1. Mercury Outboard Service Manual 200hp Saltwater Crocodile
2. Mercury Outboard Service Manual 200hp Saltwater Fish
3. Mercury 200 Service Manual

. 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. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA. TABLE OF CONTENTS Warranty Information Transfer Of Warranty.1 Warranty Registration United States And Canada.

View and Download Mercury 150 manual online. 150 Outboard Motor pdf manual download. Also for: 200. Outboard Motor Mercury 140 Service Manual (64 pages) Outboard Motor Mercury 135 Optimax User Manual. GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND. Outboard Motors We offer the most-complete line of outboard power, for fishing boats and speed boats, for pontoons and tenders, for work and for play. Mercury Outboards – Durable. Buy Mercury Engine Repair and Maintenance Manual, All 2 Stroke Engines, 2001 to 2009: Boat Motors - Amazon.com ✓ FREE DELIVERY possible on eligible.

1 Warranty Registration Outside The United States And Canada. 1 Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States.2 Outboard Limited Warranty (Middle-East, and Africa).3 3 Year Limited Warranty Against Corrosion. TABLE OF CONTENTS Operation Pre-Starting Check List.

29 Operating In Freezing Temperatures.29 Operating In Salt Water Or Polluted Water. 29 Operating at High Elevations. 29 Setting Trim Angle While Running Engine at Idle Speed.29 Engine Break-in Procedure.30 Starting The Engine. TABLE OF CONTENTS Parts And Accessories Inquiries.51 Service Assistance.51 Mercury Marine Service Offices.51 Outboard Installation Important Information.53 Avoiding Fuel Flow Restriction.53 Electric Fuel Pump.53 Boat Horsepower Capacity.53 Start in Gear Protection.54 Selecting Accessories For Your Outboard. 54 Fuel Tanks. Warranty Registration United States And Canada 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. 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.

Warranty coverage becomes available upon proper registration of the product by the authorized dealer. 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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. 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 re–manufactured 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. 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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration. WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. Water entering engine through the fuel intake, air intake or exhaust system or submersion. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high or trimmed too far out.

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. 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 authorized Mercury dealer.

RPM is within the recommended range, select a replacement or upgrade propeller with the same pitch as the current propeller. Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200. Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200. GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral.

WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. GENERAL INFORMATION The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. 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 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. 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. GENERAL INFORMATION Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. GENERAL INFORMATION WARNING Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death. GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

21622 Example of desired air flow through the boat POOR VENTILATION. 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 maintenance manuals for all your selected accessories. 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 XXXXXXXX XXXX RP M 23884 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) Specifications Models Horsepower. GENERAL INFORMATION Component Identification 3403 Top cowl Auxiliary tilt switch Bottom cowl Transom brackets Water pump indicator hole Gearcase Driveshaft housing Cooling water intake holes Anti-ventilation plate. 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.

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 IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended.

If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3. FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. 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. 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.

FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations.

For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following. Warning Horn Function Sound. 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, battery voltage, fuel consumption and engine operating hours. FEATURES AND CONTROLS Consider the following lists carefully. Trimming In or Down Can:.

Lower the bow. Result in quicker planing off, especially with a heavy load or a stern heavy boat.

Generally improve the ride in choppy water. FEATURES AND CONTROLS NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard. 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. OPERATION Engine Break-in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. GASOLINE/OIL BREAK-IN MIXTURE Do not use pre-mixed gas and oil during break-in. Oil from the oil injection system will supply adequate lubrication during engine break-in. OPERATION Squeeze the fuel line primer bulb several times until it feels firm. 19779 Set the lanyard stop switch to 'RUN' position. Refer to General Information - Lanyard Stop Switch.

19791 Shift outboard to neutral 'N' position. Ob00351 NOTE: It is not necessary to use the neutral fast idle speed feature on the remote control to increase engine speed for starting and warm up. OPERATION. Your outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R).

When shifting, always stop at neutral position and allow the engine speed to return to idle. Always shift outboard into gear with a quick motion. 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. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure. MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE. Check that the lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom. Check steering system for binding or loose components.

MAINTENANCE Remove the plug from fitting in the bottom cowl. Ob01084 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes.

Ob01085 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. Ob01086 Lift up the rear cowl latch.

MAINTENANCE Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. MAINTENANCE WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn.

This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Ob00676 Special washer head bolt (10-849838) Nylon insert locknut (13) Flat washer (2) Nylon insert locknut (13). MAINTENANCE 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. 3395 Good fuse Accessories - 20 AMP fuse Blown fuse Ignition coil circuit - 20 AMP fuse SmartCraft data bus circuit - 5 AMP. MAINTENANCE Make sure the battery is secure against movement.

Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. Make sure the battery is equipped with a non-conductive shield to prevent accidental shorting of battery terminals. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. MAINTENANCE 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 Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications. 1/4 turn or torque to specifications. Description lb. Spark plug Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants Special Lubricant 101.

Description Where Used Part No. Special Lubricant 101. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. Ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. Description Where Used Part No.

MAINTENANCE. Tilt Support Lever - Lubricate through fitting. Ob00683 Swivel bracket Tilt support lever.

Tilt Tube - Lubricate through fitting ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. 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. Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 fl. GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant.

CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug. 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).

STORAGE. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Description Where Used Part No. Corrosion Guard External metal surfaces 92-802878Q55 Gearcase.

Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase Lubrication). 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. TROUBLESHOOTING. Damaged or improper size propeller. Incorrect engine timing, adjustments, or setup.

Boat overloaded or load improperly distributed. Excessive water in bilge. Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES. Should you have a question, concern, or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance.

Mercury Marine will work with you and your dealership to resolve all problems. Telephone (954) 744-3500 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. 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. Mercury or Quicksilver Premium 2-Cycle TC-W3 Outboard Oil IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil.

Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended.

If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3. 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. OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine center line for dual engine - 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33-3/8 in.) Dual engine 151.8 cm (59-3/4 in.) Lifting the Outboard WARNING Avoid possible serious injury or death. Before lifting the outboard, 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.

OUTBOARD INSTALLATION Lifting Eye 91-90455-1 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing, or to lift entire engine for removal/ installation. 2756 Steering Cable - Starboard Side Routed Cable Lubricate O-ring seal and entire cable end. 3724 Tube Ref No. OUTBOARD INSTALLATION Torque nut to specification. 3727 Description lb. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10-849838) and self-locking nylon insert locknuts (P/N 13).

OUTBOARD INSTALLATION WARNING Avoid equipment damage, serious injury or death. Visually inspect all steering attachment components for wear, lubricate all attachment hardware, and check for proper torque tightness in accordance with the inspection and maintenance schedule. Or79 Special washer head bolt (P/N Flat washer (2) 10-849838) Nylon Locknut - used on cable coupler. OUTBOARD INSTALLATION 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.) 24305 The solid line is recommended to This line may be preferred to determine determine the outboard mounting outboard mounting height dimension for. OUTBOARD INSTALLATION 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 Drill four 13.5 mm (17/32 in.) mounting holes. 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 1/2-1 Washer - Inner 0.516 in.

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.

OUTBOARD INSTALLATION Electrical, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove screws and open the front clamp assembly. 7644 Screw (2) Front clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp.

Connect remote harness to the 14 pin connector on the engine harness. OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard or86 Red sleeve - positive (+) Cranking battery Black sleeve - negative (–) Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. Or87 Red sleeve - positive (+) Ground cable. OUTBOARD INSTALLATION FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel Hose Size - Minimum fuel line inside diameter (I.D.) is 8mm (5/16 in.), with separate fuel line/fuel tank pickup for each engine. Fasten remote fuel hose to fitting with hose clamp. Connect the remote oil hoses to the engine hose connections. OUTBOARD INSTALLATION Make the water pressure gauge hose connection to this tubing as follows: 7728 Speedometer water pick-up tube Barb hose fitting Water pressure tube Speedomer hose Coupler Water pressure tube Plug Shift and Throttle Cable COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gearcases can be identified by a 'L' stamped into the end of the propeller shaft.

OUTBOARD INSTALLATION On counter rotation outboards, the shift linkage moves in the opposite direction compared to a standard rotation outboards. 24498 Standard rotation outboards Forward gear Reverse gear 24497 Counter rotation outboards Forward gear Reverse gear Installing the Shift Cable IMPORTANT: The shift cable is the first cable to move when the remote control handle is moved out of neutral, so install/connect it to the engine first. OUTBOARD INSTALLATION Mark the reverse position as follows: a. Move the remote control handle into reverse and advance the handle to the full speed position. Ensure that the throttle control lever is touching the throttle control lever stop screw. Slowly return the handle back to the neutral detent position. OUTBOARD INSTALLATION ADJUSTING THE SHIFT CABLE To adjust the shift cable: Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable.

4362 Center mark Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder. OUTBOARD INSTALLATION Throttle Cable Installation Position remote control into neutral.

