming capability there may be times when you choose to trim your outboa...

Page 33: ... of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a normal installation height with the normal right hand rotation propeller In excess can cause boat porpoising bouncing or propeller ventilation Cause engine overheating if any cooling water intake holes are above the water line TILTING OPERATION ...

Page 34: ... can tilt the outboard beyond the maximum trim range to prevent 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 If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range AUXILIARY TILT SWITCH The auxiliary tilt switch can be us...

Page 35: ... and causing possible damage to the water pump and other components If there is a chance of ice forming on the water the outboard should be removed and drained completely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the intern...

Page 36: ...ten the engine life The engine automatically receives extra oil during the first hours of operation For most boaters this extra oil mode will be complete in about ten hours BREAK IN PROCEDURE 1 For the first hour of operation allow the engine to warm up for 30 60 seconds a Run the engine at varied throttle settings the majority of the time between 3000 and 4500 RPM or three quarter throttle b Chan...

Page 37: ...tical operating position Make sure all cooling water intake holes are submerged 3405 2 Open fuel tank vent screw in filler cap on manual venting type fuel tanks 19748 3 Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm 27348 4 Set the lanyard stop switch to RUN position Refer to General Informa...

Page 38: ...he neutral fast idle speed feature on the remote control for starting 27242 8 Turn the ignition key to START position Release the key when engine starts If engine fails to start in 10 seconds return the key to OFF position wait one second and try again 19804 NOTE The electronic starting system will automatically prime choke the engine and increase idle speed for starting 9 Check for a steady strea...

Page 39: ...ift positions to provide operation Forward F Neutral N and Reverse R When shifting always stop at neutral position and allow the engine speed to return to idle Always shift outboard into gear with a quick motion After shifting outboard into gear advance the lever further to increase speed N R F 27237 Stopping The Engine Reduce engine speed and shift outboard to neutral position Turn ignition key t...

Page 40: ...ug This engine conforms to model year EPA regulations for Marine SI engines Refer to Owner s Manual for required maintenance Valve Clearance Cold mm Intake Exhaust a b c d e f g h i 28405 a Idle speed b Engine horsepower c Timing specification d Recommended spark plug and gap e Valve clearance if applicable f Family number g Maximum emission output for the engine family h Piston placement i Date o...

Page 41: ...rim fluid See Checking Power Trim Fluid Inspect battery See Battery Inspection Check control cable adjustments 1 Lubricate splines on the driveshaft and shift shaft 1 Check tightness of bolts nuts and other fasteners Replace water pump impeller more often if overheating occurs or reduced water pressure is noted 1 Check cowl seals to make sure seals are intact and not damaged Check internal cowl so...

Page 42: ...16 2 Lift up the rear cowl latch Remove the top cowl FOURSTROKE 27817 INSTALLATION 1 Lower top cowl into position over engine 2 Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front Cleaning Care for Top Cowl IMPORTANT Dry wiping wiping the plastic surface when it is dry will result in minor surface scratches Always wet the surface before clean...

Page 43: ...a Front flange b Air intake tube c Vent hose Fuel System WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the eng...

Page 44: ...lter by turning the filter clockwise Tip the filter to drain fluid in a suitable container d Lubricate the sealing ring on the filter with oil Thread on the filter and tighten securely by hand Reconnect the wire to the filter IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter Steering Link Rod Fasteners IMPORTANT The ste...

Page 45: ... Special washer head bolt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighten until seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and self locking nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt and self locking nylon insert locknut First...

Page 46: ...inst galvanic corrosion by sacrificing its metal 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 The g...

Page 47: ...CA or 180 Ah When connecting engine battery hex nuts must be used to secure battery leads to battery posts Torque nuts to specification Description Nm lb in lb ft Hex nuts 13 5 120 IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements Decal needs to be placed on or near battery box for future service reference One 5 16 in and one 3 8 in hex n...

Page 48: ...r removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting 1 Shift outboard to neutral N position N 26838 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing spark plug leads 2 Remove spark plug leads to prevent engine from starting 26899 3 Straighten the bent tabs on the propeller nut retainer 26900 ...

Page 49: ...ease Propeller shaft 92 802867 Q1 95 2 4 C with Teflon Propeller shaft 92 802859Q1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 7 Flo Torq I Drive Hub Propellers Insta...

Page 50: ...r and torque propeller nut to specifications Description Nm lb in lb ft Propeller nut 75 55 10 Secure propeller nut by bending three of the tabs into the thrust hub grooves 26945 Spark Plug Inspection And Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging the...

