Mercury 200 Optimax Spécifications Page 1

eng i Thank Youfor your purchase of one of the finest outboards available.You have made a sound investment in boating pleasure.Your outboard has bee

x engTroubleshootingStarter Motor Will Not Crank the Engine...100Engine Will Not Start...

MAINTENANCE 88 eng2. Remove the hose cable tie and pull the air filter off the hose.a - Air filterb - Nylon washerc - Rubber washerd - Clampe - Filt

MAINTENANCEeng 89 3. Secure the filter housing with the clamp.a - Air filterb - Filter housingc - Clampd - Inlet hoseLubrication Points1. Lubricate

MAINTENANCE 90 eng• Trim rod ball ends ‑ Turn the ball ends to work thelubricant into the ball sockets.284582. Lubricate the following with Quicksil

MAINTENANCEeng 91 TubeRef No.Description Where Used Part No.952-4-C withPTFEAlternator belt tensioner pivotshaft, swivel bracket, tiltsupport lever,

MAINTENANCE 92 eng• Tilt tube ‑ Lubricate through fitting.27874! WARNINGIncorrect cable lubrication can cause hydraulic lock, leadingto seri

MAINTENANCEeng 93 Checking Power Trim Fluid1. Tilt outboard to the full up position and engage the tiltsupport lever.278772. Remove fill cap and che

MAINTENANCE 94 engGearcase LubricationWhen adding or changing gearcase lubricant, visually check forthe presence of water in the lubricant. If water

MAINTENANCEeng 95 CHECKING LUBRICANT LEVEL AND REFILLINGGEARCASE1. Place outboard in a vertical operating position.2. Remove vent plug/sealing washe

STORAGE 96 engStorage PreparationThe major consideration in preparing your outboard for storage isto protect it from rust, corrosion, and damage cau

STORAGEeng 97 3. Pull the drain hose off the right side fitting. Hold the openend of the hose over a container.4. Loosen drain screw and drain the f

eng xi Maintainance LogMaintenance Log... 137

STORAGE 98 eng10.Remove the fuel filter. See Maintenance ‑ Fuel System forprocedure.11.Pour this mixture into the fuel filter opening. Reinstall the

STORAGEeng 99 • Touch up any paint nicks. See your dealer for touch‑uppaint.• Spray Quicksilver or Mercury Precision Lubricants CorrosionGuard on ex

TROUBLESHOOTING 100 engStarter Motor Will Not Crank the EnginePOSSIBLE CAUSES• Blown 20 amp fuse in the starting circuit. Refer toMaintenance.• Outb

TROUBLESHOOTINGeng 101 Engine Runs ErraticallyPOSSIBLE CAUSES•Spark plugs fouled or defective. Refer to Maintenancesection.• Incorrect setup and adj

OWNER SERVICE ASSISTANCE 102 engLocal Repair ServiceAlways return your outboard to your local authorized dealershould the need for service arise. On

OWNER SERVICE ASSISTANCEeng 103 • Your name and address• Daytime telephone number• Model and serial number of your outboard• The name and address of

OWNER SERVICE ASSISTANCE 104 engAsia, SingaporeTelephone (65) 65466160 Brunswick Asia Pacific GroupT/A Mercury Marine Singapore Pte Ltd29 Loyang Dri

OUTBOARD INSTALLATIONeng 105 Important InformationBEFORE STARTING THE ENGINENOTICELack of oil pressure in the system can cause severe inte

OUTBOARD INSTALLATION 106 engBoat Horsepower Capacity! WARNINGExceeding the boat's maximum horsepower rating can causeserious injury or

OUTBOARD INSTALLATIONeng 107 Some accessories not manufactured or sold by Mercury Marineare not designed to be safely used with this outboard or out

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OUTBOARD INSTALLATION 108 engFUEL DEMAND VALVE (FDV) REQUIREMENTWhenever a pressurized fuel tank is used, a fuel demand valveis required to be insta

OUTBOARD INSTALLATIONeng 109 3. Turn the ignition key switch back to the "OFF" position, andsqueeze the primer bulb again until it feels f

OUTBOARD INSTALLATION 110 eng2. Thread the lifting eye into the flywheel hub for a minimum offive turns.a - Lifting eye3. Connect a hoist to the lif

OUTBOARD INSTALLATIONeng 111 2. Insert steering cable into tilt tube.37253. Torque nut to specification.3727DescriptionNm lb‑in. lb‑ftNut 47.5 35Ste

OUTBOARD INSTALLATION 112 eng! WARNINGImproper fasteners or improper installation procedures canresult in loosening or disengagement of

