Mercury Optimax User Manual
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Mercury Optimax User Manual

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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.
Details
of
your
www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose?
Please check on www.marinepower.com. If necessary,
please contact your local dealer.
Declaration of Conformity ‑ Optimax
Manufacturer:
Authorized Representative:
If the CE mark is accompanied by a notified body number, the
following Recreational Craft Directive applies:
Recreational Craft Directive:
Applicable Requirement
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engines starting (A.5.1.4) EN ISO 11547:1995
General steering system (A.5.4.1)
Exhaust emission requirements (B.
2)
Owner's manual (B.4)
Noise emission levels (C.1)
Module used for exhaust emission assessment: Module H;
Certification No. RCD‑H‑2
nearest
dealer
Mercury Marine
W6250 Pioneer Road P.O. Box 1939
Fond du Lac, WI 54935-1939 USA ,
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-2800 Verviers - Belgium,
2003/44/EC amending 94/25/EC
Standards Applied
EN ISO 10240:2004
EN ISO 8665:1995
ABYC P‑17; EN ISO 10592:1995
EN ISO 8178‑1: 1996
EN ISO 8665:1995
EN ISO 14509:2000
i
can
be
found
on

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  • 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 Mercury, Mariner Module H Starting Engine Manufacture Noise and Horsepower Serial Family Location Exhaust Number Certificate Optimax 1.5 Fond du Lac, 75, 90,115 1B227000 RCD‑H‑2 Wisconsin USA Optimax 2.5 Fond du Lac, 135, 150 1B227000 RCD‑H‑2 Wisconsin USA Optimax 3.0...
  • Page 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006. European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 5: Table Of Contents

    Transfer Of Warranty..............1 Warranty Registration United States And Canada......1 Warranty Registration Outside The United States And Canada .....................2 Optimax 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 Fuel and Oil Fuel Recommendations.............33 Fuel Requirements..............35 Fuel Additives................35 Avoiding Fuel Flow Restriction..........35 Oil Recommendation..............35 Filling Oil Injection System............35 Filling Fuel Tank................37 Features and Controls Remote Control Features............38 Warning System................39 Power Trim And Tilt..............42 Trim Tab Adjustment..............46 Operation Pre‑Starting Check List..............47 Operating In Freezing Temperatures.........
  • Page 7 TABLE OF CONTENTS Flywheel Cover Removal and Installation........59 Side Panel Removal and Installation.........60 Fuel System................61 Steering Link Rod Fasteners.............63 Fuse Replacement..............64 Corrosion Control Anode............65 Battery Inspection ..............66 Battery Information..............67 Propellers...................68 Spark Plug Inspection And Replacement........71 Compressor Air Intake Filter............72 Alternator Belt Inspection............
  • Page 8 TABLE OF CONTENTS Parts And Accessories Inquiries..........85 Service Assistance..............85 Mercury Marine Service Offices..........86 Outboard Installation Important Information..............88 Boat Horsepower Capacity............88 Start in Gear Protection.............88 Selecting Accessories For Your Outboard......... 89 Fuel Tanks.................89 Installation Specifications............89 Lifting the Outboard..............90 Steering Cable ‑ Starboard Side Routed Cable......91 Determining Recommended Outboard Mounting Height...92...

  • 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: Optimax 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. Propeller Selection The propeller on your outboard is one of the most important components in the propulsion system.
  • Page 23 When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your local...
  • Page 24 GENERAL INFORMATION 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.

  • Page 25: Outboard Remote Control Models

    RPM range when under normal full throttle operation. PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats.

  • Page 26: Remote Steering Notice

    GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 26779 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.

  • Page 27: Lanyard Stop Switch

    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.
  • Page 28 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 29: 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 30: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

  • Page 31: Wave And Wake Jumping

    GENERAL INFORMATION WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion. BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is...

  • Page 32: 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 33 WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

  • Page 34: 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 35: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of non‑approved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and...

  • Page 36: 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 37 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 38: Recording Serial Number

    Numb XXXXXXXX XXXX RP M 23884 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) 75/90/115 OptiMax Specifications Models Horsepower Kilowatts 55.2 66.2 84.6 Full Throttle RPM Range 5000‑5750 RPM Idle Speed in Forward 625‑675 RPM...

  • Page 39: Component Identification

    GENERAL INFORMATION Models Gearcase Lubricant 665 ml (22.5 fl. oz.) Capacity 1000 Marine Cranking Amps (MCA) or 800 Cold Battery Rating Cranking Amps (CCA) Charging System Output 60 Amps Component Identification 29461 Top cowl Trim tab Auxiliary tilt switch Anti‑ventilation plate Transom brackets Driveshaft housing Gearcase...

  • Page 40: Transporting

    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.

