Mercury 200 Verado Manual

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Manual (90 pages)

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Summary of Contents for Mercury 200 Verado

Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
Page 2 Vehicles, boats and internal combustion engine driven devices - SAE J551 (CISPR 12) radio disturbance characteristics EN 61000-6-2; EN 61000-4-2; EN Electrostatic discharge testing 61000-4-3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe.
Page 3 Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA...
Page 5: Table Of Contents
TABLE OF CONTENTS WARRANTY INFORMATION Transfer Of Warranty..............1 Warranty Registration United States And Canada......1 Warranty Registration Outside The United States And Canada .....................2 FourStroke Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle-East and Africa....................3 3 Year Limited Warranty Against Corrosion........6 Warranty Coverage And Exclusions..........10 General Information Boater's Responsibilities............13...
Page 6 TABLE OF CONTENTS Transporting Trailering Boat/Outboard ............32 Fuel and Oil Fuel Recommendations.............34 Filling Fuel Tank................36 Engine Oil Recommendations...........36 Checking And Adding Engine Oil..........37 Features and Controls Panel Mount Control Features and Operation......40 Single Handle Console Control Features and Operation... 43 Slim Binnacle Control Features and Operation......48 Dual Handle Console Control Features and Operation.....53 Dual Handle Console Control with CAN Trackpad Features and...
Page 7 TABLE OF CONTENTS Maintenance Outboard Care................99 EPA Emissions................ 100 Inspection and Maintenance Schedule........100 Flushing The Cooling System..........102 Cowl Removal and Installation..........103 Cleaning Care for Top and Bottom Cowls....... 105 Cleaning Care for the Powerhead (Saltwater Use)....106 Battery Inspection ..............106 DTS Battery Specifications............
Page 8 TABLE OF CONTENTS Engine Runs Erratically............133 Performance Loss..............133 Battery Will Not Hold Charge...........133 Owner Service Assistance Local Repair Service..............135 Service Away From Home............135 Parts And Accessories Inquiries..........135 Service Assistance..............135 Mercury Marine Service Offices..........136 viii...
Page 9: Warranty Information
1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.
Page 10: Warranty Registration Outside The United States And Canada
2. To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E-mail, or mail.
Page 11: Fourstroke Outboard Limited Warranty United States, Canada, Europe, Confederation Of Independent States, Middle-East And Africa
Outside the United States, Canada, Europe, Confederation of Independent States, Middle-East and Africa - check with your local distributor. WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below.
Page 12 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre–delivery inspection process is completed and documented.
Page 13 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. Purchaser in that case shall pay for all related transportation charges and/or travel time.
Page 14: Year Limited Warranty Against Corrosion
No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
Page 15 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented.
Page 16 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. Purchaser in that case shall pay for all related transportation charges and/or travel time.
Page 17 Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
Page 18: Warranty Coverage And Exclusions
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...
Page 19 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants or fluids changed as a matter of normal...
Page 20 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.
Page 21: General Information
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 on board is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
Page 22: Boat Horsepower Capacity
For additional information, obtain a copy of our Hi-Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. ob00307...
Page 23: Outboard Remote Control Models
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 remote control system. Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when...
Page 24 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.
Page 25: Protecting People In The Water
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.
Page 26: Passenger Safety Message - Pontoon Boats And Deck Boats
GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or any solid device rigidly attached to a moving boat or gearcase.
Page 27: Wave And Wake Jumping
GENERAL INFORMATION WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over. Stay back from the front end of the deck and remain seated while the boat is in motion.
Page 28: Impact With Underwater Hazards
GENERAL INFORMATION The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.
Page 29 GENERAL INFORMATION WARNING To avoid serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater obstacle maintain a top speed no greater than minimum planing speed. Striking a floating or underwater object could result in an infinite number of situations.
Page 30: Exhaust Emissions
GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines. This includes the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories.
Page 31: Selecting Accessories For Your Outboard
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and...
Page 32: Safe Boating Suggestions
GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible.
Page 33 GENERAL INFORMATION Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operators view when operating the boat above idle speed.
Page 34: Recording Serial Number
GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. rial Numb OTXXXXXX 20XX XXXX ob01322 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation 200/225/250/275 Specifications - International...
Page 35 GENERAL INFORMATION Models 200/225/250/275 Recommended Oil Refer to Fuel & Oil Right Hand Rotation Gearcase 970 ml (32.8 fl. oz.) Lubricant Capacity Left Hand Rotation Gearcase 900 ml (30.4 fl. oz.) Lubricant Capacity Engine Oil Capacity With Oil 7.0 liters (7.4 qt) Filter Replacement 1000 Marine Cranking Amps (MCA), 800 Cold Battery Rating...
