! WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. eng i 90-8M0055676 311 200/225 OptiMax DTS EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.
Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.
• • • • Provides timely service for all Mercury Marine customers. Offers extended service hours and mobile service, when appropriate. Uses, displays, and stocks adequate inventory of genuine Mercury Precision Parts. Offers a clean, neat shop with well organized tools and service literature.
Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle ☒ Outboard engine ☒ Petrol ☒ 2 stroke Identification of Engines Covered by This Declaration of Conformity Name of engine family Unique engine identification number: starting serial number EC Module H certificate number 1.5L OptiMax 75, 80, 90, 115, 125 hp 1B227000 RCD‑H‑2 2.5L OptiMax 135, 150, 175 hp 1B227000 RCD‑H‑2 3.
Name / function: Mark D.
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WARRANTY INFORMATION Warranty Registration.................................................................. 1 Transfer of Warranty.................................................................... 2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada................................. 2 Outboard Limited Warranty.......................................................... 3 3 Year Limited Warranty Against Corrosion................................
Installation Installing Outboard..................................................................... 42 Propeller Selection..................................................................... 43 Transporting Trailering Boat/Outboard .......................................................... 45 Fuel and Oil Fuel Recommendations............................................................. 46 Fuel Additives............................................................................ 48 Fuel Requirements......
Features and Controls Panel Mount Control Features and Operation........................... 53 Single Handle Console Control Features and Operation........... 56 Slim Binnacle Control Features and Operation......................... 61 Dual Handle Console Control Features and Operation............. 65 Dual Handle Console Control with CAN Trackpad Features and Operation................................................................................... 70 Shadow Mode Control Features and Operation.............
Maintenance Outboard Care......................................................................... 108 EPA Emissions Regulations.................................................... 108 Inspection and Maintenance Schedule.................................... 109 Flushing the Cooling System................................................... 111 Top Cowl Removal and Installation......................................... 112 Cleaning Care for Top Cowl....................................................
Troubleshooting Starter Motor Will Not Crank the Engine.................................. 139 Engine Will Not Start................................................................ 139 Engine Starts But Will Not Shift Into Gear............................... 140 Engine Runs Erratically........................................................... 140 Performance Loss.................................................................... 140 Battery Will Not Hold Charge..............................................
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WARRANTY INFORMATION Warranty Registration UNITED STATES AND CANADA To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, e‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration. A copy of the warranty registration should be provided to you by your selling dealer.
WARRANTY INFORMATION Transfer of Warranty UNITED STATES AND CANADA The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department.
WARRANTY INFORMATION To transfer the plan to the subsequent owner, contact Mercury Product Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
WARRANTY INFORMATION DURATION OF COVERAGE: This Limited 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 on which the product was first put into service, whichever occurs first.
WARRANTY INFORMATION WHAT MERCURY WILL DO: Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.
WARRANTY INFORMATION WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance items, tune‑ups, adjustments, normal 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,
WARRANTY INFORMATION 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 Manual, incorporated by reference into this warranty. DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED.
WARRANTY INFORMATION 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 predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
WARRANTY INFORMATION Corrosion damage caused by stray electrical currents (onshore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited Outboard Warranty.
WARRANTY INFORMATION 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 the 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 prior factory approval has been given to have the work performed at this facility). 7.
WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our 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. U.S.
WARRANTY INFORMATION d. Ignition coil and/or control module e. Ignition wires 4. Lubrication system (4‑Stroke engines excluded) a. Oil pump and internal parts b. Oil injectors c. Oil meter 5. Exhaust system a. Exhaust manifold b. Exhaust valves 6. Miscellaneous items used in above systems a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensitive valves and switches d.
WARRANTY INFORMATION WHAT IS COVERED: Mercury Marine warrants the components of the emissions control systems (see the components listed in the Emission Control System Components) of its new, 2001 model year and later outboards, sold by a California dealer to retail customers residing in California, to be free from defects in material or workmanship, that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certific
WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
WARRANTY INFORMATION 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 material caused by boat design for access to the product are not covered by this warranty.
