Mercury Optimax User manual

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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
© 2007 Mercury Marine 75/90/115 OptiMax 90-10208080 307

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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
L
Fond du Lac,
Wisconsin USA 75, 90,115 1B227000 RCD‑H‑2
Optimax 2.5
L
Fond du Lac,
Wisconsin USA 135, 150 1B227000 RCD‑H‑2
Optimax 3.0
L
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

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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

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TABLE OF CONTENTS
v
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
vi
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
1
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 [phone]
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
2
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
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.