Mercury 200 OptiMax DTS User manual

eng i

Thank You

for your purchase of one of the finest outboards available.

You have made a sound investment in boating pleasure.

Your outboard has been manufactured by Mercury Marine, a

world leader in marine technology and outboard

manufacturing since 1939. These years of experience have

been committed to the goal of producing the finest quality

products. This led to Mercury Marine's reputation for strict

quality control, excellence, durability, lasting performance,

and being the best at providing after the sale support.

Please read this manual carefully before operating your

outboard. This manual has been prepared to assist you in

the operation, safe use, and care of your outboard.

All of us at Mercury Marine took pride in building your

outboard and wish you many years of happy and safe

boating.

Again, thank you for your confidence in Mercury Marine.

EPA Emissions Regulations

Outboards sold by Mercury Marine in the United States are

certified to the United States Environmental Protection

Agency as conforming to the requirements of the regulations

for the control of air pollution from new outboard motors.

This certification is contingent on certain adjustments being

set to factory standards. For this reason, the factory

procedure for servicing the product must be strictly followed

and, wherever practicable, returned to the original intent of

the design. Maintenance, replacement, or repair of the

emission control devices and systems may be

performed by any marine engine repair establishment or

individual.

Engines are labeled with an Emission Control Information

decal as permanent evidence of EPA certification.

! WARNING

The engine exhaust from this product contains chemicals

known to the state of California to cause cancer, birth

defects or other reproductive harm.

ii eng

Warranty Message

The product you have purchased comes with a limited warranty

from Mercury Marine, the terms of the warranty are set forth in

the Warranty Information section of this manual. The warranty

statement contains a description of what is covered, what is not

covered, the duration of coverage, how to best obtain warranty

coverage, important disclaimers and limitations of damages,

and other related information. Please review this important

information.

The description and specifications contained herein were in

effect at the time this manual was approved for printing. Mercury

Marine, whose policy is one of continued improvement, reserves

the right to discontinue models at any time, to change

specifications, designs, methods, or procedures without notice

and without incurring obligation.

Mercury Marine, Fond du Lac, Wisconsin U.S.A.

Litho in U.S.A.

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,

Mercury Racing, Mercury Precision Parts, Mercury Propellers,

Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,

OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,

SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves

logo, and SmartCraft logo are all registered trademarks of

Brunswick Corporation. Mercury Product Protection logo is a

registered service mark of Brunswick Corporation.

Mercury Premier Service

Mercury evaluates the service performance of its dealers and

assigns its highest rating of "Mercury Premier" to those

demonstrating an exceptional commitment to service.

Earning a Mercury Premier Service rating means a dealer:

• Achieves a high 12 month service CSI (Customer

Satisfaction Index) score for warranty service.

• Possesses all necessary service tools, test equipment,

manuals, and parts books.

• Employs at least one Certified or Master technician.

eng iii

• Provides timely service for all Mercury Marine customers.

• Offers extended service hours and mobile service, when

appropriate.

• Uses, displays, and stocks adequate inventory of genuine

Mercury Precision Parts.

• Offers a clean, neat shop with well organized tools and

service literature.

Declaration of Conformity OptiMax ‑ For Recreational Craft

Propulsion Engines with the Requirements of Directive

94/25/EC as amended by 2003/44/EC

Name of engine manufacturer: Mercury Marine

Address: W6250 Pioneer Road P.O. Box 1939

Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Address: Parc Industriel de Petit‑Rechain

Town: Verviers Post Code: 4800 Country: Belgium

Name of Notified Body for exhaust emission assessment: Det Norske

Veritas AS

Address: Veritasveien 1

Town: Hovik Post Code:

1322

Country:

Norway ID Number: 0575

Name of Notified Body for noise emission assessment: Det Norske

Veritas AS

Address: Veritasveien 1

Town: Hovik Post Code:

1322

Country:

Norway ID Number: 0575

Conformity assessment

module used for exhaust

emissions:

☐ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G☒ H

Conformity assessment

module used for noise

emissions:

☐ A☐ Aa ☐ G☒ H

Other Community Directives applied: Safety of Machinery Directive

98/37/EC; Electromagnetic Compatibility Directive 2004/108/EC

iv eng

Description of Engines and Essential Requirements

Engine Type Fuel Type Combustion Cycle

☒ Outboard engine ☒ Petrol ☒ 2 stroke

Identification of Engines Covered by This Declaration of

Conformity

Name of engine family

Unique engine

identification number:

starting serial number

EC Module H

certificate

number

1.5L OptiMax 75, 80, 90, 115,

125 hp 1B227000 RCD‑H‑2

2.5L OptiMax 135, 150, 175 hp 1B227000 RCD‑H‑2

3.0L OptiMax 200, 225 hp 1B227000 RCD‑H‑2

Essential

requirements standards

other

normative

document/

method

technical

file

Please specify in

more detail

(* = mandatory

standard)

