Installation manual

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Page 1 of 38 Printed in U.S.A. -  2003, Mercury Marine 90-10202050 MARCH 2004

INSTALLATION MANUAL

200/225/250 OPTIMAX

Important Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Fuel Pump 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boat Horsepower Capacity 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start in Gear Protection 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Accessories For The Outboard 2. . . . . . . . . . . . . . . . .

Fuel Tank Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Outboard 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applying Counter Rotation Decals 3. . . . . . . . . . . . . . . . . . . . . . .

Steering Cable 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Link Rod 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Determining Recommended Outboard Mounting Height 6. . . . .

Installing Outboard 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical, Hoses and Control Cables 8. . . . . . . . . . . . . . . . . . . . .

Front Clamp Assembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Wiring Harness 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cable Size 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Information 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cable Connections 11. . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Hose Connection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Hose Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speedometer Tubing Connection 12. . . . . . . . . . . . . . . . . . . .

Water Pressure Tubing Connection 12. . . . . . . . . . . . . . . . . .

Shift Cable Installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Cable Installation 17. . . . . . . . . . . . . . . . . . . . . . . . . .

Filling Fuel System 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Injection Set-Up 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming the Oil Injection Pump 19. . . . . . . . . . . . . . . . . . . . . . . . .

Purging Air From the Engine Oil Tank 20. . . . . . . . . . . . . . . . . . .

Propeller Installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trim-In Stop Adjustment 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring for SmartCraft 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paddle Wheel Speed Sensor Installation 23. . . . . . . . . . . . .

Wiring Connections to Paddle Wheel Speed

Sensor, Oil Tank and Fuel Tank 27. . . . . . . . . . . . . . . . . . . . .

Typical System Layouts – Single Engine 28. . . . . . . . . . . . . .

Wiring Information for CAN

Type Gauges 30. . . . . . . . . . . . .

Wiring Accessories for CAN

Type Gauges 31. . . . . . . . . . . .

Typical Installation Configurations CAN

Type Gauges 32. .

Wiring Disconnect for Multiple Engines That Share a

Common Junction Box 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configure Engine Location for Multiple Engines That

Share a Common Junction Box 36. . . . . . . . . . . . . . . . . . . . .

Typical Installation Configurations Non CAN

Type Gauges 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTICE TO INSTALLER: After completing assembly, these instructions should be

placed with the product for the owner’s future use.

IMPORTANT: If the boat is to be water tested, the operator should be familiar with the

operation procedures in the Operation and Maintenance Manual.

Important Information

Before Starting Engine

Before starting engine for the first time, prime the oil injection pump. Procedure on page 19.

CAUTION

Prevent possible engine damage, Prime the oil injection pump before starting en-

gine for the first time.

Required Fuel

Do not use pre-mixed gas and oil in this engine. Use a clean and fresh recommended

gasoline during engine break-in and after engine break-in.

Recommended Oil

Mercury or Quicksilver Optimax/DFI 2-Cycle engine oil is recommended for your engine.

If Optimax/DFI 2-Cycle engine oil is not available, we recommend using Mercury or Quicksil-

ver TC-W3 Premium Plus 2-Cycle Oil. Severe engine damage may result from use of an

inferior oil

Avoiding Fuel Flow Restrictions

IMPORTANT: Adding components to the fuel supply system as in filters, valves, fit-

tings, etc. may restrict the fuel flow and could cause engine stalling at low speed, and/

or a lean fuel condition at high RPM, that could cause engine damage.

Summary of content (38 pages)

