Mercury 200 VERADO, 250 VERADO, 225 VERADO, 275 VERADO Installation Manual
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200/225/250/275 VERADO 4-STROKE
INSTALLATION MANUAL
Table of Contents
Notice to Installer ................................................... 2
Avoiding Loss of Throttle and Shift Control ........... 2
Accessory Electric Fuel Pump/Fuel Line Primer
Bulb ....................................................................... 2
Avoiding Fuel Flow Restriction .............................. 2
Boat Horsepower Capacity .................................... 2
Selecting Accessories For Your Outboard ............ 3
Fuel Tanks ............................................................. 3
Portable Fuel Tank ........................................... 3
Permanent Fuel Tank ....................................... 3
Determining Recommended Outboard Mounting
Height .................................................................... 4
Installing Outboard ................................................ 5
Installation Specifications..................................5
Maximum Outboard Mounting Height................5
Drilling Outboard Mounting Holes......................6
Lifting Outboard.................................................7
Fastening Outboard...........................................8
Power Steering Installation .................................. 10
Power Steering System...................................10
Installation Procedure......................................10
Connection of the Hydraulic Hoses to the Steering
Helm................................................................12
Connection of the Hydraulic Hoses to the Power
Steering Pump.................................................14
Connection of the Hydraulic Hoses to the Steering
Cylinder............................................................15
Electrical Connections to the Steering Pump..17
Filling Power Steering System with Engine Not
Running...........................................................19
Filling Power Steering System with Engine
Running...........................................................21
Routing Connections Through the Cowl..........22
Fuel Hose Connection.....................................23
Wiring And Installation ......................................... 24
Wire Color Code Abbreviations.......................24
Installation Guidelines for DTS System
Components....................................................24
Data Harness Pulling Procedure.....................24
Junction Box (If Equipped)...............................25
Non-Mercury Marine Provided Ignition Switch.25
Wiring Accessories..........................................26
System Wiring Reference Points.....................26
Battery Cable Size For Outboard Models........27
Connecting 14 Pin Data Harness - Single
Engine..............................................................29
Connecting 14 Pin Data Harness - Dual Engine
.........................................................................30
Installing DTS Command Module and Harness -
Single Engine...................................................31
Installing DTS Command Module and Harness -
Dual Engine/Single Helm.................................34
Battery Information..........................................35
Connecting Battery Cables and DTS Power
Harness...........................................................36
Connecting Fuel Tank And Speed Sensor .....39
Switched 12V Accessory Connection..............41
DTS Wiring - Single Engine.............................42
DTS Wiring - Dual Engine................................44
System Wiring Installation Checklist................45
Propeller Installation ........................................... 45
Paddle Wheel Speed Sensor Installation (If
Equipped) ............................................................ 47
Parts Provided ................................................ 47
Selecting Location .......................................... 47
Transom Angle Requirements ........................ 48
Installing Bracket ............................................ 48
Routing the Cable ........................................... 49
Installing and Removing the Paddle Wheel .... 50
Wiring Connections ......................................... 50
Template - Paddle Wheel Speed Sensor ....... 51
Page 1 / 51 © 2004 Mercury Marine 90-10238051 JUNE 2004
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Lubricant, Sealant, Adhesives
Tube Ref No. Description Where Used Part No.
Anti-Corrosion Grease Propeller shaft splines 92-802867A1
2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A1
Notice to Installer
This Product Requires Electronic Calibration Before Use.
Installation of this product will require electronic calibration. This calibration must not be
attempted by anyone other than the Original Equipment Manufacturer (OEM) or a
Mercury technician trained in Digital Throttle and Shift systems (DTS) at an authorized
Mercury dealership. Improper installation and calibration of the DTS product will result in
a system which is inoperable or unsafe for use.
Avoiding Loss of Throttle and Shift Control
WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not splice
or probe into any wire insulation of the DTS system. Splicing or probing will damage
the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring
failure and loss of throttle and shift control.
Accessory Electric Fuel Pump/Fuel Line Primer Bulb
IMPORTANT: Do not install either an accessory electric fuel pump or a fuel line primer
bulb into the fuel system of this engine.
Avoiding Fuel Flow Restriction
IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.)
may restrict the fuel flow. This may cause engine stalling at low speed, and/or a lean fuel
condition at high RPM that could cause engine damage.