Page 51: ...lug gap 0 80 mm 0 031 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or torque to specifications Description Nm lb in lb ft Spark plug 27 20 Compressor Air Intake Filter The filter should be changed every 100 hours of operation or once a season IMPORTANT Never run the engine without the air filter REMOVAL 1 Remove ...

Page 52: ... it replaced by an authorized dealer if any of the following conditions are found a Cracks or deterioration in the rubber portion of the belt b Belt surfaces rough or uneven c Signs of wear on edges or outer surfaces of belt 29398 Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101 Tube Ref No Description Where Used Part No 34 Special Lubricant ...

Page 53: ...t Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 26902 3 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Alternator be...

Page 54: ...ort lever Tilt Tube Lubricate through fitting 27874 WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant Steering Cable Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting a b 27875 a Fitting ...

Page 55: ...ce and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount of metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEARCASE 1 Place outboard in a vertical operating position 2 Place drain pan below outboard 3 Remove ve...

Page 56: ...all the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atm...

Page 57: ...ortable Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel 2 Permanently Installed Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixture into fu...

Page 58: ...iption Where Used Part No 120 Corrosion Guard External metal surfaces 92 802878Q55 Gearcase Drain and refill the gearcase lubricant refer to Maintenance Gearcase Lubrication Positioning Outboard For Storage Store outboard in an upright vertical position to allow water to drain out of outboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling pass...

Page 59: ...s disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Errati...

Page 60: ...ributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator Open circuit in the alternator output wire fused link ...

Page 61: ...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 any authorized Mercury Marine dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question conce...

Page 62: ...striel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 954 744 3535 Japan 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 Ma...

Page 63: ... certified TC W3 2 Cycle oil Periodically consult with your dealer to get the latest gasoline and oil recommendations If Mercury Precision or Quicksilver 2 Cycle Outboard Oil is not available substitute another brand of 2 Cycle outboard oil that is NMMA Certified TC W3 The use of an inferior 2 Cycle outboard oil can reduce engine durability Damage from use of inferior oil may not be covered under ...

Page 64: ...ipped with a start in neutral only protection device This prevents the engine from starting in gear Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system Acq...

Page 65: ...orting an engine during lifting can result in the engine falling causing serious injury or death Before lifting the engine verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight To lift the outboard 1 Remove the cowl from the outboard 2 Thread the lifting eye into the flywheel hub for a minimu...

Page 66: ...ad assembly from the driveshaft housing or to lift entire engine for removal installation Steering Cable Starboard Side Routed Cable 1 Lubricate O ring seal and entire cable end 3724 95 Tube Ref No Description Where Used Part No 95 2 4 C Marine Lubricant with Teflon O ring seal and entire cable end 92 802859Q1 2 Insert steering cable into tilt tube 3725 ...

Page 67: ...rt locknuts P N 11 826709113 Never replace locknuts with common nuts non locking as they will work loose vibrate off freeing link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected loss of boat control resulting serious injury or death due to occupants being thrown with...

Page 68: ...09113 c Flat washer 2 d Nylon Locknut used on cable coupler P N 11 826709113 1 Assemble steering link rod to steering cable coupler with two flat washers c and a self locking nylon insert locknut d Tighten the locknut until it seats then loosen turn 2 Assemble the steering link rod to the engine with the special washer head bolt a and self locking nylon insert locknut b 3 Torque the head bolt then...

Page 69: ...mine outboard mounting height dimension if maximum speed is the only objective d This line may be preferred to determine outboard mounting height dimension for dual outboard installation e Outboard mounting height height of outboard mounting brackets from bottom of boat transom For heights over 56 0 cm 22 in a propeller that is designed for surfacing operation is usually preferred f Maximum boat s...

Page 70: ... transom drilling fixture or69 1 a a b c a 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 13 5 mm 17 32 in mounting holes 3973 ...

Page 71: ...3 Transom bolt 1 2 20 x 5 50 in long 3 25 in thread 10 67755 2 Transom bolt 1 2 20 x 6 50 in long 2 75 in thread CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT Determine the strength of the boat transom The outboard mounting locknuts and bolts should be able to hold 75 Nm 55 lb ft of torque without the boat transom yielding or cracking If the boat transom yields or cracks under this torque the const...

Page 72: ...2 Transom reinforcement plate 67 896305 1 Apply marine sealer to shanks of bolts not the threads 2 Fasten the outboard with the correct mounting hardware Tighten locknuts to the specified torque NOTE For more accurate torque whenever possible turn tighten the mounting locknuts rather than turning the mounting bolts 3729 a b c d e a Flat washer 4 b 1 2 in diameter bolt 4 c Shank of bolt d Flat wash...

