Mercury Optimax User manual

Welcome Aboard!

Proper care and maintenance is an important part in keeping

your Mercury Product operating at peak efficiency for

maximum performance and economy. The enclosed Owner's

Registration Card is your key to trouble‑free family fun. Refer

to your Operation and Maintenance Manual for full details

of your warranty coverage.

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.

Declaration of Conformity ‑ Optimax

Manufacturer:

Mercury Marine

W6250 Pioneer Road P.O. Box 1939

Fond du Lac, WI 54935-1939 USA ,

Authorized Representative:

Marine Power Europe, Inc.

Parc Industriel de Petit-Rechain

B-2800 Verviers - Belgium,

If the CE mark is accompanied by a notified body number, the

following Recreational Craft Directive applies:

Recreational Craft Directive: 2003/44/EC amending 94/25/EC

Applicable Requirement Standards Applied

Owner's manual (A.2.5) EN ISO 10240:2004

Handling characteristics (A.4) EN ISO 8665:1995

Outboard engines starting (A.5.1.4) EN ISO 11547:1995

General steering system (A.5.4.1) ABYC P‑17; EN ISO 10592:1995

Exhaust emission requirements (B.

2) EN ISO 8178‑1: 1996

Owner's manual (B.4) EN ISO 8665:1995

Noise emission levels (C.1) EN ISO 14509:2000

Module used for exhaust emission assessment: Module H;

Certification No. RCD‑H‑2

Module used for noise emission assessment: Module H;

Certification No. RCD‑H‑2

Name of Notified Body for exhaust emission assessment and noise emission

assessment:

Det Norske Veritas AS

Veritasveien 1

1322 Hovik

Norway

Notified Body Number: 0575

Engine type:

Outboard

Fuel type:

Gasoline

Combustion cycle: 2

stroke, direct injection

Brands:

Mercury, Mariner

Engine

Family

Manufacture

Location Horsepower

Starting

Serial

Number

Module H

Noise and

Exhaust

Certificate

Optimax 1.5

Fond du Lac,

Wisconsin USA 75, 90,115 1B227000 RCD‑H‑2

Optimax 2.5

Fond du Lac,

Wisconsin USA 135, 150 1B227000 RCD‑H‑2

Optimax 3.0

Fond du Lac,

Wisconsin USA 200 1B227000 RCD‑H‑2

If the CE mark is not accompanied by the notified body number, the

following Recreational Craft Directive language applies only to product

entering the EU prior to January 1, 2007:

Recreational Craft Directive: 94/25/EC

Applicable Requirement Standards Applied

Owner's manual (A.2.5) ISO 10240

Handling characteristics (A.4) ISO 8665

Outboard engine starting (A.5.1.4) ISO 11547

Fuel tanks (A.5.2.2) ISO 13591; ISO 8469

General steering system (A.5.4.1) ABYC P‑17

The following applies to all products covered by this manual:

Safety of Machinery Directive 98/37/EC

iii

Principles of safety integration

(1.1.2) ISO 12100‑1; ISO 12100‑2; EN 1050

Noise (1.5.8) ICOMIA 39/94

Vibration (1.5.9) ICOMIA 38/94

Electromagnetic Compatibility Directive 89/336/EC

Generic emission standard EN 61000‑6‑3

Generic immunity standard EN 61000‑6‑1

Vehicles, boats and internal

combustion engine driven devices ‑

radio disturbance characteristics

SAE J551 (CISPR 12)

CISPR 12; EN 55012:2002/A1:2005

Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN

61000‑4‑3

This declaration is issued under the sole responsibility of Mercury

Marine and Marine Power Europe.

Patrick C. Mackey

President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006.

European Regulations Contact:

Regulations and Product Safety Department, Mercury Marine,

Fond du Lac, WI USA

TABLE OF CONTENTS

Warranty Information

Transfer Of Warranty...................................................................1

Warranty Registration United States And Canada......................1

Warranty Registration Outside The United States And Canada

.....................................................................................................2

Optimax Outboard Limited Warranty United States, Canada,

Europe, Confederation of Independent States, Middle‑East and

Africa............................................................................................3

3 Year Limited Warranty Against Corrosion................................6

Warranty Coverage And Exclusions..........................................10

General Information

Boater's Responsibilities............................................................13

Before Operating Your Outboard...............................................13

Boat Horsepower Capacity........................................................14

High‑Speed and High‑Performance Boat Operation................. 14

Propeller Selection.....................................................................14

Outboard Remote Control Models ............................................17

Remote Steering Notice.............................................................18

