Mercury 250 Optimax Manual - New York State Division Of Military And .

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Name of engine manufacturer: Mercury MarineAddress: W6250 W. Pioneer Road, P.O. Box 1939Town: Fond du Lac, WIPost Code: 54936‑193990-8M0080078 413Declaration of Conformity – For Recreational CraftPropulsion Engines with the Requirements of Directive94/25/EC as amended by Directive 2003/44/ECCountry: USAName of Authorized Representative: Brunswick Marine in EMEA Inc.Address: Parc Industriel de Petit‑RechainTown: VerviersPost Code: B‑2800Country: BelgiumName of Notified Body for exhaust emission assessment: DetNorske Veritas ASAddress: Veritasveien 1Post Code:1322Country:NorwayID Number: 0575Name of Notified Body for noise emission assessment: Det NorskeVeritas ASAddress: Veritasveien 1Town: HovikPost Code:1322Country:NorwayID Number: 0575Conformityassessment moduleused for exhaustemissions: B C B D B E B F GConformityassessment moduleused for noiseemissions: A Aa G250 OptiMaxTown: Hovik H HDescription of Engines and Essential RequirementsengEngine TypeFuel TypeCombustion Cycle Outboard engine Petrol 2 strokei 2013 Mercury MarineOther Community Directives applied: Safety of Machinery Directive2006/42/EC; Electromagnetic Compatibility Directive 2004/108/EC

Identification of Engines Covered by This Declaration ofConformityName of engine familyUnique engineidentificationnumber(s) or enginefamily code(s):starting serial numberModule HCertificate1.5L OptiMax 75, 90, 115, 115Pro XS, 125 hp, 80 Jet0B228000RCD‑H‑2 Rev 42.5L OptiMax 135, 150, 150Pro XS, 175 hp0B228000RCD‑H‑2 Rev 43.0L OptiMax 200, 200 Pro XS,225, 250 hp0B228000RCD‑H‑2 Rev ent/methodTechnicalfilePlease specify inmore detail(* mandatorystandard)Annex 1.B—Exhaust EmissionsB.1 engineidentification B.2 exhaustemissionrequirements * B.3 durability B.4 owner'smanual ISO 8665: 2006* EN ISO8178‑1:1996Annex 1.C—Noise EmissionsC.1 Noiseemission levels * EN ISO 14509C.2 Owner'smanual Owner's manualThis declaration of conformity is issued under the sole responsibility of themanufacturer. I declare on behalf of the engine manufacturer that the enginesmentioned preceding complies with all applicable essential requirements inthe way specified.iieng

Name / function:Mark D. Schwabero, PresidentMercury MarineDate and place of issue:September 04, 2012Fond du Lac, Wisconsin, USAWelcomeYou have selected one of the finest outboards available. Itincorporates numerous design features to ensure operating easeand durability.With proper care and maintenance, you will enjoy using thisproduct for many boating seasons. To ensure maximumperformance and carefree use, we ask that you thoroughly readthis manual.The Operation, Maintenance and Warranty Manual containsspecific instructions for using and maintaining your product. Wesuggest that this manual remain with the product for readyreference whenever you are on the water.Thank you for purchasing one of our products. We sincerelyhope your boating will be pleasant!Mercury MarineEPA Emissions RegulationsOutboards sold by Mercury Marine in the United States arecertified to the United States Environmental Protection Agencyas conforming to the requirements of the regulations for thecontrol of air pollution from new outboard motors. Thiscertification is contingent on certain adjustments being set tofactory standards. For this reason, the factory procedure forservicing the product must be strictly followed and, whereverpracticable, returned to the original intent of the design.Maintenance, replacement, or repair of the emission controldevices and systems may be performed by any marine enginerepair establishment or individual.engiii

