200/225/250/275 VERADO 4-STROKE INSTALLATION MANUAL

Transcription

1 Mrury, Mrury Mrin, MrCruisr, Mrury MrCruisr, Mrury Ring, Mrury Prision Prts, Mrury Propllrs, Mrinr, Quiksilvr, #1 On Th Wtr, Alph, Brvo, Pro Mx, OptiMx, Sport-Jt, K-Plns, MrCtho, RiGui, SmrtCrft, Zro Effort, M with Wvs logo, Mrury with Wvs logo, n SmrtCrft logo r ll rgistr trmrks of Brunswik Corportion. Mrury Prout Prottion logo is rgistr srvi mrk of Brunswik Corportion. 200/225/250/275 VERADO 4-STROKE INSTALLATION MANUAL Tl of Contnts Noti to Instllr... 2 Avoiing Loss of Throttl n Shift Control... 2 Assory Eltri Ful Pump/Ful Lin Primr Bul... 2 Avoiing Ful Flow Rstrition... 2 Bot Horspowr Cpity... 2 Slting Assoris For Your Outor... 3 Ful Tnks... 3 Portl Ful Tnk... 3 Prmnnt Ful Tnk... 3 Dtrmining Rommn Outor Mounting Hight... 4 Instlling Outor... 5 Instlltion Spifitions...5 Mximum Outor Mounting Hight...5 Drilling Outor Mounting Hols...6 Lifting Outor...7 Fstning Outor...8 Powr String Instlltion Powr String Systm...10 Instlltion Prour...10 Conntion of th Hyruli Hoss to th String Hlm...12 Conntion of th Hyruli Hoss to th Powr String Pump...14 Conntion of th Hyruli Hoss to th String Cylinr...15 Eltril Conntions to th String Pump..17 Filling Powr String Systm with Engin Not Running...19 Filling Powr String Systm with Engin Running...21 Routing Conntions Through th Cowl...22 Ful Hos Conntion...23 Wiring An Instlltion Wir Color Co Arvitions...24 Instlltion Guilins for DTS Systm Componnts...24 Dt Hrnss Pulling Prour...24 Juntion Box (If Equipp)...25 Non-Mrury Mrin Provi Ignition Swith.25 Wiring Assoris...26 Systm Wiring Rfrn Points...26 Bttry Cl Siz For Outor Mols...27 Connting 14 Pin Dt Hrnss - Singl Engin...29 Connting 14 Pin Dt Hrnss - Dul Engin...30 Instlling DTS Commn Moul n Hrnss - Singl Engin...31 Instlling DTS Commn Moul n Hrnss - Dul Engin/Singl Hlm...34 Bttry Informtion...35 Connting Bttry Cls n DTS Powr Hrnss...36 Connting Ful Tnk An Sp Snsor...39 Swith 12V Assory Conntion...41 DTS Wiring - Singl Engin...42 DTS Wiring - Dul Engin...44 Systm Wiring Instlltion Chklist...45 Propllr Instlltion Pl Whl Sp Snsor Instlltion (If Equipp)...47 Prts Provi Slting Lotion Trnsom Angl Rquirmnts Instlling Brkt Routing th Cl Instlling n Rmoving th Pl Whl Wiring Conntions Tmplt - Pl Whl Sp Snsor Pg 1 / Mrury Mrin JUNE 2004

2 Lurint, Slnt, Ahsivs Noti to Instllr Tu Rf No. Dsription Whr Us Prt No. 94 Anti-Corrosion Grs Propllr shft splins A C Mrin Lurint with Tflon Propllr shft splins A1 This Prout Rquirs Eltroni Clirtion Bfor Us. Instlltion of this prout will rquir ltroni lirtion. This lirtion must not ttmpt y nyon othr thn th Originl Equipmnt Mnufturr (OEM) or Mrury thniin trin in Digitl Throttl n Shift systms (DTS) t n uthoriz Mrury lrship. Impropr instlltion n lirtion of th DTS prout will rsult in systm whih is inoprl or unsf for us. Avoiing Loss of Throttl n Shift Control! WARNING To voi th possiility of srious injury or th from loss of ot ontrol, o not spli or pro into ny wir insultion of th DTS systm. Spliing or proing will mg th wir insultion llowing wtr to ntr th wiring. Wtr intrusion my l to wiring filur n loss of throttl n shift ontrol. Assory Eltri Ful Pump/Ful Lin Primr Bul IMPORTANT: Do not instll ithr n ssory ltri ful pump or ful lin primr ul into th ful systm of this ngin. Avoiing Ful Flow Rstrition IMPORTANT: Aing omponnts to th ful supply systm (filtrs, vlvs, fittings, t.) my rstrit th ful flow. This my us ngin stlling t low sp, n/or ln ful onition t high RPM tht oul us ngin mg. Bot Horspowr Cpity! WARNING Using n outor tht xs th mximum horspowr limit of ot n: 1) us loss of ot ontrol 2) pl too muh wight t th trnsom ltring th sign flottion hrtristis of th ot or 3) us th ot to rk prt prtiulrly roun th trnsom r. Ovrpowring ot n rsult in srious injury, th or ot mg. Pg 2 /

3 Do not ovrpowr or ovrlo your ot. Most ots will rry rquir pity plt initing th mximum ptl powr n lo s trmin y th mnufturr following rtin frl guilins. If in out, ontt your lr or th ot mnufturr. U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY XXX XXX Slting Assoris For Your Outor Ful Tnks Portl Ful Tnk o00306 Gnuin Mrury Prision or Quiksilvr Assoris hv n spifilly sign n tst for this outor Som ssoris not mnuftur or sol y Mrury Mrin r not sign to sfly us with this outor or outor oprting systm. Aquir n r th instlltion, oprtion, n mintnn mnuls for ll slt ssoris. Slt suitl lotion in th ot within th ngin ful lin lngth limittions n sur th tnk in pl. Prmnnt Ful Tnk Prmnnt ful tnks shoul instll in orn with inustry n frl sfty stnrs, whih inlu rommntions pplil to grouning, nti-siphon prottion, vntiltion, t Pg 3 / 51

