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135/150/175 Optimax - Brunswick Marine in EMEA

1. INTERNATIONAL Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 9ORON Automotive gasolines that contain fuel injector cleaner are preferred for added internal engine cleanliness Leaded gasoline is acceptable in areas where unleaded gasoline is not available USING REFORMULATED OXYGENATED FUELS UNITED STATES ONLY This type of fuel is required in certain areas of the United States The two types of reformulated ingredients in these fuels are alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenates that is used in the gasoline refer to Alcohol in Gasoline These reformulated fuels are acceptable for use in the Mercury engine ALCOHOL IN GASOLINE We do not recommend the use of gasoline which contains alcohol because of the possible adverse effect the alcohol may have on the fuel system In general if only gasoline containing alcohol is available it must not contain more than 1096 ethanol or 596 methanol and the addition of a water separating fuel filter is recommended If gasoline containing alcohol is used or if you suspect the presence of alcohol in your gasoline increase your inspection of the fuel system visually checking for fuel leaks or abnormalities Gasoline containing alcohol may cause the following problems to your outboard and fuel system Corrosion of metal parts Deterioration of elastomers and plastic parts Wear and damage of internal engine parts Start
2. Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required 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 Upon receipt of this warranty registration Mercury Marine will record the registration Upon processing the warranty registration Mercury Marine will send registration verification by mail to the purchaser of the product If this registration verification is not received within 30 days please contact your selling dealer immediately Warranty coverage is not effective until your product is registered with Mercury Marine Warranty Registration Outside The United States And Canada 1 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and address product model and serial numbe
3. 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 35 MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE Check that 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 Visually check steering link rod fasteners for proper tightness See Steering Link Rod Fasteners Check propeller blades for damage AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in salt water EVERY 100 HOURS OF USE OR ONCE YEARLY WHICHEVER OCCURS FIRST Lubricate all lubrication points Lubricate more frequently when used in salt water See Lubrication Points Replace spark plugs at first 100 hours or first year After that inspect spark plugs every 100 hours or once yearly Replace spark plugs as needed See Spark Plug Inspection and Replacement Replace water separating fuel filter See Fuel Sys
4. Product information following Start Up Normal System Test Low Oil Reserve Four Beeps every 2 Minutes Oil lever is low in the engine mounted oil reservoir Refill the engine mounted oil reservoir along with the remote oil tank Refer to Fuel amp Oil Water in Fuel Four Beeps every 2 Minutes Water in the water separating fuel filter reaches the full level Water can be removed from the filter Refer to Maintenance Fuel System for filter removal Cooling System Problem Continuous Engine Guardian System is activated Power limit will vary with level of overheat Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole If no water is coming out of the water pump indicator hole or flow is intermittent stop engine and check water intake holes for obstruction The Guardian System must be RESET before engine will operate at higher speeds Moving throttle lever back to idle resets the system Oil Level is Critically Low Continuous Engine Guardian System is activated Power will be limited The oil level is critically low in the engine mounted oil reservoir Refill the engine mounted oil reservoir along with the remote oil tank Oil Pump Failure Continuous Engine Guardian System is activated Power will be limited The warning horn is activated if the oil pump should ever stop functioning electrically No lubricating oil is being supplied to the engine 25 FEATURE
5. adjust the position of the outboard by pressing the trim switch Moving the outboard in closer to the boat transom is called trimming in or down Moving the outboard further away from the boat transom is called trimming out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating your boat on plane The term tilt is generally used when referring to adjusting the outboard further up out of the water With the engine turned off the outboard can be tilted out of the water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation 26 FEATURES AND CONTROLS ob00663 a Trim switch c Trim range of travel b Tilt range of travel POWER TRIM OPERATION With most boats operating around the middle of the trim range will give satisfactory results However to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out Along with an improvement in some performance aspects comes a greater responsibility for the operator and this is being aware of some potential control hazards The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface Avoid possible
6. cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 14 GENERAL INFORMATION WHILE BOAT IS STATIONARY 0b00317 a Running the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine running WHILE BOAT IS MOVING 0b00318 a Running the boat with the trim angle of the bow too high b Running the boat with no forward hatches open Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard These accessories are available from Mercury Marine dealers Check with your dealer before installation of accessories The misuse of acceptable accessories or the use of unacceptable accessories can result in serious injury death or product failure 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 oafe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and othe
7. designed flotation characteristics of the boat or 3 cause the boat to break apart particularly around the transom area Overpowering a boat can result in serious injury death or boat damage Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer GENERAL INFORMATION U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 0b00306 High Speed And High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat outboard combination For additional information obtain a copy of our Hi Performance Boat Operation booklet part number 90 849250 1 from your dealer distributor or Mercury Marine 0b00307 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 Avoid serious injury or death from a
