Mercruiser 4.3-5.0 MPI Engine Manual
Mercruiser 4.3-5.0 MPI Engine Manual
Mercruiser 4.3-5.0 MPI Engine Manual
Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions requirements of the directive mentioned above. This engine must not be put into service until the recreational craft in which it is to be installed has been declared in conformity, if so required, with the relevant provision of the directive. Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard Generic immunity standard EN 500811 EN 500821
Vehicles, boats and internal combustion engine SAE J551 (CISPR 12) driven devices Radio disturbance characteristics Electrostatic discharge testing EN 6100062; EN 6100042; EN6100043
The notified body responsible for surveillance of the quality system under Full Quality Assurance Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
Patrick C. Mackey
*899883180*
Openings in Hull, Deck and superstructure (A.3.4) ISO 90931; ISO 90932
90-899883180 1007
Regulatory contact: Engineering - Regulatory MerCruiser 3003 N. Perkins Rd Stillwater, Oklahoma 74075 USA (405) 377-1200
Identification Record
Please record the following information:
Engine Model and Horsepower Transom Assembly Serial Number (Sterndrive) Transmission Model (Inboard) Propeller Number Hull Identification Number (HIN) Boat Manufacturer Exhaust Gas Emissions Certification Number Boat Model Gear Ratio Gear Ratio Pitch Engine Serial Number Sterndrive Unit Serial Number Transmission Serial Number Diameter Purchase Date Length
The serial numbers are the manufacturers keys to numerous engineering details that apply to your Mercury MerCruiser power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation. Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A. 2007, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, SportJet, KPlanes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.
The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant! Mercury MerCruiser
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages and other related information. Please review this important information. Mercury Marine products are designed and manufactured to comply with our own high quality standards, applicable industry standards and regulations, as well as certain emissions regulations. At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations. All Mercury Marine product, sold as new, receives the applicable limited warranty coverage, whether the engine participated in one of the test programs described above or not.
Notice
Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the International Hazard Symbol ! , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.62006 for product safety information in product manuals, instructions, and other collateral materials. Observe them carefully. These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while performing the service, plus common sense operation, are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task.
NOTE: Indicates information that helps in the understanding of a particular step or action.
! WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
TABLE OF CONTENTS
Section 1 - Warranty
Warranty Registration: United States and Canada....................................................................2 Warranty Registration: Outside the United States and Canada....................................................................2 Transfer of Warranty................................................ 3 Mercury Product Protection Plan: United States and Canada....................................................................3 Mercury MerCruiser Limited Warranty (GasolineFueled Products Only) ...........................4 3Year Limited Warranty Against Corrosion............6 4Year Limited Corrosion Warranty: SeaCore Sterndrive Models with Gas Engines ...................... 7 Global Warranty Charts...........................................8 Consumer Application Warranty Chart...............8 Commercial Application Warranty Chart.............9 Government Application Warranty Chart..........10 Mercury Installation Quality Certification Program 10 Emission Control Information Label.......................11 Owner Responsibility........................................12
Freezing Temperature Operation..................41 Drain Plug and Bilge Pump...........................42 Protecting People in the Water............................. 42 While You Are Cruising....................................42 While Boat Is Stationary.................................. 42 HighSpeed and HighPerformance Operation.... 42 Passenger Safety in Pontoon Boats and Deck Boats.................................................................... 42 Boats Having An Open Front Deck..................43 Boats With FrontMounted, Raised Pedestal Fishing Seats...................................................43 Wave and Wake Jumping.................................... 43 Impact with Underwater Hazards......................... 44 Drive Unit Impact Protection............................45
Operating with Low Water Inlets in Shallow Water....................................................................45 Conditions Affecting Operation............................. 45 Weight Distribution (Passengers and Gear) Inside the Boat.............................................. 45 The Bottom of the Boat................................. 45 Cavitation...................................................... 46 Ventilation..................................................... 46 Elevation and Climate................................... 46 Propeller Selection........................................46 Getting Started..................................................... 47 20Hour BreakIn Period............................... 47 After BreakIn Period.....................................47 End of First Season Checkup....................... 48
Section 4 - Specifications
Fuel Requirements...............................................50 Fuel Ratings.....................................................50 Using Reformulated (Oxygenated) Gasolines (USA Only).......................................................50 Gasolines Containing Alcohol..........................50 Engine Oil.............................................................51 Engine Specifications...........................................51 Fluid Specifications (MPI).....................................52 Fluid Specifications....................................... 52 Engine...........................................................52 Alpha Sterndrive............................................53 Bravo Sterndrives..........................................53 PowerAssisted Steering and Power Trim Fluids.............................................................53 Approved PowerAssisted Steering Fluids.. 53 Approved Power Trim Fluids....................... 53
Section 5 - Maintenance
Owner/Operator Responsibilities.......................... 56 Dealer Responsibilities.........................................56 Maintenance.........................................................56 DoItYourself Maintenance Suggestions.............57 Inspection.............................................................57 Maintenance ScheduleSterndrive Models........ 58 Routine Maintenance.................................... 58 Scheduled Maintenance................................ 58 Maintenance Log..................................................59 Engine Oil.............................................................60 Checking..........................................................60 Filling............................................................... 60 Changing Oil and Filter....................................61 Easy Engine Oil Drain System....................61 Engine Oil Drain Pump............................... 62 Changing the Filter...................................... 62 Power Steering Fluid............................................63 Checking..........................................................63 Filling............................................................... 63 Changing......................................................... 64 Engine Coolant.....................................................64 Checking..........................................................64 Filling............................................................... 65 Page ii Changing ........................................................ 65 Drive Unit Oil........................................................ 66 Checking..........................................................66 Filling............................................................... 66 Changing......................................................... 67 Power Trim Fluid.................................................. 69 Checking..........................................................69 Filling............................................................... 69 Changing......................................................... 70 Battery..................................................................70 Multiple EFI Engine Battery Precautions....... 70 Cleaning the Flame Arrestor................................ 71 Positive Crankcase Ventilation Valve (PCV)... 72 Changing..................................................... 72 WaterSeparating Fuel Filter (MPI)...................... 72 WaterSeparating Fuel Filter.........................72 GEN II Models...............................................73 Removal......................................................73 Installation...................................................73 GEN III Models..............................................74 Removal......................................................74 Installation...................................................75 Lubrication............................................................75 90-899883180 OCTOBER 2007
Steering System.............................................75 Throttle Cable.................................................77 Shift Cable Typical.......................................78 Sterndrive Unit and Transom Assembly.........78 Sterndrive Ujoint Shaft Splines And Orings (Sterndrive Unit Removed).............................79 Engine Coupler............................................... 79 Driveshaft Extension Models..........................80 Propellers..............................................................80 Propeller Repair.............................................80 Alpha Propeller Removal................................ 80 Alpha Propeller Installation............................. 81 Bravo One Propeller Removal........................ 82 Bravo One Propeller Installation..................... 82 Bravo Two Propeller Removal........................ 83 Bravo Two Propeller Installation..................... 83 Bravo Three Propeller Removal.....................84 Bravo Three Propeller Installation..................85 Serpentine Drive Belt............................................. 87 Checking...........................................................87
Replacing Belt and/or Adjusting Tension..........87 Corrosion Protection..............................................89 Corrosion Information.....................................89 Maintaining Ground Circuit Continuity............89 Anodes and MerCathode System Locations. .89 Checking the Quicksilver MerCathode System...........................................................90 Power Package Exterior Surfaces.................. 91 Boat Bottom Care...........................................91 Antifouling Paint............................................91 Sterndrive Surface Care.................................93 Flushing the Power Package.................................94 General Information........................................ 94 Flushing Attachments................................... 94 Sterndrive Water Pickups............................. 95 Alternative Water Pickups............................97 SeaCore Power Package Flushing Procedure.......................................................98 Models Using The Sterndrive Water Pickup..........................................................98
