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Mercury 200

Mercury 200
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Welcome Aboard!
Proper care and maintenance is an important part in keeping
your Mercury Product operating at peak efficiency for
maximum performance and economy. The enclosed Owner's
Registration Card is your key to trouble‑free family fun. Refer
to your Operation and Maintenance Manual for full details
of your warranty coverage.
Details of your nearest dealer can be found on
www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose?
Please check on www.marinepower.com. If necessary,
please contact your local dealer.
Declaration of Conformity
If the outboard motor’s serial number plate contains the CE
mark in the lower left‑hand corner, the following statement
applies:
This outboard motor manufactured by Mercury Marine, Fond
du Lac, WI, USA or Marine Power Europe Inc. Park Industriel,
de Petit‑Rechain, Belgium complies with the requirements of
the following directives and standards, as amended:
Recreational Craft Directive: 94/25/EC
Owner's manual (A.2.5) ISO 10240
Handling characteristics (A.4) ISO 8665
Outboard engine starting (A.5.1.4) ISO 11547
Fuel tanks (A.5.2.2) ISO 13591; ISO 8469
General steering system ABYC P‑17
Safety of Machinery Directive 98/37/EC
Principles of safety integration
(1.1.2)
EN 292‑1; EN 292‑2; EN 1050
Noise (1.5.8) ICOMIA 39/94
Vibration ICOMIA 38/94
© 2007 Mercury Marine 200/225/250/3.0 Liter 90-10128080 407

Table of Contents

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Mercury 200 Specifications

General IconGeneral
Fuel Induction SystemElectronic Fuel Injection (EFI)
Displacement3.0L (181 cubic inches)
Horsepower200 HP
Alternator Output60-amp
Shaft Length20", 25"
SteeringHydraulic
Weight505 lbs (20" shaft), 515 lbs (25" shaft)
Starting SystemElectric

Summary

Declaration of Conformity

Warranty Information

Transfer of Warranty

Process for transferring limited warranty to a new owner.

Warranty Registration

Steps for registering the product for warranty coverage.

Limited Warranty Details

Outlines warranty coverage periods and conditions for different regions.

Warranty Coverage and Exclusions

Specifies what is covered and what is excluded from warranty.

General Information

Boaters Responsibilities

Operator's duties for safe operation and boat handling.

Before Operating Your Outboard

Essential pre-operation checks and safety alerts.

Boat Horsepower Capacity

Guidance on matching engine power to boat capacity.

High-Speed and High-Performance Boat Operation

Recommendations for operating high-performance boats.

Fuel and Oil

Fuel Recommendations

Guidelines for selecting and using appropriate gasoline.

Oil Recommendation

Specifies the correct type of oil for the engine.

Fuel Requirements for Engine Break-in

Specific fuel needs during the engine's initial break-in period.

Features and Controls

Remote Control Features

Overview of components and functions of the remote control.

Warning System

Explains the outboard's warning horn signals and functions.

Power Trim and Tilt

Operation and adjustment of the outboard's trim and tilt system.

Operation

Pre-Starting Check List

Essential checks to perform before starting the engine.

Operating In Freezing Temperatures

Procedures for operating the outboard in cold weather.

Operating In Salt Water Or Polluted Water

Guidelines for using the outboard in marine environments.

Maintenance

Outboard Care

General advice for keeping the outboard in optimal condition.

Inspection And Maintenance Schedule

Recommended schedule for inspections and maintenance tasks.

Troubleshooting

Engine Will Not Start

Lists common reasons for the engine failing to start.

Performance Loss

Possible causes for reduced engine performance.

Battery Will Not Hold Charge

Troubleshooting steps for battery charging issues.

Owner Service Assistance

Local Repair Service

Guidance on seeking service from authorized dealers.

Service Away From Home

Procedures for obtaining service when traveling.

Mercury Marine Service Offices

Contact information for Mercury Marine service offices worldwide.

Outboard Installation

Boat Horsepower Capacity

Guidance on matching engine power to boat capacity.

Start in Gear Protection

Safety feature preventing engine start in gear.

Selecting Accessories For Your Outboard

Guidance on selecting and installing compatible accessories.

Specifications

Component Identification

Transporting

Trailering BoatOutboard

Proper procedures for trailering the boat with the outboard.

Fuel and Oil

Avoiding Fuel Flow Restriction

Tips to prevent restrictions in the fuel supply system.

Filling Remote Oil Tank

Instructions for filling the outboard's remote oil tank.

Filling Fuel Tank

Procedures for safely filling the boat's fuel tank.

Features and Controls

Engine Guardian System

Monitors engine sensors for problems and provides protection.