WARRANTY INFORMATION California Air Resources Board Explanation of Your California Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board is pleased to explain the emission control system warranty on your 2001 model year and later outboard engine. In California, new outboard engines must be designed, built, and equipped to meet the State's stringent anti‑smog standards.
WARRANTY INFORMATION As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.
WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission 42538 The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines.
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION Boat Horsepower Capacity ! WARNING Exceeding the boat's maximum horsepower rating can cause serious 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.
GENERAL INFORMATION Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for digital throttle and shift. Start in gear protection is provided by the control system. This prevents the engine from starting when the shift is actuated in any position other than neutral. 29250 Propeller Selection The propeller on your outboard is one of the most important components in the propulsion system.
GENERAL INFORMATION IMPORTANT: To ensure proper fit, and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. The first number represents the diameter of the propeller and the second number represents the pitch.
GENERAL INFORMATION 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, the faster the car will accelerate, but with lower overall top speed. Likewise, a lower pitch propeller will accelerate quickly, but top‑end speed will be reduced. The higher the propeller pitch the faster the boat will usually go; though typically slowing acceleration.
GENERAL INFORMATION 3 BLADE VS. 4 BLADE Available in many sizes of both aluminum and stainless, 3 and 4‑blade propellers have unique performance characteristics. In general, 3‑blade propellers offer good all around performance and higher top speed than 4‑blade propellers. However, 4‑blade propellers are usually faster to plane and more efficient at cruising speeds, but lack the top end speed of a 3‑blade propeller.
GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.
GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.
GENERAL INFORMATION ! WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.
GENERAL INFORMATION 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 at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
GENERAL INFORMATION 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, 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.
GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended 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.
GENERAL INFORMATION ! WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.
GENERAL INFORMATION • • • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat. A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. Impact damage to the outboard and/or boat. Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed.
GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.
GENERAL INFORMATION GOOD VENTILATION Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
GENERAL INFORMATION 2. Examples of poor ventilation while the boat is moving: a b 21628 a - Operating the boat with the trim angle of the bow too high b - Operating the boat with no forward hatches open (station wagon effect) Selecting Accessories for Your Outboard Genuine 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.
GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) the U.S. Coast Guard Auxiliary, 2) the Power Squadron, 3) the Red Cross, and 4) your state boating 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.
GENERAL INFORMATION Watch fallen skiers. When using your boat for waterskiing 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 involved in certain boating accidents.
GENERAL INFORMATION Models Kilowatts 200 225 147 165 Full throttle RPM range 5000–5750 Idle speed in forward gear 575 ± 25 RPM Number of cylinders 6 Piston displacement 3048 cc (186 in³) Cylinder bore 92.1 mm (3.626 in.) Piston stroke 76.2 mm (3.000 in.) Recommended spark plug NGK IZFR5G Spark plug gap 0.8 mm (0.031 in.) Standard gearcase ratio 1.75:1 High altitude gearcase ratio 1.
GENERAL INFORMATION Component Identification a g b c h d i e f j 29423 eng 41 a - Top cowl b - Bottom cowl c - Water pump indicator hole d - Driveshaft housing e - Anti‑ventilation plate f - Anode plate g - Auxiliary tilt switch h - Transom brackets i - Gearcase j - Cooling water intake holes
INSTALLATION Installing Outboard ! WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. Do not accelerate above idle speed in water that may contain underwater obstacles if the outboard is not attached to the transom correctly.
INSTALLATION MAXIMUM OUTBOARD MOUNTING HEIGHT The mounting height of the outboard must not exceed 635 mm (25 in.) for EL models, 762 mm (30 in.) for EXL models, and 889 mm (35 in.) for EXXL models. Mounting the outboard higher may cause damage to the gearcase components.
INSTALLATION Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.
TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.
FUEL AND OIL Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum.
FUEL AND OIL 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).
FUEL AND OIL Fuel Additives To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickleen Engine Treatment additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container. Fuel Requirements Do not use premixed gas and oil in this engine. The engine automatically receives extra oil during engine break‑in. Use a fresh supply of the recommended gasoline during engine break‑in and after engine break‑in.