Section 6 - Storage
Cold Weather or Extended Storage.....................104 Preparing Power Package for Storage.........104 Engine and Fuel System Preparation........105 Draining the Seawater System............................106 Drain System Identification...........................107 Air Actuated Single Point Drain System.....107 Manual Single Point Drain System.............107 Three Point Manual Drain System.............108 MultiPoint Drain (MPD) System................108 AirActuated SinglePoint Drain System.......109 Boat in the Water.......................................109 Boat out of the Water.................................111 Manual Single Point Drain System...............114 Boat in the Water.......................................114 Boat out of the Water.................................115 Three Point Manual Drain System...............116 Boat in the Water.......................................116 Boat out of the Water.................................117 MultiPoint Drain (MPD) System..................118 Boat out of the Water.................................118 Boat in the Water.......................................120 Battery Storage....................................................122 Power Package Recommissioning......................122
Section 7 - Troubleshooting
Diagnosing EFI Problems....................................124 Diagnosing DTS Problems..................................124 Engine Guardian System.....................................124 Starter Motor Will Not Crank Engine, Or Cranks Slow.....................................................................124 Engine Will Not Start or Is Hard to Start..............125 Engine Runs Rough, Misses, or Backfires..........125 Poor Performance...............................................125 Excessive Engine Temperature...........................125 Insufficient Engine Temperature..........................126 Low Engine Oil Pressure.....................................126 Battery Will Not Recharge...................................126 Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds.........................127 Steering Wheel Jerks or Is Difficult to Turn.........127 Power Trim Does Not Operate (Motor Does Not Operate)..............................................................127 Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move)..........................127
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Section 1 - Warranty
Section 1 - Warranty
Table of Contents
Warranty Registration: United States and Canada .............................................................................. 2 Warranty Registration: Outside the United States and Canada.......................................................... 2 Transfer of Warranty............................................. 3 Mercury Product Protection Plan: United States and Canada................................................................. 3 Mercury MerCruiser Limited Warranty (GasolineFueled Products Only) ......................................... 4 3-Year Limited Warranty Against Corrosion......... 6 4-Year Limited Corrosion Warranty: SeaCore Sterndrive Models with Gas Engines ................... 7 Global Warranty Charts........................................ 8 Consumer Application Warranty Chart ........... 8 Commercial Application Warranty Chart ........ 9 Government Application Warranty Chart ..... 10 Mercury Installation Quality Certification Program ............................................................................ 10 Emission Control Information Label.................... 11 Owner Responsibility ................................... 12
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Section 1 - Warranty
NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruisers warranty registration department with your name, old address, new address, and engine serial number. Your dealer can also process this change of information. United States customers or dealers may contact: Mercury Marine Attn: Warranty Registration Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax 920-929-5893 Canadian customers or dealers may contact: Mercury Marine Canada Limited 2395 Meadowpine Blvd. Mississauga, ON Canada, L5N 7W6 Fax 1-800-663-8334
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Section 1 - Warranty
The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributors and dealers code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product. A copy of the warranty registration card, designated as the purchasers copy, MUST be given to you immediately after the card has been completely filled out by the selling distributor or dealer. This card represents your factory registration identification. Keep the card; if you ever need warranty service on this product, your dealer may ask you for the warranty registration card to verify date of purchase and to use the information on the card to prepare the warranty claim forms. In some countries, the distributor will issue a permanent (plastic) warranty registration card to you within 30 days after receiving the factory copy of the warranty registration card from your distributor or dealer. If you receive a plastic warranty registration card, you may discard the purchasers copy that you received from the distributor or dealer when you purchased the product. Ask your distributor or dealer if this plastic card program applies to you. For further information concerning the warranty registration card and its relationship to warranty claim processing, refer to the International Warranty. See Table of Contents.
NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event of a safety recall notification under the Federal Boat Safety Act.
Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owners name, address and engine serial number to Mercury Marines warranty registration department. In the United States mail to: Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax 920-929-5893 In Canada mail to: Mercury Marine Canada Limited 2395 Meadowpine Blvd. Mississauga, ON Canada, L5N 7W6 Fax 1-800-663-8334 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the distributor closest to you.
Section 1 - Warranty
The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty. The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. One, two, three, four, or five year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details.
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Section 1 - Warranty
Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the predelivery inspection process specified by Mercury Marine is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial (unless properly reregistered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance must be performed according to the maintenance schedule in the Operation, Maintenance & Warranty manual in order to obtain warranty coverage. Mercury Marine reserves the right to make any warranty coverage contingent upon proof of proper maintenance. What Mercury Marine Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury Marine product. Mercury Marine reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured. How to Obtain Warranty Coverage The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair. The purchaser in that case shall pay for all related transportation charges and travel time. If the service provided is not covered by this warranty, the purchaser shall pay for all related labor and material and any other expenses associated with that service. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage. What Is Not Covered This limited warranty does not cover the following: Routine maintenance items Adjustments Normal wear and tear Damage caused by abuse Abnormal use Use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation, Maintenance & Warranty manual) Operation of the product in a manner inconsistent with the recommended operation and duty cycle section of the Operation, Maintenance & Warranty manual Neglect Accident Submersion Improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product) Improper service Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product Jet pump impellers and liners Operation with fuels, oils, or lubricants that are not suitable for use with the product (see the Operation, Maintenance & Warranty manual) Alteration or removal of parts Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body Running the engine out of water Mounting the engine too high on the transom Operating the boat with the engine over trimmed
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Section 1 - Warranty
Use of the product for racing or other competitive activity, or operating with a racingtype lower unit at any point, even by a previous owner of the product, voids the warranty. Expenses related to haulout, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal or replacement of boat partitions or other material in order to gain access to the product are not covered by this warranty. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation, or warranty regarding the product, other than those contained in this limited warranty. If such affirmation, representation, or warranty is made, it shall not be enforceable against Mercury Marine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.
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Section 1 - Warranty
This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by the Customer); products used in a commercial application. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of warranty period, even if the product is only occasionally used for such purposes.
4Year Limited Corrosion Warranty: SeaCore Sterndrive Models with Gas Engines
4-YEAR LIMITED CORROSION WARRANTY: SEACORE STERNDRIVE MODELS WITH GAS ENGINES What Is Covered Mercury Marine warrants that each new MerCruiser SeaCore engine, transom, and sterndrive package will not be rendered inoperative as a direct result of corrosion for the period of time described below. Duration of Coverage This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent (noncommercialuse) purchaser upon proper reregistration of the product. Warranty coverage is terminated for used product obtained in any of the following ways: Repossession from a retail customer Purchase at auction Purchase from a salvage yard Purchase from an insurance company that obtained the product as a result of an insurance claim
Condition That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the predelivery inspection process specified by Mercury Marine is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Corrosionprevention devices specified in the Operation, Maintenance & Warranty manual must be in use on the boat, and routine maintenance outlined in the Operation, Maintenance & Warranty manual must be performed according to the maintenance schedule in the Operation, Maintenance & Warranty manual (including without limitation the replacement of sacrificial anodes, use of specified lubricants, and touchup of nicks and scratches) in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance. What Mercury Marine Will Do Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured. How to Obtain Warranty Coverage The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair. The purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, the purchaser shall pay for all related labor and material, and any other expenses associated with that service. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage. What Is Not Covered
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Section 1 - Warranty
This limited warranty does not cover the following: Electrical system corrosion Corrosion resulting from damage Corrosion that causes purely cosmetic damage Abuse or improper service Corrosion to accessories, instruments, and steering systems Corrosion to a factoryinstalled jet drive unit Damage due to marine growth Replacement parts (parts purchased by the customer) Product sold with less than a oneyear limited product warranty Products used in a commercial application. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of warranty period, even if the product is only occasionally used for such purposes.
