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 OPTIMAX DTS INSTALLATION MANUAL Tl of Contnts Noti to Instllr... 2 Instlltion Informtion... 2 Avoiing Loss of Throttl n Shift Control...2 Bfor Strting th Engin...2 Ful Rquirmnts...2 Oil Rommntion...2 Avoiing Ful Flow Rstrition... 2 Eltri Ful Pump... 3 Bot Horspowr Cpity... 3 Slting Assoris For Your Outor... 3 Ful Tnks... 3 Portl Ful Tnk... 3 Prmnnt Ful Tnk... 3 Instlltion Spifitions... 4 Lifting th Outor... 4 Applying Countr Rottion Dls... 5 String Cl - Stror Si Rout Cl... 5 String Link Ro Fstnrs... 6 Dtrmining Rommn Outor Mounting Hight... 7 Drilling Outor Mounting Hols... 8 Front Clmp Assmly... 9 Rmovl... 9 Instlltion... 9 Wiring n Instlltion... 11 Wir Color Co Arvitions...11 Instlltion Guilins for DTS Systm Componnts...11 Dt Hrnss Pulling Prour...11 Juntion Box (If Equipp)...12 Non-Mrury Mrin Provi Ignition Swith.12 Wiring Assoris...13 Systm Wiring Rfrn Points...13 Connting 14 Pin Dt Hrnss - Singl Engin...14 Connting 14 Pin Dt Hrnss - Dul Engin...15 Instlling DTS Commn Moul n Hrnss - Singl Engin...16 Instlling DTS Commn Moul n Hrnss - Dul Engin/Singl Hlm...20 Bttry Cl Siz For Outor Mols...21 Bttry Informtion...23 Connting Bttry Cls n DTS Powr Hrnss...23 Connting Ful Tnk, Oil Tnk n Sp Snsor...26 Swith 12V Assory Conntion...28 DTS Wiring - Singl Engin...29 DTS Wiring - Dul Engin...31 Systm Wiring Instlltion Chklist...32 Ful Hos n Oil Hos Conntions... 32 Ful Hos Conntion... 32 Filling th Ful Systm... 33 Filling th Oil Systm... 33 Priming Oil Injtion Pump... 34 Purging Air From th Engin Oil Tnk... 36 Propllr Instlltion... 36 Trim In Pin... 37 Pl Whl Sp Snsor Instlltion (If Equipp)...38 Prts Provi... 38 Slting Lotion... 38 Trnsom Angl Rquirmnts... 39 Instlling Brkt... 39 Routing th Cl... 40 Instlling n Rmoving th Pl Whl... 41 Wiring Conntions... 41 Tmplt - Pl Whl Sp Snsor... 42 Pg 1 / 42 2004 Mrury Mrin 90-10234050 APRIL 2004
Noti to Instllr Instlltion Informtion 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 Bfor Strting th Engin Ful Rquirmnts Oil Rommntion! 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.! CAUTION Avoi ngin mg. Prim th oil injtion pump on nw or ruilt ngins n ftr mintnn is prform on th oiling systm. Rfr to Priming th Oil Injtion Pump for instrutions. Do not us pr-mix gs n oil in this ngin. Th ngin utomtilly rivs xtr oil uring ngin rk-in. Us frsh supply of th rommn gsolin uring ngin rk-in n ftr ngin rk-in. Rommn Oil OptiMx Oil or Prmium Plus 2-Cyl TC-W3 Outor Oil OptiMx Oil or Prmium Plus TC-W3 is highr gr oil tht provis inrs lurition n xtr rsistn to ron uilup whn us with goo or vrying grs of gsolin. IMPORTANT: Oil must NMMA rtifi TC-W3 2-Cyl oil. Prioilly onsult with your lr to gt th ltst gsolin n oil rommntions. If Mrury Prision or Quiksilvr 2-Cyl Outor Oil is not vill, sustitut nothr rn of 2-Cyl outor oil tht is NMMA Crtifi TC-W3. Th us of n infrior 2-Cyl outor oil n ru ngin urility. Dmg from us of infrior oil my not ovr unr th limit wrrnty. 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. Pg 2 / 42 90-10234050