4 Dtrmining Rommn Outor Mounting Hight 66.0 m (26 in.) 63.5 m (25 in.) 60.9 m (24 in.) 58.4 m (23 in.) 56.0 m (22 in.) 53.3 m (21 in.) 50.8 m (20 in.) 48.2 m (19 in.) f o Th soli lin is rommn to trmin th outor mounting hight. - Th rokn lins rprsnt th xtrms of known sussful outor mounting hight imnsions. - Th lin my prfrr to trmin outor mounting hight imnsion, if mximum sp is th only ojtiv. - Th lin my prfrr to trmin outor mounting hight imnsion for ul outor instlltion. - Outor mounting hight (hight from point on th pstl 48 mm [1-7/8 in.] ov ntr of top mounting hol to th ottom of th ot trnsom). For hights ovr 56.0 m (22 in.), propllr sign for surfing oprtion is usully prfrr. f - Mximum ot sp (m.p.h.) ntiipt. NOTICE Th stti wtrlin, with ot t rst, must low th "MAX STATIC WATERLINE" mrk on th il rlif grommt (lot t th rr of th outor), whn th outor is fully tilt in/own. If wtrlin is ov "MAX STATIC WATERLINE" mrk, just ot lo forwr or inrs (ris) outor mounting hight to orrtly pl mrk ov wtrlin. A 12.7 m (5 in.) for XL mols n 25.4 m (10 in.) for XXL mols to list outor mounting hight. Th mounting hight of th outor must not x 63.5 m (25 in.) for XL mols n 76.2 m (30 in.) for XXL mols. Mounting th outor highr my us mg to th grs omponnts. Pg 4 /

5 Instlling Outor Instlltion Spifitions 200/225/250/275 VERADO 4-STROKE Inrsing th mounting hight will usully: Inrs top sp Inrs ot stility Cus propllr to rk loos uring plning or turning Minimum trnsom opning - Engin ntr lin for ul ngin m (26 in.) Minimum Trnsom Opning Singl ngin Dul ngin 99.0 m (39 in.) m (65 in.) Mximum Outor Mounting Hight Th mounting hight of th outor must not x 63.5 m (25 in.) for L mols, 76.2 m (30 in.) for XL mols n 88.9 m (35 in.) for XXL mols. Mounting th outor highr my us mg to th grs omponnts. o Pg 5 / 51

6 MAXIMUM STATIC WATERLINE Th stti wtrlin, with ot t rst, must low th "MAX STATIC WATERLINE" mrk on th il rlif grommt (lot t th rr of th outor) whn th outor is fully tilt in/own. If wtrlin is ov "MAX STATIC WATERLINE" mrk, just ot lo forwr or inrs (ris) outor mounting hight to orrtly pl mrk ov wtrlin. MAX STATIC WATERLINE 4224 Drilling Outor Mounting Hols IMPORTANT: Bfor rilling ny mounting hols, rfully r Dtrmining Rommn Outor Mounting Hight. Thr is 19 mm (0.75 in.) iffrn twn th outor mounting hols in th trnsom rkts.! WARNING Avoi possil srious injury or th. Do not, unr ny irumstns, llow th uppr outor mounting olts to losr thn 25.4 mm (1 in.) from th top of th ot trnsom. Nvr instll th uppr mounting olts through shims. 1. Mrk four mounting hols on th trnsom using th trnsom rilling fixtur. - Drill gui hols - Trnsom rilling fixtur - not inlu - Trnsom ntrlin or69-1 Trnsom Drilling fixtur A2 Pg 6 /

7 2. Pl msking tp irtly onto th ot whr th mounting hols will rill to hlp kp th firglss from hipping. Lifting Outor 3. Using th rill gui hols on th trnsom rilling fixtur, rill four 13 mm (17/32 in.) hols prpniulr to n through th trnsom Rmov top owl n ngin flywhl ovr. 2. Instll lifting ring/flywhl pullr to flywhl. Tightn olts surly. 3. Lift ngin using ngin lift with minimum pity of 450kg (1000 l.). 4. Avoi intrfrn y pling th lowr mounting olts into th lowr mounting slots for pling outor ginst th trnsom Pg 7 / 51

8 5. Rfr to Dtrmining Rommn Outor Mounting Hight, n instll outor to th nrst rommn mounting hight Lifting y - Mounting olts Fstning Outor Lifting Ey T01 6. Fstn outor with mounting hrwr provi. Rfr to Fstning Outor. 1. Pl lowr mounting olts into mounting slots for pling outor on trnsom. 2. Rfr to Dtrmining Rommn Outor Mounting Hight, n instll outor to th nrst rommn mounting hight. 3. Fstn outor with th stinlss stl olts, nylon insrt loknuts n flt wshrs s shown. Pg 8 /

9 ! CAUTION 200/225/250/275 VERADO 4-STROKE To voi loss of outor, nsur tht minimum of two full thrs of olt xtn yon loknut ftr tightning loknut. Ensur mounting nut is tightn ginst trnsom, not th shnk of th mounting olt. - Trnsom olts (1/2 x 20) (4) - Flt wshrs - outr (4) - Nylon insrt loknuts (4) Flt wshrs - innr (4) - Mrin slr - pply to shnk of olts, not thrs Outor Trnsom Mounting Hrwr - Suppli with Outor Prt Numr Prt Nm Dsription Trnsom olt 1/2 x 20 x 5.50 in. long (3.25 in. thr) Nylon insrt loknut 1/2 x Wshr - innr in. ID x 1.50 in. OD Wshr - outr in. ID x 1.06 in. OD Avill Trnsom Mounting Bolts Prt Numr Prt Nm Dsription Trnsom olt 1/2 x 20 x 4.00 in. long (2.25 in. thr) Trnsom olt 1/2 x 20 x 4.50 in. long (2.25 in. thr) Trnsom olt 1/2 x 20 x 6.50 in. long (2.75 in. thr) Pg 9 / 51

10 Powr String Instlltion Powr String Systm o String hlm - String ylinr on outor - Powr string pump Instlltion Prour NOTE: On som lrg/hvy ul outor ots th string fors gnrt in xtrm mnuvrs my rt los tht x th pump's prssur pity. If th hppns, th oprtor my fl intrmittnt prios of lo fk t th string whl. Th string whl my fl hr to turn for rif prios uring ths xtrm mnuvrs. If this hppns n string prformn is m unptl for th pplition, son (ssory) ylinr my rigg. Whn using son string ylinr th 40 hlm shoul rpl with 50 hlm. SELECTING LOCATION FOR THE POWER STEERING PUMP! CAUTION To nsur propr string oprtion, hyruli powr string systm must prott from ontmintion. Mk hyruli onntion in ln work r. Rout hoss with th prottiv shipping ps in pl. Rmov prottiv shipping p from hos n omponnt fitting s h onntion is m. 1. Slt mounting lotion (floor or si of intrnl ulkh) for th instlltion of th powr string pump tht mts th following rquirmnts Pg 10 /