Region
Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and Standard SeaCore with Standard SeaCore with 377 377 Models Closed Closed with Cooling Cooling Closed Cooling 1 year 1 year 1 year 2 years 1 year 2 years 1 year 3 years 3 years 3 years 3 years 1 year 3 years 3 years 3 years 1 year 1 year 2 years 1 year 3 years 1 year 3 years 1 year 1 year 2 years 1 year 3 years all Tow Sports 1 year 2 years 2 years 1 year 3 years 1 year 2 years 1 year 4 years 4 years 4 years 4 years 1 year 3 years 3 years 4 years 2 years 1 year 3 years 1 year 3 years 1 year 4 years 2 years 1 year 3 years 1 year 3 years all Tow Sports 1 year 3 years 3 years 1 year 3 years 1 year 3 years 3 years
SeaCore
USA and Canada Latin America Mexico Europe Japan Australia and New Zealand South Pacific Asia (excluding Japan, South Pacific, Australia, New Zealand)
2 years
2 years
2 years
2 years
2 years
2 years
2 years
2 years
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies. NOTE: In regions where TBD (To Be Determined) is listed, check with your local dealer for warranty length and conditions.
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Section 1 - Warranty
Region
Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and Standard SeaCore with Standard SeaCore with SeaCore 377 377 Models Closed Closed with Cooling Cooling Closed Cooling 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours none none 1 year none none none none none none 1 year none none none none
USA and Canada Latin America Mexico Europe Japan Australia and New Zealand South Pacific
Asia (excluding Japan, South 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or Pacific, 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours Australia, New Zealand)
none
none
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies
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Section 1 - Warranty
Region
Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and Standard SeaCore with Standard SeaCore with SeaCore 377 377 Models Closed Closed with Cooling Cooling Closed Cooling 1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years none 1 year none none none none 4 years none 1year none none none none
USA and Canada Latin America Mexico Europe Japan Australia and New Zealand South Pacific
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Asia (excluding Japan, South 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or Pacific, 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours Australia, New Zealand)
none
none
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies
15502
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Section 1 - Warranty
Mercury MerCruiser products installed by a Mercury Installation Quality Certified Manufacturer are Installation Quality certified products and may receive an additional one (1) year of limited warranty coverage. The Installation Quality Certification program was developed to recognize MerCruiser boatbuilder customers who have achieved higher manufacturing standards. It is the first and only comprehensive manufacturerinstallation certification program in the industry. The program has three goals: 1. To enhance overall product quality. 2. To improve the boat ownership experience. 3. To enhance overall customer satisfaction. The certification process is designed to review all facets of manufacturing and engine installation. The program is composed of design, manufacturing and installation review stages with which builders must comply. Certification applies leadingedge methodologies to create: Efficiencies and best practices specific to engine installation. Worldclass assembly and component specifications. Efficient installation processes. Industry standard endofline test procedures Boat builders that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiserpowered boats that are registered on and after the boat builder's certification date for all worldwide registrations. Mercury has designated a section of our Website to promote the Installation Quality Certification Program and communicate its benefits to consumers. For a current list of MerCruiserpowered boat brands that have earned Installation Quality Certification, visit www.mercurymarine.com/mercruiser_warranty.
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Section 1 - Warranty
NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information.
X.XL
0575
31656
Emission Control LabelCalifornia EmissionsCompliant "SERIAL#"Engine Serial Number "FAMILY"Engine Family "STD."Emissions Standard "D.O.M."Date of Manufacture "DISP"Piston Displacement
X.XL
31657
Emission Control LabelNot for Sale in California "SERIAL#"Engine Serial Number "FAMILY"Engine Family "STD."Emissions Standard "D.O.M."Date of Manufacture "DISP"Piston Displacement
Owner Responsibility
The operator must have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed their factory specifications.
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Identification
The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers.
25903
Serial numbers and maintenance color codes decal The engine serial number is also stamped in the engine block.
c d
25906
Page 14
The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers.
25907
25904
Page 15
The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers.
25905
Gimbal housing with serial number stamping a - Transom assembly serial Number
b c
RUN
74608
Accidental ejections, such as falling overboard, are more likely to occur in: lowsided sport boats bass boats high performance boats Accidental ejections can also occur from: poor operating practices sitting on the seat or gunwale at planing speeds standing at planing speeds operating at planing speeds in shallow or obstacle infested waters releasing your grip on the steering wheel that is pulling in one direction consuming alcohol or drugs high speed boating maneuvers
Page 16
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make its atrest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretchedout length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or tie a knot in the lanyard. Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power. We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).
! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard. Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components. Loss of power and directional control in heavy seas, strong current or high winds. Loss of control when docking.
! WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Instrumentation
Digital Gauges
A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, battery voltage, fuel consumption and engine operating hours. The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems. Refer to the manual with your gauge package for the warning functions monitored and basic operation of the SmartCraft Instrument package.
Page 17
Analog Gauges
The following is a brief explanation of the instrumentation typically found on some boats. As the owner or operator, you should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.
50 40 30 20 10
80 70 60 50 40 30 90
60
100 110 120
5 6 7
70
2 1
KPH 80
10 BATT
16
C TEMP
MPH
X 1000
RPM
OIL
4 FUEL
0 0 0 0 0 CRUISELOG TRIM
f
abcde-
i
fghij-
14671
Fuel gauge Hour meter Bilge blower switch Ignition switch Power trim gauge
Speedometer: indicates boat speed Tachometer: indicates engine RPM Oil pressure gauge: indicates engine oil pressure Voltmeter: indicates battery voltage Water temperature gauge: indicates engine operating temperature Fuel gauge: indicates quantity of fuel in the tank Hour meter: records engine operating time Bilge blower switch: operates the bilge blower Ignition switch: starts and stops the engine. Power trim gauge: indicates sterndrive unit angle (trim out or in)
Page 18
a f b
c d
mc77019-1
Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral. Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position, and should only be used to assist in starting the engine. Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch. Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed. Control Handle Tension Adjustment Screw - (not visible) This screw is used to adjust the effort required to move the remote control handle. Refer to instructions provided with remote control for complete adjustment instructions. Trim/Tilt Button - Refer to Power Trim.
Page 19
b d c b
a a
a - Throttle Only Button b - Control Handle
d
mc79503-1
Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position. Control Handles - Operation of the the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to increase speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed. Control Handle Tension Adjustment Screw - (not visible) This screw is used to adjust the effort required to move the remote control handle. Refer to instructions provided with remote control for complete adjustment instructions. Power Trim Switch - See Power Trim section for detailed power trim operating procedures. Trailer Switch - Used to raise drive unit for trailering, launching, beaching or shallow water operation. See Power Trim for detailed trailer switch operation.
Page 20
Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch. Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed. Shift Lock - Pressing the shift lock allows the engine to shift. The shift lock must always be pressed when moving the control handle out of the neutral position. Trim/Tilt Switch (if equipped) - Refer to Power Trim. Throttle Only Button - Allows engine throttle advancement without shifting the engine. The throttle only button can be depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up the engine. Start/Stop Button - Allows the boat operator to start or stop the engine without using the ignition key. Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.
Page 21
c
abcdefghi-
Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw
Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed. Trim/Tilt Switch (if equipped) - Refer to Power Trim. Active Light - The active light is illuminated to show the remote control is active and ready for use. Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.
NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch. Select Key - Selects System View onscreen options and confirms data entries. Arrow Trackpad - Navigates through System View onscreen function messages. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms. Refer to Dual Helm Station Transfer. Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.
Page 22
START STOP
c
abcdefgh-
h
14637
Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw
Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed. Trim/Tilt Switch (if equipped) - Refer to Power Trim. Active Light - The active light is illuminated to show the remote control is active and ready for use. Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.
NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch. Stop/Start Button - Allows the boat operator to start or stop the engine without using the ignition key. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms. Refer to Dual Helm Station Transfer. Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.
Page 23
e
SYNC
c h
abcdeTrim/tilt switch Control handles Active light Neutral light Select key
f g
fghij-
3411
Arrow trackpad Sync light Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw
Trim/Tilt Switch (if equipped) - Refer to Power Trim. Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed. Active Light - The active light is illuminated to show the remote control is active and ready for use. Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.
NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch. Select Key - Selects System View onscreen options and confirms data entries. Arrow Trackpad - Navigates through System View onscreen function messages. Sync Light - The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms. Refer to Dual Helm Station Transfer. Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.
Page 24
ACTIVE
SYNC
THROTTLE ONLY
3434
To disengage, move one or both control handles until they are more than 5 apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.