  • Page 41: 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 ‑ having a posted pump Octane Rating of 87 (R +M)/2 minimum.
  • Page 42 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).

  • Page 43: Fuel Requirements

    MercuryOptimax/DFI or Quicksilver DFI 2-Cycle Recommended Oil Engine Oil Mercury Optimax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended for your engine. If Mercury Optimax/DFI or Quicksilver DFI 2‑Cycle engine oil is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium Plus 2‑Cycle Oil.
  • Page 44 4. Slowly fill the oil tank with the specified oil. Do not overfill. Add only enough oil to bring the oil level up to the bottom of the fill neck. Capacity Fluid Type Oil tank 4.72 liters (5 qt.) Optimax/DFI 2‑Cycle Engine Oil 29465...

  • Page 45: Filling Fuel Tank

    FUEL AND OIL 5. Install oil filler cap and retighten. Reinstall the cowl cap. 29466 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.

  • Page 46: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle ‑...

  • Page 47: Warning System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch. 27755 Horn inside remote Horn connected to control ignition key switch WARNING HORN SIGNALS...
  • Page 48 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling System Continuous Engine Guardian System is Problem 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.
  • Page 49 Consult your dealer for assistance. 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, battery voltage, fuel consumption and engine operating hours.

  • Page 50: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim And Tilt Your 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.
  • Page 51 FEATURES AND CONTROLS 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. Consider the following lists carefully.
  • Page 52 FEATURES AND CONTROLS • Increase clearance over submerged objects or a shallow bottom. • Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). • In excess can cause boat porpoising (bouncing) or propeller ventilation.
  • Page 53 FEATURES AND CONTROLS 1. Turn manual tilt release valve turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 22362 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 54: Trim Tab Adjustment

    FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 55: 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 56: 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 57: Setting Trim Angle While Running Engine At Idle Speed

    NOTE: Do not use pre‑mixed gas and oil during break‑in. Use straight gasoline during engine break‑in and after engine break‑in. The engine break‑in procedure for an OptiMax outboard is important to ensure proper performance and maximum life from the engine. The following break‑in procedure allows the internal engine parts to wear‑in evenly.

  • Page 58: Starting The Engine

    OPERATION BREAK-IN PROCEDURE 1. For the first hour of operation, allow the engine to warm up for 30‑60 seconds. a. Run the engine at varied throttle settings, the majority of the time between 3000 and 4500 RPM or three‑quarter throttle. b.
  • Page 59 OPERATION 1. Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged. 26837 2. Open the fuel tank vent screw, located in the filler cap, on manual venting type fuel tanks. 19748 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up.
  • Page 60 OPERATION 5. Shift outboard to neutral ("N") position. 26838 6. For the 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: a.

  • Page 61: Gear Shifting

    OPERATION 9. Check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.

  • Page 62: Stopping The Engine

    OPERATION Stopping The Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843...

  • Page 63: Maintenance

    Record maintenance performed in the Maintenance Log at the back of this book. 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. EPA Emissions EMISSION CERTIFICATION LABEL...

  • Page 64: Inspection And Maintenance Schedule

    MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.

  • Page 65: Flushing The Cooling System

    MAINTENANCE • Check corrosion control anodes. Check more frequently when used in salt water. See Corrosion Control Anodes. • Drain and replace gearcase lubricant. See Gearcase Lubrication. • Check power trim fluid. See Checking Power Trim Fluid. • Inspect battery. See Battery Inspection. •...

  • Page 66: Top Cowl Removal And Installation

    MAINTENANCE 2. Attach a water hose to the hose adapter. 3. Turn on the water and flush the cooling system for a minimum of 3 minutes. IMPORTANT: Do not run engine above idle speed when flushing. 4. Turn off the water and remove the water hose from the hose adapter.

  • Page 67: Cleaning Care For Top Cowl

    MAINTENANCE Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Follow cleaning and waxing procedure. CLEANING AND WAXING PROCEDURE 1. Before washing, rinse the top cowl with clean water to remove dirt and dust that may scratch the surface.

  • Page 68: Side Panel Removal And Installation

    MAINTENANCE INSTALLATION Position the cover onto the three mounting pins. Insert the tabs into the slots in the side panel and push the cover down onto the mounting pins. 23754 Flywheel cover Tabs Mounting pins Side Panel Removal and Installation REMOVAL Pull the side panel off the three mounting pins.

  • Page 69: Fuel System

    MAINTENANCE INSTALLATION Position the side panel onto the three mounting pins. Insert the tabs on the flywheel cover into the upper slots and push the side panel onto the mounting pins. 23765 Side panel Mounting pins Upper slots Fuel System WARNING Fuel is flammable and explosive.
  • Page 70 MAINTENANCE Before servicing any part of the fuel system, stop 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.