Eltri Ful Pump 200/225 OPTIMAX DTS Th ful prssur must not x 28 kp (4 psi). If nssry, instll prssur rgultor. 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. 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 your outor. Ths ssoris r vill from Mrury Mrin lrs.! WARNING Chk with your lr for instlltion of ssoris. Th misus of ptl ssoris or th us of unptl ssoris n rsult in srious injury, th, or prout filur. Som ssoris not mnuftur or sol y Mrury Mrin r not sign to sfly us with your outor or outor oprting systm. Aquir n r th instlltion, oprtion, n mintnn mnuls for ll your 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. 90-10234050 Pg 3 / 42
Instlltion Spifitions O01471 - Minimum trnsom opning - Engin ntr lin for ul ngin - 66.0 m (26 in.) Minimum Trnsom Opning Singl ngin Dul ngin 99.0 m (39 in.) 165.0 m (65 in.) Lifting th Outor! WARNING Avoi possil srious injury or th. Bfor lifting th outor, vrify tht th lifting ring is thr into th flywhl for minimum of fiv turns n tht th hoist hs th orrt lifting pity for th ngin wight. 1. Rmov th owl from th outor. 2. Thr th lifting y into th flywhl hu for minimum of fiv turns. - Lifting y or138 Pg 4 / 42 90-10234050
3. Connt hoist to th lifting y. 4. Lift th outor n pl it on th ot trnsom. Applying Countr Rottion Dls 200/225 OPTIMAX DTS IMPORTANT: For ul outor ountr rottion instlltion, th lft- hn rottion outor is gnrlly pl on th port si of th trnsom. 1. Apply ountr rottion l (suppli with lft-hn rottion outor) onto right-hn rottion outor. 2. Mth l plmnt with lft-hn rottion outor. String Cl - Stror Si Rout Cl 1. Lurit O-ring sl n ntir l n. 95 3724 Tu Rf. No. Dsription Whr Us Prt Numr 95 2-4-C with Tflon O-ring sl n th ntir l n. 92-802859A1 2. Insrt string l into tilt tu. 3. Torqu nut to spifition. 3725 3727 90-10234050 Pg 5 / 42
Dsription Nm l. in. l. ft. Nut 47.5 35 String Link Ro Fstnrs IMPORTANT: Th string link ro tht onnts th string l to th ngin must fstn using spil wshr h olt ("" - Prt Numr 10-849838) n slf-loking nylon insrt loknuts ("" & "" - Prt Numr 11-826709113). Ths loknuts must nvr rpl with ommon nuts (non-loking) s thy will work loos n virt off fring th link ro to isngg.! WARNING Disnggmnt of string link ro n rsult in th ot tking full, sun, shrp turn. This potntilly violnt tion n us oupnts to thrown ovror xposing thm to srious injury or th. - Spil wshr h olt (10-849838) - Flt wshr (2) - Nylon insrt loknut (11-826709113) - Nylon insrt loknut (11-826709113) o00676 Dsription Nm l. in. l. ft. Spil wshr h olt 27 20 Nylon insrt loknut "" 27 20 Nylon insrt loknut "" Tightn until sts, thn k off 1/4 turn Assml string link ro to string l with two flt wshrs n slf-loking nylon insrt loknut. Tightn loknut until it sts, thn k nut off 1/4 turn. Assml string link ro to ngin with spil wshr h olt n slf-loking nylon insrt loknut. First torqu olt, thn torqu loknut to spifitions. Pg 6 / 42 90-10234050
Dtrmining Rommn Outor Mounting Hight 63.5 m (25 in.) 200/225 OPTIMAX DTS 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.) 10 20 30 40 50 60 70 80 f - Th soli lin is rommn to trmin th outor mouting hight. - Th rokn lins rprsnt th xtrms of known sussful outor mounting hight imnsions. - Th lin my prfr to trmin outor mounting hight imsion, if mximum sp is th only ojtiv. - Th lin my prfr to trmin outor mounting hight imsion for ul outor instlltion. - Outor mounting hight (hight of outor mounting rkts from ottom of ot trnsom). For hights ovr 56.0 m (22 in.) propllr, tht is sign for surfing oprtion is usully prfr. f - Mximum ot sp (mph) ntiipt. 