! WARNING
Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. Oneperson helm transfer should only be performed while engine is in neutral.
NOTE: Idle position is preferred when doing a station transfer. If conditions do not allow the remote control to be placed at idle position, a station transfer can be done while in gear. NOTE: Pressing and releasing station select button at new station allows the engine control to be transferred to the new station. The control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new station. Adjust control handles to the desired throttle and gear position. 1. Place active remote control lever to idle position. 2. Proceed to the inactive helm station and position remote control lever to the idle position.
Page 25
3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine.
b
ACTIVE
THROTTLE ONLY
b
ACTIVE SYNC
THROTTLE ONLY
STATION SELECT
a
a - Active light
3433
4. The active light will switch off at the original remote control station.
SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER Pressing the station select button and holding it in allows the boat operator 10 seconds to match up the control handle settings at the new station with the handle settings that are at the old (to be inactive) station. If the handles are not matched, the neutral light will flash. The light blinks faster as the handles are nearing match position. Once the light stays on continuously, the handles are matched and the button can be released. Transfer process is complete and the new station is now in control. If the button is held for over 10 seconds, the station transfer is cancelled.
5656
c - Trim/tilt switch
Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position. Throttle Lever - Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position. Trim/Tilt Switch - Refer to Power Trim. Page 26 90-899883180 OCTOBER 2007
Power Trim
Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
! WARNING
Excessive trim can cause serious injury or death at high speeds. Use caution when trimming the sterndrive, and never trim out beyond the gimbal ring support flanges while the boat is underway or at engine speeds above 1200 RPM. For best performance trim the sterndrive unit so that the boat bottom is at a 35 angle to the water.
3-5
mc79528
Trimming sterndrive unit up/out can: Generally increase top speed Increase clearance over submerged objects or a shallow bottom Cause boat to accelerate and plane off slower In excess, cause boat porpoising (bouncing) or propeller ventilation Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line
mc78529
Trimming sterndrive unit down/in can: Help the boat accelerate and plane off quicker Generally improve the ride in choppy water In most cases, reduce boat speed
Page 27
If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
mc79530
NOTE: The DTS control system limits the extent to which the sterndrive unit can be trimmed up/out when engine speed is above 3500 RPM.
NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems. If using an external tie bar, raise and lower all drives together as a unit. Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit. Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.
NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn off or disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your authorized dealer.
Page 28
1. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
22529
Yellow lever style circuit breakertypical a - Yellow levershown tripped b - Red test button 2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs.
mc74907-1
3. Four fuses are located on the port side of the engine. These fuses protect the main power, fuel pump, ignition, and accessory circuits.
mc77602-1
Page 29
4. A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped).
mc70525-1
5. The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump. The trim pump may also have an inline circuit protection device in the power trim positive lead near the battery switch or battery connection.
b
a - 20 amp spade fuse
9208
6. The Quicksilver ThreeButton Power Trim Control Panel is further protected by a 20 amp inline fuse.
mc70527-1
Page 30
7. The Quicksilver MerCathode System has a 20 amp inline fuse in the wire which connects to the positive (+) terminal on controller. If the fuse is blown, the system will not operate resulting in a loss of corrosion protection.
mc79977
NOTICE
A continuous horn indicates a critical fault. Operating the engine during a critical fault can damage components. If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation. If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If you cannot determine the cause, contact your authorized Mercury MerCruiser dealer.
Page 31
Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails. For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage from decreased water flow to the engine. If the debris passes through and full water flow is restored, engine power levels are restored to normal. To avoid a possible recurrence of the problem you should contact an authorized dealer. The ECM stores the fault and with this information the technician will be able to more rapidly diagnose problems.
Page 32
Page 33
Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement. Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when the boat is above idle or planing transition speed. Watch out for others, the water and your wake. Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier who was 61 m (200 ft.) in front of you in 5 seconds. Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.
! WARNING
Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.
Good Ventilation
Ventilate the passenger area, open the side curtains or forward hatches to remove fumes.
Page 35
mc79553-1
Poor Ventilation
Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide. 1. Examples of poor ventilation while a boat is stationary:
a
a - Operating the engine when the boat is moored in a confined space
mc79554-1
a
a - Operating the boat with the trim angle of the bow too high
mc79556-1
b - Operating the boat with no forward hatches open (station wagon effect)
OPERATION CHART
Operation Chart BEFORE STARTING AFTER STARTING Observe all gauges to check condition of engine. If not normal, stop engine. Check for fuel, oil, water, fluid and exhaust leaks. WHILE UNDERWAY AFTER STOPPING
Observe all gauges to check condition of Turn ignition key to the engine. If not "OFF" position. normal, stop engine. Listen for the audio alarm. Turn battery switch to the "OFF" position.
Page 36
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. 3. Turn ignition key to "START". Release key when engine starts and allow switch to return to "ON" position. Allow engine to warm up (610 minutes on first start of the day). 4. If engine does not start after 3 attempts: a. Push the throttle only button and position the remote control handle/throttle lever to the 1/4 throttle position. b. Turn ignition key to "START". Release key when engine starts and allow switch to return to "ON" position. 5. If engine does not start after step 4: a. Move the remote control handle/throttle lever to full throttle position, then return to 1/4 throttle. b. Turn ignition key to "START". Release key when engine starts and allow switch to return to "ON" position. 90-899883180 OCTOBER 2007 Page 37
6. Inspect the power package for fuel, oil, water and exhaust leaks. 7. Move control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting, advance throttle to desired setting.
NOTICE
Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is operating at idle.
STOPPING THE ENGINE 1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes. 2. Turn ignition key to the "OFF" position.
ThrottleOnly Operation
1. Refer to Remote Controls section for remote control features. 2. Move the control lever to the idle/neutral position. 3. Depress and hold the throttle only button, and move the control lever to the idle/forward or idle/reverse position. 4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase. IMPORTANT: Moving the control lever back to the idle/neutral position will disengage the throttle only button and allow the engine to shift into gear. 5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position. Moving the control lever from the idle/neutral position to the idle/forward or idle/reverse position without pressing the throttle only button will shift the unit into the chosen gear.
Page 38
OPERATION CHART
Operation Chart BEFORE STARTING AFTER STARTING Observe all gauges to check condition of engine. If not normal, stop engine. Check for fuel, oil, water, fluid and exhaust leaks. Check shift and throttle control operation. Check steering operation. WHILE UNDERWAY AFTER STOPPING
Observe all gauges to check condition of Turn ignition key to the engine. If not "OFF" position. normal, stop engine. Listen for the audio alarm. Turn battery switch to the "OFF" position. Close fuel shut off valve. Close seacock, if equipped. Flush cooling system if in saltwater. Drain bilge.
Turn battery switch on. Operate bilge blowers. Open fuel shut off valve. Open seacock, if equipped. Close the drain system. Place sterndrive unit in full down/in position. Check the engine oil. Perform all other checks specified by your dealer and/or boat builder. Listen for Audio Warning Alarm to sound when the ignition switch is in the "ON" position.
Page 39
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes.
NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process. When the start button is pushed, the DTS system signals the engine PCM to start the engine. If the engine does not start, the starting process times out after a few seconds or when the engine reaches 400 RPM. Attempting to start the engine with the engine already running will turn the engine off. 3. Turn ignition key to "RUN" position. 4. Turn the ignition key switch to the "START" position then release, or depress the start/ stop button and release. If the engine is cold, allow the engine to operate at idle for 6 10 minutes or until the engine temperature reaches 60 C (140 F). 5. If the engine does not start after three attempts: a. Push the throttleonly button and position the remote control handle or throttle lever to the 1/4 throttle position. b. Turn the ignition key to "start." Release key when the engine starts and allow the switch to return to the "on" position. 6. If the engine does not start after step 5: a. Move the remote control handle.throttle lever to the full throttle position, then return to 1/4 throttle. b. Turn the ignition key to "START." Release key when the engine starts and allow the switch to return to the "on" position. 7. Inspect the power package for fuel, oil, water, and exhaust leaks. 8. Move the control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting, advance throttle to desired setting.