OUTBOARD INSTALLATIONeng 113 2. Assemble the steering link rod to the engine with the specialwasher head bolt "a" and self‑locking nylon i

OUTBOARD INSTALLATION 114 engDetermining Recommended Outboard MountingHeighta - The solid line is recommended to determine the outboardmounting heig

OUTBOARD INSTALLATIONeng 115 NOTICE1. The outboard should be mounted high enough on the transom so theexhaust relief hole will stay at least 25.4 mm

OUTBOARD INSTALLATION 116 engTransom Drilling Fixture 91‑98234A25489Aids in engine installation byacting as a template for enginemounting holes.2. D

OUTBOARD INSTALLATIONeng 117 Available Outboard Mounting BoltsPart Number Description10‑67755‑003 ½‑20 x 5.50 in. long (3.25 in. thread)10‑67755‑2 ½

WARRANTY INFORMATIONeng 1 Warranty RegistrationUNITED STATES AND CANADATo be eligible for warranty coverage, the product must beregistered with Merc

OUTBOARD INSTALLATION 118 engUse a dial torque wrench to determine transom strength. If thebolt or nut continues to turn without the torque reading

OUTBOARD INSTALLATIONeng 119 NOTE: For more accurate torque, tighten the mounting locknutsrather than the outboard mounting bolts.a - 1/2 in. diamet

OUTBOARD INSTALLATION 120 engElectrical, Hoses, Control Cables, and Front ClampREMOTE WIRING HARNESSRoute the remote 14 pin boat harness through the

OUTBOARD INSTALLATIONeng 121 IMPORTANT: Battery cable size and length is critical. Refer toengine installation manual for size requirements.The deca

OUTBOARD INSTALLATION 122 engDual OutboardsConnect a common ground cable (wire size same as enginebattery cables) between negative (–) terminals on

OUTBOARD INSTALLATIONeng 123 Water Pressure and Speedometer Hose or TubingNOTE: This applies to models without SmartCraft gauges.This outboard has a

OUTBOARD INSTALLATION 124 engMake the water pressure gauge hose connection to the tubing asshown.a - Water pressure tubeb - Speedometer water pickup

OUTBOARD INSTALLATIONeng 125 INSTALLING THE SHIFT CABLEIMPORTANT: The shift cable is the first cable to move when theremote control handle is moved

OUTBOARD INSTALLATION 126 engc. Place a mark on the shift cable against the cable endguide.a - Reverse position mark3. Mark the center on the shift

OUTBOARD INSTALLATIONeng 127 Adjusting the Shift Cable1. Align the shift cable end guide with the center mark asinstructed in Locating the Center Po

WARRANTY INFORMATION 2 engTransfer of WarrantyUNITED STATES AND CANADAThe limited warranty is transferable to a subsequent purchaser,but only for th

OUTBOARD INSTALLATION 128 engc. Shift the remote control into reverse while turning thepropeller shaft. If the propeller shaft does not lock solidly

OUTBOARD INSTALLATIONeng 129 3. Adjust the cable barrel so the installed throttle cable will holdthe idle stop screw against the stop.a - Barrel sle

OUTBOARD INSTALLATION 130 eng5. Lock the barrel holder in place with the cable latch.2682FRONT CLAMP ASSEMBLY INSTALLATIONIMPORTANT: There must be s

OUTBOARD INSTALLATIONeng 131 3. Join the top half of the front clamp with the bottom half.Secure both halves together with cables ties.a - Top half

OUTBOARD INSTALLATION 132 engOil Injection Set‑UpFILLING OIL SYSTEM1. Fill remote oil tank with the recommended oil listed in theOperation and Maint

OUTBOARD INSTALLATIONeng 133 PRIMING OIL INJECTION PUMPBefore starting the engine for the first time, prime the oil injectionpump. Priming will remo

OUTBOARD INSTALLATION 134 engd. Turn the ignition key switch to the "ON" position for threeseconds. This operates the electric fuel pump.2

OUTBOARD INSTALLATIONeng 135 Trim In Pin! WARNINGOperating the boat at high speeds with the outboard trimmedtoo far under can create excess

OUTBOARD INSTALLATION 136 engThe owner may decide to limit the trim in. This can beaccomplished by purchasing a stainless steel tilt pin from yourde

MAINTAINANCE LOGeng 137 Maintenance LogRecord all maintenance performed on your outboard here. Besure to save all work orders and receipts.Date Main

WARRANTY INFORMATIONeng 3 To transfer the plan to the subsequent owner, contact MercuryProduct Protection or an authorized dealer to receive a Reque