3728 NOTICE 1. Th outor shoul mount high nough on th trnsom so tht xhust rlif hol will sty t lst 25.4 mm (1 in.) ov th wtr lin whn th ngin is running t il sp. Hving th xhust rlif hol ov th wtr lin will prvnt xhust rstritions. Exhust rstritions will rsult in poor prformn t il. 2. A 12.7 m (5 in.) for XL mols to th list outor mounting hights. 3. Th mounting hight of th outor must not x 63.5 m (25 in.) for L mols, 76 m (30 in.) for XL mols. Mounting th outor highr my us mg to th grs omponnts. Inrsing th mounting hight will usully: Lss string torqu. Inrs top sp. Inrs ot stility. Cus propllr to rk loos uring plnning. 90-10234050 Pg 7 / 42
Drilling Outor Mounting Hols IMPORTANT: Bfor rilling ny mounting hols, rfully r Dtrmining Rommn Outor Mounting Hight n instll outor to th nrst rommn mounting hight. 1. Us trnsom rilling fixtur or tth (tp) ngin mounting tmplt to ot trnsom. 2. Mrk n rill four 13.5 mm (17/32 in.) mounting hols. o01472 3973 3. Apply mrin slr to shnks of olts, not th thrs. Pg 8 / 42 90-10234050
4. Fstn outor with provi mounting hrwr. - Flt wshr (4) - 1/2 in. imtr olt (4) - Shnk of olt 3729 - Loknut (4) - Flt wshr (4) Front Clmp Assmly Rmovl Rmov two srws with rtinr n opn th front lmp. 3765 - Srws (2) - Rtinr - Clmp Instlltion IMPORTANT: Suffiint slk must xist in ngin wiring hrnss ttry ls, ful hos, n oil hoss twn lmp n ngin tthmnt point, to rliv strss n prvnt hoss from ing kink or pinh. 90-10234050 Pg 9 / 42
1. Pl th noprn wrp roun th wiring, hoss, n ontrol ls. 3766 2. Sur oth hlvs of lmp with ls tis. 3. Sur lmp ssmly into ottom owl with rtinr n two srws. 3764 - Srws (2) - Rtinr 3765 - Clmp Pg 10 / 42 90-10234050
Wiring n 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. 90-10234050 Pg 11 / 42
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. 3836 Juntion Box (If Equipp) Dt Cl Pullr 91-888462A1 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 o01481-25.4 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 12 / 42 90-10234050
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 - + 12V - 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, within 15 m (6 in.) of ttry posts. Bttry ls - Connt to th strting ttry. Vssl snsor hrnss - This hrnss onnts to th ful tnk snsor, rmot oil tnk snsor n th pl whl sp/tmprtur snsor, if quipp. 14 pin t hrnss - Connts twn th ommn moul hrnss n ngin. 90-10234050 Pg 13 / 42
Control Ar Ntwork (CAN) link hrnss - Must instll twn ommn moul hrnss for ul ngin instlltion. f 3769-14 pin t hrnss - Vssl snsor hrnss - Bttry ls - CAN link hrnss (ul ngin pplition) - DTS powr hrnss f - 5 Amp fus Connting 14 Pin Dt Hrnss - Singl Engin SINGLE HELM IMPORTANT: Avoi shrp ns in th hrnss. Minimum n rius shoul 7.6 m (3 in.). 3619-14 pin t hrnss - Clmp or l ti Pg 14 / 42 90-10234050
DUAL HELM 3682-14 pin t hrnss - Hlm 2 (uppr hlm) - uxilry - Hlm 1 (lowr hlm) - primry - Dul hlm ptr (Y hrnss) - Clmp or l ti 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.). - 14 pin t hrnss 3977 - Clmp or l ti 90-10234050 Pg 15 / 42
DUAL HELM - Hlm 2 (uppr hlm) - Hlm 1 (lowr hlm) - 14 pin t hrnss 3978 - Dul hlm ptr (Y hrnss) - Clmp or l ti Instlling DTS Commn Moul n Hrnss - Singl Engin 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. Pg 16 / 42 90-10234050