Ob00351 Attach throttle cable to the throttle lever. Secure with washer and locknut. 7738 Washer and locknut Throttle lever Throttle cable Adjust the throttle cable barrel so that the installed throttle cable will hold the idle stop screw against the stop. OUTBOARD INSTALLATION IMPORTANT: The idle stop screw must be touching the stop. 7740 Idle stop screw Idle stop Lock the barrel holder in place with the cable latch.

Front Clamp Reassembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched. OUTBOARD INSTALLATION Fasten clamp together with two screws.

7644 Screw (2) Front clamp Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: Squeeze the fuel line primer bulb until it feels firm. OUTBOARD INSTALLATION Remove cap and fill engine oil tank with oil. Reinstall the fill cap. 7745 Engine oil tank Fill cap PRIMING THE OIL INJECTION PUMP Before starting the 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. OUTBOARD INSTALLATION Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until it feels firm. 19779 Turn the ignition key switch to the 'ON' position. Ob00364 Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times. OUTBOARD INSTALLATION 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 Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque to specifications.

OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow- down planing condition called plowing. Plowing can cause bow steering or over steering and inefficiently consumes horsepower. Or116 Tilt pin (not included with engine) Stainless Steel Tilt Pin 17-49930A 1 Limits the down trim angle of the power trim.

. 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. Det Norske Veritas AS Veritasveien 1 1322 Hovik Norway Notified Body Number: 0575 Combustion cycle: 2 Engine type: Fuel type: Brands: Outboard Gasoline stroke, direct injection Mercury, Mariner Module H Starting Engine Manufacture Noise and Horsepower Serial Family Location Exhaust Number Certificate Optimax 1.5. This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe.

Mackey President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006. European Regulations Contact: Regulations and Product Safety Department, Mercury Marine. 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 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. TABLE OF CONTENTS Fuel and Oil Fuel Recommendations.33 Oil Recommendation.34 Fuel Additives.35 Fuel Requirements.35 Avoiding Fuel Flow Restriction.35 Filling Remote Oil Tank.35 Filling Engine Mounted Oil Reservoir Tank.36 Filling Fuel Tank.36 Features and Controls Remote Control Features.37 Warning System.38 Power Trim and Tilt.41 Operation Pre‑Starting Check List.45 Operating In Freezing Temperatures. TABLE OF CONTENTS Alternator Belt Inspection.56 Fuel System.56 Steering Link Rod Fasteners.59 Fuse Replacement.60 Corrosion Control Anode.62 Battery Inspection.62 Battery Information.63 Propeller Replacement.64 Spark Plug Inspection and Replacement.67 Compressor Air Intake Filter.68 Lubrication Points.70 Checking Power Trim Fluid.74 Gearcase Lubrication. TABLE OF CONTENTS Service Assistance.83 Mercury Marine Service Offices.84 Outboard Installation Important Information.86 Avoiding Fuel Flow Restriction.86 Boat Horsepower Capacity.87 Start in Gear Protection.87 Selecting Accessories For Your Outboard. 87 Fuel Tanks.88 Filling the Fuel System.88 Installation Specifications.89 Lifting the Outboard.89 Steering Cable ‑.

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. 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.

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. 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. 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. 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. 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.

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. 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.

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.

Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal.

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. 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.

For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. 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. 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.

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. GENERAL INFORMATION 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. GENERAL INFORMATION The lanyard is a cord usually 122 ‑ 152 cm (4 ‑ 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power. 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 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.

However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water. GENERAL INFORMATION 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. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward. 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.

Exhaust Emissions. GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 21622 Example of desired air flow through the boat 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. 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 maintenance manuals for all your selected 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. GENERAL INFORMATION 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.

A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is. GENERAL INFORMATION Models Recommended Spark Plug NGK IZFR5G Spark Plug Gap 0.80 mm (0.031 in.) Standard Gearcase Ratio 1.75:1 High Altitude Gearcase Ratio 1.87:1 Recommended Gasoline Refer to Fuel & Oil Recommended Oil Refer to Fuel & Oil Gearcase Lubricant Capacity 769 ml (26 fl. GENERAL INFORMATION Component Identification 29423 Top cowl Anode plate Bottom cowl Auxiliary tilt switch Water pump indicator Transom brackets hole Gearcase Driveshaft housing Cooling water intake Anti‑ventilation plate holes. 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 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 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. Severe engine damage may result from use of an inferior oil. FUEL AND OIL 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.

Remove the top cowl. Loosen the fill cap on the engine oil reservoir tank. Run the engine until all the air has been vented out of the oil reservoir tank and tank is filled with oil to the point of overflow. 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 ‑. 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. FEATURES AND CONTROLS Warning Horn Function Sound Description Water in Fuel Four Beeps every 2 Water in the water Minutes separating fuel filter reaches the full level. Water can be removed from the filter.