  • Page 71: Steering Link Rod Fasteners

    MAINTENANCE 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. 1. Pull the drain hose off the right side fitting. Hold the open end of the hose over a container.

  • Page 72: Fuse Replacement

    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 serious injury or death due to occupants being thrown within or out of the boat.

  • Page 73: Corrosion Control Anode

    MAINTENANCE 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.

  • Page 74: Battery Inspection

    MAINTENANCE Each anode requires periodic inspection, especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode.

  • Page 75: Battery Information

    NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating. 13.5Nm (120 lbs. in.)

  • Page 76: Propellers

    MAINTENANCE Propellers REMOVAL IMPORTANT: Propellers used on this product require the Mercury Marine Flo‑Torq III type hub or equivalent. WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before...
  • Page 77 1. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902...
  • Page 78 MAINTENANCE Tube Ref No. Description Where Used Part No. Anti-Corrosion 92-802867Q Propeller shaft Grease 2-4-C with Teflon Propeller shaft 92-802859A1 NOTE: The Flo‑Torq lll propeller drive hubs are designed to have a small amount of free play when installed. This free play allows the propeller to slide back and forth on the rear thrust hub [up to 3.17 mm (1/8 in.)] and rotate up to 10 degrees.

  • Page 79: Spark Plug Inspection And Replacement

    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 such as pliers, screwdriver, etc.

  • Page 80: Compressor Air Intake Filter

    MAINTENANCE 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger tight, and then tighten to the specified value. Description lb. in. lb. ft. Spark plug Compressor Air Intake Filter The filter should be changed every 100 hours of operation, or once a season.

  • Page 81: Lubrication Points

    Belt surfaces rough or uneven. c. Signs of wear on edges or outer surfaces of belt. 29477 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No.
  • Page 82 MAINTENANCE Tube Ref No. Description Where Used Part No. Swivel bracket, tilt support lever, tilt 92-802865Q0 Special Lubricant 101 tube, steering cable grease fitting Swivel bracket, tilt support lever, tilt 2-4-C with Teflon 92-802859A1 tube, steering cable grease fitting • Swivel Bracket ‑ Lubricate through fitting. •...

  • Page 83: Checking Power Trim Fluid

    MAINTENANCE 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. 29479 Fitting Steering cable end 3. Lubricate the following with light weight oil. •...

  • Page 84: Gearcase Lubrication

    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 Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 85 666 ml (22.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove the front vent plug and rear vent plug.
  • Page 86 MAINTENANCE 3. Remove fill/drain plug. Place lubricant tube into the fill/drain plug hole and add lubricant until it appears at the front vent hole. At this time install the front vent plug and sealing washer. 27001 Front vent plug Rear vent plug Front vent hole Fill/drain plug Rear vent hole...

  • Page 87: Storage

    Adding fuel stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will help clean and lubricate the fuel injectors.
  • Page 88 7. Loosen the drain screw and drain the float chamber. 23752 Left side fitting Drain hose Drain screw 8. Retighten the drain screw and reattach the hose. 9. Premix the following in a container: a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant.

  • Page 89: Protecting Internal Engine Components

    STORAGE b. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer. 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.

  • Page 90: Protecting External Outboard Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • 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 91: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 92: Engine Runs Erratically

    TROUBLESHOOTING 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. Fuel tank filter obstructed. c.

  • Page 93: 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 94: 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 (920) 929‑5040...
  • Page 95 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...

  • Page 96: Outboard Installation

    Rigging boats, which includes proper engine installation, has become more complex over the years. As a result, we recommend our engines be installed only by Mercury authorized dealers. If you intend to disregard this recommendation and install the engine yourself, please make sure to read and comply with these instructions.

  • Page 97: Selecting Accessories For Your Outboard

    Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.

  • Page 98: Lifting The Outboard

    OUTBOARD INSTALLATION Minimum Transom Opening Single engine 84.2 cm (33 in.) Dual engine 149.9 cm (59 in.) Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death. Before lifting the engine, verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight.

  • Page 99: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate O‑ring seal and entire cable end. 3724 Tube Ref No. Description Where Used Part No. 2-4-C Marine O-ring seal and entire 92-802859A1 Lubricant with Teflon cable end 2. Insert steering cable into tilt tube. 3725 3.

  • Page 100: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Description lb. in. lb. ft. 47.5 Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 18562 The solid line is recommended to determine the outboard mounting height.

  • Page 101: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent exhaust restrictions.
  • Page 102 OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. or69-1 Drill guide holes Transom centerline Transom drilling fixture Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 103: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 10‑67755‑1 Transom bolt 1/2‑20 x 4.50 in. long (2.25 in. thread) 11‑826711‑17 Nylon insert locknut 1/2‑20 12‑28421 Washer ‑...
  • Page 104 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb. ft.) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 105 OUTBOARD INSTALLATION NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. 20860 Large transom washer Transom reinforcement plate Description Part Number Large transom washer 67‑896392 Transom reinforcement plate 67‑896305...

