Mercury 75 OptiMax 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.
© 2012 Mercury Marine 75/90/115/125 OptiMax 90-10208090 1209
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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.
© 2010, Mercury Marine
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
Transfer of Warranty.................................................................... 1
Warranty Registration United States and Canada....................... 1
Warranty Registration Outside the United States and Canada
..................................................................................................... 2
Optimax Outboard Limited Warranty United States, Canada,
Europe, Confederation of Independent States, Middle‑East and
Africa............................................................................................3
3 Year Limited Warranty Against Corrosion................................ 6
Warranty Coverage and Exclusions.......................................... 10
General Information
Boater's Responsibilities............................................................ 13
Before Operating Your Outboard............................................... 13
Boat Horsepower Capacity........................................................ 14
High‑Speed and High‑Performance Boat Operation................. 14
Propeller Selection.....................................................................15
Outboard Remote Control Models ............................................ 18
Remote Steering Notice.............................................................18
Lanyard Stop Switch.................................................................. 19
Protecting People in the Water.................................................. 23
Passenger Safety Message ‑ Pontoon Boats and Deck Boats
................................................................................................... 24
Wave and Wake Jumping.......................................................... 25
Impact with Underwater Hazards...............................................26
Exhaust Emissions.................................................................... 28
Selecting Accessories for Your Outboard.................................. 30
Safe Boating Suggestions......................................................... 30
Recording Serial Number.......................................................... 32
Specifications.............................................................................33
Component Identification........................................................... 34
Transporting
Trailering Boat/Outboard .......................................................... 35
viii eng
Fuel and Oil
Fuel Recommendations............................................................. 36
Fuel Requirements.................................................................... 38
Fuel Additives............................................................................ 38
Avoiding Fuel Flow Restriction.................................................. 38
Low Permeation Fuel Hose Requirement ................................. 38
Oil Recommendation................................................................. 38
Filling Oil Injection System.........................................................39
Filling Fuel Tank........................................................................ 41
Features and Controls
Remote Control Features.......................................................... 43
Warning System........................................................................ 44
Power Trim and Tilt....................................................................47
Trim Tab Adjustment................................................................. 51
Operation
Pre‑Starting Check List.............................................................. 52
Operating in Freezing Temperatures......................................... 52
Operating in Saltwater or Polluted Water.................................. 53
Operating at High Elevations..................................................... 53
Setting Trim Angle While Running Engine at Idle Speed.......... 54
Engine Break‑In Procedure....................................................... 54
Starting the Engine.................................................................... 55
Gear Shifting.............................................................................. 58
Stopping the Engine.................................................................. 59
eng ix
Maintenance
Outboard Care........................................................................... 60
EPA Emissions.......................................................................... 61
Inspection and Maintenance Schedule...................................... 62
Flushing the Cooling System .................................................... 64
Top Cowl Removal and Installation........................................... 65
Cleaning Care for Top Cowl...................................................... 66
Flywheel Cover Removal and Installation..................................66
Side Panel Removal and Installation......................................... 67
Fuel System............................................................................... 68
Steering Link Rod Fasteners..................................................... 71
Fuse Replacement.....................................................................72
Corrosion Control Anode........................................................... 73
Battery Inspection ..................................................................... 74
Battery Information.................................................................... 74
Propellers...................................................................................75
Spark Plug Inspection and Replacement...................................79
Compressor Air Intake Filter...................................................... 80
Alternator Belt Inspection...........................................................81
Lubrication Points...................................................................... 81
Checking Power Trim Fluid........................................................83
Gearcase Lubrication.................................................................84
Storage
Storage Preparation...................................................................87
Fuel System............................................................................... 87
Protecting Internal Engine Components.................................... 89
Protecting External Outboard Components............................... 89
Gearcase................................................................................... 90
Positioning Outboard for Storage.............................................. 90
Battery Storage.......................................................................... 90
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Troubleshooting
Starter Motor Will Not Crank the Engine....................................91
Engine Will Not Start..................................................................91
Engine Runs Erratically............................................................. 92
Performance Loss......................................................................92
Battery Will Not Hold Charge..................................................... 92
Owner Service Assistance
Local Repair Service..................................................................93
Service Away from Home.......................................................... 93
Parts and Accessories Inquiries................................................ 93
Service Assistance.................................................................... 93
Mercury Marine Service Offices.................................................94
Outboard Installation
Important Information.................................................................96
Boat Horsepower Capacity........................................................ 96
Start in Gear Protection............................................................. 97
Selecting Accessories for Your Outboard.................................. 97
Fuel Tanks................................................................................. 97
Low Permeation Fuel Hose Requirement ................................. 97
Installation Specifications.......................................................... 98
Lifting the Outboard................................................................... 98
Steering Cable ‑ Starboard Side Routed Cable......................... 99
Determining Recommended Outboard Mounting Height......... 101
Drilling Outboard Mounting Holes............................................ 102
Fastening the Outboard to the Transom.................................. 103
Electrical, Fuel Hose, Flush Hose and Control Cables............ 107
Oil Injection Set‑Up.................................................................. 120
Trim In Pin............................................................................... 122
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