Mk sur ll onntions r tight n sl ll unus onntors with wthr ps. 3622 Singl Hlm Applition - DTS ommn moul hrnss - Clmp or l ti 90-10234050 Pg 17 / 42
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 18 / 42 90-10234050
Ensur th wiring hrnss onnt to th ommn moul will rh ll th onntion points. 3625 - DTS ommn moul Singl Hlm Applition - Clmp or l ti - Hlm 2 - Hlm 1 - DTS ommn moul Dul Hlm Applition f 3678 - Clmp or l ti - Trmintor rsistors, lu (CAN1 & CAN2) f - Wthr ps 90-10234050 Pg 19 / 42
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 3689 - 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 20 / 42 90-10234050
Ensur th wiring hrnss onnt to th ommn moul will rh ll th onntion points. - DTS ommn moul - Clmp or l ti 3691 - CAN link hrnss 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 or70 90-10234050 Pg 21 / 42
Coppr Bttry Cl Wir Gug Siz Wir Gug Siz Numr SAE Mols 6-25 hp 30-115 hp (xpt OptiMx) 125-250 hp (xpt OptiMx) OptiMx/Vro 2.4 m (8 ft.) 8 1. 6 1. - - 2.7 m (9 ft.) 6 4 - - 3.0 m (10 ft.) 6 4 6 1. - 3.4 m (11 ft.) 6 4 4-3.7 m (12 ft.) 6 4 4 4 1. 4.0 m (13 ft.) 6 2 4 2 4.3 m (14 ft.) 4 2 4 2 4.6 m (15 ft.) 4 2 4 2 4.9 m (16 ft.) 4 2 2 2 5.2 m (17 ft.) 4 2 2 2 5.5 m (18 ft.) 4 2 2 2 5.8 m (19 ft.) 4 2 2 2 6.1 m (20 ft) 4 2 2 2 6.4 m (21 ft.) 2 1 2 1 6.7 m (22 ft.) 2 1 2 1 7.0 m (23 ft.) 2 1 2 1 Cl Lngth 7.3 m (24 ft.) 2 1 2 1 7.6 m (25 ft.) 2 1 2 1 7.9 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 1/0 10.1 m (33 ft.) 2 2/0 1/0 2/0 10.4 m (34 ft.) 2 2/0 1/0 2/0 10.7 m (35 ft.) 1 2/0 1/0 2/0 11.0 m (36 ft.) 1 2/0 1/0 2/0 11.3 m (37 ft.) 1 2/0 1/0 2/0 11.6 m (38 ft.) 1 2/0 1/0 2/0 11.9 m (39 ft.) 1 2/0 1/0 2/0 12.2 m (40 ft.) 1 2/0 1/0 2/0 1. Stnr (originl) l lngth n wir gug siz. Pg 22 / 42 90-10234050
Bttry Informtion! CAUTION 200/225 OPTIMAX DTS 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 13.5 120 IMPORTANT: Bttry l siz n lngth is ritil. Rfr to ngin instlltion mnul for siz rquirmnts. 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. 37-895387 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. 3486 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. 3711 90-10234050 Pg 23 / 42
SINGLE ENGINE - BATTERY AT STERN 3679 - Bttry - Blk slv (ngtiv) - R slv (positiv) - DTS powr hrnss (provi) SINGLE ENGINE - BATTERY AT HELM f h g 3699-14 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 24 / 42 90-10234050
DUAL ENGINE - BATTERY AT STERN g f 3680 - R slv (positiv) - Blk slv (ngtiv) - Bttry - DTS powr hrnss (provi) - Groun l f - Dt l g - Vssl snsor hrnss 90-10234050 Pg 25 / 42
DUAL ENGINE - BATTERY AT HELM g f f h 3701 - 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, Oil Tnk n 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 26 / 42 90-10234050
BLK/ORN TAN/ORN YEL BLK GRY/BLU PUR/YEL 200/225 OPTIMAX DTS IMPORTANT: Mtl ful tnks must groun to hull or ttry groun in orn to ost gur rgultions. PNK/BLK BLK/ORN LT.BLU/BLK BLK/ORN WHT BLU 3714 - Ful tnk - Oil tnk - Oil tnk snr - Hrnss - Blk/orng wir to ful tnk snsor, if quipp 90-10234050 Pg 27 / 42
Swith 12V Assory Conntion PUR RED f + - g h o01495 - 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 28 / 42 90-10234050
ON 200/225 OPTIMAX DTS 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 3718 - 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) 90-10234050 Pg 29 / 42
