OPTIMAX Mercury User Manual

MAINTENANCE

Outboard Care

To keep your outboard in the best operating condition, it is important that
your outboard receive the periodic inspections and maintenance listed in
the Inspection and Maintenance Schedule. We urge you to keep it
maintained properly to ensure the safety of you and your passengers, and
retain its dependability.

WARNING

!

Neglected inspection and maintenance service of your outboard or
attempting to perform maintenance or repair on your outboard if you are
not familiar with the correct service and safety procedures could cause
personal injury, death, or product failure.

Record maintenance performed in Maintenance Log at the back of this
book. Save all maintenance work orders and receipts.

SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD

We recommend using original Mercury Precision or Quicksilver
replacement parts and Genuine Lubricants.

WARNING

!

Using a replacement part that is inferior to the original part could result
in personal injury, death, or product failure.

EPA Regulations

All new outboards manufactured by Mercury Marine are certified to the
United States Environmental Protection Agency, as conforming to the
requirements of the regulations for the control of air pollution from new
outboard motors. This certification is contingent on certain adjustments
being set to factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, wherever practicable,
returned to the original intent of the design. Maintenance, replacement, or
repair of the emission control devices and systems may be performed by
any marine spark ignition (SI) engine repair establishment or individual.

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MAINTENANCE

EPA Emissions

EMISSION CERTIFICATION LABEL

An emission certification label, showing emission levels and engine
specifications directly related to emissions, is placed on the engine at time
of manufacture.

EMISSION CONTROL
INFORMATION

This e ngine conforms to model year EPA regulations for Ma rine SI engines.

a

b

c

d

e

TIM ING (IN DE GREES):

Su pp ressor spar k pl ug:

Valv e C learan ce (C old) m m

Re fer to Ow ner' s Manual for require d m ainte na nce.

IDLE SPEED :

hp

Standa rd spa rk p lug :

:

GAP

a - Idle speed
b - Engine horsepower
c - Timing specification
d - Recommended spark plug

and gap

e - Valve clearance (if

applicable)

cc

Inta ke

Exhau st

FAM ILY:

FEL :

g/kW

h

f - Family number
g - Maximum emission output for

the engine family

h - Piston placement
i - Date of manufacture

f

g

h

i

ob01071

OWNER RESPONSIBILITY

The owner/operator is required to have routine engine maintenance
performed to maintain emission levels within prescribed certification
standards.

The owner/operator is not to modify the engine in any manner that would
alter the horsepower or allow emissions levels to exceed their
predetermined factory specifications.

Inspection And Maintenance Schedule

BEFORE EACH USE

• Check that lanyard stop switch stops the engine.

• Visually inspect the fuel system for deterioration or leaks.

• Check outboard for tightness on transom.

• Check steering system for binding or loose components.

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MAINTENANCE

• Visually check steering link rod fasteners for proper tightness. See
Steering Link Rod Fasteners.

• Check propeller blades for damage.

AFTER EACH USE

• Flush out the outboard cooling system if operating in salt or polluted
water. See Flushing the Cooling System.

• Wash off all salt deposits and flush out the exhaust outlet of the
propeller and gearcase with fresh water if operating in salt water.

EVERY 100 HOURS OF USE OR ONCE YEARLY,
WHICHEVER OCCURS FIRST

• Lubricate all lubrication points. Lubricate more frequently when used
in salt water. See Lubrication Points.

• Replace spark plugs at first 100 hours or first year. After that, inspect
spark plugs every 100 hours or once yearly. Replace spark plugs as
needed. See Spark Plug Inspection and Replacement.

• Replace fuel filter. See Fuel System.

• Replace compressor air intake filter. See Compressor Air Intake Filter.

• Inspect alternator belt. See Alternator Belt Inspection.

• Check corrosion control anodes. Check more frequently when used
in salt water. See Corrosion Control Anodes.

• Drain and replace gearcase lubricant. See Gearcase Lubrication.

• Check power trim fluid. See Checking Power Trim Fluid.

• Inspect battery. See Battery Inspection.

•

Check control cable adjustments.