Refer to Maintenance - Fuel System for filter removal. Moving the throttle lever back to the idle position will reset the system. 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. 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.

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. 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.

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. 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. 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. 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 pre‑mixed gas and oil during break‑in. Use straight gasoline during engine break‑in and after engine break‑in.

OPERATION Starting the Engine Before starting, read the pre‑starting check list, special operating instructions, and engine break‑in procedure in the Operation section. NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Provide a sufficient supply of water at the water inlets during operation. OPERATION 4.

Set the lanyard stop switch to the 'RUN' position. Refer to General Information ‑ Lanyard Stop Switch.

Shift outboard to the neutral ('N') position. 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. OPERATION 8.

Turn the ignition key to 'START' position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to 'OFF' position, wait one second and try again.

19804 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting. OPERATION. After shifting outboard into gear, advance the lever further to increase speed. 27237 Stopping The Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to 'OFF' position. 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. 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. 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. MAINTENANCE NOTE: Engine can be stopped or running at idle speed when flushing the cooling system.

Do not flush engine using a water system that exceeds 310.26 kPa (45 psi). Remove the plug from fitting in the bottom cowl.

MAINTENANCE CLEANING AND WAXING PROCEDURE 1. Before washing, rinse the top cowl with clean water to remove dirt and dust that may scratch the surface. Wash the top cowl with clean water and a mild non‑abrasive soap. Use a soft clean cloth when washing.

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. MAINTENANCE Installation 1. Lubricate the O‑ring seals with oil. 29599 Filter Link rod O‑ring seals 2. Install the fuel filter and tighten securely. Reconnect the link rod.

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.

MAINTENANCE 3. Retighten the drain screw and reattach hose. 24607 Drain hose Drain screw Side fitting IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the chamber. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ('a'. 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. 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.

MAINTENANCE Corrosion Control Anode Your outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion. MAINTENANCE IMPORTANT: Read the safety and maintenance instructions which accompany your battery. Turn off the engine before servicing the battery. Add water, as necessary, to keep the battery full.

Make sure the battery is secure against movement. MAINTENANCE Decal needs to be placed on or near battery box for future service reference. And one 3/8 in. Hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting.

MAINTENANCE 2. Remove spark plug leads to prevent engine from starting. Straighten the bent tabs on the propeller nut retainer. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut.

MAINTENANCE 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref No.

Description Where Used Part No. Anti-Corrosion 92-802867Q Propeller shaft Grease 2-4-C Marine Propeller shaft 92-802859A1 Lubricant with Teflon. MAINTENANCE 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. 26941 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub 9.

MAINTENANCE 1. Remove the spark plug leads. Twist the rubber boots slightly and pull off. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled.

MAINTENANCE IMPORTANT: Never run the engine without the compressor air intake filter. Open the clamp and lift out the filter housing. Rotate the filter housing 1/4 turn clockwise to the unlock position and remove the air filter. Remove the hose cable tie and and pull the air filter off the hose. Reinstall the hose and secure with a cable tie. Secure the filter housing with the clamp. Lubrication Points 1.

Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Description Where Used Part No. MAINTENANCE. Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets.

Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Description Where Used Part No. MAINTENANCE Tube Ref No. Description Where Used Part No.

Alternator belt tensioner pivot shaft, 2-4-C with Teflon swivel bracket, tilt 92-802859A1 support lever, tilt tube, steering cable. Alternator Belt Tensioner Pivot Shaft ‑ Lubricate through fitting.

2884. Swivel Bracket ‑ 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. 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. GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity approximately 970 ml (32.8 fl.

GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. Remove vent plug/sealing washer.

MAINTENANCE 3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.

22693 Vent hole Fill hole IMPORTANT: Replace sealing washers if damaged. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube.

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.

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. Premix the following in a container: a. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Quickleen lubricant. 8 cc (0.27 oz.) or 2 teaspoons of Mercury Precision Fuel Stabilizer.

Remove the fuel filter. See Maintenance - Fuel System for procedure. Pour this mixture into the fuel filter opening. Reinstall the fuel filter. Prime the fuel system. See Operation - Starting The Engine. 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). Description Where Used Part No. 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. 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.

Engine fuel filter is obstructed. Refer to Maintenance section. Fuel tank filter obstructed. 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. 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. 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. IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3.