Engines are labeled with an emission control information decalas permanent evidence of EPA certification.! WARNINGThe engine exhaust from this product contains chemicalsknown to the state of California to cause cancer, birth defectsor other reproductive harm.Warranty MessageThe product you have purchased comes with a limited warrantyfrom Mercury Marine. The terms of the warranty are set forth inthe Warranty Information section of this manual. The warrantystatement contains a description of what is covered, what is notcovered, the duration of coverage, how to best obtain warrantycoverage, important disclaimers and limitations of damages, andother related information. Please review this information.The description and specifications contained herein were ineffect at the time this manual was approved for printing. MercuryMarine, whose policy is one of continued improvement, reservesthe right to discontinue models at any time, and to changespecifications, designs, methods, or procedures without noticeand without incurring obligation.Mercury Marine, Fond du Lac, Wisconsin U.S.A.Printed in the U.S.A. 2013, Mercury MarineAlpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M withWaves Logo, K‑planes, Mariner, MerCathode, MerCruiser,Mercury, Mercury with Waves Logo, Mercury Marine, MercuryPrecision Parts, Mercury Propellers, Mercury Racing,MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook,SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus,and #1 On the Water are registered trademarks of BrunswickCorporation. Mercury Product Protection is a registered servicemark of Brunswick Corporation.iveng

Mercury Premier ServiceMercury evaluates the service performance of its dealers andassigns its highest rating of "Mercury Premier" to thosedemonstrating an exceptional commitment to service.Earning a Mercury Premier Service rating means a dealer: Achieves a high 12‑month service Customer SatisfactionIndex (CSI) score for warranty service. Possesses all of the necessary service tools, testequipment, manuals, and parts books. Employs at least one certified or master technician. Provides timely service for all Mercury Marine customers. Offers extended service hours and mobile service, whenappropriate. Uses, displays, and stocks an adequate inventory ofgenuine Mercury Precision Parts. Offers a clean, neat shop with well‑organized tools andservice literature.engv

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WARRANTY INFORMATIONWarranty Registration United States and Canada. 1Transfer of Warranty United States and Canada. 1Transfer of Mercury Product Protection (Extended ServiceCoverage) Plan United States and Canada. 23 Year Limited Warranty Against Corrosion. 3Warranty Coverage and Exclusions. 6U.S. EPA Emissions Limited Warranty. 8Emission Control System Components. 8California Emissions Limited Warranty. 9California Air Resources Board Explanation of Your CaliforniaEmission Control Warranty Statement. 13Emission Certification Star Label. 14Warranty Policy—Australia and New Zealand. 15Global Warranty Charts Outboard and Jets. 21engvii

General InformationBoater's Responsibilities. 27Before Operating Your Outboard. 27Boat Horsepower Capacity. 28High‑Speed and High‑Performance Boat Operation. 28Outboard Remote Control Models . 29Propeller Selection. 29Remote Steering Notice. 32Lanyard Stop Switch. 33Protecting People in the Water. 37Passenger Safety Message ‑ Pontoon Boats and Deck Boats. 38Wave and Wake Jumping. 39Impact with Underwater Hazards. 40Exhaust Emissions. 41Selecting Accessories for Your Outboard. 44Safe Boating Recommendations. 44Recording Serial Number. 48250 OptiMax Specifications. 48Component Identification. 50TransportingTrailering Boat/Outboard . 51viiieng

Fuel and OilFuel Recommendations. 52Oil Recommendation. 54Fuel Additives. 54Fuel Requirements. 54Avoiding Fuel Flow Restriction. 54Low Permeation Fuel Hose Requirement . 55EPA Pressurized Portable Fuel Tank Requirements. 55Fuel Demand Valve (FDV) Requirement. 55Mercury Marine's Pressurized Portable Fuel Tank. 56Filling Remote Oil Tank. 57Filling Engine Mounted Oil Reservoir Tank. 58Filling Fuel Tank. 59Features and ControlsRemote Control Features. 60Warning System. 61Power Trim and Tilt. 64OperationImportant Information. 69Engine Break‑in. 70Engine Break‑in Fuel Mixture. 71Prestarting Check List. 71Operating in Freezing Temperatures. 71Operating in Saltwater or Polluted Water. 71Operating at High Elevations. 72Effects of Elevation and Weather on Performance. 72Setting Trim Angle While Running Engine at Idle Speed. 73Operating in Shallow Water. 73Starting the Engine. 74Gear Shifting. 77Stopping the Engine. 78engix