NOTICE
Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is operating at idle.
STOPPING THE ENGINE 1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes. 2. The engine can be stopped by any one of the following 4 methods: a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop and the control system will be deactivated. b. Depress the start/stop button, if equipped. The engine will stop and the control system will remain active.
Page 40 90-899883180 OCTOBER 2007
c.
d.
Momentarily move the ignition key switch to the "START" position, then release immediately. The control system will recognize that the engine is running and will stop the engine. The control system will remain active. Moving the ignition key switch to the "START" position again will issue a start request to the control system and the control system will start the engine, if appropriate. Activate the lanyard stop switch, if equipped. The engine will stop, but the control system will remain active. The control system will not allow the engine to start if the lanyard stop switch is activated.
ThrottleOnly Operation
NOTE: When operating in throttle only (neutral) mode, the DTS Control System will not allow the engine speed to increase above 3500 RPM. Zero effort remote controls: Zero effort remote controls have seperate throttle control and shift control levers. Advancing the throttle control lever beyond the idle position while the shift control lever is in the neutral position will cause engine speed to increase, but only up to the maximum neutral engine speed of 3500 RPM.
! WARNING
The Digital Throttle and Shift (DTS) Zero Effort control can shift the engine or transmission at speeds greater than idle, causing unexpected boat movement, which may result in injury, death, or property damage due to loss of boat control. Always place the throttle control lever in the idle position before moving the shift control lever into forward or reverse gear position. Panel Mount and Console Mount Remote Controls: Panel mount and console mount remote controls are equipped with a throttle only button. To activate throttle only mode: 1. Refer to Remote Controls section for remote control features. 2. Move the control lever to the idle/neutral position. 3. Depress the throttle only button, and move the control lever to the idle/forward or idle/ reverse position. The DTS control system will sound two beeps on the audio warning horn to indicate throttle only mode is active. On console mount remote controls, the neutral light will begin to blink. 4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase. IMPORTANT: Moving the control lever back to the idle/neutral position will deactivate the throttle only mode and allow the engine to shift into gear. 5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position. Moving the control lever from the idle/neutral position to the idle/forward or idle/reverse position without pressing the throttle only button will shift the unit into the chosen gear.
21604
Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.
mc79555-1
! WARNING
Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
mc79557-1
mc79680-1
Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat reenters the water. The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.
Page 43
There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer sharply to one side.
mc79679-1
IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of 24 to 40 km/h (15 to 25 mph). Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could result in the following: The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat. A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat. Impact damage to the underwater drive components, rudder and/or boat. Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles. After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair. The boat should be checked for hull fractures, transom fractures and water leaks. Operating with damaged underwater drive components, rudder or boat bottom could cause additional damage to other parts of the power package, or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.
! WARNING
Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
Page 44
a
a - Low Water Inlets
mc75827-1
NOTICE
Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water. Also, avoid beaching a boat with the engine operating.
Clean, free of barnacles and marine growth Free of distortion; nearly flat where it contacts the water Straight and smooth, fore and aft Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the water inlets and cause the engine to overheat.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fastmoving underwater object such as a gear housing or a propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear housing or the propeller. Common causes of cavitation are: Weeds or other debris snagged on the propeller Bent propeller blade Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speedup and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by: Drive unit trimmed out too far. A missing propeller diffuser ring. A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing. Drive unit installed too high on transom.
Propeller Selection
IMPORTANT: The engines covered in this manual are equipped with an RPM revlimiter that is set to an upper RPM limit. This limit, which is slightly above the normal operating range of the engine, helps prevent damage from excessive engine RPM. Once the RPM returns to the recommended operating RPM range, normal engine operation resumes. The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer to Mercury Marine's web page http:// www.mercurymarine.com/everything_you_need_to_know_about_propellers6. Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load. Page 46 90-899883180 OCTOBER 2007
If fullthrottle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause higher than normal wear and damage. After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch. Warmer weather and greater humidity cause a loss of RPM. Operating in a higher elevation causes a loss of RPM. Operating with a dirty boat bottom causes a loss of RPM. Operating with increased load (additional passengers, pulling skiers) causes a loss of RPM. For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. When not pulling skiers, do not operate at full throttle when using the lower pitch propeller.
Getting Started
20Hour BreakIn Period
IMPORTANT: The first 20 hours of operation is the engine breakin period. Correct breakin is essential to obtain minimum oil consumption and maximum engine performance. During this breakin period, the following rules must be observed: Do not operate below 1500 RPM for extended periods of time for the first 10 hours. Shift into gear as soon as possible after starting and advance the throttle above 1500 rpm if conditions permit safe operation. Do not operate at one speed consistently for extended periods. Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is permissible (5 minutes at a time maximum). Avoid full throttle acceleration from idle speed. Do not operate at full throttle until the engine reaches normal operating temperature. Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the breakin period.
1. Require fluid and filter change after the first 25 hours and then every 100 hours.
Page 47
Page 48
Section 4 - Specifications
Section 4 - Specifications
Table of Contents
Fuel Requirements............................................. 50 Fuel Ratings ................................................. 50 Using Reformulated (Oxygenated) Gasolines (USA Only) ................................................... 50 Gasolines Containing Alcohol ...................... 50 Engine Oil........................................................... 51 Engine Specifications......................................... 51 Fluid Specifications (MPI)................................... 52 Fluid Specifications.......................................52 Engine...........................................................52 Alpha Sterndrive............................................53 Bravo Sterndrives..........................................53 Power-Assisted Steering and Power Trim Fluids ......................................................................53 Approved Power-Assisted Steering Fluids ...................................................... 53 Approved Power Trim Fluids .................. 53
Page 49
Section 4 - Specifications
Fuel Requirements
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.
Fuel Ratings
Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canadahaving a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline [92 (R+M)/2 Octane] is also acceptable. Do not use leaded gasoline. Outside USA and Canadahaving a posted pump Octane Rating of 90 RON minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation. Because of possible adverse effects of alcohol in gasoline, we recommend only alcoholfree gasoline when possible. If the only fuel available contains alcohol or if you do not know whether the fuel contains alcohol, inspect for leaks and abnormalities more frequently.
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Section 4 - Specifications
IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, do not store the gasoline in the fuel tank for long periods. Whereas cars normally consume alcoholblend fuels before they can absorb enough moisture to cause trouble, boats often sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components.
Engine Oil
To maintain optimum engine performance and to provide maximum protection, we recommend the following oil:
Application All MerCruiser engines with Emissions Control Recommended Oil Mercury MerCruiser FullSynthetic Engine Oil, 20W40, NMMA FCW rated
IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for noncatalyzed engines. Some marinegrade lubricants contain high levels of phosphorus, which can damage the catalyst system on MerCruiser engines. Although these highphosphorus lubricants may allow for acceptable engine performance, exposure over time will damage the catalyst. Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If the Mercury MerCruiser FullSynthetic, 20W40 oil is unavailable, you can use the following lubricants, listed in order of recommendation, for short periods of time: 1. Mercury/Quicksilver 25W40 Synthetic Blend, NMMA FCW rated 4cycle oil 2. Other recognized brands of NMMA FCWrated oils
NOTE: We do not recommend nondetergent oils, multiviscosity oils (other than as specified), non FCWrated synthetic oils, lowquality oils, or oils that contain solid additives.
Mercury MerCruiser Full-Synthetic Engine Oil, 20W-40, NMMA FC-W rated
ORDER OF PREFERENCE
MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle oil Other recognized brands of NMMA FC-W rated oils
SAE40W
SAE30W
SAE 20W
0 C (32 F)
10 C (50 F)
31655
AIR TEMPERATURE
Engine Specifications
NOTE: Performance ratings are obtained and corrected in accordance with SAE J1228/ ISO 8665 Crankshaft Power. NOTE: All measurements are taken with the engine at normal operating temperature.
