Mercury Optimax Page 78 User Manual Download

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MAINTENANCE

Tube Ref No.

Description

Where Used

Part No.

Anti-Corrosion

Grease

Propeller shaft

92-802867Q

2-4-C with Teflon

Propeller shaft

92-802859A1

NOTE: The Flo‑Torq lll propeller drive hubs are designed to have

a small amount of free play when installed. This free play allows

the propeller to slide back and forth on the rear thrust hub [up to

3.17 mm (1/8 in.)] and rotate up to 10 degrees.

2. Flo‑Torq III Drive Hub Propellers ‑ Install the forward thrust

hub, replaceable drive sleeve, propeller, thrust hub, propeller

nut retainer, and propeller nut onto the shaft.

3223

a -

Propeller nut

b -

Propeller nut retainer

c -

Rear thrust hub

d -

Propeller

e -

Replaceable drive

sleeve

f -

Forward thrust hub

3. Place a block of wood between the gearcase and propeller.

Torque the propeller nut to specification.

Description

lb. in.

lb. ft.

Propeller nut

4. Secure the propeller nut by bending three of the tabs into the

thrust hub grooves.

26945

Summary of Contents for Optimax

Page 1: ...rcury Marine W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54935 1939 USA Authorized Representative Marine Power Europe Inc Parc Industriel de Petit Rechain B 2800 Verviers Belgium If the CE mark is accompanied by a notified body number the following Recreational Craft Directive applies Recreational Craft Directive 2003 44 EC amending 94 25 EC Applicable Requirement Standards Applied Owner s manu...

Page 2: ...5 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...

Page 3: ...d 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 Patrick C Mackey President Mercury Marine Fond du Lac WI USA on May 1 2006 European Regulations Contact...

Page 4: ...iv ...

Page 5: ...sponsibilities 13 Before Operating Your Outboard 13 Boat Horsepower Capacity 14 High Speed and High Performance Boat Operation 14 Propeller Selection 14 Outboard Remote Control Models 17 Remote Steering Notice 18 Lanyard Stop Switch 19 Protecting People In The Water 21 Passenger Safety Message Pontoon Boats And Deck Boats 22 Wave And Wake Jumping 23 Impact With Underwater Hazards 24 Exhaust Emissi...

Page 6: ... Tab Adjustment 46 Operation Pre Starting Check List 47 Operating In Freezing Temperatures 47 Operating In Salt Water Or Polluted Water 48 Operating at High Elevations 48 Setting Trim Angle While Running Engine at Idle Speed 49 Engine Break in Procedure 49 Starting the Engine 50 Gear Shifting 53 Stopping The Engine 54 Maintenance Outboard Care 55 EPA Emissions 55 Inspection and Maintenance Schedul...

Page 7: ...rnator Belt Inspection 72 Lubrication Points 73 Checking Power Trim Fluid 75 Gearcase Lubrication 76 Storage Storage Preparation 79 Fuel System 79 Protecting Internal Engine Components 81 Protecting External Outboard Components 82 Gearcase 82 Positioning Outboard For Storage 82 Battery Storage 82 Troubleshooting Starter Motor Will Not Crank the Engine 83 Engine Will Not Start 83 Engine Runs Errati...

Page 8: ...Gear Protection 88 Selecting Accessories For Your Outboard 89 Fuel Tanks 89 Installation Specifications 89 Lifting the Outboard 90 Steering Cable Starboard Side Routed Cable 91 Determining Recommended Outboard Mounting Height 92 Drilling Outboard Mounting Holes 93 Fastening the Outboard to the Transom 95 Electrical Fuel Hose Flush Hose and Control Cables 98 Oil Injection Set Up 111 Trim In Pin 112...

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

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

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

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

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

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

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

Page 16: ...aser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage a...

Page 17: ...ween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 18: ... is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection ...

Page 19: ...nance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition wh...

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

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

Page 22: ...PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 High Speed and High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator exp...