Boat Horsepower Capacity
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1) cause
loss of boat control 2) place too much weight at the transom altering the designed
flotation characteristics of the boat or 3) cause the boat to break apart particularly
around the transom area. Overpowering a boat can result in serious injury, death or
boat damage.
Page 2 / 51 90-10238051
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
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Do not overpower or overload your boat. Most boats will carry a required capacity plate
indicating the maximum acceptable power and load as determined by the manufacturer
following certain federal guidelines. If in doubt, contact your dealer or the boat
manufacturer.
Selecting Accessories For Your Outboard
Genuine Mercury Precision or Quicksilver Accessories have been specifically designed
and tested for this outboard
Some accessories not manufactured or sold by Mercury Marine are not designed to be
safely used with this outboard or outboard operating system. Acquire and read the
installation, operation, and maintenance manuals for all selected accessories.
200/225/250/275 VERADO 4-STROKE
Fuel Tanks
Portable Fuel Tank
Select a suitable location in the boat within the engine fuel line length limitations and
secure the tank in place.
Permanent Fuel Tank
Permanent fuel tanks should be installed in accordance with industry and federal safety
standards, which include recommendations applicable to grounding, anti-siphon
protection, ventilation, etc.
90-10238051 Page 3 / 51
(20 in.)
(21 in.)
(22 in.)
(23 in.)
(24 in.)
(25 in.)
(26 in.)
(19 in.)
10
20 30 40 50 60 70 80
66.0 cm
63.5 cm
60.9 cm
58.4 cm
56.0 cm
53.3 cm
50.8 cm
48.2 cm
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Determining Recommended Outboard Mounting Height
a - The solid line is recommended to determine the outboard mounting height.
b - The broken lines represent the extremes of known successful outboard
mounting height dimensions.
c - The line may be preferred to determine outboard mounting height dimension,
if maximum speed is the only objective.
d - The line may be preferred to determine outboard mounting height dimension
for dual outboard installation.
e - Outboard mounting height (height from a point on the pedestal 48 mm
[1-7/8 in.] above center of top mounting hole to the bottom of the boat
transom). For heights over 56.0 cm (22 in.), a propeller designed for surfacing
operation is usually preferred.
f - Maximum boat speed (m.p.h.) anticipated.
NOTICE
• The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE" mark on the
idle relief grommet (located at the rear of the outboard), when the outboard is fully tilted in/down. If
waterline is above "MAX STATIC WATERLINE" mark, adjust boat load forward or increase (raise)
outboard mounting height to correctly place mark above waterline.
• Add 12.7 cm (5 in.) for XL models and 25.4 cm (10 in.) for XXL models to listed outboard mounting
height.
• The mounting height of the outboard must not exceed 63.5 cm (25 in.) for XL models and 76.2 cm
(30 in.) for XXL models. Mounting the outboard higher may cause damage to the gearcase
components.
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Increasing the mounting height will usually:
• Increase top speed
• Increase boat stability
• Cause propeller to break loose during planing or turning
Installing Outboard
Installation Specifications
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a - Minimum transom opening
b - Engine center line for dual engine - 66.0 cm (26 in.)
Minimum Transom Opening
Single engine 99.0 cm (39 in.)
Dual engine 165.0 cm (65 in.)
Maximum Outboard Mounting Height
The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models,
76.2 cm (30 in.) for XL models and 88.9 cm (35 in.) for XXL models. Mounting the outboard
higher may cause damage to the gearcase components.
90-10238051 Page 5 / 51
MAX STATIC
WATERLINE
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MAXIMUM STATIC WATERLINE
The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE"
mark on the idle relief grommet (located at the rear of the outboard) when the outboard
is fully tilted in/down. If waterline is above "MAX STATIC WATERLINE" mark, adjust boat
load forward or increase (raise) outboard mounting height to correctly place mark above
waterline.
Drilling Outboard Mounting Holes
IMPORTANT: Before drilling any mounting holes, carefully read Determining
Recommended Outboard Mounting Height. There is a 19 mm (0.75 in.) difference
between the outboard mounting holes in the transom brackets.
WARNING
Avoid possible serious injury or death. Do not, under any circumstances, allow the upper
outboard mounting bolts to be closer than 25.4 mm (1 in.) from the top of the boat
transom. Never install the upper mounting bolts through shims.