Operation

Operating at High Elevations

How engine performance is affected by altitude.

Setting Trim Angle While Running Engine at Idle Speed

Adjusting trim angle for idle operation to prevent issues.

Starting the Engine

Step-by-step guide for starting the outboard engine.

Operation

Gear Shifting

Proper procedures for shifting gears on the outboard.

Stopping The Engine

How to safely shut down the outboard engine.

Maintenance

EPA Emissions

Information on the emission certification label and its meaning.

Selecting Replacement Parts

Guidance on choosing genuine Mercury replacement parts.

Owner Responsibility

Owner's duties regarding engine maintenance and emissions.

Flushing The Cooling System

Instructions for flushing the cooling system with fresh water.

Maintenance

Top Cowl Removal And Installation

Steps for removing and reinstalling the engine's top cowl.

Exterior Care

How to clean and protect the outboard's exterior finish.

Maintenance

Fuel System

Maintenance and inspection of the fuel system components.

Steering Link Rod Fasteners

Proper use and torque for steering link rod fasteners.

Maintenance

Fuse Replacement

Procedure for replacing blown fuses in the wiring circuits.

Corrosion Control Anode

Role and inspection of anodes for corrosion protection.

Battery Inspection

Importance and steps for inspecting the outboard's battery.

Maintenance

Propeller Replacement

Step-by-step guide for replacing the outboard propeller.

Maintenance

Spark Plug Inspection And Replacement

How to inspect, gap, and replace spark plugs.

Lubrication Points

Locations and methods for lubricating outboard components.

Maintenance

Checking Power Trim Fluid

How to check and refill the power trim fluid.

Gearcase Lubrication

Procedures for checking and changing gearcase lubricant.

Maintenance

Submerged Outboard

Service requirements for an outboard that has been submerged.

Storage

Storage Preparation

Steps to prepare the outboard for long-term storage.

Protecting Internal Engine Components

How to protect internal engine parts during storage.

Protecting External Outboard Components

Protecting external parts from corrosion and damage during storage.

Positioning Outboard For Storage

Correct orientation of the outboard for storage.

Troubleshooting

Engine Runs Erratically

Addresses issues causing the engine to run unevenly.

Owner Service Assistance

Parts And Accessories Inquiries

How to inquire about replacement parts and accessories.

Service Assistance

Steps to follow if dealership cannot resolve a problem.

Outboard Installation

Fuel Requirements

Specific fuel needs during the engine's initial break-in period.

Oil Recommendation

Specifies the correct type of oil for the engine.

Avoiding Fuel Flow Restriction

Tips to prevent restrictions in the fuel supply system.

Outboard Installation

Fuel Tanks

Information on portable and permanent fuel tank installation.

Filling the Fuel System

Steps for filling and priming the fuel system.

Outboard Installation

Installation Specifications

Transom opening and engine centerline specifications.

Lifting the Outboard

Safety precautions and procedure for lifting the outboard.

Outboard Installation

Steering Cable - Starboard Side Routed Cable

Instructions for routing and installing the starboard steering cable.

Steering Link Rod Fasteners

Proper use and torque for steering link rod fasteners.

Outboard Installation

Determining Recommended Outboard Mounting Height

Chart and guidelines for selecting the optimal outboard mounting height.

Drilling Outboard Mounting Holes

Steps for accurately drilling mounting holes on the transom.

Outboard Installation

Fastening the Outboard to the Transom

Procedures for securely attaching the outboard to the boat transom.

Checking Boat Transom Construction

How to verify the strength of the boat transom for mounting.

Outboard Installation

Electrical, Hoses, Control Cables and Front Clamp

Connecting electrical, fuel, oil, and control systems.

Battery Information

Requirements and safety for engine starting batteries.

Battery Cable Connections

Proper connection of battery cables to the starting battery.

Hose and Tubing Connections

Connecting fuel, oil, and water hoses/tubing.

Outboard Installation

Installing the Shift Cable

Procedure for installing the shift cable to the engine.

Locating the Center Point of the Shift Cable

Finding the cable's center point for proper adjustment.

Adjusting the Shift Cable

Steps for adjusting the shift cable for correct engagement.

Installing the Throttle Cable

Procedures for installing and adjusting the throttle cable.

Outboard Installation

Trim In Pin

Adjusting the trim limit pin for safe operation.

Front Clamp Assembly Installation

Steps for installing the front clamp assembly for routing cables.

Outboard Installation

Oil Injection Set-Up

Procedures for filling the oil system for the outboard.

Priming Oil Injection Pump

Steps to prime the oil injection pump before starting.

Purging Air From The Engine Oil Tank

How to remove air from the engine oil tank.

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