Mercury 225 OptiMax DTS User Manual

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Page 1 / 42 © 2004 Mercury Marine 90-10234050 APRIL 2004
200/225 OPTIMAX DTS
INSTALLATION MANUAL
Table of Contents
Notice to Installer ................................................... 2
Installation Information .......................................... 2
Avoiding Loss of Throttle and Shift Control.......2
Before Starting the Engine................................2
Fuel Requirements............................................2
Oil Recommendation.........................................2
Avoiding Fuel Flow Restriction .............................. 2
Electric Fuel Pump ................................................ 3
Boat Horsepower Capacity .................................... 3
Selecting Accessories For Your Outboard ............ 3
Fuel Tanks ............................................................. 3
Portable Fuel Tank ........................................... 3
Permanent Fuel Tank ....................................... 3
Installation Specifications ...................................... 4
Lifting the Outboard ............................................... 4
Applying Counter Rotation Decals ........................ 5
Steering Cable - Starboard Side Routed Cable ....5
Steering Link Rod Fasteners ................................. 6
Determining Recommended Outboard Mounting
Height .................................................................... 7
Drilling Outboard Mounting Holes ......................... 8
Front Clamp Assembly .......................................... 9
Removal ............................................................ 9
Installation ......................................................... 9
Wiring and Installation ......................................... 11
Wire Color Code Abbreviations.......................11
Installation Guidelines for DTS System
Components....................................................11
Data Harness Pulling Procedure.....................11
Junction Box (If Equipped)...............................12
Non-Mercury Marine Provided Ignition Switch.12
Wiring Accessories..........................................13
System Wiring Reference Points.....................13
Connecting 14 Pin Data Harness - Single
Engine..............................................................14
Connecting 14 Pin Data Harness - Dual Engine
.........................................................................15
Installing DTS Command Module and Harness -
Single Engine...................................................16
Installing DTS Command Module and Harness -
Dual Engine/Single Helm.................................20
Battery Cable Size For Outboard Models........21
Battery Information..........................................23
Connecting Battery Cables and DTS Power
Harness...........................................................23
Connecting Fuel Tank, Oil Tank and Speed
Sensor.............................................................26
Switched 12V Accessory Connection..............28
DTS Wiring - Single Engine.............................29
DTS Wiring - Dual Engine................................31
System Wiring Installation Checklist................32
Fuel Hose and Oil Hose Connections ................. 32
Fuel Hose Connection .................................... 32
Filling the Fuel System ........................................ 33
Filling the Oil System .......................................... 33
Priming Oil Injection Pump .................................. 34
Purging Air From the Engine Oil Tank ................. 36
Propeller Installation ............................................ 36
Trim In Pin ........................................................... 37
Paddle Wheel Speed Sensor Installation (If
Equipped) ............................................................ 38
Parts Provided ................................................ 38
Selecting Location .......................................... 38
Transom Angle Requirements ........................ 39
Installing Bracket ............................................ 39
Routing the Cable ........................................... 40
Installing and Removing the Paddle Wheel .... 41
Wiring Connections ......................................... 41
Template - Paddle Wheel Speed Sensor ....... 42

Mercury 225 OptiMax DTS Specifications

General

Brand	Mercury
Model	225 OptiMax DTS
Category	Outboard Motor
Language	English

Summary

Installation Information

Avoiding Loss of Throttle and Shift Control

Safety warning about not splicing DTS system wiring to prevent water intrusion and control loss.

Pre-Start Engine Procedures

Before Starting the Engine

Caution to avoid engine damage by priming the oil injection pump before starting.

Oil Recommendation

Recommends NMMA certified TC-W3 2-Cycle oil, advises consulting dealer for latest recommendations.

Avoiding Fuel Flow Restriction

Warning about components restricting fuel flow, which can cause stalling or lean conditions.

System Specifications

Boat Horsepower Capacity

Warning against exceeding boat's maximum horsepower limit to prevent loss of control or damage.

Selecting Accessories For Your Outboard

Recommends genuine Mercury accessories and advises checking with dealer before installing any accessories.

Outboard Mounting and Lifting

Installation Specifications

Lifting the Outboard

Safety warning and steps for properly lifting the outboard using a lifting eye and hoist.

Determining Recommended Outboard Mounting Height

Wiring and Installation Procedures

DTS System Component Installation Guidelines

Guidelines for installing DTS system components.

Data Harness Pulling Procedure

Connecting 14 Pin Data Harness - Single Engine

Connecting 14 Pin Data Harness - Dual Engine

Installing DTS Command Module and Harness - Single Engine

Installing DTS Command Module and Harness - Dual Engine

Installing DTS Command Module and Harness - Dual Engine/Single Helm

Battery Cable Sizing For Outboard Models

Battery Installation and Connections

Battery Information

Connecting Battery Cables and DTS Power Harness

CAUTION to secure DTS power harness to battery cables and connect it only to the starting battery.

DTS Wiring - Single Engine

PANEL CONTROL

DTS Wiring - Dual Engine

CONSOLE CONTROL

System Wiring Installation Checklist

Priming Oil Injection Pump

Propeller Installation