Annex 1.B—Exhaust Emissions

B.1 engine

identification ☐ ☐ ☒

B.2 exhaust

emission

requirements

☒* ☐ ☐ * EN ISO

8178‑1:1996

B.3 durability ☐ ☐ ☒

B.4 owner's

manual ☒ ☐ ☐ ISO 8665: 1995

Annex 1.C—Noise Emissions

C.1 Noise emission

levels ☒* ☐ ☐ EN ISO 14509

C.2 Owner's

manual ☐ ☒ ☐ Owner's manual

This declaration of conformity is issued under the sole responsibility of the

manufacturer. I declare on behalf of the engine manufacturer that the engines

mentioned preceding complies with all applicable essential requirements in

the way specified.

eng v

Name / function:

Mark D. Schwabero, President, Mercury

Outboard

Date and place of issue:July 24, 2008

Fond du Lac, Wisconsin, USA

vi eng

eng vii

WARRANTY INFORMATION

Warranty Registration.................................................................. 1

Transfer of Warranty.................................................................... 2

Transfer of Mercury Product Protection (Extended Service

Coverage) Plan United States and Canada.................................2

Outboard Limited Warranty..........................................................3

3 Year Limited Warranty Against Corrosion................................ 7

Warranty Coverage and Exclusions.......................................... 11

U.S. EPA Emissions Limited Warranty...................................... 13

Emission Control System Components..................................... 13

California Emissions Limited Warranty...................................... 14

California Air Resources Board Explanation of Your California

Emission Control Warranty Statement.......................................18

Emission Certification Star Label............................................... 19

General Information

Boater's Responsibilities............................................................ 21

Before Operating Your Outboard............................................... 21

Boat Horsepower Capacity........................................................ 22

High‑Speed and High‑Performance Boat Operation................. 22

Outboard Remote Control Models ............................................ 23

Propeller Selection.....................................................................23

Remote Steering Notice.............................................................26

Lanyard Stop Switch.................................................................. 27

Protecting People in the Water.................................................. 30

Passenger Safety Message ‑ Pontoon Boats and Deck Boats

................................................................................................... 31

Wave and Wake Jumping.......................................................... 32

Impact with Underwater Hazards...............................................33

Exhaust Emissions.................................................................... 35

Selecting Accessories for Your Outboard.................................. 37

Safe Boating Suggestions......................................................... 37

Recording Serial Number.......................................................... 39

200/225 OptiMax DTS Specifications........................................ 39

Component Identification........................................................... 41

viii eng

Installation

Installing Outboard.....................................................................42

Propeller Selection.....................................................................43

Transporting

Trailering Boat/Outboard .......................................................... 45

Fuel and Oil

Fuel Recommendations............................................................. 46

Fuel Additives............................................................................ 48

Fuel Requirements.................................................................... 48

Avoiding Fuel Flow Restriction.................................................. 48

Low Permeation Fuel Hose Requirement ................................. 48

EPA Pressurized Portable Fuel Tank Requirements................. 48

Fuel Demand Valve (FDV) Requirement................................... 49

Mercury Marine's Pressurized Portable Fuel Tank.................... 49

Filling Fuel Tank........................................................................ 51

Oil Recommendation................................................................. 51

Filling Remote Oil Tank............................................................. 51

Filling Engine Mounted Oil Reservoir Tank............................... 52

eng ix

Features and Controls

Panel Mount Control Features and Operation........................... 53

Single Handle Console Control Features and Operation...........56

Slim Binnacle Control Features and Operation......................... 61

Dual Handle Console Control Features and Operation............. 65

Dual Handle Console Control with CAN Trackpad Features and

Operation................................................................................... 70

Shadow Mode Control Features and Operation........................ 75

Shadow Mode Control with CAN Trackpad Features and

Operation................................................................................... 83

Warning System........................................................................ 92

Power Trim and Tilt....................................................................95

Operation

Pre‑Starting Check List............................................................ 100

Operating in Freezing Temperatures....................................... 100

Operating in Saltwater or Polluted Water................................ 101

Operating at High Elevations................................................... 101

Setting Trim Angle While Running Engine at Idle Speed........ 101

Engine Break‑In Procedure..................................................... 102

Starting the Engine.................................................................. 103

Gear Shifting............................................................................ 106

Stopping the Engine................................................................ 107

x eng

Maintenance

Outboard Care......................................................................... 108

EPA Emissions Regulations.................................................... 108

Inspection and Maintenance Schedule.................................... 109

Flushing the Cooling System................................................... 111

Top Cowl Removal and Installation......................................... 112

Cleaning Care for Top Cowl.................................................... 112

Alternator Belt Inspection.........................................................113

Fuel System............................................................................. 113

Steering Link Rod Fasteners................................................... 116

Fuse Replacement...................................................................118

DTS Wiring System................................................................. 119

Corrosion Control Anode......................................................... 119

Battery Inspection ................................................................... 120

Battery Information.................................................................. 121

Propeller Replacement............................................................ 122

Spark Plug Inspection and Replacement.................................125

Compressor Air Intake Filter.................................................... 126

Lubrication Points.................................................................... 128

Checking Power Trim Fluid......................................................132

Gearcase Lubrication...............................................................133

Submerged Outboard.............................................................. 134

Storage

Storage Preparation.................................................................135

Fuel System............................................................................. 135

Protecting Internal Engine Components.................................. 137

Protecting External Outboard Components............................. 137

Gearcase................................................................................. 138

Positioning Outboard for Storage............................................ 138

Battery Storage........................................................................ 138

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