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Section 4 - Specifications
Models Power Number of cylinders Displacement Bore and stroke Compression ratio Idle RPM in neutral Specified WOT RPM range Minimum oil pressure at idle Thermostat (seawatercooled models) Thermostat (closed cooling models) Timing at idle Firing order Electrical system Alternator rating Recommended minimum battery rating (NonDTS models) Recommended minimum battery rating (DTS models) Spark plug type Spark plug gap 165432 65 A 750 CCA, 950 MCA, or 180 Ah 800 CCA, 1000 MCA, or 190 Ah AC Platinum (AC 41993) 1.5 mm (0.060 in.) 44004800 41 kPa (6 psi) 71 C (160 F) 77 C (170 F) Not adjustable 18436572 12 V negative () ground 4.3 MPI and SeaCore 4.3 164 kW (220 hp) 6 4.3 L (262 cid) 9.2:1 600 46005000 5.0 MPI and SeaCore 5.0 194 kW (260 hp) 8 5.0 L (305 cid) 9.4:1
101.6 88.39 mm (4.012 3.48 in.) 94.89 88.39 mm (3.735 3.48 in.)
Engine
IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines). Always use the dipstick to determine the exact quantity of oil or fluid required.
Description Engine oil (with filter) Seawater cooling system (winterization use only) 4.3 MPI and SeaCore 4.3 Models 3.8 L (4 US qt) 5.0 MPI and SeaCore 5.0 Models 4.25 L (4.5 US qt) Fluid Type Mercury MerCruiser FullSynthetic Engine Oil, 20W40 Propylene glycol and purified water Mercury Extended Life Coolant Antifreeze or extendedlife ethylene glycol 5/100 antifreeze mixed 50/50 with purified water
20 L (21 US qt)
Page 52
Section 4 - Specifications
Alpha Sterndrive
NOTE: Oil capacity includes gear lube monitor.
Model Alpha One Capacity 1892 mL (64 oz) Fluid Type High Performance Gear Lubricant
Bravo Sterndrives
NOTE: Oil capacity includes gear lube monitor.
Model Bravo One Bravo Two Bravo Three (single seawater pickup) Bravo Three (dual seawater pickup) Capacity 2736 mL (921/2 oz) 3209 mL (1081/2 oz) 2972 mL (1001/2 oz) 2736 mL (921/2 oz) High Performance Gear Lubricant Fluid Type
Page 53
Section 4 - Specifications
Notes:
Page 54
Section 5 - Maintenance
Section 5 - Maintenance
Table of Contents
Owner/Operator Responsibilities........................ 56 Dealer Responsibilities....................................... 56 Maintenance....................................................... 56 Do-It-Yourself Maintenance Suggestions........... 57 Inspection........................................................... 57 Maintenance ScheduleSterndrive Models...... 58 Routine Maintenance....................................58 Scheduled Maintenance................................58 Maintenance Log................................................ 59 Engine Oil........................................................... 60 Checking ...................................................... 60 Filling ............................................................ 60 Changing Oil and Filter ................................ 61 Easy Engine Oil Drain System ............... 61 Engine Oil Drain Pump ........................... 62 Changing the Filter ................................. 62 Power Steering Fluid.......................................... 63 Checking ...................................................... 63 Filling ............................................................ 63 Changing ...................................................... 64 Engine Coolant................................................... 64 Checking ...................................................... 64 Filling ............................................................ 65 Changing ..................................................... 65 Drive Unit Oil....................................................... 66 Checking ...................................................... 66 Filling ............................................................ 66 Changing ...................................................... 67 Power Trim Fluid................................................. 69 Checking ...................................................... 69 Filling ............................................................ 69 Changing ...................................................... 70 Battery................................................................ 70 Multiple EFI Engine Battery Precautions.......70 Cleaning the Flame Arrestor............................... 71 Positive Crankcase Ventilation Valve (PCV) ........................................................... 72 Changing ................................................ 72 Water-Separating Fuel Filter (MPI)..................... 72 Water-Separating Fuel Filter.........................72 GEN II Models...............................................73 Removal ................................................. 73 Installation .............................................. 73 GEN III Models..............................................74 Removal ................................................. 74 Installation .............................................. 75 Lubrication.......................................................... 75 Steering System............................................75 Throttle Cable................................................77 Shift Cable - Typical......................................78 Sterndrive Unit and Transom Assembly........ 78 Sterndrive U-joint Shaft Splines And O-rings (Sterndrive Unit Removed)............................79 Engine Coupler.............................................79 Driveshaft Extension Models.........................80 Propellers............................................................ 80 Propeller Repair............................................80 Alpha Propeller Removal..............................80 Alpha Propeller Installation...........................81 Bravo One Propeller Removal......................82 Bravo One Propeller Installation...................82 Bravo Two Propeller Removal......................83 Bravo Two Propeller Installation...................83 Bravo Three Propeller Removal....................84 Bravo Three Propeller Installation.................85 Serpentine Drive Belt.......................................... 87 Checking ...................................................... 87 Replacing Belt and/or Adjusting Tension ..... 87 Corrosion Protection........................................... 89 Corrosion Information....................................89 Maintaining Ground Circuit Continuity...........89 Anodes and MerCathode System Locations ......................................................................89 Checking the Quicksilver MerCathode System ......................................................................90 Power Package Exterior Surfaces................91 Boat Bottom Care..........................................91 Anti-fouling Paint...........................................91 Sterndrive Surface Care................................93 Flushing the Power Package.............................. 94 General Information......................................94 Flushing Attachments ............................. 94 Sterndrive Water Pickups ....................... 95 Alternative Water Pickups ...................... 97 SeaCore Power Package Flushing Procedure ......................................................................98 Models Using The Sterndrive Water Pickup .................................................... 98
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Section 5 - Maintenance
Owner/Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/ operator and as such, are not considered defects in workmanship or material within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service. Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your overall operating expenses at a minimum. See your authorized Mercury MerCruiser dealer for service aids.
Dealer Responsibilities
In general, a dealer's responsibilities to the customer include predelivery inspection and preparation such as: Ensure that the boat is properly equipped. Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. Make all necessary adjustments for maximum efficiency. Familiarize the customer with the onboard equipment. Explain and demonstrate the operation of the power package and boat. Provide you with a copy of a Predelivery Inspection Checklist. Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product.
Maintenance
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components.
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package. IMPORTANT: Refer to the maintenance schedule for complete listing of all scheduled maintenance to be performed. Whereas you can perform some items, others should be performed only by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, we recommend that you purchase a Mercury MerCruiser service manual and read it thoroughly.
NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.
Page 56
Section 5 - Maintenance
Maintenance Point Color Codes Blue Yellow Orange Black Brown Coolant Engine oil Fuel Gear lube oil (sterndrive models only) Transmission (inboard models only)
Inspection
Inspect your power package often, and at regular intervals, to help maintain its top operating performance and correct potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts. Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as necessary. Check plug leads and electrical leads for damage. Remove and inspect the propeller. If badly nicked, bent or cracked, contact your authorized Mercury MerCruiser dealer. Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer. 90-899883180 OCTOBER 2007 Page 57
Section 5 - Maintenance
Scheduled Maintenance
NOTE: Only perform maintenance that applies to your particular power package.
Task Interval After the initial 20hour breakin period Maintenance to Be Performed Change the engine oil and filter. Every 100 hours or annually (whichever occurs first) Touch up the paint on the power package. Change the engine oil and filter. Change the sterndrive gear lube. Tighten the connection of the gimbal ring to the steering shaft to specifications. Replace the waterseparating fuel filter element. Check the steering system and the remote control for loose, missing, or damaged parts. Lubricate the cables and the linkages. Check the continuity circuit for loose or damaged connections. If the package is equipped with a MerCathode, test the MerCathode unit output. Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped.
NOTE: On MerCruiser V6 models, the PCV valve is a nonserviceable, internal component of the valve cover assembly. Inspect the condition and the tension of the belts. Check the coolant level and antifreeze concentration for adequate freeze protection. Correct if necessary. Refer to the Specifications section.
On driveshaft extension models, lubricate the driveshaft Ujoints and tailstock input and output bearings.
