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© 2004 Mercury Marine
90-10234050 APRIL 2004
200/225 OPTIMAX DTS
INSTALLATION MANUAL
Table of Contents
Notice to Installer ................................................... 2
Installation Information .......................................... 2
Avoiding Loss of Throttle and Shift Control.......2
Before Starting the Engine................................2
Fuel Requirements............................................2
Oil Recommendation.........................................2
Avoiding Fuel Flow Restriction .............................. 2
Electric Fuel Pump ................................................ 3
Boat Horsepower Capacity .................................... 3
Selecting Accessories For Your Outboard ............ 3
Fuel Tanks ............................................................. 3
Portable Fuel Tank ........................................... 3
Permanent Fuel Tank ....................................... 3
Installation Specifications ...................................... 4
Lifting the Outboard ............................................... 4
Applying Counter Rotation Decals ........................ 5
Steering Cable - Starboard Side Routed Cable .... 5
Steering Link Rod Fasteners ................................. 6
Determining Recommended Outboard Mounting
Height .................................................................... 7
Drilling Outboard Mounting Holes ......................... 8
Front Clamp Assembly .......................................... 9
Removal ............................................................ 9
Installation ......................................................... 9
Wiring and Installation ......................................... 11
Wire Color Code Abbreviations.......................11
Installation Guidelines for DTS System
Components....................................................11
Data Harness Pulling Procedure.....................11
Junction Box (If Equipped)...............................12
Non-Mercury Marine Provided Ignition Switch.12
Wiring Accessories..........................................13
System Wiring Reference Points.....................13
Connecting 14 Pin Data Harness - Single
Engine..............................................................14
Connecting 14 Pin Data Harness - Dual Engine
.........................................................................15
Installing DTS Command Module and Harness -
Single Engine...................................................16
Installing DTS Command Module and Harness -
Dual Engine/Single Helm.................................20
Battery Cable Size For Outboard Models........21
Battery Information..........................................23
Connecting Battery Cables and DTS Power
Harness...........................................................23
Connecting Fuel Tank, Oil Tank and Speed
Sensor.............................................................26
Switched 12V Accessory Connection..............28
DTS Wiring - Single Engine.............................29
DTS Wiring - Dual Engine................................31
System Wiring Installation Checklist................32
Fuel Hose and Oil Hose Connections ................. 32
Fuel Hose Connection .................................... 32
Filling the Fuel System ........................................ 33
Filling the Oil System .......................................... 33
Priming Oil Injection Pump .................................. 34
Purging Air From the Engine Oil Tank ................. 36
Propeller Installation ............................................ 36
Trim In Pin ........................................................... 37
Paddle Wheel Speed Sensor Installation (If
Equipped) ............................................................ 38
Parts Provided ................................................ 38
Selecting Location .......................................... 38
Transom Angle Requirements ........................ 39
Installing Bracket ............................................ 39
Routing the Cable ........................................... 40
Installing and Removing the Paddle Wheel .... 41
Wiring Connections ......................................... 41
Template - Paddle Wheel Speed Sensor ....... 42