8. out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty Mercury Marine Two Years Limited Warranty Europe WHAT IS COVERED Mercury Marine warrants each new Mercury Outboard Mariner Outboard Jet Products Thruster Electric Trolling Motors Mercruiser Inboard or Sterndrive engine products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for two 2 years from the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial users of these products receive warranty coverage of two 2 years from the date of first retail sale or the accumulation of 500 hours of operation whichever occurs first Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can
9. product is first put into service whichever occurs first Commercial users of these products receive warranty coverage of one 1 years from the date of first retail sale or the accumulation of 500 hours of operation whichever occurs first Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to a subsequent purchaser upon proper re registration of the product WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial unless properly re registered may void the warranty at the sole discretion of Mercury Marine Routine mai
10. range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboards durability Check full throttle RPM using an accurate tachometer with the engine trimmed out to a balanced steering condition steering effort equal in both directions without causing the propeller to break loose 20 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 0b01074 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propeller from spinning freely 21 FUEL AND OIL Gasoline Recommendations UNITED STATES AND CANADA Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 87 Mid grade automotive gasolines that contain fuel injector cleaner are preferred for added internal engine cleanliness Leaded gasoline is not recommended
11. rough or uneven c Signs of wear on edges or outer surfaces of belt 46 MAINTENANCE Lubrication Points 0b01560 1 Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101 Trim Rod Ball Ends Turn the ball ends to work the lubricant into the ball sockets 2 0b01093 Teflon Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 0600378 3 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Alternator Belt Tensioner Pivot Shaft Lubricate through fitting 0b01561 Swivel Bracket Lubricate through fitting 47 MAINTENANCE Tilt Support Lever Lubricate through fitting 0b00683 a Swivel bracket b Tilt support lever Tilt Tube Lubricate through fitting 0b00684 The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked A hydraulically locked steering cable will cause loss of steering control possibly resulting in serious injury or death Steering Cable Rotate st
12. serious injury or death When the outboard is trimmed in or out beyond a neutral steering condition a pull on the steering wheel or tiller handle in either direction may result Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely The boat can now spin out or go into a very tight maximum turn which if unexpected can result in occupants being thrown within the boat or out of the boat Consider the following lists carefully 1 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 Increase steering torque or pull to the right with the normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered 27 FEATURES AND CONTROLS Avoid possible serious injury or death Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle In
13. warranty are The jet drive impeller and jet drive liner damaged by impact or wear and water damaged drive shaft bearings as a result of improper maintenance 3 Damage caused by neglect lack of maintenance accident abnormal operation or improper installation or service 4 Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reasonable access must be provided to the product for warranty service Customer must deliver product to an authorized dealer 5 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 10 11 12 13 14 15 16 WARRANTY INFORMATION Labor performed by other than an authorized dealer may be covered only under following circumstances When performed on emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work performed at this facility 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 norma
14. water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard Battery Storage Follow the battery manufacturer s instructions for storage and recharging Remove the battery from the boat and check water level Recharge if necessary Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage 52 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 Ignition key switch failure Wiring or electrical connection faulty Starter motor solenoid or slave solenoid failure Engine Will Not Start POSSIBLE CAUSES Lanyard stop switch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty e Fuel filter is obstructed Refer to Maintenance section Fuel pump failure Fuel tank filter obstructed Open 20 amp fuse Check fuses refer to Maintenance section Threaded connection of an air hose is loose Ig
15. 0 Operating In Freezing Temperatures ENEE 30 Operating In Salt Water Or Polluted Web eege A A iia 30 Operating ac High Elevation EE 30 Setting Trim Angle While Running Engine at Idle Gpoeed ANNE 30 Engine Break WE een UE 31 Starting The an gle gls eee eee T Ed 31 E en Lda Le DEE EE 33 SLOP PING D Ba ne UE 34 Maintenance COULD OSG e 35 EPA EMISSIONS EE 35 Inspection And Maintenance Schedule ANEN EEN 36 FISHING Ree ue E EE 36 Top Cowl Removal Ard In talla EE 37 Cleaning Gare for Top COW EE 38 Flywheel Cover Removal and Installation 2 erai rii eter aene nune ra rnnt d nod aan nnd eti 38 SIE RE 38 Steering ink ROG EE E 39 FUSE Replacements sn AD A AA IR IEA 40 Corrosion GOTO ANDE masticar dida TA Multa dca daa 41 Battery INSPECCIONES 41 Battery Informationer caro NS A a Oe 42 Propeller Replacement niii EA 43 Spark Plug Inspection AndJREplACeMO NM ecdvisssiccccascannnetuearaavederssabiede cavsvaarannnsrsetuecdecedawetiacdssvseiunnnnlsessaedidaaeatuness 45 Compressor Air Intake EE 46 Alternator BeltINS pe e WEEN 46 LUDFIGATION POIS EE 47 Gearcase CUDNCAUON e 49 UMS MO Ujiole s 19 DEE 50 Storage Storage Prepara si N aa 51 Protecting Internal Engine Components ENEE 51 Protecting External Outboard GCompOFerits ss Ee 51 ET e A S O ree Tyree Ri re eo TT te S 51 Positioning Outboard FOF Str AAA a 52 Bae gre ie f Le EE 52 TABLE OF CONTENTS Troubleshooting Starter M
16. 3 INSTALLATION 1 Lower top cowl into position over engine 2 Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front 37 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 2 Wash the top cowl with clean water and a mild non abrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a non abrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth Flywheel Cover Removal and Installation REMOVAL 1 Remove the flywheel cover by lifting off 2 Pull out the vent hose INSTALLATION 1 Install flywheel cover as follows a Place cover onto the front flange b Push rear of the cover down onto the rear pin and air intake tube for the air compressor c Insert vent hose into hole IMPORTANT Make sure the flywheel cover is pushed down on the air intake tube for the air compressor A IOn oy P A gt TERM a e LA N li AJ A S D I Sis y S GC Hi A LN AE TIR y TNE E E Se Xy IE TO g e Z e 0b01557 a Front
17. ECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug 3 Remove fill drain plug Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole 49 MAINTENANCE a Vent plug c Fill drain plug b Vent hole IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine 50 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 Never start or operate your outboard even momentarily without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump running dry or overheating of the engine FUEL SYSTEM IMPORTANT Gasoline containing alcoh
18. ND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY 3 Year Limited Warranty Against Corrosion WHAT IS COVERED Mercury Marine warrants that each new Mercury Mariner Mercury Racing Sport Jet M2 Jet Drive Tracker by Mercury Marine Outboard MerCruiser Inboard or sterndrive engine Product will not be rendered inoperative as a direct result of corrosion for the period of time described below DURATION OF COVERAGE This limited corrosion warranty provides coverage for three 3 years from either the date the product is first sold or the date on which the product is first put into service whichever occurs first The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to subsequent non commercial use purchaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the O
19. O HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY Warranty Coverage And Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The following information explains some of the types of services that are not covered by warranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure the International Limited Outboard Warranty and the United States and Canada Limited Outboard Warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship Installation errors accidents normal wear and a variety of other causes that affect the product are not covered Warranty is limited to defects in material or workmanship but only when the consumer sale is made in the country to which distribution is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection with normal services 2 Factory installed jet drive units Specific parts excluded from the
20. S AND CONTROLS Engine Overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum allowable RPM The system will limit the engine speed to within the allowable range Engine overspeed indicates a condition that should be corrected Overspeed could be caused by incorrect propeller pitch engine height trim angle etc Sensor out of Range Continuous Engine Guardian System is activated Power will be limited Intermittent Beep ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems The system will respond to a problem by emitting a continuous beep and or reducing engine power in order to provide engine protection If Guardian System has been activated reduce throttle speed The horn will turn off when throttle speed is within the allowable limit 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 The SmartCraft Instrument package will also aid in Engine Guardian diagnostics The SmartCraft Instrument package will display critical engine alarm data and potential problems Power Trim And Tilt Your outboard has a trim tilt control called power trim This enables the operator to easily
21. 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 nearest dealer can be found on 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 If the outboard motor s serial number plate contains the CE mark in the lower left hand corner the following statement applies This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industrel de Petit Rechain Belgium complies with the requirements of the following directives and standards as amended Recreational Craft Directive 94 25 EC std ISO 8665 ISO 11547 Machinery Directive 98 37 EC EMC Directive 89 336 EC std EN50081 1 SAE J551 CISPR Pub 12 EN 50082 1 IEC 61000 PT4 2 IEC 61000 PT4 3 fe Patrick C Mackey President Mercury Marine Fond du Lac WI USA European Regulations Contact Product Environmental Engineering Department Mercury Marine Fond du Lac WI USA 90 10199050 204 135 150 175 Optimax 2004 Mercury Marine TABLE OF CONTENTS Warranty Info
22. ance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury death or product failure Record maintenance performed in 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 Using a replacement part that is inferior to the original part could result in personal injury death or product failure EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture EMISSION CONTROL Z ERCURY INFORMATION This engine conforms to L__ model year EPA regulations for Marine SI engines Refer to Owner s Manual for required maintenance IDLE SPEED L__ FAMILY ED hp E c we FE El gkwh TIMING IN DEGREES L 1 Standard spark plug LL Suppressor spark plug L GAP BEEN Intake 227 Valve Clearance Cold mm Exhaust MMMM a Idle speed f Family number b Engine horsepower g Maximum emission output for the engine c Timing specification family d Recommended spark plug and gap h Piston placement e Valve clearance if applicable i Date of manufacture
23. and 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 boat Falling over the front of the boat between the two pontoons will position them to be run over by the outboard BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water 0600312 Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over by the outboard 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 Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat 0b00313 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating However when this activity is done with
24. aser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage abuse or improper service corrosion to accessories instruments steering systems corrosion to factory installed jet drive unit damage due to marine growth product sold with less than a one year limited Product warranty replacement parts parts purchased by customer products used in a commercial application Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes WARRANTY INFORMATION Corrosion damage caused by stray electrical currents on shore power connections nearby boats submerged metal is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system such as the Mercury Precision Parts or Quicksilver MerCathode system and or Galvanic Isolator Corrosion damage caused by improper application of copper base ant
25. assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent w
26. be transferred to one recreational use to a subsequent recreational use customer upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is availble 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 Warranty coverage becomes available upon proper registration of the product by the authorized dealer Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial unless properly re registered may void the warranty at the sole discretion of Mercury Marine Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to maintain warranty coverage If this maintenance is performed by the retail customer Mercury Marine reserves the right to make future warranty coverage contingent on proof of proper maintenance 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