ON 200/225 OPTIMAX DTS CONSOLE 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 3717 - 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 30 / 42 90-10234050
DTS Wiring - Dul Engin CONSOLE CONTROL m n o p q l l k j j i i h + g g f f i s r 3309 - 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) 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 90-10234050 Pg 31 / 42
Systm Wiring Instlltion Chklist DATA CABLE JUNCTION BOX (IF EQUIPPED) 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.) of th juntion ox. 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 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. Ful Hos n Oil Hos Conntions Ful Hos Conntion Ful Hos Siz - Minimum ful lin insi imtr (I.D.) is 8mm (5/16 in.), with sprt ful lin/ful tnk pikup for h ngin. 1. Fstn rmot ful hos to fitting with hos lmp. Pg 32 / 42 90-10234050
2. Connt th rmot oil hoss to th ngin hos onntions. Fstn hos onntions with l tis. - Hos lmp - Cl ti - Oil hos without lu strip 3767 - Oil hos with lu strip - Rmot ful hos Filling th Ful Systm Whn strting n ngin for th first tim, or strting n ngin tht rn out of ful or ws rin of ful, fill n prim th ful systm. 1. Squz th ful lin primr ul until it fls firm. o00349 2. Turn th ky swith to th "ON" position for thr sons. This oprts th ltri ful pump. OFF ACC ON START OFF ACC ON START o00364 3484 3. Turn th ky swith k to th "OFF" position n squz th primr ul gin until it fls firm. OFF ACC ON START OFF ACC ON START o00360 3482 Filling th Oil Systm 4. Turn th ky swith to th "ON" position gin for thr sons. 5. Continu this prour until th ful lin primr ul stys firm. 1. Fill th rmot oil tnk with th rommn oil list in th Oprtion n Mintnn Mnul. 90-10234050 Pg 33 / 42
2. Tightn th fill p. - Fill p or111 3. Rmov th p n fill th ngin oil tnk with oil. - Fill p 3763 - Engin oil tnk 4. Rinstll th fill p. Priming Oil Injtion Pump IMPORTANT: DTS hlm onfigurtion must omplt for prforming th following prour. Bfor strting th ngin for th first tim, prim th oil injtion pump. Priming will rmov ny ir tht my in th pump, oil supply hos or intrnl pssgs. 3768 - Oil supply hos - Oil injtion pump Pg 34 / 42 90-10234050
! CAUTION Avoi ful pump mg. Alwys fill th ngin ful systm with ful for priming th oil injtion pump. Othrwis, th ful pump will run without ful uring th priming pross. 1. Fill th ful systm.. Connt ful hos.. Fill th ful systm y squzing th primr ul.. Squz th ful lin primr ul until it fls firm. o00349. Turn th ignition ky swith to th "ON" position for thr sons. This oprts th ltri ful pump. OFF ACC ON START OFF ACC ON START o00364 3484. Turn th ignition ky swith k to th "OFF" position, n squz th primr ul gin until it fls firm. f. Turn th ignition ky swith to th "ON" position gin for thr sons. g. Continu this prour until th ful primr ul stys firm. 2. Turn th ignition ky swith to th "ON" position. OFF ACC ON START OFF ACC ON START o00364 3484 3. Within th first 10 sons ftr th ky swith hs n turn on, mov th rmot ontrol hnl from nutrl (N) into forwr (F). This will utomtilly strt th priming pross. N N F R F R 3413 3417 90-10234050 Pg 35 / 42