WARRANTY INFORMATION 4 engDURATION OF COVERAGE: This Limited Warranty providescoverage for three (3) years from the date the product is first soldto

WARRANTY INFORMATIONeng 5 WHAT MERCURY WILL DO: Mercury's sole and exclusiveobligation under this warranty is limited to, at our option,repairi

WARRANTY INFORMATION 6 engWHAT IS NOT COVERED: This limited warranty does not coverroutine maintenance items, tune‑ups, adjustments, normal wearand

WARRANTY INFORMATIONeng 7 For additional information regarding events and circumstancescovered by this warranty, and those that are not, see theWarr

ii engWarranty MessageThe product you have purchased comes with a limited warrantyfrom Mercury Marine, the terms of the warranty are set forth inth

WARRANTY INFORMATION 8 engCONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGE: Warranty coverage is available onlyto retail customers th

WARRANTY INFORMATIONeng 9 HOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repair,and reasonable a

WARRANTY INFORMATION 10 engCorrosion damage caused by stray electrical currents (onshorepower connections, nearby boats, submerged metal) is notcove

WARRANTY INFORMATIONeng 11 Warranty Coverage and ExclusionsThe purpose of this section is to help eliminate some of the morecommon misunderstandings

WARRANTY INFORMATION 12 eng5. Additional service work requested by customer other thanthat necessary to satisfy the warranty obligation.6. Labor per

WARRANTY INFORMATIONeng 13 16.Our limited warranty does not apply to any damage to ourproducts caused by the installation or use of parts andaccesso

WARRANTY INFORMATION 14 engd. Ignition coil and/or control modulee. Ignition wires4. Lubrication system (4‑Stroke engines excluded)a. Oil pump and i

WARRANTY INFORMATIONeng 15 WHAT IS COVERED: Mercury Marine warrants the componentsof the emissions control systems (see the components listed inthe

WARRANTY INFORMATION 16 engHOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repairand reasonable a

WARRANTY INFORMATIONeng 17 Expenses related to haul‑out, launch, towing, storage, telephone,rental, inconvenience, slip fees, insurance coverage, lo

eng iii • Provides timely service for all Mercury Marine customers.• Offers extended service hours and mobile service, whenappropriate.• Uses, displ

WARRANTY INFORMATION 18 engCalifornia Air Resources Board Explanation ofYour California Emission Control WarrantyStatementYOUR WARRANTY RIGHTS AND O

WARRANTY INFORMATIONeng 19 As the outboard engine owner, you should, however, be awarethat Mercury Marine may deny you warranty coverage if youroutb

WARRANTY INFORMATION 20 eng42538Three Stars ‑ Ultra Low EmissionThe Three Star label identifies engines that meetthe Air Resources Board's Pers

GENERAL INFORMATIONeng 21 Boater's ResponsibilitiesThe operator (driver) is responsible for the correct and safeoperation of the boat and safet

GENERAL INFORMATION 22 engBoat Horsepower Capacity! WARNINGExceeding the boat's maximum horsepower rating can causeserious injury or dea

GENERAL INFORMATIONeng 23 Outboard Remote Control ModelsThe remote control connected to your outboard must beequipped with a start in neutral only p

GENERAL INFORMATION 24 engChoose a propeller for your boating application that will allow theengine to operate within the specified full throttle op

GENERAL INFORMATIONeng 25 Diameter ‑ The diameter is the distance across the imaginarycircle that is made when the propeller rotates. The correctdia

GENERAL INFORMATION 26 engPROPELLER MATERIALMost propellers manufactured by Mercury Marine are made fromeither aluminum or stainless steel. Aluminum

GENERAL INFORMATIONeng 27 ! WARNINGImproper fasteners or improper installation procedures canresult in loosening or disengagement of the

iv engDescription of Engines and Essential RequirementsEngine Type Fuel Type Combustion Cycle☒ Outboard engine ☒ Petrol ☒ 2 strokeIdentification of

GENERAL INFORMATION 28 engThe lanyard is a cord usually 122–152 cm (4–5 feet) in lengthwhen stretched out, with an element on one end made to beinse

GENERAL INFORMATIONeng 29 Important Safety Information: The purpose of a lanyard stopswitch is to stop the engine when the operator moves far enough

GENERAL INFORMATION 30 eng! WARNINGAvoid serious injury or death from deceleration forces resultingfrom accidental or unintended stop switch activat

GENERAL INFORMATIONeng 31 Protecting People in the WaterWHILE YOU ARE CRUISINGIt is very difficult for a person standing or floating in the water to

GENERAL INFORMATION 32 engPassenger Safety Message ‑ Pontoon Boats andDeck BoatsWhenever the boat is in motion, observe the location of allpassenger

GENERAL INFORMATIONeng 33 BOATS WITH FRONT MOUNTED, RAISED PEDESTALFISHING SEATSElevated fishing seats are not intended for use when the boat istrav

GENERAL INFORMATION 34 eng! WARNINGWave or wake jumping can cause serious injury or death fromoccupants being thrown within or out of the boat.