27. check cooling water intake holes for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system This condition will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage 0b00331 Gear Shifting IMPORTANT Observe the following Never shift outboard into gear unless engine speed is at idle Do not shift outboard into reverse when the engine is not running 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 After shifting outboard into gear advance the lever further to increase speed 33 OPERATION 0b00557 Stopping The Engine Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position OFF O A LYVLS ob00360 34 MAINTENANCE Outboard Care To keep your outboard in the best operating condition it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability Neglected inspection and maintenance service of your outboard or attempting to perform mainten
28. d motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking 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 0b0031 1 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury WHILE BOAT IS STATIONARY Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gearcase or any solid device rigidly attached to a moving boat or gearcase Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat 11 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 st
29. e 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 0b00329 a Control handle forward neutral reverse b Neutral release lever c Trim tilt switch if equipped Refer to Features amp Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch off on start h Fastidle lever Refer to Operation Starting the Engine i Throttle only button Refer to Operation Starting the Engine 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 ob00662 a Horn inside remote control b Horn connected to ignition key switch WARNING HORN SIGNALS When the key switch is turned to the ON position the horn will turn on for a moment as a test to show the horn is working 24 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
30. eats then back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt and self locking nylon insert locknut First torque bolt then torque locknut to specifications Fuse Replacement IMPORTANT Always carry spare 5 and 20 AMP fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same rating 40 MAINTENANCE a Good fuse b Blown fuse c SmartCraft data bus circuit 5 AMP fuse d Accessories 20 AMP fuse e Ignition coil circuit 20 AMP fuse f Electric fuel pump ECM driver power oil pump circuit 20 AMP fuse 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 eroded instead of the outboard metals 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 The gearcase has two corrosion control an
31. ed NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation 1 Turn out the manual tilt release valve 3 turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 28 FEATURES AND CONTROLS ob00665 SHALLOW WATER OPERATION When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes stay submerged at all times 3 Operate the engine at slow speed only If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system ob00666 a Auxiliary tilt switch 29 OPERATION Pre Starting Check List Operator knows safe navigation boating and operating procedures An approved personal flotation device of suitable size for each person aboard and readily accessible it is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know the boats maximum load capacity Look at the boat capacity plate Fuel supply OK Oil supply oil injection OK e Arrange passe
32. ed to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard 0b00310 a Lanyard cord b Lanyard stop switch Read the following Safety Information before proceeding 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 Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boats high performance boats and light sensitive handling fishing boats operated by a hand tiller Falling overboard and accidental ejections are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds standing at planing speeds sitting on elevated fishing boat decks operating at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel or tiller handle that is pulling
33. eering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting E 4 0b00685 a Fitting b Cable end 4 Lubricate the following with Light Weight Oil Steering Link Rod Pivot Points Lubricate pivot points 48 MAINTENANCE Gearcase Lubrication When adding or changing gearcase lubricant visually check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount of metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEARCASE 1 Place outboard in a vertical operating position 2 Place drain pan below outboard 3 Remove vent plug and fill drain plug and drain lubricant a Vent plug b Fill drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml 22 5 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant CH
34. en the engine life The engine automatically receives extra oil during the first hours of operation For most boaters this extra oil mode will be complete in about ten hours 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 Change engine speed approximately every two minutes and avoid continuous operation at idle speed for more than ten minutes Short bursts of full throttle for periods up to ten seconds are acceptable C Avoid trimming the outboard out up beyond a vertical trim position during operation NOTE It is the driver s responsibility to always drive in a safe manner Improper trim angle of the outboard when driving at speed can be difficult and dangerous The purpose of specifying trim angle is to help guide the operator in determining how to put the propel load on the engine They are intended to be guidelines and do not suggest or require unsafe boat operation 2 Forthe next three hours of operation change engine speed every ten minutes Starting The Engine Before starting read the Pre Starting Check List Special Operating Instructions and Engine Break in Procedure in the Operation Section Never start or operate your outboard even momentarily without water circulating through all the cooling water intake holes in the gearcase to prev
35. ent damage to the water pump running dry or overheating of the engine 1 Lower the outboard to the vertical operating position Make sure all cooling water intake holes are submerged 31 a OPERATION 0b00350 Shift outboard to neutral N position 0b00351 For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel the fuel system should be filled as follows a Squeeze the fuel line primer bulb until it feels firm b Turnthe ignition key switch to the ON position for three seconds This operates the electric fuel pump c Turnthe ignition key switch back to the OFF position and squeeze the primer bulb again until it feels firm Turn the ignition key switch to the ON position again for three seconds Continue this procedure until the fuel line primer bulb stays firm Do not advance the neutral fast idle speed feature on the remote control for starting 32 OPERATION ob00560 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 OFF 0b00354 NOTE The electronic starting system will automatically prime choke the engine and increase idle speed for starting 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