  • Page 106: Electrical, Fuel Hose, Flush Hose And Control Cables

    OUTBOARD INSTALLATION NOTE: For more accurate torque, whenever possible turn/tighten the mounting locknuts rather than turning the mounting bolts. 3729 Flat washer (4) Flat washer (4) 1/2 in. diameter bolt Locknut (4) Shank of bolt Description lb. in. lb. ft. Outboard mounting locknuts and bolts Electrical, Fuel Hose, Flush Hose and Control...
  • Page 107 OUTBOARD INSTALLATION 1. Pull up the cowl seal. Remove the access cover from the bottom cowl. 23714 Access cover Screws 2. Insert the lower alignment pin on the grommet into the hole in the lower cover. Ensure the lettered side of the grommet is facing out.
  • Page 108 OUTBOARD INSTALLATION 4. Install the flush hose after removing the knockouts. Refer to Flush Hose Routing. 23638 Flush hose Upper alignment pin Grommet SmartCraft harness or additional harness Remote boat harness opening Shift cable Water pressure tube Throttle cable Battery cables Fuel hose Lower alignment pin 5.
  • Page 109 OUTBOARD INSTALLATION 6. Attach two cable ties around the grommet tube. 23639 Cable tie FLUSH HOSE ROUTING If desired, the flush hose can be routed outside the cowling as follows: 1. Using a needle nose pliers, break out the semi‑circular knockouts in the access cover and lower cover.
  • Page 110 OUTBOARD INSTALLATION REMOTE BOAT HARNESS Route the remote boat harness through the grommet. Connect the remote harness to the 14 pin connector on the engine harness. 23699 Remote 14 pin boat harness BATTERY INFORMATION WARNING Failure to properly secure the battery leads could 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.
  • Page 111 NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating. 13.5Nm (120 lbs. in.)
  • Page 112 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ positive (+) Ground cable Black sleeve ‑ negative Cranking battery (–)
  • Page 113 OUTBOARD INSTALLATION SMARTCRAFT HARNESS CONNECTION If SmartCraft gauges are being used with the outboard, route the SmartCraft wiring harness through the grommet and connect it to the SmartCraft harness connector on the engine. 23700 SmartCraft harness connector WATER PRESSURE TUBE CONNECTION If a water connection to the engine is required for a water pressure gauge, make the connection as follows:...
  • Page 114 OUTBOARD INSTALLATION 1. The water pressure tube is coiled and attached on the side of the engine. Cut the cable tie and route the water pressure tube out through the grommet. 23702 Water pressure tube 2. Remove the plug from the coupler and make the connection. A barb fitting (22‑859731) can be installed for larger diameter hose connection.
  • Page 115 OUTBOARD INSTALLATION FUEL HOSE CONNECTION Remote Fuel Hose Size Minimum fuel hose inside diameter (ID) is 8 mm (5/16/in.) with separate fuel hose/fuel tank pickup for each engine. Fuel Hose Connection Fasten the remote fuel hose to the fitting with a hose clamp. 23709 Hose clamp Remote fuel hose...
  • Page 116 OUTBOARD INSTALLATION 3. Measure the distance between pin and center of barrel pocket. 23720 Distance between pin and center of lower hole Barrel pocket 4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain distance measured in Step 3. 23721 Shift cable end Cable barrel...
  • Page 117 OUTBOARD INSTALLATION 5. Place the cable barrel into the pocket. Fasten the cable with locknut and flat washer. 7736 Cable barrel Flat washer Locknut 6. Check shift cable adjustments as follows: a. Shift the remote control into forward. The propeller shaft should be locked in gear.
  • Page 118 OUTBOARD INSTALLATION 1. Position remote control into neutral. 26838 2. Install the throttle cable to the throttle arm with a flat washer and locknut. Tighten the locknut, then back off the locknut 1/4 turn. 3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.

  • Page 119: Oil Injection Set-Up

    Fluid Type Oil tank 4.72 liters (5 qt.) Optimax/DFI 2‑Cycle Engine Oil PRIMING THE OIL INJECTION PUMP Before starting engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages.

  • Page 120: Trim In Pin

    OUTBOARD INSTALLATION Prime the oil injection pump as follows: 1. Fill the engine fuel tank with fuel. NOTE: Use the primer bulb located in the fuel hose to the engine to draw fuel from the tank to fill the engine fuel system. 2.
  • Page 121 OUTBOARD INSTALLATION Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to be trimmed further in or under. This greater trim under capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations.

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