PAGE 1
INSTALLATION MANUAL 200/225/250 OPTIMAX Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Boat Horsepower Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Start in Gear Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Selecting Accessories For The Outboard . . . . . . . . . . . . . . . . . 2 Fuel Tank Installation . . . . . . .
PAGE 2
00/225/250 OPTIMAX Electric Fuel Pump If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If necessary, install a pressure regulator to regulate the pressure. Boat Horsepower Capacity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overload the boat.
PAGE 3
200/225/250 OPTIMAX Installation Specifications a a b a – Transom Opening – Minimum Single Engine (Remote) – 33-3/8 in. (848 mm) Dual Engines – 59-3/4 in. (1518 mm) b – Engine Center Line For Dual Engine 26 in. (660mm) Minimum Lifting Outboard Use Flywheel Puller/Lifting Eye (91-83164M). Applying Counter Rotation Decals IMPORTANT: For dual outboard counter rotation installations, the left-hand rotation outboard is generally placed on the port side of boat transom.
PAGE 4
200/225/250 OPTIMAX Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate O-ring seal and entire cable end. 95 95 2-4-C With Teflon (92-825407A12) 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 N·m).
PAGE 5
200/225/250 OPTIMAX Steering Link Rod 1. Install steering link rod per illustration. a c d b a b c d - Special Bolt (10-849838) Torque to 20 lb. ft. (27 N·m) - Nylon Insert Locknut (11-34863) Torque to 20 lb. ft.
PAGE 6
200/225/250 OPTIMAX Determining Recommended Outboard Mounting Height 26 in. (660mm) 25 in. (635mm) 24 in. (609mm) b (e) 23 in. Outboard (584mm) Mounting Height (See 22 in. NOTE Below) (560mm) e c 21 in. (533mm) a d 20 in. (508mm) 19 in. (482mm) 10 NOTE: Add 5 in. (127mm) for XL models to the listed outboard mounting height. 20 30 40 50 60 70 80 Maximum Boat Speed Anticipated IMPORTANT NOTICE TO INSTALLER 1.
PAGE 7
200/225/250 OPTIMAX Installing Outboard 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (located in this manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Refer to “Determining Recommended Outboard Motor Mounting Height,” preceding and install outboard to the nearest recommended mounting height. 4. Fasten outboard with provided mounting hardware shown. d b a c e a - 1/2 in.
PAGE 8
200/225/250 OPTIMAX Electrical, Hoses, and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. Front Clamp Assembly REMOVAL Remove two screws with retainer and open the front clamp.
PAGE 9
200/225/250 OPTIMAX 3. Secure clamp assembly into bottom cowl with retainer and 2 screws. b b a 57803 a - Retainer b - Screws Remote Wiring Harness 1. Connect wiring. Place harness into the holder.
PAGE 10
200/225/250 OPTIMAX Battery Cable Wire Gauge Size Mercury/Mariner Outboards Battery Cable Length 8 ft. 9 ft. 10ft. 11ft. 12ft. 13ft. 14ft. 15ft. 16ft. 17ft. 18ft. 19ft. 20ft. 21ft. 22ft. 23ft. 24ft. 2.4m 2.7m 3.0m 3.4m 3.7m 4.0m 4.3m 4.6m 4.9m 5.2m 5.5m 5.8m 6.1m 6.4m 6.7m 7.0m 7.3m Models Wire Gauge Size No.
PAGE 11
200/225/250 OPTIMAX Battery Cable Connections SINGLE OUTBOARD b c (+) a (–) a b c d d - Black Sleeve (Negative) - Red Sleeve (Positive) - Hex nuts – Torque to 13.5 Nm (120 lb. in.) - Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries.
PAGE 12
200/225/250 OPTIMAX Fuel Hose Connection Fuel Hose Size – Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate fuel line/fuel tank pickup for each engine. Fasten remote fuel hose to fitting with hose clamp. Oil Hose Connections Connect the remote oil hoses to the engine hose connections as shown. Fasten hose connections with sta-straps.
PAGE 13
200/225/250 OPTIMAX Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Prior to installing shift and throttle cables on engine, for ease of installation, it is recommended that the bottom cowl be loosened and spread apart to avoid possibly kinking control cables during installation. 1. Remove the front clamp. a a - Clamp 2. Separate the front end of the bottom cowl as follows: a.
PAGE 14
200/225/250 OPTIMAX Counter Rotation Outboards Counter rotating (left hand) gear cases can be identified by a “L” stamped into the end of the propeller shaft. The Quicksilver Dual Engine Console Mount Control, P/N 88688A22 or 88688A52, is required to shift the counter rotation outboard. The installation instructions shipped with the control explain the procedure required to connect this control to a counter rotation outboard.
PAGE 15
200/225/250 OPTIMAX Installation IMPORTANT: Step 1 must be followed for proper adjustment of the shift cable. 1. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to the neutral. Place a mark (a) on the cable against the cable end guide. b.