Page 23: ...orrect propeller Choose a propeller for your boating application that will allow the engine to operate within the specified full throttle operating range When operating the boat at full throttle under normal load conditions the engine RPM should be in the upper half of the recommended full throttle RPM range Refer to Specifications If engine RPM is above that range select a propeller of increased ...

Page 24: ...as been predetermined for the design of your outboard However when more than one diameter is available for the same pitch use a larger diameter for heavy boat applications and a smaller diameter for lighter applications Pitch The pitch is the theoretical distance in inches that a propeller travels forward during one revolution Pitch can be thought of similar to gears in a car The lower the gear th...

Page 25: ...e 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 of sizes and styles that allow you to dial in the ultimate performance for your boat 3 BLADE VS 4 BLADE Available in many sizes of both aluminum and stainless 3 and 4 blade propellers have unique performance character...

Page 26: ...ese self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate 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 wit...

Page 27: ... cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should t...

Page 28: ...hallow or obstacle infested waters releasing your grip on a steering wheel or tiller handle that is pulling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the bo...

Page 29: ...nt of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even...

Page 30: ...tand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of the boat Falling over the front of the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN OPEN FR...

Page 31: ...ended 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 result in the elevated passenger falling over the front of the boat 26783 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done wit...

Page 32: ...boat pitches down far enough while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward The boat may also steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in a...

Page 33: ...oat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles After striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any h...

Page 34: ...soning can lead to unconsciousness brain damage or death Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas...

Page 35: ...Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard These accessories are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of non approved accessories can damage the product Some accessories not manufactured or sold by Mercury Marine are not design...

Page 36: ...ing law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT Make sure everyone in the boat is properly seated Do not allow anyone to sit or ride on any part of the boat that was not intended for such use This includes the back of seats gunwales transom bow decks raised fishing seats any rotating fishing seat or...

Page 37: ...g or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involve...

Page 38: ...signia as applicable 75 90 115 OptiMax Specifications Models 75 90 115 Horsepower 75 90 115 Kilowatts 55 2 66 2 84 6 Full Throttle RPM Range 5000 5750 RPM Idle Speed in Forward Gear 625 675 RPM Number of Cylinders 3 Piston Displacement 1523 5 cc 92 9 cu in Cylinder Bore 92 11 mm 3 63 in Piston Stroke 76 2 mm 3 0 in Recommended Spark Plug IZFR5J Spark Plug Gap 0 80 mm 0 030 in Gear ratio 2 33 1 2 0...

Page 39: ...king Amps MCA or 800 Cold Cranking Amps CCA Charging System Output 60 Amps Component Identification a j i h b g f e d c 29461 a Top cowl b Auxiliary tilt switch c Transom brackets d Gearcase e Cooling water intake holes f Trim tab g Anti ventilation plate h Driveshaft housing i Water pump indicator hole j Bottom cowl ...

Page 40: ...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 41: ...rand of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol These Reformulated Gasolines are acceptable for use in your Mercury M...

Page 42: ...n 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 frequency for leaks and abnormalities is r...

Page 43: ...ion 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 Oil Recommendation Recommended Oil MercuryOptimax DFI or Quicksilver DFI 2 Cycle Engine Oil Mercury Optimax DFI or Quicksilver DFI 2 Cycle Engine Oil is recommended for yo...

Page 44: ...ers 1 qt low The second ball marker indicates 1 89 liters 2 qt low a b 29464 a First ball marker b Second ball marker 4 Slowly fill the oil tank with the specified oil Do not overfill Add only enough oil to bring the oil level up to the bottom of the fill neck Capacity Fluid Type Oil tank 4 72 liters 5 qt Optimax DFI 2 Cycle Engine Oil 29465 ...

Page 45: ...do not smoke or allow open flames 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 pr...

Page 46: ... handle forward neutral reverse b Neutral release lever c Trim tilt switch if equipped Refer to Features 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 Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON START h Fast idle leve...

Page 47: ...orn will emit either a continuous beep or intermittent short beeps This will alert the operator and help identify the following listed situations For visual display of the specific engine functions and for additional engine data refer to SmartCraft Product information following Warning Horn Function Sound Description Start Up One Beep Normal System Test Low Oil Four Beeps every 2 Minutes Oil level...