•

Lubricate splines on the driveshaft and shift shaft.

• Check tightness of bolts, nuts, and other fasteners.

EVERY 300 HOURS OF USE OR THREE YEARS

• Replace water pump impeller (more often if overheating occurs or
reduced water pressure is noted).

BEFORE PERIODS OF STORAGE

• Refer to Storage procedure. See Storage section.

1.

1.

1.

Flushing The Cooling System

Flush the internal water passages of the outboard with fresh water after
each use in salt, polluted, or muddy water. This will help prevent a buildup
of deposits from clogging the internal water passages.

1. These items should be serviced by an authorized dealer.

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MAINTENANCE

Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing
attachment.

WARNING

!

To avoid possible injury when flushing, remove the propeller. Refer to
Propeller Replacement.

1. Remove propeller. Refer to Propeller Replacement. Install the flushing
attachment so the rubber cups fit tightly over the cooling water intake.

ob01604

2. Attach a water hose to the flushing attachment. Turn on the water and
adjust the flow so water is leaking around the rubber cups to ensure
the engine receives an adequate supply of cooling water.

ob00570

3. Start the engine and run it at idle speed in neutral shift position.

IMPORTANT: Do not run engine above idle when flushing.

4. Adjust water flow (if necessary) so excess water continues leaking out
from around the rubber cups to ensure the engine is receiving an
adequate supply of cooling water.

ob00571

5. Check for a steady stream of water flowing out of the water pump
indicator hole. Continue flushing the outboard for 3 to 5 minutes,
carefully monitoring water supply at all times.

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MAINTENANCE

6. Stop the engine, turn off the water, and remove the flushing
attachment. Reinstall the propeller.

Flushing The Cooling System ‑ Models With
Accessory Hose Flush Attachment

Flush the internal water passages of the outboard with fresh water after
each use in salt, polluted, or muddy water. This will help prevent a build up
of deposits from clogging the internal water passages.

1. Thread a water hose into hose adaptor.

2. Remove dust cover and push the host adaptor into the flush connector
until it locks (snaps) in place.

a

a - Flush connector
b - Button

NOTE: Engine can be stopped or running at idle speed in neutral when
flushing the cooling system. Do not flush engine using a water source that
exceeds 6.5 kPa (45 psi).

3. Turn on the water and flush the cooling system for a minimum of 3
minutes.

NOTE: The hose adaptor shuts off the water flow whenever it is
disconnected from the flush connector.

4. Push button in to release the hose adaptor.

5. Reinstall dust cover.

b

d

c

ob01605

c - Hose adaptor
d - Dust cover

FREEZING TEMPERATURE

The water should be drained out of the engine flush hose if there is a
chance of freezing temperature. Drain water as follows:

1. Remove water hose from the hose adaptor.

2. Insert the adaptor only into the flush connector.

3. Tilt the outboard up until all the water has drained out of the hose.

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MAINTENANCE

Top Cowl Removal And Installation

REMOVAL

1. Unlock the rear latch by pushing lever up.

2. Lift rear of cowl and disengage front hook.

ob01606

INSTALLATION

1. Engage the front hook and push cowl back over the cowl seal.

2. Push cowl down and move the rear latch lever down to lock.

Cleaning Care for Top Cowl

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will
result in minor surface scratches. Always wet the surface before cleaning.
Follow cleaning and waxing procedure.

CLEANING AND WAXING PROCEDURE

1. Before washing, rinse the top cowl with clean water to remove dirt and
dust that may scratch the surface.

2. Wash the top cowl with clean water and a mild non‑abrasive soap.
Use a soft clean cloth when washing.

3. Dry thoroughly with a soft clean cloth.

4. Wax the surface using a non‑abrasive automotive polish (polish
designed for clear coat finishes). Remove the applied wax by hand
using a clean soft cloth.

Fuel System

WARNING

!

Avoid serious injury or death from gasoline fire or explosion. Carefully
follow all fuel system service instructions. Always stop the engine and do
not smoke or allow open flames or sparks in the area while servicing any
part of the fuel system.

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