PAGE 16
200/225/250 OPTIMAX 2. Position remote control and outboard into neutral. N 3. Slide the shift cable retainer forward until resistance is felt, then slide cable anchor toward rear until resistance is felt. Center the anchor pin between resistance points. a a - Anchor Pin 4. Align the shift cable end guide with the center mark as instructed in Step 1. 5. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder. 6. Secure shift cable with shift cable retainer.
PAGE 17
200/225/250 OPTIMAX c. Shift remote control into reverse while turning propeller. The propshaft should lock solidly in gear. If not, adjust barrel away from cable end guide. Repeat steps a thru c. d. Return remote control handle to neutral. The propeller should turn freely without drag. If not, adjust barrel closer to cable end guide. Repeat steps a thru d. Throttle Cable Installation 1. Position remote control into neutral. N 2. Attach throttle cable to the throttle lever.
PAGE 18
200/225/250 OPTIMAX 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse. F N R b. Return remote control 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.
PAGE 19
200/225/250 OPTIMAX • Turn the ignition key switch back 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. Oil Injection Set-Up 1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten fill cap. a a - Fill Cap 2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
PAGE 20
0/225/250 OPTIMAX Prime the oil injection pump as follows: 1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until it fells firm. 2. Turn the ignition key switch to the “ON” position. 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. N F NOTE: It may take a few minutes for the pump to complete the priming process.
PAGE 21
200/225/250 OPTIMAX Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.
PAGE 22
200/225/250 OPTIMAX Trim-In Stop Adjustment Some outboard 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”.
PAGE 23
200/225/250 OPTIMAX Wiring for SmartCraft Gauges Paddle Wheel Speed Sensor Installation (If Equipped) PARTS PROVIDED b j f a f h e i c a b c d e f g h i j d g - Paddle Wheel - Bracket - Flat Washer (2) - #10 - 3/4 in. (19 mm) Screw (2) - Cable Cap - # 6 - 1/2 in. (12 mm) Screw (4) - Clamp (2) - Connector - Wire Retainer - Spare Pin Yoke SELECTING LOCATION Single engine installation – Mount on paddle wheel on the transom where the propeller blade is rotating upward.
PAGE 24
200/225/250 OPTIMAX Paddle Wheel Speed Sensor Installation (If Equipped) TRANSOM ANGLE REQUIREMENTS Standard 13° to 20° transoms – No special adjustments required. Stepped or undercut transom with 3° angles – A small shim of tapered plastic, metal or wood must be fabricated and installed as shown. Mount the paddle wheel on the step for best performance. 13° Transom Angle OK 20° Transom Angle OK Shim NO Stepped Transom OK Stepped Transom Stepped Transom INSTALLING BRACKET 1.
PAGE 25
200/225/250 OPTIMAX Paddle Wheel Speed Sensor Installation (If Equipped) ROUTING THE CABLE NOTE: You can choose to drill a hole through the transom for routing the cable, or you can route the cable over the transom or through a drain hole above the water line. If you choose to drill a hole through the transom, follow these instructions: 1. Select a transom location for the hole above the water line that does not interfere with other cables and controls. 2. Drill a 5/8 in. (15 mm) diameter Hole. 3.
PAGE 26
200/225/250 OPTIMAX Paddle Wheel Speed Sensor Installation (If Equipped) INSTALLING AND REMOVING THE PADDLE WHEEL Installation – slide the pins into the slots in the bracket and snap the tabs into place. Removal – squeeze open (unlock) the tabs and pull up on the paddle wheel. b a a - Pins b - Tabs WIRE CONNECTIONS IMPORTANT: Before making wire connections, make sure wires are routed through the transom. NOTE: Wires can only be pushed into the connector one way.
PAGE 27
200/225/250 OPTIMAX Wiring Connections to Paddle Wheel Speed Sensor, Oil Tank and Fuel Tank a IMPORTANT: DO NOT connect the Black/Orange wire to the fuel tank sensor when there is a engine battery ground strap connected to the fuel tank or sender assembly. If not used, plug the unused open bullet connector with rubber plug P/N 13541.
PAGE 28
200/225/250 OPTIMAX Typical System Layouts – Single Engine Product Configurations Speedometer and Tachometer Non CAN Type Gauges NOTE: Non CAN type gauges can be used on all V-6 Model outboards that are equipped for SmartCraft Tachometer Speedometer Key Switch Standard Key Switch Harness 5 Pin Tachometer Plug CAN Type Gauges NOTE: CAN Type Gauges Can only be used on 2002 Model Year and newer V-6 model outboards that are equipped for SmartCraft Speedometer Tachometer GPS Connection System Link Gauges