Page 36: Component Identification
GENERAL INFORMATION Component Identification ob01302 Rear cowl Spray plate Lower cowl chaps Pedestal Anti-ventilation plate Engine flush Gearcase Auxiliary tilt switch Cooling water intake Top cowl holes...
Page 37: Installation
INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. IMPORTANT: For optimum boat performance and detailed engine installation instructions, refer to the outboard installation manual, supplied with the outboard.
Page 38 INSTALLATION MAXIMUM OUTBOARD MOUNTING HEIGHT The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76.2 cm (30 in.) for XL models and 88.9 cm (35 in.) for XXL models. Mounting the outboard higher may cause damage to the gearcase components.
Page 39: Propeller Selection
INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information - Specifications).
Page 40: Trailering Boat/Outboard
TRANSPORTING Trailering Boat/Outboard When transporting the boat on a trailer, the outboard should be positioned and/or supported in one of the following ways: 1. If the boat trailer provides sufficient ground clearance, the outboard may be tilted down to the vertical operating position with no additional support required.
Page 41 TRANSPORTING 3. For maximum ground clearance, the outboard can be tilted to the full tilt position and supported using the outboards tilt support bracket and/or an accessory transom support device. ob01267 Additional clearance may be required for railroad crossings, driveways and trailer bouncing. Refer to your local dealer for recommendations.
Page 42: Fuel And Oil
FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada - Model 275: Having a posted pump Octane Rating of 92 (R+M)/2 Octane is required for best performance.
Page 43 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.
Page 44: Filling Fuel Tank
FUEL AND OIL IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol-blend fuels...
Page 45: Checking And Adding Engine Oil
FUEL AND OIL IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Mercury or Quicksilver NMMA FC-W certified oil or a major brand NMMA FC-W certified oil), synthetic oils, low quality oils or oils that contain solid additives are not recommended.
Page 46 FUEL AND OIL IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil level is correct as long as it appears in the operating range (cross hatched region). 15730 Oil level operating range 6.
Page 47 FUEL AND OIL IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
Page 48: Features And Controls
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.
Page 49 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.
Page 50 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.
Page 51: Single Handle Console Control Features And Operation
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. 5171 Detent tension Control handle tension...
Page 52 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).
Page 53 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).
Page 54 FEATURES AND CONTROLS 9. 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.
Page 55 FEATURES AND CONTROLS NOTE: The active light on the remote control will be illuminated at the helm that is in control of the engine. 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.
Page 56: Slim Binnacle Control Features And Operation
FEATURES AND CONTROLS Synchronizing Helms Prior To Helm Transfer Pressing the throttle only/station select button one time allows the boat operator 10 seconds to match up the control handle setting at the new station with the handle setting that is at the old (to be inactive) station.
Page 57 FEATURES AND CONTROLS 2. Trim switch (if equipped) - Pressing the trim switch allows the engine to trim up or down. 12874 Trim switch 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).
Page 58 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 the screw clockwise will increase tension. Adjust to the desired tension.
Page 59 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.
Page 60 FEATURES AND CONTROLS NOTE: The active light on the remote control will be illuminated at the helm that is in control of the engine. 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.
Page 61: Dual Handle Console Control Features And Operation
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.
Page 62 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. ob01170 Detent tension Control handle friction...
Page 63 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.
Page 64 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.
Page 65 FEATURES AND CONTROLS 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. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine.
Page 66: Dual Handle Console Control With Can Trackpad Features And Operation
FEATURES AND CONTROLS 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.
Page 67 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.
Page 68 FEATURES AND CONTROLS 9. Sync button - Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22133 Neutral LEDS Throttle only Troll button 1 lever button Transfer button Sync button Dock button 10.
Page 69 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.
Page 70 FEATURES AND CONTROLS To disengage the auto synchronization feature, press the "SYNC" button. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22590 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.
Page 71: Shadow Mode Control Features And Operation
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 "TRANSFER" button again will re-initiate a helm transfer. NEUTRAL TROLL SYNC...
Page 72 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Port engine throttle and shift = controlled by port control handle Starboard engine throttle and shift = controlled by starboard control handle Running Running Running Center engine throttle = average of port and starboard engines Center engine shift =...