11 To ru nois on luminum or mtl hulls, isolt string hoss from hull with suitl non-rsiv hngrs. String hoss from string whl hlm must fr of twists or strss. Gntly sur hos unl togthr with l ti, lot pproximtly 25.4 m (10 in.) from th string whl hlm. Do not mount pump on n ngl grtr thn 15 from vrtil position. Th pump ltril wiring must within rh of th uxiliry ttry. Pump shoul mount in n r tht llows soun nlosur, ovr rmovl, n sy ss to th fill p. Instll pump in n r whr ilg wtr will not ontmint th pump. To ru trnsmitt nois, mount pump on woo or firglss surf. Avoi mounting pump on luminum or stl surfs. REQUIRED MOUNTING CLEARANCES FOR THE POWER STEERING PUMP mm (8 1/2 in.) mm (12 7/32 in.) to top ovr (not shown) mm (11 1/4 in.) mm (17 in.) lrn rquir for ovr rmovl o01458 INSTALLING POWER STEERING PUMP 1. Th powr string pump n mount two wys: On si of th intrnl ulkh Mount on th floor Pg 11 / 51

12 2. Mount th powr string pump t th slt lotion, using pproprit fstning hrwr suitl for th typ of mtril n thiknss of th mounting surf. Mount on intrnl ulkh - Lg srws or thru-olts (3 or 4) - Mounting hrwr o01459 Mount on floor Conntion of th Hyruli Hoss to th String Hlm NOTE: Hoss must rout up through string hlm opning in sh n sur to hlm fittings prior to mounting th string hlm. 1. Pl th string hoss through on king plt on th intrnl si of th shor. Rout th string hoss through th rill opning, n pl th rquir mount of king plts on th hoss on th xtrnl si of th shor. NOTE: Th numr of king plts vris pning on hlm isplmnt. - Bking plts Rmov n isr th shipping ps from ns of th four fittings on th string hlm. Ensur th O-ring sls i not lift off with th shipping ps. Pg 12 /

13 3. Ensur O-ring sls r in pl on n of string hlm fittings. 200/225/250/275 VERADO 4-STROKE - O-ring sls (4) o Plug - not us 4. Mk th hos onntions to th string hlm s shown. Us thin wrnh n hol th hlm fittings from turning whil tightning hoss. Do not ovr-tightn th hos onntions. P T R STAR L PORT o Thin wrnh - Hlm hx fitting wrnh siz (P & T) - 19 mm (3/4 in.) - Hlm hx fitting wrnh siz (R & L) - 16 mm (5/8 in.) - Hyruli hos hx fitting wrnh siz (P & T) - 21 mm (13/16 in.) - Hyruli hos hx fitting wrnh siz (R STAR & L PORT) - 18 mm (11/16 in.) Hlm Fitting ID Mrk Hos ID Mrk Dsription P P Prssur from pump to hlm T T Tnk low prssur rturn to pump Pg 13 / 51

14 Hlm Fitting ID Mrk Hos ID Mrk Dsription R R-STAR Hos onnts to stror si of string ylinr L L-PORT Hos onnts to port si of string ylinr Conntion of th Hyruli Hoss to th Powr String Pump 1. Rmov n isr th yllow prottor p from n of tnk low prssur fitting. 2. Connt th low prssur hyruli hos from th string hlm to th low prssur fitting on th pump rsrvoir s shown. Fstn hos to fitting with onstnt tnsion spring lmp. o Yllow prottor p (rmov n isr) - Low prssur hyruli hos from string hlm - Clmp 3. Ensur tht O-ring sl is on n of hos. Pg 14 /

15 4. Connt th high prssur hyruli hos from th string hlm to th pump s shown. - O-ring o High prssur hyruli string hos Conntion of th Hyruli Hoss to th String Cylinr 1. Rout th hyruli hoss to th outor string ylinr. Bulkh fittings r vill if n opning os not xist in th ngin wll. o Bulkh fitting - ulkh thiknss up to 1.9 m (0.75 in.) ( ) - Bulkh fitting - ulkh thiknss up to 7.62 m (3 in.) ( ) NOTE: Th 90 hos fittings on th string ylinr n rott to lign with hos routing. Stright hos fittings ( ) r lso vill Pg 15 / 51

16 L PORT R STAR 200/225/250/275 VERADO 4-STROKE 2. Position th 90 hos fittings to th sir irtion. Loosn fstning nuts in orr to rott. Position fittings n r-tightn fstning nuts. o Position fittings - 90 fitting - Stright fitting 3. Rmov n isr th shipping ps from th two fittings on th string ylinr. Ensur O-ring sls i not lift off with shipping ps. 4. Ensur O-ring sls r in pl on n of h fitting. - O-rings o Mk th hyruli string hos onntions to th string ylinr s shown. - Port fitting (L PORT) o Stror fitting (R STAR) Pg 16 /

17 Eltril Conntions to th String Pump 200/225/250/275 VERADO 4-STROKE NOTE: For singl ngin instlltion, th powr string pump ttry ls shoul onnt irtly to th outor strting ttry. k + - j f i g h Singl Engin Applition - Engin - Bttry l - DTS powr hrnss - Bttry - Powr string fus - 90 Amp f - Powr string pump 12V positiv hrnss 4250 g - Powr string pump h - Drivr moul i - Powr string pump groun hrnss j - Powr string signl hrnss k - Engin signl hrnss Pg 17 / 51

18 NOTE: On multipl instlltions, th Automti Bttry Swith (ABS) ( K01), must us to onnt ll outor strting ttris to th powr string pump. Th ABS llows ttry voltg to rwn from th strting ttry with th highst stt of hrg. k + - f g m + k - h i m l Dul Engin Applition - Port ngin - Stror ngin - Port ttry - Stror ttry - Automti Powr Swith (APS) f - Powr String Pump g - Powr string pump 12V positiv hrnss j 4154 h - Powr string pump groun hrnss i - Drivr moul j - Dul ngin powr string ptor k - DTS powr hrnss l - Powr string signl hrnss m -Engin signl hrnss Pg 18 /