36. es when not in use 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 Operating at High Elevations Your engine automatically compensates for high elevation changes A different pitch propeller may help reduce some normal performance loss resulting from reduced oxygen in the air Consult your dealer Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full in while running at idle speed This will cause exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim the outboard up until the exhaust relief hole is out of the water The outboard should be lowered for accelerating from a standing start or from idle speed 30 OPERATION 0b01079 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 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 Incorrect engine break in can short
37. flange c Vent hose b Air intake tube Fuel System Avoid serious injury or death from gasoline fire or explosion Carefully follow all fuel system service instructions Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system 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 Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage 38 MAINTENANCE FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced WATER SEPARATING FUEL FILTER NOTE The warning system will turn on when water in the fuel filter reaches the full level See Features amp Controls Warning System The water separating fuel filter removes moisture and also debris from the fuel If the filter becomes filled with water the water can be removed If the filter becomes plugged with debris the filter must be replaced with a new filter hee quee NX 0b01089 1 Remove and replace filter as follows a Turn i
38. gnition key switch to OFF position b Disconnect wire at bottom of filter c Remove filter by turning the filter clockwise Tip the filter to drain fluid in a suitable container d Lubricate the sealing ring on the filter with oil Thread on the filter and tighten securely by hand Reconnect the wire to the filter IMPORTANT Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm forcing fuel into the filter 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 Part Number 10 849838 and self locking nylon insert locknuts c amp d Part Number 11 826709113 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage 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 39 MAINTENANCE 0b00676 a Special washer head bolt 10 849838 b Flat washer 2 c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 20 Nylon insert locknut c Tighten until seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and self locking nylon insert locknut Tighten locknut until it s
39. i fouling paints is also not covered by this limited warranty If anti fouling protection is required Tri Butyl Tin Adipate TBTA base anti fouling paints are recommended on Outboard and MerCruiser boating applications In areas where TBTA base paints are prohibited by law copper base paints can be used on the hull and transom Do not apply paint to the outboard or MerCruiser product In addition care must be taken to avoid an electrical interconnection between the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED INDURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALS
40. in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers 10 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 We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator 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 This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forwar
41. ing and operating difficulties Vapor lock or fuel starvation Some of these adverse effects are due to the tendency of gasoline containing alcohol to absorb moisture from the air resulting in a phase of water and alcohol which separates from the gasoline in the fuel tank The adverse effects of alcohol are more severe with methanol and are worse with increasing content of alcohol Oil Recommendation Recommended Oil Optimax DFI 2 Cycle Engine Oil Mercury or Quicksilver Optimax DFI 2 Cycle Engine Oil is recommended for your engine If Optimax DFI 2 Cycle engine oil is not available we recommend using Mercury or Quicksilver TC W3 Premium Plus 2 Cycle Oil Severe engine damage may result from use of an inferior oil Fuel Additives To minimize carbon deposit buildup in the engine it is recommended to add Mercury or Quicksilver Quickleen Engine Treatment additive to the engine s fuel at each tank fill throughout the boating season Use additive as directed on container Fuel Requirements Do not use pre mixed gas and oil in this engine The engine automatically receives extra oil during engine break in Use a fresh supply of the recommended gasoline during engine break in and after engine break in 22 FUEL AND OIL Avoiding Fuel Flow Restriction IMPORTANT Adding components to the fuel supply system filters valves fittings etc may restrict the fuel flow This may cause engine stalling at low speed and or a lean fuel conditio
42. ith the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation and Maintenance Manual alteration or removal of parts or water entering the engine through the fuel intake air intake or exhaust system Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal and or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty 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 sha
43. l maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty 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 Use of fuels and lubricants which are not suitable for use with or on the product Refer to the Maintenance section 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 o
44. lacement Metric hex nuts are not supplied DO NOT USE DEEP CYCLE BATTERIES DTS Digital Throttle and Shift applications and Optimax engines must use a marine starting battery with pss MCA 800 CCA or 180 Ah 13 5Nm 120 Ibs in DO NOT USE WING IMPORTANT NUTS Battery cable size and length is critical Refer to engine installation manual for size requirements 37 895387 Place decal on or near battery box for future service reference 5 16 and 3 8 hex nuts supplied for wing nut replacement Metric hex nuts not supplied 3486 42 MAINTENANCE Propeller Replacement If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller 1 Shift outboard to neutral N position 0b00351 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing spark plug leads 2 Remove spark plug leads to prevent engine from starting VI 3 Straighten the bent tabs on the propeller nut retainer 0b00376 4 Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut 0b01672 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be