1. Mark four mounting holes on the transom using the transom drilling fixture.
a - Drill guide holes
b - Transom drilling fixture - not included
c - Transom centerline
Transom Drilling fixture 91-98234A2
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2. Place masking tape directly onto the boat where the mounting holes will be drilled to
3. Using the drill guide holes on the transom drilling fixture, drill four 13 mm (17/32 in.)
Lifting Outboard
1. Remove top cowl and engine flywheel cover.
2. Install lifting ring/flywheel puller to flywheel. Tighten bolts securely.
3. Lift engine using engine lift with a minimum capacity of 450kg (1000 lb.).
4. Avoid interference by placing the lower mounting bolts into the lower mounting slots
200/225/250/275 VERADO 4-STROKE
help keep the fiberglass from chipping.
holes perpendicular to and through the transom.
before placing outboard against the transom.
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5. Refer to Determining Recommended Outboard Mounting Height, and install outboard
to the nearest recommended mounting height.
Lifting Eye 91-895343T01
6. Fasten outboard with mounting hardware provided. Refer to Fastening Outboard.
Fastening Outboard
1. Place lower mounting bolts into mounting slots before placing outboard on transom.
2. Refer to Determining Recommended Outboard Mounting Height, and install outboard
to the nearest recommended mounting height.
3. Fasten outboard with the stainless steel bolts, nylon insert locknuts and flat washers
as shown.
a - Lifting eye b - Mounting bolts
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CAUTION
To avoid loss of outboard, ensure that a minimum of two full threads of bolt extend
beyond locknut after tightening locknut. Ensure mounting nut is tightened against
transom, not the shank of the mounting bolt.
a - Transom bolts (1/2 x 20) (4)
b - Flat washers - outer (4)
c - Nylon insert locknuts (4)
Outboard Transom Mounting Hardware - Supplied with Outboard
Part Number Part Name Description
10-67755003 Transom bolt 1/2 x 20 x 5.50 in. long (3.25 in. thread)
11-826711-17 Nylon insert locknut 1/2 x 20
12-28421 Washer - inner 0.516 in. ID x 1.50 in. OD
12-895062 Washer - outer 0.551 in. ID x 1.06 in. OD
Available Transom Mounting Bolts
Part Number Part Name Description
10-814259 Transom bolt 1/2 x 20 x 4.00 in. long (2.25 in. thread)
10-67755-1 Transom bolt 1/2 x 20 x 4.50 in. long (2.25 in. thread)
10-67755-2 Transom bolt 1/2 x 20 x 6.50 in. long (2.75 in. thread)
d - Flat washers - inner (4)
e - Marine sealer - apply to shank of
bolts, not threads
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Power Steering Installation
Power Steering System
a - Steering helm
b - Steering cylinder on outboard
Installation Procedure
NOTE: On some large/heavy dual outboard boats the steering forces generated in
extreme maneuvers may create loads that exceed the pump's pressure capacity. If the
happens, the operator may feel intermittent periods of load feedback at the steering
wheel. The steering wheel may feel hard to turn for brief periods during these extreme
maneuvers. If this happens and steering performance is deemed unacceptable for the
application, a second (accessory) cylinder may be rigged. When using a second steering
cylinder the 40cc helm should be replaced with a 50cc helm.
SELECTING LOCATION FOR THE POWER STEERING PUMP
c - Power steering pump
CAUTION
To ensure proper steering operation, hydraulic power steering system must be
protected from contamination. Make hydraulic connection in a clean work area. Route
hoses with the protective shipping caps in place. Remove protective shipping cap from
hose and component fitting as each connection is made.
1. Select a mounting location (floor or side of internal bulkhead) for the installation of the
power steering pump that meets the following requirements
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• To reduce noise on aluminum or metal hulls, isolate steering hoses from hull with
suitable non-abrasive hangers.
• Steering hoses from steering wheel helm must be free of twists or stress. Gently
secure hose bundle together with a cable tie, located approximately 25.4 cm
(10 in.) from the steering wheel helm.
• Do not mount pump on an angle greater then 15° from vertical position.
• The pump electrical wiring must be within reach of the auxiliary battery.
• Pump should be mounted in an area that allows sound enclosure, cover removal,
and easy access to the fill cap.
• Install pump in an area where bilge water will not contaminate the pump.