19 1. Mk ltril onntions to th pump s shown. - Powr string pump - Auxiliry ttry (prfrr) - Dio hrnss BLK R E D - + o Bttry ls - 3 pin onntor from ngin Filling Powr String Systm with Engin Not Running Us SAE 0W-30 Full Synthti Powr String Flui in th powr string systm. In n mrgny, if rommn powr string flui is not vill, th us of ny full synthti ngin oil n tmporrily us. Th powr string flui shoul thn rin n rpl with SAE 0W-30 Full Synthti Powr String Flui s soon s possil, to voi loss of prformn in powr string systm. Flui Typ Cpity Mrury Prt Numr SAE 0W-30 Full Synthti Powr String Flui 1-2 litrs (1-2 qurts) pning on lngth of string hoss K01 1. Disonnt powr string signl hrnss from ngin signl hrnss. 2. Connt th Powr String Primr Moul Kit to th powr string pump n 12 volt positiv powr sour s shown. BLK - R E D + - Powr string pump - Primry ttry o Bttry ls - Powr string primr moul Powr String Primr Moul Kit K01 3. Rmov th fillr p n filtr from th powr string pump Pg 19 / 51

20 4. Fill th pump tnk with rommn powr string flui. - Fill p - Filtr Full lvl IMPORTANT: Th powr string moul primr hs two swiths, "POWER" - "ON" n "OFF", n "PUMP" - "ON" n "OFF". To powr up n tivt th powr string pump, thr r two stps: 1) Turn th "POWER" swith to th "ON" position to powr up pump, wit for two sons, thn, 2) Turn th "PUMP" swith to th "ON" position to tivt pump. IMPORTANT: Do not run pump out of flui. If pump rws ir uring ling, th rsulting r-ling will tk two to thr tims longr thn initil ling. 5. Powr up n tivt th pump until flui rops hlfwy. Turn off oth swiths on th powr string primr moul n rfill th pump tnk. Rpt this oprtion until pump tnk stys full. 6. Powr up n tivt th pump whil slowly turning th string whl towrs th full lok position in on irtion. Crfully monitor th flui lvl until flui rops hlfwy, stop turning th string whl n rfill th pump tnk. Rpt this oprtion turning th string whl from full lok to full lok 10 tims until pump tnk stys full. 7. For ling ny ir lft in th string systm, powr up n tivt th pump. Turn th string whl in on irtion until th full lok position is mt. 8. Atth n 8 mm I.D. (5/16 in. I.D.) trnsprnt l hos to th l vlv on th n of th string ylinr tht th ngin is pointing to. Rout l hos into pump tnk (o not l powr string flui into iffrnt ontinr, this will only pumping flui out of th systm tht ws just fill up). Pg 20 /

21 9. Opn l vlv to rls ny rmining ir in th powr string systm. Allow qut tim, pning on lngth of powr string hos, for ir to sp from systm. Tightn l vlv surly n rmov l hos. - Bl hos Bl vlv in string ylinr 10. Turn th string whl to opposit full lok position, n rpt stps 8 n Rpl th filtr n fill p on th powr string pump. 12. If sir, th powr string systm n rhk ftr sitting ovrnight to rmov ny ir tht my possily lft in th systm. Rpt stps for ling string systm, pring. 13. Turn off oth swiths, rmov th powr string primr moul n ronnt th powr string signl hrnss from th ngin to th pump. Filling Powr String Systm with Engin Running 1. Rmov th fillr p n filtr from th powr string pump. 2. Fill th pump tnk with rommn powr string flui. - Cp - Filtr Full lvl 3. Strt n run th ngin until th string pump flui rops hlfwy. Turn off th ngin n rfill th pump. Rpt this oprtion until pump stys full. 4. Strt n run th ngin whil slowly turning th string whl towrs th full lok position in on irtion. Crfully monitor th flui lvl until flui rops hlfwy. Stop turning whl, turn off ngin, n rfill th pump tnk. Rpt this oprtion turning th string whl to full lok to full lok 10 tims until pump tnk stys full Pg 21 / 51

22 5. For ling ny ir lft in th string systm, strt n run th ngin, n turn th string whl in on irtion until th full lok position is mt. 6. Atth n 8 mm (5/16 in.) I.D. trnsprnt l hos to th l vlv on th n of th string ylinr tht th ngin is pointing to. Rout l hos into pump tnk (o not l powr string flui into iffrnt ontinr, s this will only pumping flui out of th systm tht ws just fill). 7. Opn l vlv to rls ny rmining ir in th powr string systm. Allow qut tim, pning on lngth of powr string hos, for ir to sp from systm. Tightn l vlv surly n rmov l hos. - Bl hos Bl vlv in string ylinr 8. Turn th string whl to opposit full lok position, n rpt prour for ling string systm. 9. Rpl th filtr n fillr p on th powr string pump. 10. If sir, th powr string systm n rhk ftr sitting ovrnight to rmov ny ir tht my possily lft in th systm. Rpt stps for ling string systm, pring. Routing Conntions Through th Cowl IMPORTANT: Ensur tht suffiint xss xists in th wiring hrnss n ttry ls rout twn th owl fitting n th ngin tthmnt point to rliv strss n prvnt hoss from ing kink or pinh. Ensur tht xss xists in ll hoss n ls in full lft n right turns n full tilt position. NOTE: Mrury Mrin suggsts routing th wiring, ls n ful hos through rigging hos or flxil slv from th ngin to th ot's gunnl or motor wll. Follow th instlltion instrutions inlu with th Rigging Hos or Flxil Slv Kit. Pg 22 /

23 1. Pull out th grommt fitting from th front owl opning. Rout th wiring hrnsss, ttry ls, n ful hos through th orrt opnings in th rur grommt s shown. f F B H B AWT h g Rur grommt - Ful hos - 14 pin t hrnss - DTS powr hrnss, vssl snsor hrnss, powr string pump hrnss - Lrg imtr ttry ls f - Smll imtr ttry ls g - Grommt fitting h - Front owl opning Ful Hos Conntion FUEL HOSE SIZE 2. Insrt rur grommt into fitting n sur fitting in front owl opning. IMPORTANT: Ful lin insi imtr (I.D.) must 10 mm (3/8 in.) with sprt ful lin/ful tnk pikup for h ngin. Fstn rmot ful hos to fitting with hos lmp. F E - Rmot ful hos Hos lmp Pg 23 / 51