FUEL AND OIL • • An air inlet that opens to allow air to enter as the fuel is drawn out of the tank. An air outlet that opens (vents) to the atmosphere if pressure exceeds 34.4 kPa (5.0 psi). Fuel Demand Valve (FDV) Requirement Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and primer bulb. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.
FUEL AND OIL • When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening. The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal. • Since sealed fuel tanks are not openly vented, they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air. This is normal.
FUEL AND OIL 4. Follow Filling Fuel Tank instructions for refueling. Filling Fuel Tank ! WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and 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.
FUEL AND OIL IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air leak will prevent oil flow to the engine. 2723 Filling Engine Mounted Oil Reservoir Tank NOTE: Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated. 1. Remove the top cowl. 2. Loosen the fill cap on the engine oil reservoir tank.
FEATURES AND CONTROLS Panel Mount Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling back to increase speed. N R F 3413 2. Shift lock ‑ Pressing the shift lock allows the engine to shift.
FEATURES AND CONTROLS 3. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5152 4. Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn indicates throttle only is engaged. Advance throttle to increase engine RPM.
FEATURES AND CONTROLS 5. Stop/start button ‑ Allows the boat operator to start or stop the engine without using the ignition key. The ignition key must be in the "ON" position to start the engine. 3414 6. Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch. a - Lanyard stop switch a 22964 7.
FEATURES AND CONTROLS 8. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to tension desired. a - + b a - Detent tension adjustment screw b - Control handle tension adjustment screw 5171 Single Handle Console Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle.
FEATURES AND CONTROLS 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down. 5185 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the remote control handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to the desired tension. 4.
FEATURES AND CONTROLS 6. Select button ‑ Selects the System View on‑screen options and confirm data entries. Holding the select button for two seconds will pause the slide show if selected in Favorites. Holding the select button for three seconds will activate the reset data function (except when in the slide show function). Holding the select button for five seconds or more will bring up the Home page. 7. Neutral LED ‑ The neutral LED illuminates when engine is in neutral gear position.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Idle position is preferred when doing a helm transfer.
FEATURES AND CONTROLS 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine. b a ACTIVE THROTTLE ONLY STATION SELECT a b ACTIVE SYNC THROTTLE ONLY STAT ION SELECT 22753 a - Active light b - Throttle only/station select button 4. The "ACTIVE" light will switch off at the original helm.
FEATURES AND CONTROLS Slim Binnacle Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pushing back to increase speed. N F R 12871 2. Trim switch (if equipped) ‑ Pressing the trim switch allows the engine to trim up or down.
FEATURES AND CONTROLS 3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the remote control handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to the desired tension. 4.
FEATURES AND CONTROLS 8. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn will sound once and the neutral light will start flashing. The horn will sound twice when throttle only is engaged. Advance throttle to increase engine RPM.
FEATURES AND CONTROLS The helm transfer function allows the boat operator to select which helm is in control of engine operation. Pressing the throttle only/station select button two times allows engine control to be transferred to a new helm. When a helm transfer is initiated, the control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new helm. Adjust the control handles to the desired throttle and gear position.
FEATURES AND CONTROLS Dual Handle Console Control Features and Operation 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling back to increase speed. N R F 3417 2.
FEATURES AND CONTROLS 4. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning screw clockwise will increase tension. Adjust to the desired tension. a b a - Detent tension adjustment screw b - Control handle friction adjustment screw 28556 5. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear.
FEATURES AND CONTROLS 8. Neutral LEDs ‑ The neutral LEDs illuminate when engines are in neutral gear position. The lights will flash when in throttle only mode. NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the control handle. 9. Active LED ‑ The active LED illuminates to show the remote control is active and ready for use. 10. Sync LED ‑ The sync LED illuminates when the RPM of the two engines are being synchronized by the DTS system.
FEATURES AND CONTROLS Engine auto synchronization will automatically engage when engine speed is over 900 RPM for two seconds and remote control handles are positioned within 10% of each other. The "SYNC" light will turn on when the engines are synchronized. Auto synchronization will stay engaged up to 95% throttle opening. To disengage, move one or both control handles until they are more than 10% apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.