MaintenanceOutboard Care. 79EPA Emissions Regulations. 79Inspection and Maintenance Schedule. 80Flushing the Cooling System. 83Top Cowl Removal and Installation. 84Cleaning Care for Top Cowl. 85Alternator Belt Inspection. 85Fuel System. 86Steering Link Rod Fasteners. 88Fuses . 90Corrosion Control Anode. 91Battery Inspection . 91Battery Information. 92Propeller Replacement. 93Spark Plug Inspection and Replacement. 97Air Compressor Filter. 99Lubrication Points. 101Checking Power Trim Fluid. 104Gearcase Lubrication. 105Submerged Outboard. 107StorageStorage Preparation. 108Fuel System. 108Protecting Internal Engine Components. 110Protecting External Outboard Components. 110Gearcase. 111Positioning Outboard for Storage. 111Battery Storage. 111xeng

TroubleshootingStarter Motor Will Not Crank the Engine. 112Engine Will Not Start. 112Engine Runs Erratically. 113Performance Loss. 113Warning Horn Activates (With Power Loss). 113Warning Horn Activates (No Power Loss). 114Battery Will Not Hold Charge. 114Owner Service AssistanceLocal Repair Service. 115Service Away from Home. 115Parts and Accessories Inquiries. 115Service Assistance. 115Ordering Literature. 118Outboard InstallationMercury Marine Validated Engine Mounting Hardware. 120Boat Horsepower Capacity. 121Start in Gear Protection. 121Selecting Accessories for Your Outboard. 121Fuel System. 122Installation Specifications. 124Lifting the Outboard. 124Steering Cable ‑ Starboard Side Routed Cable. 125Steering Link Rod Fasteners. 126Determining Recommended Outboard Mounting Height. 129Drilling Outboard Mounting Holes. 130Fastening the Outboard to the Transom. 131Electrical, Hoses, Control Cables, and Front Clamp. 137Oil Injection Set‑Up. 150Trim In Pin. 153engxi

Maintenance LogMaintenance Log. 155xiieng

WARRANTY INFORMATIONWarranty Registration United States and CanadaTo be eligible for warranty coverage, the product must beregistered with Mercury Marine.At the time of sale, the selling dealer should complete thewarranty registration and immediately submit it to MercuryMarine via MercNET, e‑mail, or mail. Upon receipt of thiswarranty registration, Mercury Marine will record the registration.A copy of the warranty registration should be provided to you byyour selling dealer.NOTE: Registration lists must be maintained by Mercury Marineand any dealer of Mercury Marine products sold in the UnitedStates, should a safety recall notification under the FederalSafety Act be required.You may change your registered address at any time, includingat time of warranty claim, by calling Mercury Marine or sending aletter or fax with your name, old address, new address, andengine serial number to Mercury Marine’s warranty registrationdepartment. Your dealer can also process this change ofinformation.Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Fax 1 920 907 6663OUTSIDE UNITED STATES AND CANADAFor products purchased outside the United States and Canada,contact the distributor in your country, or the Marine PowerService Center closest to you.Transfer of Warranty United States and CanadaThe limited warranty is transferable to a subsequent purchaser,but only for the remainder of the unused portion of the limitedwarranty. This will not apply to products used for commercialapplications.eng1

WARRANTY INFORMATIONTo transfer the warranty to the subsequent owner, send or fax acopy of the bill of sale or purchase agreement, new owner’sname, address, and engine serial number to Mercury Marine’swarranty registration department. In the United States andCanada, mail to:Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Fax 1 920 907 6663Upon processing the transfer of warranty, Mercury Marine willrecord the new owner's information.There is no charge for this service.OUTSIDE THE UNITED STATES AND CANADAFor products purchased outside the United States and Canada,contact the distributor in your country, or the Marine PowerService Center closest to you.Transfer of Mercury Product Protection (ExtendedService Coverage) Plan United States and CanadaThe remaining coverage period of the Product Protection Plan istransferable to the subsequent purchaser of the engine withinthirty (30) days from the date of sale. Contracts not transferredwithin thirty (30) days of the subsequent purchase will no longerbe valid and the product will no longer be eligible for coverageunder the terms of the contract.To transfer the plan to the subsequent owner, contact MercuryProduct Protection or an authorized dealer to receive a Requestfor Transfer form. Submit to Mercury Product Protection areceipt/bill of sale, a completed Request of Transfer form, and acheck payable to Mercury Marine in the amount of 50.00 (perengine) to cover the transfer fee.Plan coverage is not transferable from one product to anotherproduct or for noneligible applications.2eng

