Mercury optimax 115, optimax 75, optimax 90 Installation Manual
INSTALLATION MANUAL
75/90/115 OPTIMAX
Important Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 2. . . . . . . . . . . . . . . . . . . . . . . .
Start in Gear Protection 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 2. . . . . . . . . . . .
Fuel Tank Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting Outboard 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining Recommended Outboard Mounting
Height 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTICE TO INSTALLER: After completing assembly, these instructions should be
placed with the product for the owner’s future use.
IMPORT ANT: If the boat is to be water tested, the operator should be familiar with the
operation procedures in the Operation and Maintenance Manual.
Electrical, Fuel Hose and Control Cables 8. . . . . . . . . . . .
Front Cover Assembly 8. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Wiring Harness 9. . . . . . . . . . . . . . . . . . . . . . . .
Battery Cable Connections 10. . . . . . . . . . . . . . . . . . . .
Fuel Hose Connection 11. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 12. . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation 14. . . . . . . . . . . . . . . . . . . . .
Filling Fuel System 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling the Oil Injection Tank 15. . . . . . . . . . . . . . . . . . . . . . .
Priming the Oil Injection Pump 16. . . . . . . . . . . . . . . . . . . .
Propeller Installation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim-In Stop Adjustment 18. . . . . . . . . . . . . . . . . . . . . . . . .
Important Information
Before Starting Engine
Before starting engine for the first time, prime the oil injection pump. Procedure on page 16.
Prevent possible engine damage, Prime the oil injection pump before starting engine for the first time.
Required Fuel
Do not use pre-mixed gas and oil in this engine. Use a clean and fresh recommended
gasoline during engine break-in and after engine break-in.
Recommended Oil
Mercury or Quicksilver Optimax/DFI 2-Cycle engine oil is recommended for your engine. If Optimax/DFI 2-Cycle engine oil i s not a vailable, we r ecommend u sing Mercury o r Q uicksilver TC-W3
Premium Plus 2-Cycle Oil. Severe engine damage may result from use of an inferior oil.
Avoiding Fuel Flow Restrictions
IMPORTANT: Adding components to the fuel supply system as in filters, valves, fittings, etc. may restrict the fuel flow and could cause engine stalling at low speed, and/
or a lean fuel condition at high RPM, that could cause engine damage.
CAUTION
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If
necessary, install a pressure regulator to regulate the pressure.
Page 1 of 18 Printed in U.S.A. - 2004, Mercury Marine 90-10209050 JANUARY 2004
75/90/115 OPTIMAX
Boat Horsepower Capacity
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
Do not overpower or overload the 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.
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.
WARNING
Start in Gear Protection
The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear.
WARNING
Avoid serious injury or death from a sudden unexpected acceleration when starting
your engine. The design of this outboard requires that the remote control used with
it must have a built in start-in-gear protection device.
Selecting Accessories For The Outboard
Genuine Quicksilver Parts and Accessories have been specifically designed and tested for
this outboard.
Some accessories not manufactured or sold by Quicksilver 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.
Fuel Tank Installation
PORTABLE FUEL TANK
Select a suitable location in boat within engine fuel line length limitations and secure tank
in place.
PERMANENT FUEL TANK
These should be installed in accordance with industry and federal safety standards which
include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.
Page 2 of 18
Installation Specifications
a
a – Transom Opening – Minimum
Single Engine (Remote) – 33-3/8 in. (848 mm)
Dual Engines – 59-3/4 in. (1518 mm)
75/90/115 OPTIMAX
a
b
b – Engine Center Line For Dual Engine
26 in. (660mm) Minimum
Lifting Outboard
Use Flywheel Puller/Lifting Eye (91-83164M).
Page 3 of 18
75/90/115 OPTIMAX
Steering Cable
STARBOARD SIDE ROUTED CABLE
1. Lubricate O-ring seal and entire cable end.
95
95
2-4-C With Teflon (92-825407A12)
2. Insert steering cable into tilt tube.
3. Torque nut to 35 lb. ft. (47.5 N·m).
Page 4 of 18
Steering Link Rod
1. Install steering link rod per illustration.
75/90/115 OPTIMAX
a
c
d
b
a-Special Bolt (10-849838) Torque to 20 lb. ft. (27 N·m)
b-Nylon Insert Locknut (11-34863) Torque to 20 lb. ft. (27 N·m)
c-Flat Washer (2)
d-Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut
Off 1/4 Turn
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special bolt (“a” - Part Number 10-848838) and self locking
nuts (“b” & “c” - Part Number 1 1-34863). These locknuts must never be replaced with
common nuts (non locking) as they will work loose and vibrate off, freeing the link
rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death.
Page 5 of 18
75/90/115 OPTIMAX
Determining Recommended Outboard Mounting Height
26 in.
(660mm)
25 in.
(635mm)
24 in.
(609mm)
(e)
Outboard
Mounting
Height (See
e
NOTE Below)
23 in.
(584mm)
22 in.
(560mm)
21 in.
(533mm)
20 in.
(508mm)
c
a
d
b
19 in.
(482mm)
NOTE: Add 5 in. (127mm) for XL models to the listed outboard mounting
height.
IMPORTANT
NOTICE TO INSTALLER
1. The outboard should be mounted high enough on the transom so that the exhaust
relief hole will stay at least 1 in. (25.4 mm) above the water line when the engine is
running at idle speed. Having the exhaust relief hole above the water line will prevent
exhaust restriction. Exhaust restriction will result in poor performance at idle.
2. However, keep in mind that the mounting height (e) of the outboard must not exceed
25 in. (635 mm) for L models, 30 in. (762 mm) for XL models. Mounting the outboard
higher may cause damage to the gear case components.
This solid line is recommended to determine the out-
a.
board mounting height.
IMPORTANT: Increasing the height of outboard generally will provide the following: 1) Less steering torque,
2) more top speed, 3) greater boat stability , but, 4) will
cause more prop “break loose” which may be particularly noticeable when planing off or with heavy load.
These broken lines represent the extremes of known
b.
successful outboard mounting height dimensions.
10
20 30 40 50 60 70 80
Maximum Boat Speed Anticipated
c.
This line may be preferred to determine outboard
mounting height dimension, if maximum speed is the
only objective.
d.
This line may be preferred to determine outboard
mounting height dimension for dual outboard installation.
Outboard mounting height (height of outboard transom
e.
brackets from bottom of boat transom). For heights over
22 in. (560mm), a propeller, that is designed for surfacing operation is usually preferred.
Page 6 of 18
Loading...