Page 73: ...e front clamp Connect remote harness to the 14 pin connector on the engine harness a b 11033 a 14 pin connector b Remote 14 pin boat harness BATTERY INFORMATION WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift DTS system leading to serious injury or death due to loss of boat control Secure the battery leads to the battery posts wi...

Page 74: ...x nut are supplied per battery for wing nut replacement Metric hex nuts are not supplied Place decal on or near battery box for future service reference 5 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...

Page 75: ...ing batteries a a b b c d d 15497 a Red sleeve positive b Black sleeve negative c Ground cable d Cranking battery FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel Hose Size Minimum fuel line inside diameter I D is 8mm 5 16 in with separate fuel line fuel tank pickup for each engine 1 Fasten remote fuel hose to fitting with hose clamp ...

Page 76: ...rtCraft gauges This outboard has a speedometer water pick up located in the leading edge of the gearcase If you want to use this water pickup for the speedometer disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl Install coupler provided with outboard on end of tubing Make the water pressure gauge hose connection to this tubing as follows 7728 c e d g f...

Page 77: ...hat are generated when running under constant high RPM and thrust conditions On counter rotation outboards the shift linkage moves in the opposite direction compared to a standard rotation outboard Forward Gear Reverse Gear 7724 Forward Gear Reverse Gear 7726 Standard Rotation Counter Rotation INSTALLING THE SHIFT CABLE IMPORTANT The shift cable is the first cable to move when the remote control h...

Page 78: ...owly return the handle back to the neutral detent position c Place a mark on the shift cable against the cable end guide 4356 a a Reverse position mark 3 Mark the center on the shift cable midway between the forward and reverse marks 4361 a a Center mark 4 Align the cable end guide against this center mark when installing the cable to the engine 5 Position the remote control and outboard into neut...

Page 79: ...he Shift Cable 4362 a a Center mark 2 Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder 3 Secure the shift cable with the shift cable retainer a b 4364 a Cable barrel b Shift cable retainer 4 Check the shift cable adjustments as follows a Shift the remote control to forward while turning the propeller shaft If the propeller...

Page 80: ... adjust the barrel away from the cable end guide Repeat steps a through c d Return the remote control handle to neutral If the propeller shaft does not turn freely without drag adjust the barrel closer to the cable end guide Repeat steps a through d 5 Return the safety stop switch to the RUN position THROTTLE CABLE INSTALLATION 1 Position remote control into neutral N 26838 2 Attach throttle cable...

Page 81: ...rol to neutral Place a thin piece of paper between idle adjustment screw and idle stop Adjustment is correct when the paper can be removed without tearing but has some drag on it Readjust cable barrel if necessary IMPORTANT The idle stop screw must be touching the stop a b 7740 a Idle stop screw b Idle stop 5 Lock the barrel holder in place with the cable latch Front Clamp Reassembly IMPORTANT Suf...

Page 82: ...fuel or was drained of fuel fill and prime the fuel system To fill and prime the fuel system 1 Squeeze the fuel line primer bulb until it feels firm 2 Turn the key switch to the ON position for three seconds This operates the electric fuel pump 3 Turn the key switch back to the OFF position and squeeze the primer bulb again until it feels firm 4 Turn the key switch to the ON position again for thr...

Page 83: ...ING OIL SYSTEM 1 Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual Tighten fill cap a 2683 a Fill cap 2 Remove cap and fill engine oil tank with oil Reinstall the fill cap a b 7745 a Engine oil tank b Fill cap ...

Page 84: ... pump as follows 1 Fill the engine fuel system with fuel Connect fuel hose and squeeze primer bulb until it feels firm 19779 2 Turn the ignition key switch to the ON position 26846 3 Within the first 10 seconds after the key switch has been turned on move the remote control handle from neutral into forward gear 3 to 5 times This will automatically start the priming process NOTE It may take a few m...

Page 85: ...t hub propeller nut retainer and propeller nut onto the shaft a b c d e f 26908 a Propeller nut b Propeller nut retainer c Rear thrust hub d Continuity washer e Propeller f Forward thrust hub 2 Flo Torq II Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft a b c d e f 26941 a Propeller nut b Propelle...

Page 86: ...nd in some cases may be necessary to plane off a boat with aft live wells given the variety of available propellers and height range of engine installations However once on plane the engine should be trimmed to a more intermediate position to avoid a bow down planing condition called plowing Plowing can cause bow steering or over steering and inefficiently consumes horsepower a or116 a Tilt pin no...

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