Purging Air From th Engin Oil Tnk IMPORTANT: DTS hlm onfigurtion must omplt for prforming th following prour. 1. Loosn th fill p on th ngin oil tnk. 2. Strt th ngin. 3. Oprt th ngin until ll th ir hs vnt out n oil strts to flow out of th tnk. 4. R-tightn fill p. Propllr Instlltion! WARNING If th propllr shft is rott whil th ngin is in gr, thr is th possiility tht th ngin will rnk ovr n strt. To prvnt this typ of intl ngin strting n possil srious injury us from ing struk y rotting propllr, lwys shift outor to nutrl position n rmov sprk plug ls whn you r srviing th propllr. 1. Flo-Torq I Driv Hu Propllrs - Instll forwr thrust hu, propllr, ontinuity wshr, rr thrust hu, propllr nut rtinr, n propllr nut onto th shft. - Propllr nut - Propllr nut rtinr - Rr thrust hu f o00382 - Continuity wshr - Propllr f - Forwr thrust hu 2. Flo-Torq II Driv Hu 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 - Rr thrust hu o00421 - Propllr - Rpll riv slv f - Forwr thrust hu 3. Pl lok of woo twn grs n propllr n torqu to spifitions. Dsription Nm l. in. l. ft. Propllr nut 75 55 Pg 36 / 42 90-10234050
4. Sur propllr nut y ning thr of th ts into th thrust hu groovs. o00422 Trim In Pin! WARNING Avoi possil srious injury or th. Ajust outor to n intrmit trim position s soon s ot is on pln to voi possil jtion u to ot spin out. Do not ttmpt to turn ot whn on pln if outor is trimm xtrmly in or own n thr is pull on th string whl. Som ots, prtiulrly som ss ots, r uilt with grtr thn norml trnsom ngl, whih will llow th outor to trimm furthr in or unr. This grtr trim unr pility is sirl to improv lrtion, ru th ngl n tim spnt in ow high ot uring plning off, n in som ss, my nssry to pln off ot with ft liv wlls, givn th vrity of vill propllrs n hight rng of ngin instlltions. Howvr, on on pln, th ngin shoul trimm to mor intrmit position to voi ow-own plning onition ll plowing. Plowing n us ow string or ovr string n inffiintly onsums horspowr. or116 - Tilt pin (not inlu with ngin) Stinlss Stl Tilt Pin 17-49930A1 Th ownr my i to limit th trim in. This n omplish y purhsing stinlss stl tilt pin from your lr n insrt it in whtvr justmnt hol in th trnsom rkts is sir. A non-stinlss stl shipping olt shoul not us in this pplition othr thn on tmporry sis. 90-10234050 Pg 37 / 42
Pl Whl Sp Snsor Instlltion (If Equipp) Prts Provi 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. - 50 mm (2 in.) o01506 Pg 38 / 42 90-10234050
Trnsom Angl Rquirmnts Stnr 13 to 20 trnsoms - No spil justmnt rquir. o01507-13 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 o01508 1. 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. 90-10234050 Pg 39 / 42
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 o01509 - 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 40 / 42 90-10234050
WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL) Rout th l ovr th trnsom or through rin hol tht is ov th wtr lin. o01510 - Splsh wll rin hol - Cl p - Cl lmp - Pl whl ssmly - Distn twn first l lmp n top of pl whl - 25.4 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. o01511 - Ts - Pins Wiring Conntions IMPORTANT: Bfor mking wir onntions, mk sur wirs r rout through th trnsom. 90-10234050 Pg 41 / 42
D C 200/225 OPTIMAX DTS 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 o01512 - Conntor - Wir rtinr Tmplt - Pl Whl Sp Snsor o01513 - Drill hols hr - Align ott lin with th trnsom ottom g n fol unr Pg 42 / 42 90-10234050