Page 73 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Starboard engine throttle and shift = Running controlled by starboard control handle Center engine throttle and shift = Off (ignition key Off (ignition key Running neutral/idle unless switch turned on) switch turned on) both control handles are in the same gear...
Page 74 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner and outer engines throttle and shift = controlled by port control handle Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by...
Page 75 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner engine throttle Off (ignition and shift = key switch Running Running Running controlled by turned off) starboard control handle Starboard inner engine Off (ignition key throttle and...
Page 76 FEATURES AND CONTROLS Turning off the starboard outer engine while underway will cause the starboard inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then re-engaging.
Page 77 FEATURES AND CONTROLS TRIM SWITCH AND KEY PAD FEATURES 1. Trim switch (if equipped) - Operates the trim for all engines. An accessory trim switch panel is required for trimming engines individually. 13853 2. Throttle only/station select button - Allows the boat operator to increase engine RPM for warm-up, without shifting the engine into gear.
Page 78 FEATURES AND CONTROLS 5. 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. 6.
Page 79 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.
Page 80: Shadow Mode Control With Can Trackpad Features And Operation
FEATURES AND CONTROLS 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. The "ACTIVE" light will illuminate to indicate the remote control is in control of the engine.
Page 81 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Port engine throttle and shift = controlled by port control handle Starboard engine throttle and shift = controlled by starboard control handle Running Running Running Center engine throttle = average of port and starboard engines Center engine shift =...
Page 82 FEATURES AND CONTROLS Control Handle Port Engine Center Engine Starboard Engine Function Starboard engine throttle and shift = Running controlled by starboard control handle Center engine throttle and shift = Off (ignition key Off (ignition key Running neutral/idle unless switch turned on) switch turned on) both control handles are in the same gear...
Page 83 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner and outer engines throttle and shift = controlled by port control handle Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by...
Page 84 FEATURES AND CONTROLS Port Outer Port Inner Starboard Starboard Control Handle Engine Engine Inner Engine Outer Engine Function Port inner engine throttle Off (ignition and shift = key switch Running Running Running controlled by turned off) starboard control handle Starboard inner engine Off (ignition key throttle and...
Page 85 FEATURES AND CONTROLS Turning off the starboard outer engine while underway will cause the starboard inner engine to go into forced neutral/idle. Operation to the inner engine can be restored by turning the starboard outer engine ignition key to the on position and moving the starboard control handle back into neutral position and then re-engaging.
Page 86 FEATURES AND CONTROLS TRIM SWITCH AND KEY PAD FEATURES 1. Trim switch (if equipped) - Operates the trim for all engines. An accessory trim switch panel is required for trimming engines individually. 22943 2. Neutral lights - The neutral lights illuminate when the engine is in neutral gear position.
Page 87 FEATURES AND CONTROLS 5. Dock button - Pressing the "DOCK" button initiates docking mode. Docking mode reduces throttle capacity approximately 50% of normal throttle. To turn off docking mode, shift the engine into neutral and press the "DOCK" button. 6. Throttle only button - Allows the boat operator to increase engine RPM for warm-up, without shifting the engine into gear.
Page 88 FEATURES AND CONTROLS 8. Sync button - Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22945 Neutral LEDS Throttle only Troll button 1 lever button Transfer button Sync button Dock button 9.
Page 89 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.
Page 90 FEATURES AND CONTROLS To disengage the auto synchronization feature, press the "SYNC" button. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22590 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.
Page 91: Warning System
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 "TRANSFER" button again will re-initiate a helm transfer. NEUTRAL TROLL SYNC...
Page 92 FEATURES AND CONTROLS Warning Horn Function Sound Description Water in fuel Four beeps every 2 Water in engine mounted minutes fuel filter. Refer to Maintenance - Water Separating Fuel Filter. Low battery Four beeps every 2 Battery charging unable to minutes keep up with demand.
Page 93 FEATURES AND CONTROLS Warning Horn Function Sound Description Engine overspeed Continuous The warning horn is activated any time the engine speed exceeds the maximum allowable RPM. The system will limit the engine speed to within the allowable range. Engine overspeed indicates a condition that should be corrected.
Page 94 FEATURES AND CONTROLS SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption and engine operating hours.
Page 95: Power Trim And Tilt
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 trimming down.
Page 96 FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim the outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, this being an awareness of some potential control hazards.
Page 97 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"...
Page 98 FEATURES AND CONTROLS MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. ob01143 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.
Page 99 FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. 1. Reduce engine speed below 2000 RPM. 2. Tilt outboard up. Make sure all the water intake holes stay submerged at all times.