Page 48: ...ctivated Power limit will allow a fast idle The oil level is critically low in the oil tank Refill the oil tank Refer to Fuel Oil Oil Pump Failure Continuous Engine Guardian System is activated Power limit will allow a fast idle The warning horn is activated if the oil pump should ever stop functioning electrically No lubricating oil is being supplied to the engine Engine Overspeed Continuous The ...

Page 49: ...ons of problems The system will respond to a problem by emitting a continuous beep and or reducing engine power in order to provide engine protection If Guardian System has been activated reduce throttle speed The horn will turn off when throttle speed is within the allowable limit Consult your dealer for assistance SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased...

Page 50: ...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 NOTE When traveling at slow speeds a slight drop in engine RPM may be noticed on occasion when engaging power trim This condition is normal and has no adverse affect on the outboard With most boats operating around the middle of the trim range will g...

Page 51: ...ter while on plane This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered WARNING 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 that prevents ...

Page 52: ...o the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down Lower the outboard b a 27778 a Tilt support ...

Page 53: ... 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 54: ... adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 50 mm 2 inches or more above the boat bottom Operate your boat at normal cruising speed trimmed to the desired position Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small a...

Page 55: ...operate a boat while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Maintenance Schedule Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down a...

Page 56: ...tely 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 corrosion control anodes as this will reduce the effectiveness of the anodes Operating at High Elevatio...

Page 57: ...engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures GASOLINE OIL BREAK IN MIXTURE NOTE Do not use pre mixed gas and oil during break in Use straight gasoline during engine break in and after engine break in The engine break in procedure for an OptiMax outboard is important to ensure proper perform...

Page 58: ...ility to always drive in a safe manner Improper trim angle of the outboard when driving at speed can be difficult and dangerous The purpose of specifying trim angle is to help guide the operator in determining how to put the propel load on the engine They are intended to be guidelines and do not suggest or require unsafe boat operation 2 For the next three hours of operation change engine speed ev...

Page 59: ... tank vent screw located in the 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 Information Lanyard Stop Switch 19791 ...

Page 60: ...to the OFF position and squeeze the primer bulb again until it feels firm Turn the ignition key switch to the ON position again for three seconds Continue this procedure until the fuel line primer bulb stays firm 7 Do not advance the 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 ...

Page 61: ...y your dealer Operating the engine while overheated will cause engine damage 19805 Gear Shifting IMPORTANT Observe the following Never shift outboard into gear unless engine speed is at idle Do not shift outboard into reverse when the engine is not running Your outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R When shifting always stop at neutral positi...

Page 62: ...OPERATION 54 Stopping The Engine Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position 26843 ...

Page 63: ...ement parts and Genuine Lubricants EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture EMISSION CONTROL INFORMATION TIMING IN DEGREES FAMILY FEL cc IDLE SPEED hp GAP g kW h Standard spark plug Suppressor spark plug This engine conforms to model year ...

Page 64: ... proper tightness See Steering Link Rod Fasteners Check propeller blades for damage AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in salt water EVERY 100 HOURS OF USE OR ONCE YEARLY WHICHEVER OCCURS FIR...

Page 65: ... hose clamps and rubber boots if equipped on the air intake assembly EVERY 300 HOURS OF USE OR THREE YEARS Replace water pump impeller more often if overheating occurs or reduced water pressure is noted 1 Replace the in line oil filter that is located in the oil hose between the oil tank and the oil injection pump 1 BEFORE PERIODS OF STORAGE Refer to Storage procedure See Storage section Flushing ...

Page 66: ... and remove the water hose from the hose adapter Reinstall the cover into the hose adapter a b c 22703 a Hose Adapter b Sealing washer c Cover Top Cowl Removal And Installation REMOVAL 1 Unlock the rear latch by pushing lever up 2 Lift rear of cowl and disengage front hook 29468 INSTALLATION 1 Engage the front hook and push cowl back over the cowl seal 2 Push cowl down and move the rear latch leve...