FEATURES AND CONTROLS NOTE: There is a 10 second time frame to complete a helm transfer. If the helm transfer is not completed, the action will be cancelled and a double beep will sound. Pressing the throttle only/station select button again will reinitiate a helm transfer. 1. Place active remote control lever to idle position. 2. Proceed to the inactive helm and position remote control lever to the idle position. 3. Press throttle only/station select button two times.
FEATURES AND CONTROLS Dual Handle Console Control with CAN Trackpad Features and Operation DUAL-HANDLE CONSOLE CONTROL WITH CAN TRACKPAD: FEATURES AND OPERATION 1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear.
FEATURES AND CONTROLS 4. Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering. To activate, move the control handles into forward detent and press the button. Use the ‑ or + buttons to decrease or increase speed, up to a maximum of 1000 RPM.
FEATURES AND CONTROLS 9. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines. a L RA UT NE b NEUTRAL - TROLL + SYNC c TRANSFER g 1 LEVER THROTTLE ONLY DOCK d f e abcdefg- 22133 Neutral LEDS Troll button Transfer button Dock button Throttle only 1 lever button Sync button 10.
FEATURES AND CONTROLS 11. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Neutral position is preferred when doing a station transfer.
FEATURES AND CONTROLS Synchronizing Helms Prior to Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash. The light blinks faster as the handles are nearing match position. Once the light stays on continuously, the handles are matched and the button can be pressed again to complete the transfer.
FEATURES AND CONTROLS Port Engine Center Engine Starboard Engine Control Handle Function Port engine throttle and shift = controlled by port control handle Running Off Running Running Off Off Port engine throttle and shift = controlled by port control handle Off Off Running Starboard engine throttle and shift = controlled by starboard control handle Off (ignition key switch turned on) Running Off (ignition key switch turned on) Center engine throttle and shift = neutral/idle unless both co
FEATURES AND CONTROLS Port Outer Engine Port Inner Engine Starboard Inner Engine Starboard Outer Engine Control Handle Function Port inner and outer engines throttle and shift = controlled by port control handle Running Running Off Running Running Off Off (ignition key switch Running turned on) Running Running Off (ignition key switch Running turned off) Running eng Running Running Running Starboard inner and outer engines throttle and shift = controlled by starboard control handle Off
FEATURES AND CONTROLS Port Outer Engine Running Port Inner Engine Off Off (ignition key switch Running turned on) Starboard Inner Engine Off Running Starboard Outer Engine Running Off (ignition key switch turned on) Control Handle Function Port outer engine throttle and shift = controlled by port control handle Starboard outer engine throttle and shift = controlled by starboard control handle Port inner engine throttle and shift = controlled by port control handle Starboard inner engine throttle
FEATURES AND CONTROLS If a failure should occur while underway which causes the starboard outer engines into forced neutral/idle condition, the inner starboard engine will also be forced to neutral/idle. Operation to the inner engine can be restored by moving the starboard control handle back into neutral and then reengaging. If a failure should occur while underway which causes the port outer engines into forced neutral/idle condition, the inner port engine will also be forced to neutral/idle.
FEATURES AND CONTROLS 2. Throttle only/station select button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button while moving the control handle ahead to the forward detent. The horn will sound once and the neutral light will start flashing. The horn will sound twice when throttle only is engaged. Advance throttle to increase engine RPM.
FEATURES AND CONTROLS 7. Sync LED ‑ The "SYNC" LED illuminates when the RPM of the engines are being synchronized by the DTS system. a b NEUTRAL c SELECT SYNC ACTIVE THROTTLE ONLY STATION SELECT f d e abcde- Neutral LEDS Select button Arrow trackpad Sync LED Throttle only/station select button f - Active LED 13854 SYNCHRONIZING ENGINES The auto synchronizing feature, when engaged, will automatically adjust all engine speeds to match the speed of the starboard engine.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Idle position is preferred when doing a helm transfer.