Page 100: Operation
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.
Page 101: Operating In Salt Water Or Polluted Water
Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.
Page 102 OPERATION CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. 1. Make sure the cooling water intake is submerged. ob01310 2.
Page 103 OPERATION 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information - Lanyard Stop Switch. 19791 5. Shift outboard to neutral (N) position. 3413 3417 NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows: Turn the ignition key switch to the "ON"...
Page 104: Gear Shifting
OPERATION 6. Ignition key starting - Turn the ignition key to "START" position and release the key. The electronic starting system will automatically crank the engine for starting. If the engine fails to start, the engine will stop cranking. Turn the key to "START" position again until engine starts.
Page 105 OPERATION • When shifting, always stop at neutral position and allow the engine speed to return to idle. • Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position. 3428 •...
Page 106: Stopping The Engine
OPERATION Stopping The Engine IMPORTANT: Turning key to the "START" position while the engine is running will result in engine shut down, while leaving the DTS system active. This will allow the use of the power trim/tilt from the remote control handle. Reduce engine speed and shift outboard to neutral position.
Page 107: Outboard Care
Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could...
Page 108: Epa Emissions
MAINTENANCE EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. 21096 Idle speed Family number Engine horsepower Maximum emission output for the engine Piston displacement family Part number...
Page 109 MAINTENANCE • Check steering system for binding or loose components. • Visually check power steering fittings and hoses for leaks or signs of damage. Check tie bar fasteners (multiple outboard rigs) for proper tightness. • Check propeller blades for damage. AFTER EACH USE •...
Page 110: Flushing The Cooling System
MAINTENANCE Tube Ref No. Description Where Used Part No. Anti-Seize Spark plug threads 92-881091K1 Compound • Check wiring and connectors. • Check tightness of bolts, nuts, and other fasteners. • Check cowl seals to make sure seals are intact and not damaged.
Page 111: Cowl Removal And Installation
MAINTENANCE NOTE: The outboard can be tilted or in the vertical operating position during flushing. 1. With the engine turned off, place the outboard in either the operating position (vertical) or in a tilted position. 2. Disconnect the flush connector from fitting on the bottom cowl. ob01236 3.
Page 112 MAINTENANCE 1. Pull up on the top cowl lock latch. ob01324 2. Pull top cowl forward and lift off. 3. Pull lower cowl release latch up. 4. Remove rear cowl towards aft of outboard. ob01257 COWL INSTALLATION 1. Position lower cowl from aft side of outboard. Make sure it fits properly in the rubber seal.
Page 113: Cleaning And Waxing Procedure
MAINTENANCE 2. Lock cowl in place by pulling lower cowl latch down. ob01671 3. Place top cowl into position over engine, front first. Ensure cowl fits properly into the rubber seal. 4. The top cowl will lock into place when downward pressure is applied to the back side of cowl.
Page 114: Cleaning Care For The Powerhead (Saltwater Use)
MAINTENANCE 5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92-859026K 1). Cleaning Care for the Powerhead (Saltwater Use) If the outboard is operated in saltwater, remove the top cowl and flywheel cover. Inspect the powerhead and powerhead components for salt build-up.
Page 115: Dts Battery Specifications
MAINTENANCE 5. Make sure the battery is equipped with a non-conductive shield to prevent accidental shorting of battery terminals. DTS Battery Specifications IMPORTANT: Do not use deep cycle batteries for the main engine starting battery. IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery.
Page 116: Air Filter
MAINTENANCE IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine installation manual for size requirements. Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement.
Page 117 MAINTENANCE 2. Remove crankcase ventilation hose. 3664 Crankcase ventilation Filter assembly hose Clamp screw Fuel System Module (FSM) purge valve hose 3. Remove air filter assembly and disconnect Fuel System Module (FSM) purge valve hose by rotating the air filter assembly and pulling on hose.
Page 118 MAINTENANCE Tube Ref No. Description Where Used Part No. 4 Stroke 10W30 Air filter element 92-802833A1 Outboard Oil AIR FILTER INSTALLATION 1. Install Fuel System Module (FSM) purge valve hose to air filter assembly. 3665 2. Install crankcase ventilation hose. 3.
Page 119: Fuel System
MAINTENANCE Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system. IMPORTANT: Use an approved container to collect and store fuel.
Page 120 MAINTENANCE 2. Remove fuel vapor purge relief valve cap (green cap located aft of starter motor). 3470 CAUTION Fuel vapor vent system is under pressure. Cover valve assembly with a rag or towel to prevent fuel or fuel vapor spray. Relieve pressure slowly.