24 Wiring An Instlltion Wir Color Co Arvitions Wir Color Arvitions BLK Blk BLU Blu BRN Brown GRY Gry GRN Grn ORN or ORG Orng PNK Pink PPL or PUR Purpl RED R TAN Tn WHT Whit YEL Yllow LT or LIT Light DK or DRK Drk Instlltion Guilins for DTS Systm Componnts DATA HARNESS! WARNING To voi th possiility of srious injury or th from loss of ot ontrol, o not spli or pro into ny wir insultion of th DTS systm. Spliing or proing will mg th wir insultion llowing wtr to ntr th wiring. Wtr intrusion my l to wiring filur n loss of throttl n shift ontrol.! WARNING To voi th possiility of srious injury or th from loss on ot ontrol, o not pull on l onntors whn pulling l into ot. Osrv orrt pulling prour. Pulling on onntors n loosn trminls rsulting in opn or poor ltril onntions. Opn or poor ltril onntions my rsult in loss of throttl n shift ontrol. CONNECTORS IMPORTANT: Conntors shoul nvr hv to for into th rptl. Ensur tht onntors r fr of ny lurint or iltri grs for instlltion. Whn th onntor is proprly lign, it will only tk smll mount of prssur to insrt it into th rptl. Rott th loking ollr to sur th ltril onntion. NOTE: Connt only on t hrnss of th rquir lngth twn th ngin n hlm. If t hrnss is too short, o not onnt multipl hrnsss togthr to mk up th rquir lngth. For instlltions rquiring t hrnss lngth longr thn 12.2 m (40 ft.), ontt Mrury Mrin for mor informtion. Dt Hrnss Pulling Prour IMPORTANT: Do not rout t hrnss nr ngin ignition omponnts (oils, sprk plug ls, n sprk plugs), high powr VHF ox or rios. An ltril fil gnrt from ths omponnts oul us intrfrn with t trnsmission. IMPORTANT: Do not rout t hrnss nr shrp gs, hot surfs or moving prts. Fstn ls wy from ny shrp gs, fstnrs or ojts tht oul wr into th hrnss. IMPORTANT: Avoi shrp ns in th t hrnss. Minimum n rius shoul 7.6 m (3 in.) for th finl wiring instlltion. Pg 24 /

25 1. Inspt th routing pth to mk sur surfs r fr of ny shrp gs or urrs tht oul ut th hrnss. 2. Instll l pulling tool to t hrnss. 3. Sur pulling tool with 2 l tis. IMPORTANT: Th ls tis must tight to prvnt ny slipping uring instlltion Juntion Box (If Equipp) Dt Cl Pullr A1 IMPORTANT: Crfully inspt t hrnss pins to nsur ll pins r surly fstn to t hrnss onntor n following instlltion. NOTE: Dt hrnss shoul sur with mounting lips or l tis long th routing pth. Although th juntion ox onntions r wtrtight, it is rommn tht th juntion ox mount in n r tht stys rltivly ry. Mount in n r whr th wiring onntion will not gt stpp on or istur. Mount in n r tht is ssil for troulshooting n srviing th systm. Ensur th DTS ommn moul hrnss will rh ll th onntion points. Fstn ll juntion ox onntions within 25.4 m (10 in.) of th juntion ox. Sl ll unus onntions with wthr ps. - Clmp - Wthr p (859318T 2) - Juntion ox o m (10 in.) - DTS Commn Moul hrnss Non-Mrury Mrin Provi Ignition Swith! CAUTION Prvnt unxpt ngin strt-up. Non-Mrury Mrin ignition swiths my llow suffiint urrnt lkg to us ngin to strt unxptly Pg 25 / 51

26 IMPORTANT: Corrt ignition ky swith must us. If non-mrury Mrin ignition ky swith is ing us, mk sur tht th ignition swith ing us mts th rquirmnt list. IMPORTANT: Currnt lkg xing 5 ma t 12 volts oul us ngin to strt unxptly. Ignition ky swith must pss ingrss prottion tsting pr IEC IP66 spifition minimum. Swiths tht o not pss this spifition oul lk urrnt. Swiths must ontin n mrgny stop iruit. Y E L / R E D R E D B L K / Y E L R E D B L K Y E L / R E D B L K / Y E L B L K f g P P L P P L / WHT h 3641 P P L / WHT P P L 4 Position Ky Swith - Conntor - Pkr Mtripk 150 Sris Sl (6 pin) - Ignition swith - Crnk V - Lnyr stop f - Groun g - Run h - Assory - 4 position ky swith Wiring Assoris NOTE: Rfr to Mrury Prision Prts Assoris Gui. Systm Wiring Rfrn Points FEATURES DTS powr hrnss - Provis 12V powr to th DTS systm. Rquirs onntion to th strting ttry. If strting ttry is lot t th hlm, DTS powr hrnss ssory kit is rquir to minimiz voltg rop. Us l tis to sur powr hrnss ls to ttry ls, ginning within 15 m (6 in.) of ttry posts n ontinuing long th ntir lngth of th hrnss. Bttry ls - Connt to th strting ttry. Vssl snsor hrnss - This hrnss onnts to th min ful tnk snsor, uxiliry ful tnk n th pl whl sp/tmprtur snsor, if quipp. Pg 26 /

27 14 pin t hrnss - Connts twn th ommn moul hrnss n ngin. f pin t hrnss - Powr string pump hrnss - Vssl snsor hrnss - Bttry ls - DTS powr hrnss f - 5 Amp fus Bttry Cl Siz For Outor Mols IMPORTANT: Only us oppr ttry ls. Do not us luminum ls for ny outor mrin instlltions. If longr ttry ls r rquir, th wir gug siz must inrs. S hrt following for orrt wir gug siz. DTS L mols r quipp with 3.7 m (12 ft.) ls. DTS XL n XXL mols r not shipp with ttry ls. - Wir gug siz - Bttry l lngth or Pg 27 / 51