Page 67: ...se the top cowl with clean water to remove dirt and dust that may scratch the surface 2 Wash the top cowl with clean water and a mild non abrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a non abrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth Flywheel Cover Rem...

Page 68: ...hree mounting pins Insert the tabs into the slots in the side panel and push the cover down onto the mounting pins c a b 23754 a Flywheel cover b Mounting pins c Tabs Side Panel Removal and Installation REMOVAL Pull the side panel off the three mounting pins ...

Page 69: ...slots c Mounting pins 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 engine and wipe up any spi...

Page 70: ... INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced FUEL FILTER REPLACEMENT Removal 1 Use fuel filter tool 91 896661 or use the shaft of a screwdriver between the lugs on the filter cap and unscrew the filter a b ob01673 a Filter b O...

Page 71: ...743 a Drain hose b Right side fitting c Drain screw 3 Retighten the drain screw and reattach the hose IMPORTANT Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm forcing fuel into the chamber Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part N...

Page 72: ...t washer 2 c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 Description Nm lb in lb ft 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 A...

Page 73: ...e same rating a b 5 e 20 20 20 15 c d g h 2 23793 f a Good fuse b Blown fuse c 14 pin remote control harness cowl trim switch main power relay 15 AMP fuse d Ignition coil circuit 20 amp fuse e SmartCraft data bus circuit 5 amp fuse f Diagnostics terminal 2 AMP fuse g Spare fuse 20 AMP fuse h Fuel injectors direct injectors oil pump PCM 20 AMP fuse Corrosion Control Anode Your outboard has corrosio...

Page 74: ...a Anode 2 on each side of gearcase b Anode on transom bracket assembly Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 Make sure the battery is ...

Page 75: ...escription Nm lb in lb ft Hex nuts 13 5 120 Decal needs to be placed on or near battery box for future service reference One 5 16 in and one 3 8 in hex 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 O...

Page 76: ...er installed Before installing or removing a propeller place the drive unit in neutral and disable the ignition system by removing the keys from the ignition if equipped and engaging the lanyard stop switch to prevent the engine from starting 1 Shift the outboard to the neutral N position N 26838 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing spark plug leads 2 Remove the sp...

Page 77: ...emoved have the propeller removed by an authorized dealer INSTALLATION 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 1 Coat the propeller shaft with Quicksilver or Merc...

Page 78: ...n and rotate up to 10 degrees 2 Flo Torq III Drive Hub Propellers Install the forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft 3223 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 3 Place a block of wood between the gearcase and propeller Torque...

Page 79: ... spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to remove the spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap to specifications 26947 Spark...

Page 80: ...ration or once a season IMPORTANT Never run the engine without the air filter REMOVAL 1 Remove three screws and filter cover from engine 2 Remove filter from the cover a b 29476 a Cover b Filter INSTALLATION 1 Install filter into cover 2 Fasten filter cover with three screws Alternator Belt Inspection WARNING Inspecting the belts with the engine running may cause serious injury or death Turn off t...

Page 81: ...Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C with Teflon Propeller shaft 92 802859A1 Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corrodin...

Page 82: ...t tilt support lever tilt tube steering cable grease fitting 92 802859A1 Swivel Bracket Lubricate through fitting Tilt Support Lever Lubricate through fitting a b 27873 a Swivel bracket b Tilt support lever Tilt Tube Lubricate through fitting 29478 Steering Cable Grease Fitting If equipped Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through f...

Page 83: ...trol Completely retract the end of the steering cable before applying lubricant a b 29479 a Fitting b Steering cable end 3 Lubricate the following with light weight oil Steering Link Rod Pivot Points Lubricate pivot points 29480 Checking Power Trim Fluid 1 Tilt outboard to the full up position and engage the tilt support lever 27877 ...

Page 84: ...ut 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 metal particles A small amount of metal particles indicates nor...

Page 85: ... LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml 22 5 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug ...

Page 86: ...bricant until it appears at the rear vent hole 5 Stop adding lubricant Install the rear vent plug and sealing washer before removing lubricant tube 6 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 attent...