45. ling Outboard Before operation the outboard must be correctly installed with the required mounting hardware as shown Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury death or property damage We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the transom with the four 12 7 mm 1 2 in diameter mounting bolts and locknuts provided Install two bolts through the upper set of holes and two bolts through the lower set of holes ob00658 MAXIMUM OUTBOARD MOUNTING HEIGHT The mounting height of the outboard must not exceed 635 mm 25 in for EL models and 762 mm 30 in for EXL models Mounting the outboard higher may cause damage to the gearcase components 0b01523 19 INSTALLATION Propeller Selection For best all around performance from your outboard boat combination select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded refer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed 0b00323 If changing conditions cause the RPM to drop below the recommended
46. ll not be enforceable against Mercury Marine For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED INDURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY Mercury Marine One Year Limited Warranty Confederation of Independent States Middle East Africa WHAT IS COVERED Mercury Marine warrants each new Mercury outboard Mariner outboard Jet Products Thruster Electric Trolling Motors Mercruiser Inboard or Sterndrive engine products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for one 1 year from the date the product is first sold to a recreational use retail purchaser or the date on which the
47. n at high RPM that could cause engine damage Filling Remote Oil Tank Remove filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 galllons Replace filler cap and tighten securely IMPORTANT Always make sure the oil tank caps are threaded on tight An air leak will prevent oil flow to the engine or27 Filling Engine Mounted Oil Reservoir Tank NOTE Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated 1 Remove the top cowl 2 Loosen the fill cap on the engine oil reservoir tank 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 3 Re tighten the fill cap Stop the engine and replace the top cowl 0b01556 Filling Fuel Tank 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 Always stop engine before refilling tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled 23 FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with on
48. need occur He knows your engine best Service Away From Home If you are away from your local dealer and the need arises for service contact the nearest authorized dealer 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 The dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or any authorized Mercury Marine dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 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 The following information will be needed by the service office Your name and address Daytime telephone
49. ngers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where you are going and when you expect to return It is illegal to operate a boat while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Maintenance Schedule Operating In Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at all times so the gearcase is submerged This prevents trapped water in gearcase from freezing and causing possible damage to the water pump and other components If there is a chance of ice forming on the water the outboard should be removed and drained completely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing The Cooling System If you keep your boat moored in the water always tilt the outboard so the gearcase is completely out of water except in freezing temperatur
50. nition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erratically POSSIBLE CAUSES Spark plugs fouled or defective Refer to Maintenance section Incorrect setup and adjustments Fuel is being restricted to the engine Engine fuel filter is obstructed Refer to Maintenance section Fuel tank filter obstructed Stuck anti siphon valve on built in fuel tank Fuel line is kinked or pinched D agog Injector plugged Threaded connection of an air hose is loose Fuel pump failure Ignition system component failure 53 TROUBLESHOOTING Performance Loss POSSIBLE CAUSES Throttle not fully open Damaged propeller or improper propeller size Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator Open circuit in the alternator output wire fused link 54 OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools equipment and genuine parts and accessories to properly service your engine should the
51. ntenance outlined in the Operation and Maintenance Manual must be timely performed in order to maintain warranty coverage If this maintenance is performed by the retail customer Mercury Marine reserves the right to make future warranty coverage contingent on proof of proper maintenance 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 HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related laborand material and any other expenses associated with that service Purchaser shall not unless requested by Merc
52. number Model and serial number of your outboard The name and address of your dealership Nature of problem Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax correspondence United States W6250 W Pioneer Road EE P O Box 1939 Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Fax 905 567 8515 Mississauga Ontario LON 7W6 Canada 55 OWNER SERVICE ASSISTANCE Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Fax 61 3 9793 5880 Dandenong Victoria 3164 Australia Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Rechain Fax 32 87 31 19 65 ER ER Belgium Mexico Central America South America Caribbean Telephone 954 744 3513 Mercury Marine 11650 Interchange Circle North 954 744 3535 Miramar FL 33025 U S A Japan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Fax 81 053 423 2510 Shizuoka ken Japan 435 0005 Japan Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 56
53. nvolved 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 complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record this number for future reference The serial number is located on the outboard as shown Serial Number XXXXXXXX ob00656 a Serial number d Year manufactured b Model year e Certified Europe Insignia as applicable c Model designation 135 150 175 OptiMax Specifications Horsepower GENERAL INFORMATION eee Full Throttle RPM Speed 5250 5750 RPM CN Standard Gearcase Gear 2 00 1 4 87 1 Ratio High Altitude Gearcase 2 30 1 2 00 1 Gear Ratio Recommended Gasoline Refer to Fuel amp Oil Recommended Oil Refer to Fuel amp Oil Gearcase Lubricant 665 ml 22 5 fl oz Capacity 1000 Marine Cranking Amps MCA or 800 Cold Cranking Amps CCA Charging System Output 60 Amps Battery Rating 17 OQO CO Oo oboe a4 GENERAL INFORMATION Component Identification Top cowl Bottom cowl Water pump indicator hole Driveshaft housing Anti ventilation plate lj 3403 f Auxiliary tilt switch g Transom brackets h Gearcase i Cooling water intake holes 18 INSTALLATION Instal