FEATURES AND CONTROLS 3. Press throttle only/station select button two times. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine. b a ACTIVE THROTTLE ONLY a b ACTIVE STATION SELECT SYNC THROTTLE ONLY STAT ION SELECT 22753 a - Active light b - Throttle only/station select button 4. The "ACTIVE" light will switch off at the original helm.
FEATURES AND CONTROLS Port Engine Center Engine Starboard Engine Control Handle Function Port engine throttle and shift = controlled by port control handle Running Running Running Starboard engine throttle and shift = controlled by starboard control handle Center engine throttle = average of port and starboard engines Center engine shift = neutral unless both engines are in the same gear Running Running Off Port and center engine throttle and shift = controlled by port control handle Off Runnin
FEATURES AND CONTROLS If a failure should occur while underway which causes one of the outer engines into forced neutral/idle condition, the center engine will also be forced to neutral/idle. Operation to the center engine can be restored by moving the control handle of the functioning outer engine back into neutral and then reengaging.
FEATURES AND CONTROLS Port Outer Engine Port Inner Engine Off (ignition key switch Running turned off) Running Running Running Off Off (ignition key switch Running turned on) Starboard Inner Engine Starboard Outer Engine Control Handle Function Running Running Port inner engine throttle and shift = controlled by starboard control handle Running Off (ignition key switch turned off) Starboard inner engine throttle and shift = controlled by port control handle Off Running Running Off (ignit
FEATURES AND CONTROLS Turning off the port outer engine while underway will cause the port inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the port outer engine ignition key to the on position and moving the port control handle back into neutral position and then reengaging. The inner engine speed and gear shift will then be controlled by the port control handle.
FEATURES AND CONTROLS 2. Neutral lights ‑ The neutral lights illuminate when the engine is in neutral gear position. The lights will flash when the engine is in throttle only mode. NOTE: Gear position is determined by the position of the shift actuator on the engine, not the position of the control handle. 3. Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering.
FEATURES AND CONTROLS 7. 1 lever button ‑ Pressing the "1 LEVER" button initiates single lever mode. Single lever mode enables the throttle and shift functions of both engines to be controlled by the port control handle. To turn off single lever mode, shift the engine into neutral and press the "1 LEVER" button. 8. Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines.
FEATURES AND CONTROLS 10. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions (cover must be removed). Turning the screw clockwise will increase tension. Adjust to tension desired.
FEATURES AND CONTROLS HELM TRANSFER ! WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral. NOTE: Neutral position is preferred when doing a station transfer.
FEATURES AND CONTROLS Synchronizing Helms Prior to Transfer Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control handle settings at the new helm with the handle settings that are at the old (to be inactive) helm. If the handles are not matched, the neutral lights will flash. The light blinks faster as the handles are nearing match position. Once the light stays on continuously, the handles are matched and the button can be pressed again to complete the transfer.
FEATURES AND CONTROLS Warning Horn Function Sound Cooling system problem Continuous Engine Guardian System is activated. Power limit will vary with level of overheat. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check water intake holes for obstruction. Oil level is critically low Continuous Engine Guardian System is activated.
FEATURES AND CONTROLS ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications 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 problem will need to be identified and corrected, if possible. The system must be reset before the engine will operate at higher speeds.
FEATURES AND CONTROLS Power Trim and Tilt The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the outboard within the first 20° range of travel.
FEATURES AND CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so the propeller shaft is not parallel to the water surface. ! WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
FEATURES AND CONTROLS • In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The nonstainless steel shipping bolt should not be used in this application other than on a temporary basis. 2.
FEATURES AND CONTROLS TILTING TO FULL UP POSITION Tilt At Helm NOTE: The trim/tilt switch will remain active for 15 minutes after the ignition key switch has been turned off. 1. If the ignition key switch has been turned off for over 15 minutes, turn it to the "ON" position. 2. Press the trim/tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position.
FEATURES AND CONTROLS Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 22362 AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system.
OPERATION Pre‑Starting Check List • • • • • • • • • • • Operator knows safe navigation, boating, and operating procedures. An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). A ring type life buoy or buoyant cushion designed to be thrown to a person in the water. Know the boat's maximum load capacity. Look at the boat capacity plate. Fuel supply OK. Oil supply (oil injection) OK.