Page 58
Section 5 - Maintenance
Task Interval Every 200 hours or 3 years Maintenance to Be Performed Inspect the Ujoints, the splines, and the bellows. Check the clamps. Check the engine alignment. Lubricate the Ujoint splines and cross bearing, if equipped with grease fittings. Lubricate the gimbal bearing and the engine coupler.
NOTE: Lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time.
Every 300 hours or 3 years Every 5 years Check the engine mounts for tightness and tighten to specifications if necessary. Check the electrical system for loose, damaged, or corroded fasteners. Check the cooling system and the exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. Disassemble and inspect the seawater pump and replace worn components. Clean the seawater section of the closedcooling system. Clean, inspect, and test the pressure cap. Inspect the exhaust system components. If the package was equipped with water shutters (flapper valves), verify that they are not missing or worn. Replace the coolant/anitifreeze. Replace every two years if not using extendedlife coolant/antifreeze.
Maintenance Log
Record all maintenance performed on your power package here. Be sure to save all work orders and receipts.
Date Maintenance Performed Engine Hours
Page 59
Section 5 - Maintenance
Engine Oil
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
Checking
1. Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water. 2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.
NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end).
a
a - Dipstick tube
6095
IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. 3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and add. Reinstall the dipstick into the dipstick tube.
Filling
IMPORTANT: Do not overfill the engine with oil. IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required.
Page 60
Section 5 - Maintenance
6065
IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. 2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. Recheck oil level. 3. Replace the fill cap.
Engine Model 4.3 MPI and SeaCore 4.3 5.0 MPI and SeaCore 5.0 Engine Oil Capacity 3.8 L (4 US qt) 4.25 L (4.5 US qt) Fluid type Mercury MerCruiser FullSynthetic Engine Oil, 20W40
EASY ENGINE OIL DRAIN SYSTEM NOTE: Boat must be out of water to perform this procedure. 1. Loosen the oil filter to vent the system.
a b
f c
d
a - Bilge drain plug b - Tether c - Clip
e
d - Oil drain hose plug e - Oil drain hose f - Bilge drain flange
7284
Page 61
Section 5 - Maintenance
2. Remove the bilge drain plug. 3. Pull tether through the bilge drain. 4. Place the oil drain hose in a suitable container. 5. Remove the drain plug from the oil drain hose. 6. After oil has drained completely, install the drain plug in the oil drain hose. 7. Push the hose through bilge drain and install the plug. ENGINE OIL DRAIN PUMP 1. Loosen the oil filter to vent the system. 2. Remove the dipstick. 3. Install the oil pump onto the dipstick tube.
a b
a - Typical oil pump b - Dipstick tube
c
mc70571-1
4. Insert the hose end of the crankcase oil pump onto an appropriate container and, using the handle, pump until the crankcase is empty. 5. Remove the pump. 6. Install the dipstick. CHANGING THE FILTER 1. Remove and discard the oil filter.
a
a - Oil filter
6068
2. Coat the sealing ring on the new filter with engine oil and install. 3. Tighten the oil filter securely (following filter manufacturer's instructions). Do not overtighten. 4. Remove oil fill cap. Page 62 90-899883180 OCTOBER 2007
Section 5 - Maintenance
IMPORTANT: Use dipstick to determine exactly how much oil is required. 5. Add recommended engine oil to bring the level up to the bottom of the OK range on the dipstick. 6. With the boat at rest in the water, check the oil level and add specified fluid to bring the oil level up to, but not over, the full or OK range.
NOTE: Adding 0.95 L (1 qt) of engine oil will raise the level from the add mark to the top of the OK range.
Engine Model 4.3 MPI and SeaCore 4.3 5.0 MPI and SeaCore 5.0 Engine Oil Capacity 3.8 L (4 US qt) 4.25 L (4.5 US qt) Fluid type Mercury MerCruiser FullSynthetic Engine Oil, 20W40
7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water.
b a
c
6100
c - Warm range
3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer.
Filling
1. Remove the fill cap/dipstick and observe the level. 2. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.
Page 63
Section 5 - Maintenance
Tube Ref No.
114
Changing
Power steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer.
Engine Coolant
Checking
! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap. 1. Remove the cap from the heat exchanger and observe the fluid level.
6101
a - Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger. IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck. 4. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.
Page 64
Section 5 - Maintenance
5. The coolant level should be between the "ADD" and "FULL" marks.
6102
Filling
NOTICE
Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
NOTICE
Air trapped in the closed cooling system can cause the engine to overheat, resulting in engine damage. Minimize the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine is higher than the rear of the engine.
NOTE: Add coolant only when engine is at normal operating temperature. 1. Remove the fill cap from the coolant recovery bottle. 2. Fill to the "FULL" line with the specified coolant.
Tube Ref No.
122
Changing
Contact your authorized Mercury MerCruiser dealer.
Page 65
Section 5 - Maintenance
Checking
NOTE: Oil level will fluctuate during operation. Oil level should be checked with the engine cold, before starting. 1. Check the gear lube oil level. Keep the oil level within the recommended operating range. If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
6107
6105
Filling
IMPORTANT: If more than 59 mL (2 fl oz) of High Performance Gear Lubricant is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer. 1. Remove the gear lube monitor cap. 2. Fill the monitor with the specified fluid so that the oil level is in the operating range. Do not overfill.
Tube Ref No.
87
Page 66
Section 5 - Maintenance
Changing
1. Remove the gear lube monitor from the bracket.
6109
a - Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
b
a - Oil fill/drain screw
mc79506-1
b - Sealing washer
Page 67
Section 5 - Maintenance
5. All Other Models: Place the sterndrive unit in full trim limit out position, remove the oil fill/drain screw and sealing washer and drain the oil.
b a
mc79507-1
b - Sealing washer
6. Remove the oil vent screw and sealing washer. Allow the oil to drain completely.
a b
mc77106-1
b - Sealing washer
IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an airfree stream of lubricant flows from oil vent hole.
Tube Ref No.
87
IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in sterndrive unit. 8. Install the oil vent screw and sealing washer. 9. Continue to pump gear lubricant into the gear lube monitor circuit until the gear lubricant appears in the gear lube monitor. 10. Fill the monitor so that the oil level is in the operating range. Do not overfill. Ensure that the rubber gasket is inside the cap and install. Do not overtighten.
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Section 5 - Maintenance
Model Alpha One Bravo One Bravo Two Bravo Three Capacity 1892 mL (64 oz) 2736 mL (921/2 oz) 3209 mL (1081/2 oz) 2972 mL (1001/2 oz) High Performance Gear Lubricant Fluid Type
11. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and oil fill/drain screw. Tighten securely. 12. Reinstall the propeller. Refer to Propellers. 13. Recheck the oil level after the first use. IMPORTANT: Oil level in the gear lube monitor will rise and fall during sterndrive operation. Check the oil level only when the sterndrive is cool and the engine is shut down.
a
a - Reservoir
b
7876
Filling
1. Remove the fill cap from the reservoir.
NOTE: Fill cap is vented. 2. Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir.
Tube Ref No.
114
Page 69
Section 5 - Maintenance
Changing
Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer.
Battery
Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
! WARNING
Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.
! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
Page 70
Section 5 - Maintenance
a b
d e
6110
f
a - Engine cover knob b - Engine cover c - Nuts, flame arrestor 4. 5. 6. 7. d - Cover mount bracket e - Flame arrestor f - Crankcase ventilation hose
Clean the flame arrestor with warm water and a mild detergent. Inspect the flame arrestor for holes, cracks or deterioration. Replace if necessary. Allow the flame arrestor to air dry completely before use. Clean the crankcase ventilation hose with warm water and a mild detergent. Dry with compressed air or allow to air dry completely. 8. Inspect the crankcase ventilation hose for cracks or deterioration. Replace if necessary. 9. Install the flame arrestor and flame arrestor bracket. Torque the flame arrestor bracket nuts.
Description Flame arrestor bracket nut Nm 12 lb. in. 106 lb. ft.
10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. 11. Install the engine cover.