The use of an inferior 2‑Cycle outboard oil can reduce engine durability. The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting in gear. Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard. OUTBOARD INSTALLATION 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. OUTBOARD INSTALLATION Installation Specifications 18552 Minimum transom opening Engine center line for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33‑3/8 in.) Dual engine 151.8 cm (59‑3/4 in.) Lifting the Outboard WARNING Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death.

OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. 28495 Lifting eye 3. Connect a hoist to the lifting eye. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead assembly. OUTBOARD INSTALLATION 2.

Insert steering cable into tilt tube. Torque nut to specification. 3727 Description lb. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cables to the engine must be fastened using special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 13). OUTBOARD INSTALLATION 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.

OUTBOARD INSTALLATION 3. Torque the head bolt, then the locknut to specifications. Description lb. Tighten locknut until it seats, then Cable Coupler Nylon Locknut 'd' loosen ¼ turn.

Head Bolt Nylon Locknut 'b' Special washer head bolt. OUTBOARD INSTALLATION 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.) 24305 The solid line is recommended to determine the outboard mounting height. 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. 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.

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 1/2‑1 Washer ‑. OUTBOARD INSTALLATION When first determining transom strength, use a dial torque wrench.

If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate.

OUTBOARD INSTALLATION NOTE: For more accurate torque, whenever possible turn/tighten the mounting locknuts rather than turning the mounting bolts. 3729 Flat washer (4) Locknut (4) 1/2 in. Diameter bolt Flat washer (4) Shank of bolt Description lb. Outboard mounting locknuts and bolts. OUTBOARD INSTALLATION Electrical, Hoses, Control Cables and Front Clamp REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp opening in the bottom cowl. Connect remote harness to the 14 pin connector on the engine harness. 28742 14 pin connector BATTERY INFORMATION.

OUTBOARD INSTALLATION Decal needs to be placed on or near battery box for future service reference. And one 3/8 in. Hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied. NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES!

Mercury Outboard Service Manual 200hp Saltwater Crocodile

DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting. 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 (–) HOSE AND TUBING CONNECTIONS Fuel Hose The minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with a separate fuel line/fuel tank pickup for each engine. OUTBOARD INSTALLATION This outboard has a speedometer water pick‑up located in the leading edge of the gearcase. If you want to use this water pickup for the speedometer, disconnect the water pickup tubing from the speedometer sensor and route tubing out of the cowl. Install the coupler provided with the outboard on the end of the tubing. OUTBOARD INSTALLATION Locating the Center Point of the Shift Cable IMPORTANT: Locate the center point of the slack or lost motion that exists in the shift cable for proper adjustment of the shift cable. Mark the forward position as follows: a.

OUTBOARD INSTALLATION 3. Mark the center on the shift cable midway between the forward and reverse marks. 4361 Center mark 4. Align the cable end guide against this center mark when installing the cable to the engine. Position the remote control and outboard into neutral position. OUTBOARD INSTALLATION 2. Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder.

Mercury Outboard Service Manual 200hp Saltwater Fish

Secure the shift cable to the anchor pin with the retainer clip. 28749 Cable barrel Retainer clip. OUTBOARD INSTALLATION 2. Attach the throttle cable to the throttle lever. Secure with a washer and locknut. Tighten the locknut to the specified value.

Or107 Nylon washer Locknut Description lb. Throttle cable locknut 'b' Tighten then loosen 1/4 turn. OUTBOARD INSTALLATION c. Place a thin piece of paper between the idle adjustment screw and the idle stop.

The adjustment is correct when the paper can be removed without tearing, but has some drag on it. IMPORTANT: The idle stop screw must be touching the stop. Or109 Idle stop screw Idle stop.

OUTBOARD INSTALLATION 2. Place the neoprene wrap around the wiring, hoses, and control cables, and place into the lower half of the front clamp. 29073 Neoprene wrap Lower half of the front clamp 3. Join the top half of the front clamp with the bottom half. Secure both halves together with cables ties. OUTBOARD INSTALLATION 5.

Mercury 200 Service Manual

Reinstall the cowl seal. 29075 Retainer Filling the Fuel System When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system. To fill and prime the fuel system: 1. OUTBOARD INSTALLATION Oil Injection Set‑Up FILLING OIL SYSTEM 1.

Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual. Tighten fill cap. 2683 Fill cap 2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.

OUTBOARD INSTALLATION PRIMING OIL INJECTION PUMP Before starting the 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. 3768 Oil supply hose Oil injection pump IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump. OUTBOARD INSTALLATION d.

Turn the ignition key switch to the 'ON' position for three seconds. This operates the electric fuel pump. Turn the ignition key switch back to the 'OFF' position, and squeeze the primer bulb again until it feels firm. 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.