• To reduce transmitted noise, mount pump on wood or fiberglass surface. Avoid
mounting pump on aluminum or steel surfaces.
REQUIRED MOUNTING CLEARANCES FOR THE POWER STEERING PUMP
a - 215 mm (8 1/2 in.)
b - 310 mm (12 7/32 in.) to top cover (not shown)
c - 285 mm (11 1/4 in.)
d - 432 mm (17 in.) clearance required for cover removal
INSTALLING POWER STEERING PUMP
1. The power steering pump can be mounted two ways:
• On a side of the internal bulkhead
• Mounted on the floor
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2. Mount the power steering pump at the selected location, using appropriate fastening
hardware suitable for the type of material and thickness of the mounting surface.
Mounted on internal bulkhead Mounted on floor
a - Lag screws or thru-bolts (3 or 4)
b - Mounting hardware
Connection of the Hydraulic Hoses to the Steering Helm
NOTE: Hoses must be routed up through steering helm opening in dash and secured to
helm fittings prior to mounting the steering helm.
1. Place the steering hoses through one backing plate on the internal side of the
dashboard. Route the steering hoses through the drilled opening, and place the
required amount of backing plates on the hoses on the external side of the dashboard.
NOTE: The number of backing plates varies depending on helm displacement.
a - Backing plates
2. Remove and discard the shipping caps from ends of the four fittings on the steering
helm. Ensure the O-ring seals did not lift off with the shipping caps.
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L PORT
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3. Ensure O-ring seals are in place on end of steering helm fittings.
a - O-ring seals (4) b - Plug - not used
4. Make the hose connections to the steering helm as shown. Use a thin wrench and
hold the helm fittings from turning while tightening hoses. Do not over-tighten the hose
connections.
a - Thin wrench
b - Helm hex fitting wrench size (P & T) - 19 mm (3/4 in.)
c - Helm hex fitting wrench size (R & L) - 16 mm (5/8 in.)
d - Hydraulic hose hex fitting wrench size (P & T) - 21 mm (13/16 in.)
e - Hydraulic hose hex fitting wrench size (R STAR & L PORT) - 18 mm
Helm Fitting ID Mark Hose ID Mark Description
P P Pressure from pump to helm
90-10238051 Page 13 / 51
T T Tank low pressure return to pump
(11/16 in.)
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Helm Fitting ID Mark Hose ID Mark Description
R R-STAR Hose connects to starboard side of steering cylinder
L L-PORT Hose connects to port side of steering cylinder
Connection of the Hydraulic Hoses to the Power Steering Pump
1. Remove and discard the yellow protector cap from end of tank low pressure fitting.
2. Connect the low pressure hydraulic hose from the steering helm to the low pressure
fitting on the pump reservoir as shown. Fasten hose to fitting with constant tension
spring clamp.
a - Yellow protector cap (remove and discard)
b - Low pressure hydraulic hose from steering helm
c - Clamp
3. Ensure that O-ring seal is on end of hose.
Page 14 / 51 90-10238051
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4. Connect the high pressure hydraulic hose from the steering helm to the pump as
shown.
a - O-ring b - High pressure hydraulic steering
hose
Connection of the Hydraulic Hoses to the Steering Cylinder
1. Route the hydraulic hoses to the outboard steering cylinder. Bulkhead fittings are
available if an opening does not exist in the engine well.
a - Bulkhead fitting - bulkhead thickness up to 1.9 cm (0.75 in.) (22-892517)
b - Bulkhead fitting - bulkhead thickness up to 7.62 cm (3 in.) (22-892518)
NOTE: The 90° hose fittings on the steering cylinder can be rotated to align with hose
routing. Straight hose fittings (22-892519) are also available.
90-10238051 Page 15 / 51
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200/225/250/275 VERADO 4-STROKE
2. Position the 90° hose fittings to the desired direction. Loosen fastening nuts in order
to rotate. Position fittings and re-tighten fastening nuts.
a - Position fittings
c - Straight fitting
b - 90° fitting
3. Remove and discard the shipping caps from the two fittings on the steering cylinder.
Ensure O-ring seals did not lift off with shipping caps.
4. Ensure O-ring seals are in place on end of each fitting.
a - O-rings
5. Make the hydraulic steering hose connections to the steering cylinder as shown.
Page 16 / 51 90-10238051
a - Port fitting (L PORT) b - Starboard fitting (R STAR)
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