28 Coppr Bttry Cl Wir Gug Siz Wir Gug Siz Numr SAE Mols 6-25 hp hp (xpt OptiMx) hp (xpt OptiMx) OptiMx/Vro 2.4 m (8 ft.) m (9 ft.) m (10 ft.) m (11 ft.) m (12 ft.) m (13 ft.) m (14 ft.) m (15 ft.) m (16 ft.) m (17 ft.) m (18 ft.) m (19 ft.) m (20 ft) m (21 ft.) m (22 ft.) m (23 ft.) Cl Lngth 7.3 m (24 ft.) m (25 ft.) m (26 ft.) 2 1/0 1 1/0 8.2 m (27 ft.) 2 1/0 1 1/0 8.5 m (28 ft.) 2 1/0 1 1/0 8.8 m (29 ft.) 2 1/0 1 1/0 9.1 m (30 ft.) 2 1/0 1 1/0 9.4 m (31 ft.) 2 1/0 1 1/0 9.8 m (32 ft.) 2 1/0 1 1/ m (33 ft.) 2 2/0 1/0 2/ m (34 ft.) 2 2/0 1/0 2/ m (35 ft.) 1 2/0 1/0 2/ m (36 ft.) 1 2/0 1/0 2/ m (37 ft.) 1 2/0 1/0 2/ m (38 ft.) 1 2/0 1/0 2/ m (39 ft.) 1 2/0 1/0 2/ m (40 ft.) 1 2/0 1/0 2/0 1. Stnr (originl) l lngth n wir gug siz. Pg 28 /

29 Connting 14 Pin Dt Hrnss - Singl Engin SINGLE HELM 200/225/250/275 VERADO 4-STROKE IMPORTANT: Avoi shrp ns in th hrnss. Minimum n rius shoul 7.6 m (3 in.) pin t hrnss - Clmp or l ti DUAL HELM pin t hrnss - Hlm 2 (uppr hlm) - Hlm 1 (lowr hlm) - Dul hlm ptr (Y hrnss) - Clmp or l ti Pg 29 / 51

30 Connting 14 Pin Dt Hrnss - Dul Engin SINGLE HELM IMPORTANT: Avoi shrp ns in th hrnss. Minimum n rius shoul 7.6 m (3 in.) pin t hrnss Clmp or l ti DUAL HELM - Hlm 2 (uppr hlm) - Hlm 1 (lowr hlm) - 14 pin t hrnss Dul hlm ptr (Y hrnss) - Clmp or l ti Pg 30 /

31 Instlling DTS Commn Moul n Hrnss - Singl Engin HARNESS INSTALLATION 200/225/250/275 VERADO 4-STROKE Lot routing pth for th hrnss onntions so thy rh thir instlltion points. Inspt th routing pth to mk sur surfs r fr of ny shrp gs or urrs tht oul ut th hrnss. Fstn n support th hrnss with lmps or l tis long th routing pth. Mk sur ll onntions r tight n sl ll unus onntors with wthr ps Singl Hlm Applition - DTS ommn moul hrnss - Clmp or l ti Pg 31 / 51

32 NOTE: For ul hlm pplition - Rmov CAN 1 n CAN 2 trmintor rsistors from hlm 1 (hlm losst to th ngin), n sl onntors with wthr ps. Trmintor Trmintor CAN 1 CAN 2 f h g 3677 Dul Hlm Applition - Hlm 2 (uppr hlm) - Hlm 1 (lowr hlm) - DTS ommn moul hrnss - Clmp or l ti - CAN 1 onntor f - CAN 2 onntor g - Wthr ps h - Trmintor rsistors, lu (CAN1 & CAN2) MODULE INSTALLATION Although th Commn Moul onntion is wtrtight, it is rommn tht it mount in n r tht stys rltivly ry. Mount in n r whr th wiring onntion will not gt stpp on or istur. Mount in n r tht is ssil for troulshooting n srviing th systm. Pg 32 /

33 Ensur th wiring hrnss onnt to th ommn moul will rh ll th onntion points DTS ommn moul Singl Hlm Applition - Clmp or l ti - Hlm 2 - Hlm 1 - DTS ommn moul Dul Hlm Applition f Clmp or l ti - Trmintor rsistors, lu (CAN1 & CAN2) f - Wthr ps Pg 33 / 51

34 Instlling DTS Commn Moul n Hrnss - Dul Engin/Singl Hlm HARNESS INSTALLATION Lot routing pth for th hrnss onntions so thy rh thir instlltion points. Inspt th routing pth to mk sur surfs r fr of ny shrp gs or urrs tht oul ut th hrnss. Fstn n support th hrnss with lmps or l tis long th routing pth. Mk sur ll onntions r tight n sl ll unus onntors with wthr ps. Trmintor CAN 1 Trmintor CAN 2 Trmintor CAN 2 Trmintor CAN 1 - CAN link hrnss - CAN 2 Trmintor rsistors - o not rmov - CAN 1 onntors Clmp or l ti - DTS ommn moul hrnss MODULE INSTALLATION Although th Commn Moul onntion is wtrtight, it is rommn tht it mount in n r tht stys rltivly ry. Mount in n r whr th wiring onntion will not gt stpp on or istur. Mount in n r tht is ssil for troulshooting n srviing th systm. Pg 34 /

35 Ensur th wiring hrnss onnt to th ommn moul will rh ll th onntion points. - DTS ommn moul - Clmp or l ti CAN link hrnss Bttry Informtion! CAUTION Hx nuts must us to sur ttry ls to ttry posts to voi loss of ltril powr. Do not us p yl ttris. Engins must us mrin strting ttry with 1000 MCA, 800 CCA or 180 Ah. Whn onnting ngin ttry, hx nuts must us to sur ttry ls to ttry posts. Torqu nuts to spifition. Dsription Nm l. in. l. ft. Hx nuts IMPORTANT: Bttry l siz n lngth is ritil. Rfr to ngin instlltion mnul for siz rquirmnts Pg 35 / 51