GENERAL INFORMATIONeng 35 • The boat could move suddenly in a new direction. Such asharp change in direction can cause occupants to be thrownout of

GENERAL INFORMATION 36 engExhaust EmissionsBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide (CO) is a deadly gas that is present in theexhaust f

GENERAL INFORMATIONeng 37 GOOD VENTILATIONVentilate the passenger area, open side curtains or forwardhatches to remove fumes.Example of desired air

eng v Name / function:Mark D. Schwabero, President, MercuryOutboardDate and place of issue:July 24, 2008Fond du Lac, Wisconsin, USA

GENERAL INFORMATION 38 eng2. Examples of poor ventilation while the boat is moving:a - Operating the boat with the trim angle of the bow too highb -

GENERAL INFORMATIONeng 39 Know and obey all nautical rules and laws of the waterways.Boat operators should complete a boating safety course.Courses

GENERAL INFORMATION 40 engWatch fallen skiers. When using your boat for waterskiing orsimilar activities, always keep a fallen or down skier on theo

GENERAL INFORMATIONeng 41 Models 200 225 250Kilowatts 147 165 184Full throttle RPM range 5000–5750 RPM 5500–6000 RPMIdle speed in forward gear 575 ±

GENERAL INFORMATION 42 engComponent Identificationa - Top cowlb - Bottom cowlc - Water pumpindicator holed - Driveshafthousinge - Anti‑ventilationpl

TRANSPORTINGeng 43 Trailering Boat/OutboardTrailer your boat with the outboard tilted down in a verticaloperating position.If additional ground clea

FUEL AND OIL 44 engFuel RecommendationsIMPORTANT: Use of improper gasoline can damage yourengine. Engine damage resulting from the use of improperga

FUEL AND OILeng 45 The fuel system components on your Mercury Marine engine willwithstand up to 10% alcohol content in the gasoline. We do notknow w

FUEL AND OIL 46 engOil RecommendationRecommended OilMercury OptiMax/DFI or Quicksilver DFI 2‑CycleEngine OilMercury OptiMax/DFI or Quicksilver DFI 2

FUEL AND OILeng 47 • Low permeation hose is USCG Type B1‑15 or Type A1‑15,defined as not exceeding 15/gm²/24 h with CE 10 fuel at23 °C as specified

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FUEL AND OIL 48 engSPECIAL FEATURES OF THE PORTABLE FUEL TANK• The fuel tank has a two‑way valve which allows air to enterthe tank as the fuel is dr

FUEL AND OILeng 49 DIRECTIONS FOR USING THE PRESSURIZED PORTABLEFUEL TANK1. When installing the fuel tank cap, turn the cap to the rightuntil you he

FUEL AND OIL 50 eng3. Retighten the fill cap. Stop the engine and replace the topcowl.29424Filling Fuel Tank! WARNINGAvoid serious injury or death f

FEATURES AND CONTROLSeng 51 Remote Control FeaturesYour boat may be equipped with one of the Mercury Precision orQuicksilver remote controls shown.

FEATURES AND CONTROLS 52 engWarning SystemThe outboard warning system incorporates a warning horn insidethe boat. The warning horn may be located in

FEATURES AND CONTROLSeng 53 Warning HornFunction Sound DescriptionCoolingSystemProblemContinuous Engine Guardian System is activated. Powerlimit wil

FEATURES AND CONTROLS 54 engIf Guardian System has been activated, reduce throttle speed.The problem will need to be identified and corrected, if po

FEATURES AND CONTROLSeng 55 Power Trim and TiltYour outboard has a trim/tilt control called power trim. Thisenables the operator to easily adjust th

FEATURES AND CONTROLS 56 engThe most significant control hazard is a pull or torque that can befelt on the steering wheel or tiller handle. This ste

FEATURES AND CONTROLSeng 57 • In rare circumstances, the owner may decide to limit thetrim in. This can be accomplished by purchasing astainless ste

eng vii WARRANTY INFORMATIONWarranty Registration... 1Transfer of Warranty...