PAGE 29
200/225/250 OPTIMAX Typical System Layouts – Single Engine Product Configurations System Monitor (CAN) NOTE: System Monitor can be used on 2001 model year and newer outboards that are equipped for SmartCraft System Monitor System Link Gauges System Link Connector SC1000-2RSL System Monitor Harness Tachometer Only CAN Type Gauge NOTE: CAN Type Gauges Can only be used on 2002 Model Year and newer outboards that are equipped for SmartCraft System Tachometer System Link Gauges System Link Connector SC100
PAGE 30
200/225/250 OPTIMAX Wiring Information for CAN Type Gauges REQUIREMENTS SmartCraft communications are via the Controller Area Network (CAN), electrically implemented on a twisted pair of wires. signals. Note: SmartCraft harnesses include other signals besides CAN. The maximum distance between any two modules on the SmartCraft bus is 40 meters (130 feet). This distance is calculated as the total harness length between the modules (trunk length plus drop lengths).
PAGE 31
200/225/250 OPTIMAX Wiring Accessories for CAN Type Gauges Junction Boxes 6 Way 8 Way ** Junction Box Weather Cap * Junction Box Terminator/Resistor 4 Way 859318T-2 859318T-1 878492A4 878492A6 878492A8 * For correct placement on these terminator/resistors, refer to Wiring Installation Guidelines preceding and Typical Installation configurations following. * * All unused junction box ports must be covered using these weather caps.
PAGE 32
200/225/250 OPTIMAX Typical Installation Configurations CAN Type Gauges NOTE: The typical installation configurations shown on this page and the next few pages are the lowest cost solutions. Other solutions are also possible. See Page 15 for general guidelines. SINGLE ENGINE APPLICATIONS System Monitor– 2001 Model Year and Newer Monitor b Accessory Horn (816492A9) Connection for Water Depth Warning a System Link Connection Engine Optional Depth Transducer c Ref. Part Number Description Qty.
PAGE 33
200/225/250 OPTIMAX Typical Installation Configurations CAN Type Gauges DUAL ENGINE APPLICATIONS System Monitor – 2001 Model Year and Newer Outboards c c Accessory Horn (816492A9) Connection for Water Depth Warning a Engine Termination Resistor On This End Engine d e d b Optional Depth Transducer is Available IMPORTANT: Make Wiring Disconnect On One Of The Engines. Refer to Wiring Disconnect for Multiple Engine s That Share A Common Junction Box following. Ref. Part Number Description Qty.
PAGE 34
200/225/250 OPTIMAX Typical Installation Configurations CAN Type Gauges TRIPLE ENGINE APPLICATIONS – 2002 MODEL YEAR AND NEWER System Tachometer and Speedometer Accessory Horn (816492A9) Connection for Water Depth Warning j Termination Resistor On This End g h a d f Engine i Engine Air Temp Sensor IMPORTANT: Make Wiring Disconnect On One Of The Engines. Refer to Wiring Disconnect for Multiple Engine s That Share A Common Junction Box following.
PAGE 35
200/225/250 OPTIMAX Typical Installation Configurations CAN Type Gauges SYSTEM MONITOR – SINGLE ENGINE – DUAL STATION – 2001 MODEL YEAR AND NEWER e Accessory Horn (816492A9) Connection for Water Depth Warning Terminator /Resistor On This End TAN/BLUE PURPLE d System Link Connection a g c Engine e f b c System Link Connection d Optional Depth Transducer is Available Ref. Part Number g Description Qty.
PAGE 36
200/225/250 OPTIMAX Wiring Disconnect for Multiple Engines That Share a Common Junction Box CAUTION Prevent possible engine electrical component damage, Make this wiring disconnect before powering up the engines. Each CAN Bus must only be powered from one engine. On dual engine installations that share a common junction box (as shown), the CAN Bus power (3 wire) connector on one of the engines must be disconnected. The CAN Bus power connector is located in the engine wiring approximately 3 in.
PAGE 37
200/225/250 OPTIMAX Typical Installation Configurations Non CAN Type Gauges + 12 Volt (Connect to Same Circuit as Engine Starting Battery) + 12 Volt (Connect to RED Same Circuit as Engine Starting Battery) RED Tachometer Single Engine BRN WHT GRY Speedometer Tachometer Dual Engine BRN WHT GRY ECM 84-859314A1 84-859315A1 Connection For Optional Visual Warning Light Key Switch Harness Tachometer/Accessory Plug Air Temp Sensor BLUE Diagnostic Port Plug WHITE TAN/BLUE + – NMEA GPS Connect
PAGE 38
200/225/250 OPTIMAX Products of Mercury Marine W6250 Pioneer Road Fond du Lac, WI 54936-1939 Page 38 of 38 The following are registered trademarks of Brunswick Corporation: Autoblend, Force, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.