Lanyard Stop Switch..................................................................19

Protecting People In The Water.................................................21

Passenger Safety Message ‑ Pontoon Boats And Deck Boats. 22

Wave And Wake Jumping......................................................... 23

Impact With Underwater Hazards..............................................24

Exhaust Emissions.................................................................... 26

Selecting Accessories For Your Outboard.................................27

Safe Boating Suggestions......................................................... 28

Recording Serial Number.......................................................... 30

75/90/115 OptiMax Specifications.............................................30

Component Identification...........................................................31

Transporting

Trailering Boat/Outboard .......................................................... 32

TABLE OF CONTENTS

Fuel and Oil

Fuel Recommendations.............................................................33

Fuel Requirements....................................................................35

Fuel Additives............................................................................35

Avoiding Fuel Flow Restriction..................................................35

Oil Recommendation.................................................................35

Filling Oil Injection System.........................................................35

Filling Fuel Tank........................................................................37

Features and Controls

Remote Control Features..........................................................38

Warning System........................................................................39

Power Trim And Tilt...................................................................42

Trim Tab Adjustment.................................................................46

Operation

Pre‑Starting Check List..............................................................47

Operating In Freezing Temperatures.........................................47

Operating In Salt Water Or Polluted Water................................48

Operating at High Elevations.....................................................48

Setting Trim Angle While Running Engine at Idle Speed..........49

Engine Break‑in Procedure........................................................49

Starting the Engine....................................................................50

Gear Shifting..............................................................................53

Stopping The Engine.................................................................54

Maintenance

Outboard Care...........................................................................55

EPA Emissions..........................................................................55

Inspection and Maintenance Schedule......................................56

Flushing the Cooling System ....................................................57

Top Cowl Removal And Installation...........................................58

Cleaning Care for Top Cowl......................................................59

TABLE OF CONTENTS

vii

Flywheel Cover Removal and Installation..................................59

Side Panel Removal and Installation.........................................60

Fuel System...............................................................................61

Steering Link Rod Fasteners.....................................................63

Fuse Replacement.....................................................................64

Corrosion Control Anode...........................................................65

Battery Inspection .....................................................................66

Battery Information....................................................................67

Propellers...................................................................................68

Spark Plug Inspection And Replacement..................................71

Compressor Air Intake Filter......................................................72

Alternator Belt Inspection...........................................................72

Lubrication Points......................................................................73

Checking Power Trim Fluid........................................................75

Gearcase Lubrication.................................................................76

Storage

Storage Preparation...................................................................79

Fuel System...............................................................................79

Protecting Internal Engine Components....................................81

Protecting External Outboard Components...............................82

Gearcase...................................................................................82

Positioning Outboard For Storage.............................................82

Battery Storage..........................................................................82

Troubleshooting

Starter Motor Will Not Crank the Engine....................................83

Engine Will Not Start..................................................................83

Engine Runs Erratically.............................................................84

Performance Loss......................................................................84

Battery Will Not Hold Charge.....................................................84

Owner Service Assistance

Local Repair Service..................................................................85

Service Away From Home.........................................................85

TABLE OF CONTENTS

viii

Parts And Accessories Inquiries................................................85

Service Assistance....................................................................85

Mercury Marine Service Offices.................................................86

Outboard Installation

Important Information.................................................................88

Boat Horsepower Capacity........................................................88

Start in Gear Protection.............................................................88

Selecting Accessories For Your Outboard.................................89

Fuel Tanks.................................................................................89

Installation Specifications..........................................................89

Lifting the Outboard...................................................................90

Steering Cable ‑ Starboard Side Routed Cable.........................91

Determining Recommended Outboard Mounting Height...........92

Drilling Outboard Mounting Holes..............................................93

Fastening the Outboard to the Transom....................................95

Electrical, Fuel Hose, Flush Hose and Control Cables..............98

Oil Injection Set‑Up..................................................................111

Trim In Pin...............................................................................112

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. In the United States and Canada, mail to:

Mercury Marine

Attn: Warranty Registration Department

W6250 W. Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54936-1939

920-929-5054

Fax 920-929-5893

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 Marine Power Service

Center closest to you.

Warranty Registration United States And Canada

Outside United States and Canada ‑ Check with your local

distributor.

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. Your dealer can also process this change of

information.

WARRANTY INFORMATION

Mercury Marine

Attn: Warranty Registration Department

W6250 W. Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54936-1939

920-929-5054

Fax 920-929-5893

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.

3. 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.

2. The Warranty Registration Card identifies your name and

address, product model and serial numbers, 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.

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