Page 87: ... line and engine fuel system The most effective method of storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on the containers to the fuel tank before the last operation of the boat Adding fuel stabilizer will help prevent the formation of varnish and gum in the gasoline The Mercury Precision Quickleen pro...

Page 88: ... hose 6 Pull the drain hose off the left side fitting Hold the open end of the hose over a container 7 Loosen the drain screw and drain the float chamber a b c 23752 a Left side fitting b Drain screw c Drain hose 8 Retighten the drain screw and reattach the hose 9 Premix the following in a container a 8 cc 0 27 oz or 2 teaspoons of Mercury Precision Quickleen lubricant ...

Page 89: ...l the fuel system Flushing Device 91 44357Q 2 9192 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the engine Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceeding IMPORTANT Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark...

Page 90: ...cation 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 trap water in cooling passages due to inadequate drainage In freezing temperatures remaining cooling water or rain water trapped in the propeller exhaust outlet in the gearcase can freeze damaging the outboard Store the ...

Page 91: ...tch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel tank is empty 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 failure Fuel tank fi...

Page 92: ...ed connection of an air hose is loose Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not fully open Damaged propeller or improper propeller size Boat overloaded or load improperly distributed 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 l...

Page 93: ...he dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or a...

Page 94: ...ebsite www mercurymarine com Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9793 5880 Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Recha...

Page 95: ...pan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Singapore 508762 Fax 5467789 ...

Page 96: ...ious injury or death Overpowering the boat can affect boat control and flotation characteristics or break the transom Do not install an engine that exceeds 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 manufacturer following certain federal guidelines If in...

Page 97: ...ly used with this outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all selected accessories Fuel Tanks PORTABLE FUEL TANK Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place PERMANENT FUEL TANK Permanent fuel tanks should be installed in accordance with industry and federal s...

Page 98: ... 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 minimum of five turns 15363 Lifting Eye 91 90455 1 2756 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing or to lift entire engine f...

Page 99: ...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 802859A1 2 Insert steering cable into tilt tube 3725 3 Torque nut to specification 3727 ...

Page 100: ... lines represent the extremes of known successful outboard mounting height dimensions c This line may be preferred to determine 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 transo...

Page 101: ...odels to the listed outboard mounting heights 3 The mounting height of the outboard must not exceed 63 5 cm 25 in for L models 76 cm 30 in for XL models Mounting the outboard higher may cause damage to the gearcase components Increasing the mounting height will usually Reduce steering torque Increase top speed Increase boat stability Cause propeller to break loose during planing Drilling Outboard ...

Page 102: ... 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 103: ... in ID x 1 50 in OD 12 54012 Washer Outer 0 53 in ID x 0 87 in OD Available Transom Mounting Bolts Part Number Part Name Description 10 67755005 Transom bolt 1 2 20 x 2 50 in long 1 25 in thread 10 67755006 Transom bolt 1 2 20 x 3 50 in long 1 25 in thread 10 814259 Transom bolt 1 2 20 x 4 00 in long 2 25 in thread 10 67755 1 Transom bolt 1 2 20 x 4 50 in long 2 25 in thread 10 67755 003 Transom b...

Page 104: ...ue the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased 18961 a b a Transom yielding under bolt torque b Transom cracking under bolt torque When first determining transom strength use a dial torque wrench If the bolt or nut continues to turn without the torque reading on the dial increasing it is an indication that the transo...

Page 105: ...e for the upper transom bolts a b 20860 a Large transom washer b Transom reinforcement plate Description Part Number Large transom washer 67 896392 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 ...

Page 106: ...eter bolt 4 c Shank of bolt d Flat washer 4 e Locknut 4 Description Nm lb in lb ft Outboard mounting locknuts and bolts 75 55 Electrical Fuel Hose Flush Hose and Control Cables FRONT COWL GROMMET NOTE Sufficient slack must exist in wiring battery cables and hose that are routed between the grommet and engine attachment points to relieve stress and prevent hoses from being kinked or pinched ...