OPERATION Operating in Saltwater or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water. This will prevent a buildup of deposits from clogging the water passages. Refer to Maintenance ‑ Flushing the Cooling System. If you keep your boat moored in the water, always tilt the outboard so the gearcase is completely out of water (except in freezing temperatures) when not in use.
OPERATION Engine Break‑In Procedure IMPORTANT: Failure to follow the 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 premixed 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 performance and maximum life from the engine.
OPERATION 2. For the next three hours of operation, change engine speed every ten minutes. Starting the Engine Before starting, read the pre‑starting check list, special operating instructions, engine break‑in procedure and Gear Shifting in the Operation section, and the remote control features and operation in the Features and Controls section. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
OPERATION 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 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift the outboard to the neutral ("N") position. N F N R R F 3413 3417 6.
OPERATION b. Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump. c. 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. 7. Ignition key starting ‑ Turn the ignition key to "START" position and release the key.
OPERATION Gear Shifting DTS PANEL MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). N R F 3427 • • When shifting, always stop at neutral position and allow the engine speed to return to idle.
OPERATION DTS CONSOLE MOUNT REMOTE CONTROL IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into forward or reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). N R F 3417 • • When shifting, always stop at neutral position and allow the engine speed to return to idle. Advance the control lever to further increase speed.
MAINTENANCE Outboard Care To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.
MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION a CALIFORNIA AND U.S.
MAINTENANCE • • • • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retorque the outboard mounting fasteners to 75 Nm (55 lb‑ft). Check steering system for binding or loose components. Visually check steering link rod fasteners for 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.
MAINTENANCE • • • • • • • Lubricate splines on the driveshaft and shift shaft.1. Check tightness of bolts, nuts, and other fasteners. Check cowl seals to make sure seals are intact and not damaged. Check internal cowl sound reduction foam (if equipped) to make sure foam is intact and not damaged. Check that the intake silencer (if equipped) is in place. Check that the idle relief muffler (if equipped) is in place. Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly.
MAINTENANCE 2. Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. 29445 Top Cowl Removal and Installation REMOVAL 1. Release the front and side cowl latches. 2. Lift the top cowl from the outboard. 29447 INSTALLATION 1. Position the top cowl over the engine. 2. Ensure the bottom rubber seal fits properly and lock the front and side latches.
MAINTENANCE 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. Alternator Belt Inspection 1. Inspect the alternator belt and have 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.
MAINTENANCE Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well‑ventilated area. Inspect any completed service work for sign of fuel leakage.
MAINTENANCE Installation 1. Lubricate the O‑ring seals with oil. a b 3388 a - Filter b - O‑ring seals 2. Install the fuel filter and tighten securely. IMPORTANT: Visually inspect for fuel leakage from the filter while squeezing the primer bulb until firm, forcing fuel into the filter. DRAINING WATER FROM THE FUEL FILTER CHAMBER NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on. Draining the water from the fuel filter chamber is required.
MAINTENANCE 3. Retighten the drain screw and reattach the hose. a b c 24686 a - Drain hose b - Side fitting c - Drain screw IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber.
MAINTENANCE ! 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 in 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.
MAINTENANCE Fuse Replacement IMPORTANT: Always carry spare 2, 5 and 20 amp fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating.
MAINTENANCE DTS Wiring System ! WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. • • • Verify the harnesses are not routed near sharp edges, hot surfaces, or moving parts.
MAINTENANCE The gearcase has three anodes. Two anodes are located on each side of the gearcase, and a third is an anode plate installed underneath the anti‑ventilation plate. If a trim tab should be installed, this anode plate will be removed. Another anode is installed on the bottom of the transom bracket assembly.
MAINTENANCE 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 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.
MAINTENANCE Propeller Replacement ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Shift outboard to neutral (N) position.
MAINTENANCE 3. Straighten the bent tabs on the propeller nut retainer. 26900 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 29592 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Ref No. Description Where Used Part No.
MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. a b c d e abcdef- f 26908 Propeller nut Propeller nut retainer Rear thrust hub Continuity washer Propeller Forward thrust hub 8. 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.
MAINTENANCE 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 spark plug boots, do not use any sharp object or metal tool 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.
MAINTENANCE 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 Spark plug 27 lb‑in. lb‑ft 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 compressor air intake filter. REMOVAL 1. Open the clamp and lift out the filter housing.
MAINTENANCE 2. Remove the hose cable tie and and pull the air filter off the hose.
MAINTENANCE a b c d 28738 abcd- Air filter Filter housing Clamp Inlet hose INSTALLATION 1. Place the nylon washer and rubber washer onto the air filter and insert the filter into the housing. Rotate the filter 1/4 turn to the lock position. 2. Position the filter housing so that the inlet hose is facing towards the back of the engine. Reinstall the hose and secure with a cable tie. 3. Secure the filter housing with the clamp. Lubrication Points 1.
MAINTENANCE • Trim rod ball ends ‑ Turn the ball ends to work the lubricant into the ball sockets. 28458 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Ref No. Description Where Used Part No. 94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1 95 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller.
MAINTENANCE Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Alternator belt tensioner pivot shaft, swivel bracket, tilt support lever, tilt tube, steering cable 92-802859A 1 • Alternator belt tensioner pivot shaft ‑ Lubricate through fitting. 2884 • Swivel bracket ‑ Lubricate through fitting. • Tilt support lever ‑ Lubricate through fitting.
MAINTENANCE • 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 a - Fitting b - Cable end 27875 4. Lubricate the following with lightweight oil.
MAINTENANCE Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lever. 27877 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricant Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF). 28460 Tube Ref No. 114 Description Power Trim and Steering Fluid Where Used Part No.
MAINTENANCE Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out 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.
MAINTENANCE CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove vent plug/sealing washer. 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. a b 22693 a - Vent hole b - Fill hole IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5.
STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
STORAGE 3. Pull the drain hose off the right side fitting. Hold the open end of the hose over a container. 4. Loosen drain screw and drain the fuel filter chamber. a - Drain screw b - Drain hose c - Right side fitting a c b 23751 5. Retighten the drain screw and reattach the 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 - Left side fitting b - Drain screw c - Drain hose a b c 23752 8.
STORAGE 10. Remove the fuel filter. See Maintenance ‑ Fuel System for procedure. 11. Pour this mixture into the fuel filter opening. Reinstall the fuel filter. 12. Prime the fuel system. See Operation ‑ Starting The Engine. 13. Place the outboard in water or use the flush hose or flushing device or for circulating cooling water. Start the engine and run at idle speed for five minutes to allow the treated fuel to fill the fuel system.
STORAGE • • Touch up any paint nicks. See your dealer for touch‑up paint. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. 120 Description Corrosion Guard Where Used Part No. External metal surfaces 92-802878 55 Gearcase • Drain and refill the gearcase lubricant (refer to Gearcase Lubrication).
TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 5 amp fuse. Check DTS power harness circuit fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Shift actuator failure. "Gear Shift Diff" error message shown on System View. Refer to Maintenance section. • Weak battery or battery connections are loose or corroded. • Ignition key switch failure. • Wiring or electrical connection faulty.
TROUBLESHOOTING • Spark plugs fouled or defective. Refer to Maintenance section. Engine Starts But Will Not Shift Into Gear • Shift actuator failure. "Gear Shift Diff" error message shown on System View. Refer to Maintenance section. Engine Runs Erratically POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section. b.
TROUBLESHOOTING • • • • • eng 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).
OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Service Away from Home If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer.
OWNER SERVICE ASSISTANCE • • • • • Your name and address Daytime telephone number Model and serial number of your outboard The name and address of your dealership Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada Telephone English ‑ (920) 929‑5040 Français ‑ (905) 636‑4751 Fax English ‑ (920) 929‑5893 Français ‑ (905) 636‑1704 Website www.mercurymarine.
OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Fax (65) 65467789 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore, 508944 144 eng
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