WARRANTY INFORMATIONThe certified preowned engine plans are not transferable.For help or assistance, contact Mercury Product ProtectionDepartment at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST,Monday–Friday or e‑mail mpp support@mercmarine.com.3 Year Limited Warranty Against CorrosionWHAT IS COVERED: Mercury Marine warrants that each newMercury, Mariner, Mercury Racing, Sport‑Jet, M2 Jet Drive,Tracker by Mercury Marine Outboard, Mercury MerCruiserInboard or Sterndrive Engine (Product) will not be renderedinoperative as a direct result of corrosion for the period of timedescribed below.DURATION OF COVERAGE: This limited corrosion warrantyprovides coverage for three (3) years from either the date theproduct is first sold, or the date on which the product is first putinto service, whichever occurs first. The repair or replacement ofparts, or the performance of service under this warranty, doesnot extend the life of this warranty beyond its original expirationdate. Unexpired warranty coverage can be transferred tosubsequent (noncommercial use) purchaser upon properreregistration of the product.CONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGE: Warranty coverage is available onlyto retail customers that purchase from a Dealer authorized byMercury Marine to distribute the product in the country in whichthe sale occurred, and then only after the Mercury Marinespecified predelivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Corrosionprevention devices specified in the Operation and MaintenanceManual must be in use on the boat, and routine maintenanceoutlined in the Operation and Maintenance Manual must betimely performed (including, without limitation, the replacement ofsacrificial anodes, use of specified lubricants, and touch‑up ofnicks and scratches) in order to maintain warranty coverage.Mercury Marine reserves the right to make warranty coveragecontingent upon proof of proper maintenance.eng3

WARRANTY INFORMATIONWHAT MERCURY WILL DO: Mercury's sole and exclusiveobligation under this warranty is limited to, at our option,repairing a corroded part, replacing such part or parts with newor Mercury Marine certified remanufactured parts, or refundingthe purchase price of the Mercury product. Mercury reserves theright to improve or modify products from time to time withoutassuming an obligation to modify products previouslymanufactured.HOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repair,and reasonable access to the product for warranty service.Warranty claims shall be made by delivering the product forinspection to a Mercury dealer authorized to service the product.If purchaser cannot deliver the product to such a dealer, writtennotice must be given to Mercury. We will then arrange for theinspection and any covered repair. Purchaser, in that case, shallpay for all related transportation charges and/or travel time. If theservice provided is not covered by this warranty, purchaser shallpay for all related labor and material, and any other expensesassociated with that service. Purchaser shall not, unlessrequested by Mercury, ship the product or parts of the productdirectly to Mercury. Proof of registered ownership must bepresented to the dealer at the time warranty service is requestedin order to obtain coverage.WHAT IS NOT COVERED: This limited warranty does not coverelectrical system corrosion; corrosion resulting from damage,corrosion which causes purely cosmetic damage, abuse, orimproper service; corrosion to accessories, instruments, steeringsystems; corrosion to factory installed jet drive unit; damage dueto marine growth; product sold with less than a one year limitedProduct warranty; replacement parts (parts purchased bycustomer); products used in a commercial application.Commercial use is defined as any work or employment relateduse of the product, or any use of the product which generatesincome, for any part of the warranty period, even if the product isonly occasionally used for such purposes.4eng

WARRANTY INFORMATIONCorrosion damage caused by stray electrical currents (onshorepower connections, nearby boats, submerged metal) is notcovered by this corrosion warranty and should be protectedagainst by the use of a corrosion protection system, such as theMercury Precision Parts or Quicksilver MerCathode systemand/or Galvanic Isolator. Corrosion damage caused by improperapplication of copper base antifouling paints is also not coveredby this limited warranty. If antifouling protection is required,Tri‑Butyl‑Tin‑Adipate (TBTA) base antifouling paints arerecommended on Outboard and MerCruiser boating applications.In areas where TBTA base paints are prohibited by law, copperbase paints can be used on the hull and transom. Do not applypaint to the outboard or MerCruiser product. In addition, caremust be taken to avoid an electrical interconnection between thewarranted product and the paint. For MerCruiser product, anunpainted gap of at least 38 mm (1.5 in.) should be left aroundthe transom assembly. Refer to the Operation and MaintenanceManual for additional details.For additional information regarding events and circumstancescovered by this warranty, and those that are not, see theWarranty Coverage section of the Operation and MaintenanceManual, incorporated by reference into this warranty.DISCLAIMERS AND LIMITATIONS:THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THEEXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIEDWARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGESARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOMESTATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOUSPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGALRIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TOCOUNTRY.eng5

