Mercury OptiMax Outboard factory engine maintenance service manual application: 2000-2001 Mercury 115hp (115 hp) 135hp (135 hp) 150hp (150 hp) 175hp (175 hp) DFI (Direct Fuel Injection) outboard motor.
Maintenance
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Gear Case Lubricant Capacity . . . . . . . . . . . . . . 1B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . . . . 1B-2
Inspection and Maintenance Schedule . . . . . . . . . . 1B-4
Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4
After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4
Every 100 Hours of Use or Once yearly,
Whichever occurs first . . . . . . . . . . . . . . . . . . . . . 1B-4
Flushing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Flushing Cooling System – Using Cowl
Flush Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Flushing Cooling System – Using Flushing
Attachment 44357A2 . . . . . . . . . . . . . . . . . . . . . . 1B-5
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Water Separating Fuel Filter . . . . . . . . . . . . . . . . 1B-6
Corrosion Control Anode . . . . . . . . . . . . . . . . . . . . . . 1B-7
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Compressor Air intake Filter . . . . . . . . . . . . . . . . . . . 1B-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Checking Power Trim Fluid . . . . . . . . . . . . . . . . . . . 1B-11
Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Inspection and Maintenance Schedule
Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear
case with fresh water if operating in salt water.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. 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.
3. Replace water separating fuel filter
4. Replace compressor air intake filter.
5. Check corrosion control anodes. Check more frequently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft and shift shaft.
*
8. Check power trim fluid.
9. Inspect battery.
10. Check control cable adjustments.
*
11. Check tightness of bolts, nuts, and other fasteners.
Flushing Cooling System – Using Cowl Flush Plug
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.
NOTE:
Engine can be stopped or running at idle speed when flushing the cooling system.
Do not flush engine using a water system that exceeds 45 psi.
Flushing Cooling System – Using Flushing Attachment 44357A2
WARNING
When flushing, verify that area in vicinity of propeller is clear and that no person
is standing nearby – to avoid possible injury. It is recommended to remove propeller
as a precautionary measure.
1. Install Quicksilver Flushing Attachment 44357A2 (or equivalent tool) on the gear
housing from the FRONT side, positioning the rubber cups over the water intake
openings.
2. Connect hose [1/2 in. (12.7mm) I.D. or larger] between flushing attachment and water
tap.
IMPORTANT: To prevent water pump damage, do not start or run engine unless
cooling water is flowing.
3. With the outboard in the normal operating position (vertical), partially open water tap
(IT IS NOT NECESSARY to use full water pressure) and adjust water flow so that
there is a significant water loss around the rubber cups.
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.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an approved
receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of deterioration or damage. If any of these conditions is found, the fuel line or primer
bulb must be replaced.
Water Separating Fuel Filter
NOTE:
The warning system will turn on when water in the fuel filter reaches the full level.
1. This filter removes moisture and also debris from the fuel. If the filter becomes filled
with water, the water can be removed. If the filter becomes plugged with debris, the
filter must be replaced with a new filter.
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting
capability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Lubrication Points
Lubricate Point 1 with Quicksilver Special Lubricant 101.
1. Trim Rod Ball Ends – Turn the ball ends to work the lubricant into the ball sockets.
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Lubricate Point 2 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
2. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the
propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub
from corroding and seizing to the shaft.
2
Lubricate Points 3 thru 6 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special
Lubricate 101.
3. Swivel Bracket – Lubricate through fitting.
4. Tilt Support Lever – Lubricate through fitting.
Checking Power Trim Fluid
8. Tilt outboard to the full up position and engage the tilt support lock.
8
9. Remove fill cap and check fluid level. The fluid level should be even with the bottom
of the fill hole. Add Quicksilver Power Trim & Steering Fluid. If not available, use automotive
(ATF) automatic transmission fluid.
Gear Case Lubrication
When adding or changing gear case lubricant, visually check for the presence of water
in the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer.Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE
NOTE:
Some models may have the vent and fill/drain plugs on the opposite side.
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer (a) before removing
the lubricant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer (d).
1. Place outboard in a vertical operating position.
2. Remove vent plug (a).
3. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent
hole (c).