Page 107: ...rom the bottom cowl a b 23714 a Access cover b Screws 2 Insert the lower alignment pin on the grommet into the hole in the lower cover Ensure the lettered side of the grommet is facing out 3 Route the hoses wiring and cables through the correct opening in the grommet as shown ...

Page 108: ... W a c d e f g h i j k b 23638 a Flush hose b Grommet c Remote boat harness d Shift cable e Throttle cable f Fuel hose g Upper alignment pin h SmartCraft harness or additional harness opening i Water pressure tube j Battery cables k Lower alignment pin 5 Reinstall the access cover with two bolts Reattach the cowl seal ...

Page 109: ...f desired the flush hose can be routed outside the cowling as follows 1 Using a needle nose pliers break out the semi circular knockouts in the access cover and lower cover Smooth the edges of the knockout with sandpaper or a small knife 2 Route the flush hose through this opening a b 23642 a Knockout b Flush hose ...

Page 110: ...lt 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 with hex nuts to avoid loose connections Do not use deep cycle batteries Engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah When connecting engine battery hex nuts must be used to secure battery leads...

Page 111: ...rvice 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 NUTS DO NOT USE DEEP CYCLE BATTERIES 13 5Nm 120 lbs in DTS Digital Throttle and Shift applications and Optimax engines must use a marine...

Page 112: ...l Outboards Connect a common ground cable wire size same as engine battery cables between negative terminals on starting batteries a a b b c d d 15497 a Red sleeve positive b Black sleeve negative c Ground cable d Cranking battery ...

Page 113: ...utboard route the SmartCraft wiring harness through the grommet and connect it to the SmartCraft harness connector on the engine a 23700 a SmartCraft harness connector WATER PRESSURE TUBE CONNECTION If a water connection to the engine is required for a water pressure gauge make the connection as follows ...

Page 114: ...ne Cut the cable tie and route the water pressure tube out through the grommet a 23702 a Water pressure tube 2 Remove the plug from the coupler and make the connection A barb fitting 22 859731 can be installed for larger diameter hose connection c a b 23708 a Plug b Coupler c Barb fitting 22 859731 ...

Page 115: ...ose to the fitting with a hose clamp a b 23709 a Hose clamp b Remote fuel hose SHIFT CABLE INSTALLATION NOTE Install the shift cable to the engine first The shift cable is the first cable to move when the remote control handle is moved out of neutral Install cables into the remote control following the instructions provided with the remote control 1 Position remote control into neutral N 26838 2 S...

Page 116: ...er of barrel pocket N R F a b c 23720 a Distance between pin and center of lower hole b Pin c Barrel pocket 4 Push in on the shift cable end until resistance is felt Adjust the cable barrel to attain distance measured in Step 3 a b 23721 a Shift cable end b Cable barrel ...

Page 117: ...ller shaft should turn freely without drag If not adjust the barrel away from the cable end Repeat steps a and b c Shift the remote control into reverse while turning propeller The propeller shaft should be locked in gear If not adjust the barrel away from the cable end Repeat steps a through c d Shift the remote control back to neutral The propeller shaft should turn freely without drag If not ad...

Page 118: ...en the locknut then back off the locknut 1 4 turn 3 Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop 4 Place the cable barrel into the barrel retainer 5 Lock the retainer and cables in place with the cable latch a b c d e 15317 a Flat washer b Locknut c Barrel retainer d Cable barrel e Cable latch ...

Page 119: ...Oil tank 4 72 liters 5 qt Optimax DFI 2 Cycle Engine Oil PRIMING THE OIL INJECTION PUMP Before starting engine for the first time prime the oil injection pump Priming will remove any air that may be in the pump oil supply hose or internal passages a b 7912 a Oil injection pump b Oil supply hose IMPORTANT Fill the engine fuel system with fuel before priming the oil injection pump Otherwise the fuel...

Page 120: ...on key switch to the ON position 26846 4 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 minutes for the pump to complete the priming process Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far un...

Page 121: ... 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 not included with engine Stainless Steel Tilt Pin 17 49930A 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 en...

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