WARRANTY INFORMATIONWarranty Coverage and ExclusionsThe purpose of this section is to help eliminate some of the morecommon misunderstandings regarding warranty coverage. Thefollowing information explains some of the types of services thatare not covered by warranty. The provisions set forth followinghave been incorporated by reference into the Three Year LimitedWarranty Against Corrosion Failure, the International LimitedOutboard Warranty, and the United States and Canada LimitedOutboard Warranty.Keep in mind that warranty covers repairs that are needed withinthe warranty period because of defects in material andworkmanship. Installation errors, accidents, normal wear, and avariety of other causes that affect the product are not covered.Warranty is limited to defects in material or workmanship, butonly when the consumer sale is made in the country to whichdistribution is authorized by us.Should you have any questions concerning warranty coverage,contact your authorized dealer. They will be pleased to answerany questions that you may have.GENERAL EXCLUSIONS FROM WARRANTY1. Minor adjustments and tune‑ups, including checking,cleaning, or adjusting spark plugs, ignition components,carburetor settings, filters, belts, controls, and checkinglubrication made in connection with normal services.2. Factory installed jet drive units ‑ Specific parts excludedfrom the warranty are: the jet drive impeller and jet driveliner damaged by impact or wear, and water damageddriveshaft bearings as a result of improper maintenance.3. Damage caused by neglect, lack of maintenance, accident,abnormal operation, or improper installation or service.4. Haul‑out, launch, towing charges, removal and/orreplacement of boat partitions or material because of boatdesign for necessary access to the product, all relatedtransportation charges and/or travel time, etc. Reasonableaccess must be provided to the product for warranty service.Customer must deliver product to an authorized dealer.6eng

WARRANTY INFORMATION5. Additional service work requested by customer other thanthat necessary to satisfy the warranty obligation.6. Labor performed by other than an authorized dealer may becovered only under the following circumstances: whenperformed on emergency basis (providing there are noauthorized dealers in the area who can perform the workrequired or have no facilities to haul‑out, etc., and priorfactory approval has been given to have the work performedat this facility).7. All incidental and/or consequential damages (storagecharges, telephone or rental charges of any type,inconvenience or loss of time or income) are the owner'sresponsibility.8. Use of other than Mercury Precision or Quicksilver partswhen making warranty repairs.9. Oils, lubricants, or fluids changed as a matter of normalmaintenance is customer's responsibility unless loss orcontamination of same is caused by product failure thatwould be eligible for warranty consideration.10. Participating in or preparing for racing or other competitiveactivity or operating with a racing type lower unit.11. Engine noise does not necessarily indicate a serious engineproblem. If diagnosis indicates a serious internal enginecondition which could result in a failure, conditionresponsible for noise should be corrected under thewarranty.12. Lower unit and/or propeller damage caused by striking asubmerged object is considered a marine hazard.13. Water entering engine through the fuel intake, air intake, orexhaust system or submersion.14. Failure of any parts caused by lack of cooling water, whichresults from starting motor out of water, foreign materialblocking inlet holes, motor being mounted too high, ortrimmed too far out.15. Use of fuels and lubricants which are not suitable for usewith or on the product. Refer to the Maintenance section.eng7

WARRANTY INFORMATION16. Our limited warranty does not apply to any damage to ourproducts caused by the installation or use of parts andaccessories which are not manufactured or sold by us.Failures which are not related to the use of those parts oraccessories are covered under warranty if they otherwisemeet the terms of the limited warranty for that product.U.S. EPA Emissions Limited WarrantyConsistent with the obligations created by 40 CFR Part 1045,Subpart B, Mercury Marine provides a five year or 175 hours ofengine use, whichever occurs first, to the retail customer, thatthe engine is designed, built, and equipped so as to conform atthe time of sale with applicable regulations under section 213 ofthe Clean Air Act, and that the engine is free from defects inmaterials and workmanship which cause the engine to fail toconform with applicable regulations. This emission‑relatedwarranty covers all the components listed in the EmissionControl Syste

WARRANTY INFORMATION eng 1 Warranty Registration United States and Canada To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, e‑mail, or mail. Upon receipt of this