54. odes one on each side A third anode is installed on the bottom of the transom bracket assembly a Anode 2 on each side of gearcase b Anode on transom bracket assembly Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability 41 MAINTENANCE IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 Make sure the battery is secure against movement 4 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative 5 Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals Battery Information Hex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power Do not use deep cycle batteries Engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah When connecting engine battery hex nuts must be used to secure battery leads to battery posts Torque nuts to specifications pe RRCLLLCSS remem IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements Decal needs to be placed on or near battery box for future service reference One 5 16 in and one 3 8 in hex nut are supplied per battery for wing nut rep
55. ol ethanol or methanol can cause a formation of acid during storage and can damage the fuel system If the gasoline being used contains alcohol it is advisable to drain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision fuel Stabilizer and Mercury Precision Quickleen products as described on their containers to the fuel tank before the last operation of the boat 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 1 Portable Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel 2 Permanently Installed Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixture into fuel tank 3 Remove the water separating fuel filter from the engine Empty the fuel into a suitable container and discard the filter properly 4 Premix the following in a container 8 cc 0 27 oz or two teaspoons of Mercury Precision Quickleen lubricant 8 cc 0 27 oz or two teaspoons of Mercury Precision Fuel Stabilizer 5 Pou
56. ol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the outboard and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the outboard into neutral is not sufficient 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 Never drive your boat directly behind a water skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier 61 m 200 ft in front of you in 5 seconds Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is i
57. on caused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to remove spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off al jet 0b00375 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 0b00423 3 Set the spark plug gap to specification 0b00424 Spark Plug Spark plug gap 0 80 mm 0 031 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or torque to specifications 45 MAINTENANCE wn e ECTS EC Compressor Air Intake Filter The filter should be changed every 100 hours of operation or once a season IMPORTANT Never run the engine without the air filter REMOVAL 1 Remove flywheel cover from engine 2 Snap out the retainer and remove filter 0b01559 a Retainer b Filter INSTALLATION 1 Install filter into cover 2 Secure filter into cover with retainer Alternator Belt Inspection 1 Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found a Cracks or deterioration in the rubber portion of the belt b Belt surfaces
58. otor Will Not Crank the Enge ENEE EEN SEENEN Eegenen eet Engine R s Le ele Battery Will Not Hold enee EE Local Repa SERVIC nee Rx Service AWAY From MN Parts And Accessories Te Le El EE Mercury Marine Service Re TEEN WARRANTY INFORMATION Transfer Of Warranty The limited warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to products used for commercial applications To transfer the warranty to the subsequent owner send or fax a copy of the bill of sale or purchase agreement new owner s name address and engine serial number to Mercury Marine s warranty registration department Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Mercury Marine Service Office closest to you Warranty Registration United States And Canada 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
59. peration and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a corroded 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 HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purch
60. peration 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 Before Operating Your Outboard Read this manual carefully Learn how to operate your outboard properly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed A DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage It may also be used to alert against unsafe practices Boat Horsepower Capacity Using an outboard that exceeds the maximum horsepower limit of a boat can 1 cause loss of boat control 2 place too much weight at the transom altering the
61. r 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 Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate If in doubt contact your dealer or the boats manufacturer Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made 15 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squadron 3 The Red Cross and 4 your state boating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT Make sure everyone in the boat is properly seated Do not allow anyone to sit or ride on any part of the boat that was not intended for such use This includes the back of seats gunwales transom bow decks raised fishing seats any rotating fishing seat or anywhere that an unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat Never be under the influence of alcoh
62. rare circumstances the owner may decide to limit the trim in This can be accomplished by purchasing a stainless steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired The non stainless steel shipping bolt should not be used in this application other than on a temporary basis 2 Trimming Out or Up can Lift the bow higher out of the water Generally increase top speed 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 Cause engine overheating if any cooling water intake holes are above the water line TILTING OPERATION To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down Lower the outboard b 0b00664 a Tilt support lever b Knob MANUAL TILTING If the outboard cannot be tilted using the power trim tilt switch the outboard can be manually tilt
63. removed have the propeller removed by an authorized dealer 43 MAINTENANCE 6 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon Im 0b00378 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed T Flo Torq Drive Hub Propellers Install forward thrust hub propeller continuity washer rear thrust hub propeller nut retainer and propeller nut onto the shaft Y 0b00382 a Propeller nut d Continuity washer b Propeller nut retainer e Propeller c Rear thrust hub f Forward thrust washer 8 Flo Torq Il Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft WA Pf a 0b00421 a Propeller nut d Propeller b Propeller nut retainer e Replaceable drive sleeve c Rear thrust hub f Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications mmm o9 E 10 Secure propeller nut by bending three of the tabs into the thrust hub grooves 44 MAINTENANCE 0b00422 Spark Plug Inspection And Replacement Avoid serious injury or death from fire or explosi