36 Dl ns to pl on or nr ttry ox for futur srvi rfrn. On 5/16 in. n on 3/8 in. hx nut r suppli pr ttry for wing nut rplmnt. Mtri hx nuts r not suppli. NOTICE - DTS & Optimx Engins DO NOT USE DEEP CYCLE BATTERIES! DTS (Digitl Throttl n Shift) pplitions n Optimx ngins must us mrin strting ttry with 1000 MCA, 800 CCA, or 180 Ah. rting. 13.5Nm (120 ls. in.) DO NOT USE WING IMPORTANT: NUTS. Bttry l siz n lngth is ritil. Rfr to ngin instlltion mnul for siz rquirmnts Pl l on or nr ttry ox for futur srvi rfrn. 5/16" n 3/8" hx nuts suppli for wing nut rplmnt. Mtri hx nuts not suppli Connting Bttry Cls n DTS Powr Hrnss! CAUTION To voi th possiility of loss of ltril powr u to th DTS powr hrnss onntion ing pull off ttry, fstn th DTS powr hrnss to on of th ttry ls nr th ttry with l ti. Instll DTS powr hrnss irtly to th strting ttry only. Do not xtn l lngth of hrnss. S ssory mnul for optionl l onntion kit Pg 36 /

37 SINGLE ENGINE - BATTERY AT STERN Bttry - Blk slv (ngtiv) - R slv (positiv) - DTS powr hrnss (provi) SINGLE ENGINE - BATTERY AT HELM f h g pin t hrnss - DTS ommn moul hrnss - Juntion ox - DTS powr hrnss (optionl) - R slv (Positiv) f - Blk slv (Ngtiv) g - Vssl snsor hrnss h - Wthr ps Pg 37 / 51

38 DUAL ENGINE - BATTERY AT STERN g f R slv (positiv) - Blk slv (ngtiv) - Bttry - DTS powr hrnss (provi) - Groun l f - Dt l g - Vssl snsor hrnss Pg 38 /

39 DUAL ENGINE - BATTERY AT HELM g f f h Blk slv (ngtiv) - R slv (positiv) - DTS powr hrnss (optionl) - DTS ommn moul hrnss - Juntion ox wthr ps f - 14 pin t hrnss g - Groun l h - Vssl snsor hrnss Connting Ful Tnk An Sp Snsor IMPORTANT: Do not onnt th lk/orn wir (if quipp) to th ful tnk snsor whn thr is n ngin ttry groun strp onnt to th ful tnk or snr ssmly. If not us, plug th unus opn ullt onntor with rur plug. IMPORTANT: If ful tnk is plsti n ful snsor mounting plt is not onnt to ttry groun, onnt lk/orn wir (if quipp) to ful snr mounting plt Pg 39 / 51

40 YEL WHT LT.BLU/BLK 200/225/250/275 VERADO 4-STROKE IMPORTANT: Mtl ful tnks must groun to hull or ttry groun in orn to ost gur rgultions. PNK/BLK BLK/ORG PUR/YEL GRY/BLU TAN/ORG BLK/ORG BLK/ORG BLK BLU Pl whl kit - Vssl hrnss - Blk/orng wir onntion, if quipp - Ful tnk - To son ful tnk Pg 40 /

41 Swith 12V Assory Conntion 200/225/250/275 VERADO 4-STROKE PUR RED f + - g h o Bttry - Fus - 40 Amp - Powr hrnss with 40 Amp fus - Swith 12V - Complt kit f - Trminl lok g - Assory powr rly h - DTS Commn Moul hrnss Pg 41 / 51

42 ON 200/225/250/275 VERADO 4-STROKE DTS Wiring - Singl Engin PANEL CONTROL OFF BLK/YEL BLK/YEL BLK BLK WHITE BLUE + - BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED f g j i h Strt/stop swith (optionl) - SmrtCrft Systm Viw (optionl) - SmrtCrft Link Gug (optionl) - GPS onntion - Displ hrnss f - Cl ptor (ml to fml) g - Wthr ps h - Juntion ox (optionl) i - Assory powr rly (optionl) j - Foot throttl (optionl) Pg 42 /

43 ON CONSOLE CONTROL 200/225/250/275 VERADO 4-STROKE OFF BLK/YEL BLK/YEL BLK BLK WHITE BLUE + - BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED f g j i h Strt/stop swith (optionl) - SmrtCrft Systm Viw (optionl) - SmrtCrft Link Gug (optionl) - GPS onntion - Disply hrnss f - Cl ptor (ml to fml) g - Wthr ps h - Juntion ox i - Assory powr rly (optionl) j - Foot throttl (optionl) Pg 43 / 51

44 DTS Wiring - Dul Engin CONSOLE CONTROL m n o p q l l k j j i i h + g g f f - To port ngin - Trmintor rsistor - DTS Commn Moul - Juntion ox onntion (optionl) - Conntor - Zro Effort ontrols f - Horn g - Assory powr rly (optionl) h - DTS Commn Moul hrnss i - Clmp j - Conntor - stop/strt swith (optionl) i s 3309 k - Rmot ontrol onntions l - Ky swith m -Rmot ontrol n - To port ngin o - Lnyr stop swith p - To stror ngin q - Systm Viw (optionl) r - To stror ngin s - CAN link hrnss r Pg 44 /

45 Systm Wiring Instlltion Chklist DATA CABLE JUNCTION BOX (IF EQUIPPED) 200/225/250/275 VERADO 4-STROKE Vrify th t hrnss is not rout nr shrp gs, hot surfs or moving prts. Vrify t hrnss is not rout nr ignition omponnts (oils, sprk plug ls, n sprk plugs), high powr VHF ox or rios. Vrify th t hrnss is not rout nr shrp gs, hot surfs or moving prts. Ensur th hrnss onntions r fstn within 25.4 m (10 in.). Vrify tht ll unus rptls r ovr with wthr p. NON-MERCURY MARINE SUPPLIED IGNITION KEY SWITCH ELECTRONIC REMOTE CONTROL DTS COMMAND MODULE HARNESS BATTERY LANYARD STOP SWITCH Propllr Instlltion If non-mrury Mrin ignition ky is us, vrify tht it psss th ingrss prottion tsting pr IEC IP66 spifition minimum. Ignition swiths must pss this spifition. Ensur Eltroni Rmot Control (ERC) onntions r omplt following ERC instlltion instrutions prior to ngin oprtion. Vrify tht ll onntors r proprly insrt n lok in thir rptl (rmot ontrol, ky swith, ommn moul, lnyr stop swith n juntion ox, if quipp). Vrify tht whil moving th rmot ontrol hnl (full forwr n full rvrs) th hrnss hs unostrut movmnt (movs frly). Vrify tht th lnyr stop swith is wir into th systm orrtly. Vrify tht th hrnss is fstn long th routing pth. Vrify tht ll unus onntors hv wthr ps to prvnt orrosion. Vrify tht wing nuts hv n rpl with hx nuts, provi. Vrify tht ll ngin ttry ls r onnt to th orrt trminls. Vrify tht th DTS powr hrnss ls r onnt to th strting ttry n sur with loknuts. Ensur th 5 Amp fus for th DTS powr hrnss is ssil. Vrify tht th swith is instll. Vrify tht th swith is onnt to th DTS ommn moul hrnss.! WARNING Whn instlling or rmoving propllr, nsur th rmot ontrol is in nutrl position n th ky swith is "OFF". Pl lok of woo twn th nti-vittion plt n propllr to prvnt intl strting n to prott hns from propllr ls whil rmoving or instlling nut. 1. To i in futur rmovl of th propllr, lirlly ot th propllr shft splins with on of th following Mrury/Quiksilvr prouts: Pg 45 / 51