Page 121 MAINTENANCE 4. Unscrew the filter in a counterclockwise direction to remove. ob01253 Filter Draining 1. Slide filter holder up to release from bracket. Hoses and wire harness can remain attached to filter holder. 2. Tip the filter holder to drain any fluid into an approved container.
Page 122: Corrosion Control Anode
MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition key to the run position, forcing fuel into the filter. ob01258 Corrosion Control Anode The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
Page 123: Propeller Replacement
4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/ Quicksilver products: Tube Ref No. Description Where Used Part No.
Page 124: Spark Plug Inspection And Replacement
MAINTENANCE 6. 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. ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Thrust hub Forward thrust hub 7.
Page 125 MAINTENANCE 3. Remove mounting bolts, using a twisting motion, and pull pencil coils from spark plugs. 3658 Wiring harness Bolt connector Pencil coil 4. Remove the spark plugs to inspect. Replace spark plug if electrode is worn, threads of seal area are corroded, or the insulator is rough, cracked, broken, blistered or fouled.
Page 126: Fuses
MAINTENANCE 8. 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 lb. in. lb. ft. Spark plug 9. Push pencil coils into place over the spark plugs using a twisting motion.
Page 127 MAINTENANCE 1. Remove top cowl. Locate fuse holder on starboard side of engine. ob01516 2. Remove the plastic cover from the fuse holder. 3. Remove fuse puller from fuse holder. 4. Remove suspected blown fuse to determine if the silver colored band is broken.
Page 128: Dts Wiring System
MAINTENANCE ob01259 Electronic Control Spare fuses - 20 amp fuse Module and purge valve Injector power and boost "ECM" - 20 amp fuse valve "INJ. PWR." - 20 Ignition coils "IGN. amp fuse COILS" - 20 amp fuse Fuel delivery "FUEL" - 20 amp fuse DTS Wiring System WARNING...
Page 129: Checking Power Trim Fluid
Power trim fill cap Pedestal 5. The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
Page 130: Checking Power Steering Fluid
MAINTENANCE Checking Power Steering Fluid Remove power steering cover and fill cap to check fluid level. The fluid level should be slightly below the bottom of the fill hole. Use SAE 0W-30 synthetic power steering fluid, if needed. ob01527 Power steering cover Fill/full level Fill cap Tube Ref No.
Page 131 MAINTENANCE IMPORTANT: The pump method is preferred to remove engine oil from XXL models. If the drain method is used, an oil drain funnel must be used to divert oil from the lower splash plate and into the container. 1. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump.
Page 132 MAINTENANCE 4. Loosen the drain plug/seal washer. Install the oil drain funnel over the drain plug/seal washer and slide the tool onto the splash plate. ob01264 Drain plug/seal Oil drain funnel washer Oil Drain Funnel 91-892866A01 Diverts draining engine oil from contacting the anti-splash and anti-cavitation plates.
Page 133 MAINTENANCE 3. Unscrew old filter by using oil filter wrench tool and turning the filter counterclockwise. ob01251 Oil Filter Wrench 91-802653Q02 Assists in removal of oil filter. 5221 4. Clean the oil filter mounting base. 5. Apply film of clean oil to filter gasket. Do not use grease. 6.
Page 134: Gearcase Lubrication
MAINTENANCE OIL FILLING 1. Remove the oil fill cap and add recommended oil to the midpoint of the operating range (midpoint of cross hatched region). Adding approximately 7 liters (7.4 quarts) will bring oil level to midpoint of cross hatched region. ob01250 2.
Page 135 970 ml (32.8 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. 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.
Page 136 MAINTENANCE IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
Page 137: Storage Preparation
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).
Page 138: Protecting External Outboard Components
Stabilizer Protecting External Outboard Components • 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. Description Where Used Part No.
Page 139: Battery Storage
STORAGE CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. Battery Storage • Follow the battery manufacturer's instructions for storage and recharging.
Page 140: Troubleshooting
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. •...
Page 141: Engine Runs Erratically
TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Overheating - Warning horn not working. • Low oil pressure. Check oil level. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a.
Page 142 TROUBLESHOOTING • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator. • Open circuit in the alternator output wire (fused link).
Page 143: Owner Service Assistance
Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts And Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.
Page 144: Mercury Marine Service Offices
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 Telephone...
Page 145 OWNER SERVICE ASSISTANCE Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 5467789 Singapore, 508762...

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