FEATURES AND CONTROLS 58 engMANUAL TILTINGIf the outboard cannot be tilted using the power trim/tilt switch,the outboard can be manually tilted.NOTE

FEATURES AND CONTROLSeng 59 AUXILIARY TILT SWITCHThis switch can be used to tilt the outboard up or down using thepower trim system.a - Auxiliary ti

OPERATION 60 engPre‑Starting Check List• Operator knows safe navigation, boating, and operatingprocedures.• An approved personal flotation device of

OPERATIONeng 61 Operating in Saltwater or Polluted WaterWe recommend that you flush the internal water passages ofyour outboard with fresh water aft

OPERATION 62 engEngine Break‑In ProcedureIMPORTANT: Failure to follow the engine break‑in procedurescan result in poor performance throughout the li

OPERATIONeng 63 2. For the next three hours of operation, change engine speedevery ten minutes.Starting the EngineBefore starting, read the pre‑star

OPERATION 64 eng3. Position the fuel line primer bulb so the arrow on the side ofthe bulb is pointing up. Squeeze the fuel line primer bulbseveral t

OPERATIONeng 65 c. Turn the ignition key switch back to the "OFF" position,and squeeze the primer bulb again until it feels firm. Turnthe

OPERATION 66 engIMPORTANT: If no water is coming out of the water pumpindicator hole, stop engine and check cooling water intake holesfor obstructio

OPERATIONeng 67 Stopping the EngineReduce engine speed and shift outboard to neutral position. Turnignition key to "OFF" position.26843

viii engTransportingTrailering Boat/Outboard ... 43Fuel and OilFuel Recommendations...

MAINTENANCE 68 engOutboard CareTo keep your outboard in the best operating condition, it isimportant that your outboard receive the periodic inspect

MAINTENANCEeng 69 EMISSION CERTIFICATION LABELAn emission certification label, showing emission levels andengine specifications directly related to

MAINTENANCE 70 eng• Inspect the outboard for tightness to the boat transom. If anylooseness of the outboard or mounting fasteners exist,retorque the

MAINTENANCEeng 71 • Check the power trim fluid. See Checking Power Trim Fluid.• Inspect the battery. See Battery Inspection.•Check the control cable

MAINTENANCE 72 eng1. Remove the plug from fitting in the bottom cowl.294442. Attach a water hose to the fitting. Turn on the water andflush for 3 to

MAINTENANCEeng 73 CLEANING AND WAXING PROCEDURE1. Before washing, rinse the top cowl with clean water toremove the dirt and dust that may scratch th

MAINTENANCE 74 engFuel System! WARNINGFuel is flammable and explosive. Ensure that the key switch isoff and the lanyard is positioned so that

MAINTENANCEeng 75 Installation1. Lubricate the O‑ring seals with oil.a - Filterb - O‑ring sealsc - Link rod2. Install the fuel filter and tighten se

MAINTENANCE 76 eng3. Retighten the drain screw and reattach the hose.a - Drain hoseb - Side fittingc - Drain screwIMPORTANT: Visually inspect for f

MAINTENANCEeng 77 ! WARNINGImproper fasteners or improper installation procedures canresult in loosening or disengagement of the steeri

eng ix MaintenanceOutboard Care... 68EPA Emissions Regulations...

MAINTENANCE 78 engFuse Replacement ‑ 200 and 225 HP ModelsIMPORTANT: Always carry spare 5 and 20 amp fuses.The electrical wiring circuits on the out

MAINTENANCEeng 79 Open the fuse holder and look at the silver colored band insidethe fuse. If the band is broken, replace the fuse with a new fuseof

MAINTENANCE 80 engThe electrical wiring circuits on the outboard are protected fromoverload by fuses in the wiring. If a fuse is blown, try to locat

MAINTENANCEeng 81 The gearcase has three anodes. Two anodes are located oneach side of the gearcase, and a third is an anode plate installedundernea

MAINTENANCE 82 engBattery Information! WARNINGFailure to properly secure the battery leads can result in a lossof power to the Digital Throttle and

MAINTENANCEeng 83 Propeller Replacement! WARNINGRotating propellers can cause serious injury or death. Neveroperate the boat out of the

MAINTENANCE 84 eng3. Straighten the bent tabs on the propeller nut retainer.269004. Place a block of wood between gearcase and propeller tohold prop

MAINTENANCEeng 85 TubeRef No.Description Where Used Part No.94Anti-CorrosionGreasePropeller shaft 92-802867Q 1952-4-C MarineLubricant withPTFEPropel

MAINTENANCE 86 eng9. Place a block of wood between gearcase and propeller andtorque propeller nut to specifications.Description Nm lb. in. lb. ft.Pr

MAINTENANCEeng 87 2. Remove the spark plugs to inspect. Replace spark plug ifelectrode is worn or the insulator is rough, cracked, broken,blistered,