46 Tu Rf No. Dsription Whr Us Prt No. 94 Anti-Corrosion Grs Propllr shft splins A C Mrin Lurint with Tflon Propllr shft splins A1 2. Flo-Torq II Driv Propllrs - Instll forwr thrust hu, rpll riv slv, propllr, thrust hu, propllr nut rtinr, n propllr nut onto th shft. f - Propllr nut - Propllr nut rtinr - Thrust hu o Propllr - Rpll riv slv f - Forwr thrust hu 3. Pl lok of woo twn grs n propllr n torqu nut to spifition. Dsription Nm l. in. l. ft. Nut Sur propllr nut y ning thr of th ts into th thrust hu groovs. o00422 Pg 46 /

47 Pl Whl Sp Snsor Instlltion (If Equipp) Prts Provi 200/225/250/275 VERADO 4-STROKE i i A B C D - Spr pin yok - Wir rtinr - Conntor - Brkt - Pl whl f g h j o01505 f - Flt wshr (2) g - #10-19 mm (3/4 in.) srw (4) h - Cl p i - #6-12 mm (1/2 in.) srw (4) j - Clmp (2) Slting Lotion Singl ngin instlltion - Mount pl whl on th trnsom whr th propllr l is rotting ownwr. Usully th right (stror) si to minimiz vittion. If fsil, mount t lst 50 mm (2 in.) yon th swing rius of th propllr. Dul ngin instlltion - Mount th pl whl twn th ngins s los to th ntr lin (kl) of th ot s possil. On slowr, hvir isplmnt ots, howvr, positioning it frthr from th kl is ptl. NOTE: Do not mount th pl whl irtly hin ny stks, ris, intks or outlts for liv wlls or ny protrusion tht my us turuln or vittion mm (2 in.) o Pg 47 / 51

48 Trnsom Angl Rquirmnts Stnr 13 to 20 trnsoms - No spil justmnt rquir. o trnsom ngl - 20 trnsom ngl Stpp or unrut trnsom with 3 ngls - A smll shim of tpr plsti, mtl or woo must frit n instll s shown. Mount th pl whl on th stp for st prformn. Instlling Brkt - Shim o Cut out th tmplt. At th lotion slt, tp th tmplt to th trnsom. Mk sur th lk ott lin on th tmplt is lign with th trnsom ottom g, s shown. NOTE: Th mounting tmplt provi is lot on th lst pg of this instrution sht. 2. Using #28 or 9/64 in. it, rill two 22 mm (7/8 in.) p hols whr init on th tmplt. To prvnt rilling too ply, wrp msking tp roun th rill it 22 mm (7/8 in.) from th point n of rill it. NOTE: In firglss hulls, first hmfr th glot using 6 mm (1/4 in.) rill; rilling out 15 mm (1/16 in.) p to prvnt surf rks. 3. To prvnt wtr spg into th trnsom, pply mrin slr (suh s RTV) to th two #10 srws provi. Using th wshr provi, tth n tightn th rkt to th hull mking sur th rkt is flush with th unrsi of th hull. Pg 48 /

49 4. Fill ny gp twn th housing n th trnsom with ulking mtril, s shown. Using putty knif, smooth th surf to nsur propr wtr flow. - Tmplt - 50 mm (2 in.) - #10 srw o Flt wshr (2) - Culking Routing th Cl DRILLING HOLE THROUGH TRANSOM (OPTIONAL) 1. Slt trnsom lotion for th hol ov th wtr lin tht os not intrfr with othr ls n ontrols. 2. Drill 15 mm (5/8 in.) imtr hol. 3. Rout th l through th rill hol. Sl th trnsom hol with silion (RTV) or omprl mrin slr ftr th l hs n rout through. NOTE: Th hol for th first lmp shoul 25 mm (1 in.) ov th pl whl. Th hol for th son lmp shoul position hlfwy twn th first lmp n th p ovring th trnsom hol rill for th l. 4. Using 2.8 mm (7/64 in.) it, rill hols for th lmps n p pproximtly 13 mm (1/2 in.) p. 5. Apply silion slr (RTV) or omprl mrin slr to th srw thrs, instll th l lmps n f th l through l p Pg 49 / 51

50 WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL) Rout th l ovr th trnsom or through rin hol tht is ov th wtr lin. o Splsh wll rin hol - Cl p - Cl lmp - Pl whl ssmly - Distn twn first l lmp n top of pl whl mm (1.0 in.) Instlling n Rmoving th Pl Whl Instlltion - Sli th pins into th slots in th rkt n snp th ts into pl. Rmovl - squz opn (unlok) th ts n pull on th pl whl. o Ts - Pins Wiring Conntions IMPORTANT: Bfor mking wir onntions, mk sur wirs r rout through th trnsom. Pg 50 /

51 D C 200/225/250/275 VERADO 4-STROKE NOTE: Wirs n only push into th onntor on wy. Align th wir trminl with th ts insi th onntor. Hv th wiring rout through th trnsom. Push h wir trminl into its rsptiv lotion in th onntor. Push wir in until thy snp into pl. Sur wirs into onntor with th wir rtinr. W H T Y E L B L U B L K D C B A B A o Conntor - Wir rtinr Tmplt - Pl Whl Sp Snsor o Drill hols hr - Align ott lin with th trnsom ottom g n fol unr Pg 51 / 51