64. res transom fractures or water leaks Operating a damaged outboard could cause additional damage to other parts of the outboard or could affect control of the boat If continued running is necessary do so at greatly reduced speeds Avoid serious injury or death from loss of boat control Continued boating with major impact damage can result in sudden outboard component failure with or without subsequent impacts Have the outboard thoroughly inspected and any necessary repairs made 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 Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea 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 0b00316 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed
65. rmation WRISTS el EE 1 Warranty Registration United States And Canada ENNEN ENN 1 Warranty Registration Outside The United States And Canada 1 Mercury Marine Two Years Limited Warranty Europe 2 Mercury Marine One Year Limited Warranty Confederation of Independent States Middle East Africa 3 3 Year Limited Warranty Against E elt e Mir AA 5 Warranty Coverage And Exclusions ee ee vi E EE WI Ee EES 6 Boaters ee ell 8 Before Operating Your ee EE 8 Boat Horsep wer EA Ae Ee 8 High Speed And High Performance Boat Operation 9 Outboard Remote Control Oe e EEN 9 leed Le He Leder 9 Luet 10 Protecting People In The WALT TEE 11 Passenger Safety Message Pontoon Boats And Deck Boats eene 12 Wave And E ET ln hel Le WEE 12 Iripact Widinderwalter FIaZaEds TT 13 Exhaust EMISSIONS TEE 14 Selecting Accessories For Your QUO Ainara EA CEE EEE SAE EEE re EEErer EnEn 15 Sate Boating DUG IESO EE 15 Recording Seral Tino 16 135 150179 OptiMax Specifications ET 16 E eine ien Ae Ende en DEE 18 Installation Installing OUI ON A DEE 19 de E 20 Transporting Trallering Bost QUID WEE 21 Gasoline nl A EEN 22 ORE COMMMCH GAO E 22 SIE elek ER Fuel Requirements TE 22 Avoiding Fuel e Ode de E 23 Filling Remote Ol Tank TT 23 Filling Engine Mounted Oil Reservoir Tank ENEE 23 AN A o TEE 23 TABLE OF CONTENTS Features and Controls SUR ll reg LEE 24 WY NIT gt SM T RN DEN 24 POWER TiM ANd KEE 26 Operation Pr re Starting Check EE 3
66. rs date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product A copy of the Warranty Registration Card designated as the Purchaser s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms WARRANTY INFORMATION 4 n some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills
67. rthis mixture in a new water separating fuel filter Reinstall the fuel filter Prime the fuel system as outlined in the Operation Starting the Engine Place the outboard in water or use the flushing attachment for circulating cooling water Start the engine and run at idle speed for 10 minutes to allow the treated fuel to fill the fuel system Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceeding IMPORTANT Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark plug leads 1 Remove the spark plugs and add approximately 30 ml 1 oz of engine oil into each spark plug hole 2 Rotate the flywheel manually several times to distribute the oil in the cylinders 3 Reinstall spark plugs 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 Gearcase Drain and refill the gearcase lubricant refer to Maintenance Gearcase Lubrication 51 STORAGE Positioning Outboard For Storage Store outboard in an upright vertical position to allow water to drain out of outboard If outboard is stored tilted up in freezing temperature trapped cooling
68. rwater object is to control the boat speed Under these conditions boat speed should be kept to a minimum planing speed 24 to 40 km h 15 to 25 MPH To avoid serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater obstacle maintain a top speed no greater than minimum planing speed Striking a floating or underwater object could result in an infinite number of situations Some of these situations could result in the following Part of the outboard or the entire outboard could break loose and fly into the boat The boat could move suddenly in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat 13 GENERAL INFORMATION A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles After striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractu
69. sudden unexpected acceleration when starting your engine The design of this outboard requires that the remote control used with it must have a built in start in neutral only protection device 0500308 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self locking nuts These self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage GENERAL INFORMATION 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 ob00655 a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote control units are equipped with a lanyard stop switch A lanyard stop switch can be installed as an accessory generally on the dashboard or side adjacent to the operator s position 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 The lanyard is coil
70. 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 12 GENERAL INFORMATION 0b00314 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 Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to a boat hand hold 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 The boat may also steer sharply to one side 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 The most important thing you can do to help reduce injury or impact damage from striking a floating or unde
71. telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not coveredby this warranty Also expenses associated with the removal and or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty 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 For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED INDURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS A
72. tem Replace compressor air intake filter See Compressor Air Intake Filter Inspect alternator belt See Alternator Belt Inspection 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 Check control cable adjustments 1 Lubricate splines on the driveshaft and shift shaft Check tightness of bolts nuts and other fasteners Replace water pump impeller more often if overheating occurs or reduced water pressure is noted BEFORE PERIODS OF STORAGE Refer to Storage procedure See Storage section Flushing The Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt polluted or muddy water This will help prevent a buildup of deposits from clogging the internal water passages 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 1 Remove the plug from fitting in the bottom cowl 1 These items should be serviced by an authorized dealer 36 MAINTENANCE 2 0b01085 Top Cowl Removal And Installation REMOVAL 1 Pull out the front cowl latch 0b00672 2 Liftup the rear cowl latch Remove the top cowl 0b0067
73. ury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identificationand must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation and Maintenance Manual alteration or removal of parts or water entering the engine through the fuel intake air intake or exhaust system Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage

135/150/175 Optimax - Brunswick Marine in EMEA

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