Page 71
Section 5 - Maintenance
NOTE: On V6 models the PCV valve is nonserviceable and is an internal component of the valve cover. 1. Remove the PCV valve from the port valve cover.
a
a - PCV valve
mc71925-1
b - Hose
2. Disconnect the PCV valve from the hose and discard the valve. 3. Install a new PCV valve in the valve cover and reconnect the hose. 4. Ensure that the PCV valve is tightly seated in the valve cover.
! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and skin from pressurized fuel and vapors.
Page 72
Section 5 - Maintenance
GEN II Models
a b c
6527
c - Fuel filter
REMOVAL
1. Allow the engine to cool down.
NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close the fuel supply valve, if equipped. 3. Wrap the waterseparating fuel filter with a cloth to help catch any fuel spills or spray. 4. Remove and discard the waterseparating fuel filter and sealing ring from the mounting bracket.
INSTALLATION
1. Coat the sealing ring on the new filter with engine oil.
Tube Ref No.
80
2. Thread filter onto the mounting bracket and tighten securely by hand. Do not use a filter wrench. 3. Open fuel supply valve, if equipped. 4. Ensure that the engine compartment is properly ventilated.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 5. Supply cooling water to the engine. 6. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, wipe up any spilled fuel, and properly ventilate the engine compartment. If leaks continue, stop the engine immediately and contact your authorized Mercury MerCruiser dealer.
Page 73
Section 5 - Maintenance
a
8837
abcd-
Cool Fuel Module Cool Fuel Module harness Filter cap Filter assembly retaining screw
efgh-
Fuel filter element Filter cup Cool Fuel Module filter reservoir Oring
REMOVAL
1. Allow the engine to cool down.
NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness. 4. Turn the key switch to the start position and allow the starter to operate for 5 seconds. 5. Turn key switch to off position. 6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap. 7. Unseat the filter assembly by grasping the filter assembly handle and pulling upward. Do not remove the filter assembly from the Cool Fuel Module at this time. 8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool Fuel Module filter reservoir. 9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a clockwise direction while holding the filter cup stationary. 10. Remove the used waterseparating fuel filter element from the filter cup, place it in a clean, approved container. 11. Dispose of any water or debris that may be in the filter cup.
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Section 5 - Maintenance
INSTALLATION
1. Install a new waterseparating fuel filter element into the filter cup. Push the element into the cup until completely seated. 2. Install new Oring on the filter cup. 3. Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter clockwise direction while holding the filter cup stationary, until the filter cap locks securely into place. 4. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel, and align the screws retained in the filter cap with the screw holes in the Cool Fuel Module. Tighten the filter assembly retaining screws until hand tight. 5. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each filter assembly retaining screw.
Description Filter assembly retaining screw Nm 6 lb. in. 53 lb. ft.
6. Open fuel supply valve, if equipped. 7. Reconnect the Cool Fuel Module harness to the engine wiring harness. 8. Properly ventilate the engine compartment.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 9. Supply cooling water to the engine. 10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer.
Lubrication
Steering System
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant.
NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased.
Page 75
Section 5 - Maintenance
1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical handoperated grease gun.
6221
2. Turn steering wheel until steering cable fully extended. Lightly lubricate the exposed part of cable.
6222
Page 76
Section 5 - Maintenance
a
mc71904-1
a - Steering pin
Tube Ref. No. Description Synthetic Blend MerCruiser Engine Oil SAE25W40 Where Used Steering pin Part No. 92883725K01
5. Upon first starting engine, turn steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway.
Throttle Cable
1. Lubricate the pivot points and the guide contact surfaces.
a a
5577
a - Pivot points
Tube Ref. No. Description Synthetic Blend MerCruiser Engine Oil SAE25W40
Page 77
Section 5 - Maintenance
a
mc79736
a - Pivot points
Tube Ref. No. Description
Synthetic Blend MerCruiser Engine Shift cable pivot points & guide Oil SAE25W40 contact surfaces
mc77068-1
Page 78
Section 5 - Maintenance
8591
a - Driveshaft splines
Tube Ref No.
91
Engine Coupler
1. Lubricate engine coupler splines through grease fittings on coupler by applying approximately 810 pumps of grease from a typical handoperated grease gun.
NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated Bravo Models every 50 hours; Alpha Models every 150 hours.
a a
Alpha drive coupler a - Grease fitting
Tube Ref No.
91
6213 6212
NOTE: Alpha Models Your power package is equipped with a sealed engine coupler and PermaLube Ujoints. The sealed coupler and shaft splines can be lubricated without removing the sterndrive unit. The PermaLube Ujoints do not require lubrication.
Page 79
Section 5 - Maintenance
NOTE: Bravo Models The coupler and shaft splines can be lubricated without removing the sterndrive unit. Apply lubricant from a typical handoperated grease gun until a small amount of grease begins to push out. The PermaLube Ujoints do not require lubrication.
c b
a
a - Driveshaft grease fittings b - Transom end grease fitting
Tube Ref No.
42
17014
Where Used Transom end grease fitting, engine end grease fitting, driveshaft grease fittings
Propellers
Propeller Repair
Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.
Page 80
Section 5 - Maintenance
NOTICE
Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.
a b c
e f
6215
g
abcdPropeller shaft Thrust hub FloTorq II drive hub Propeller e - Drive sleeve f - Locking tab washer g - Propeller nut
1. Apply a liberal coat of one of the following lubricants to the propeller shaft.
Tube Ref No.
34 94 95
Description Special Lubricant 101 Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon
2. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub. 3. Install FloTorq II Drive Hub into propeller.
NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued. 4. Align splines and place propeller on propeller shaft. 5. Install drive sleeve and locking tab washer. 6. Install and torque the propeller nut.
Description Propeller nut (minimum) Nm 75 lbin. lbft 55
7. Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller. 90-899883180 OCTOBER 2007 Page 81
Section 5 - Maintenance
NOTICE
Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.
a b c
e f
6215
g
abcdPropeller shaft Thrust hub FloTorq II drive hub Propeller e - Drive sleeve f - Locking tab washer g - Propeller nut
1. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub. 2. Apply a liberal coat of one of the following lubricants to the propeller shaft.
Tube Ref No.
34 94 95
Description Special Lubricant 101 Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon
3. Install FloTorq II Drive Hub into propeller. Page 82 90-899883180 OCTOBER 2007
Section 5 - Maintenance
NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued. 4. Align splines and place propeller on propeller shaft. 5. Install drive sleeve and locking tab washer. 6. Install and torque the propeller nut.
Description Propeller nut (minimum) Nm 75 lbin. lbft 55
IMPORTANT: The propeller torque stated is a minimum torque value. Some special use propellers may have a different torque value. Use the installation information provided with the propeller to determine if another torque value is appropriate to your propeller. 7. Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.
NOTICE
Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.
c e d a b f
a - Propeller shaft b - Thrust hub c - Propeller
14946
Page 83
Section 5 - Maintenance
1. Slide thrust hub into propeller hub with stepped side toward propeller hub. 2. Apply a liberal coat of one of the following lubricants to the propeller shaft.
Tube Ref No.
34 94 95
Description Special Lubricant 101 Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon
3. Align splines and place propeller on propeller shaft. 4. Install spline washer and tab washer. 5. Install and torque the propeller nut.
Description Propeller nut (minimum) Nm 81 lbin. lbft 60
6. Bend 3 tabs on the tab washer down into the grooves in spline washer. After the first use, bend the 3 tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.
c d
5303
4. Turn aft propeller shaft nut 37 mm (17/16 in.) counterclockwise to remove nut. 5. Slide propeller and thrust hub off propeller shaft. Page 84 90-899883180 OCTOBER 2007
Section 5 - Maintenance
6. Turn front propeller shaft nut 70 mm (23/4 in.) counterclockwise to remove nut. 7. Slide propeller and thrust hub off propeller shaft.
NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.
e f b a j
5304
i g h
abcde-
Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller
fghij-
Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode
NOTICE
Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval.
e f b a j
5304
i g h
abcde-
Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller
fghij-
Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode
1. Slide forward thrust hub onto propeller shaft with tapered side toward propeller hub (toward end of shaft). 90-899883180 OCTOBER 2007 Page 85
Section 5 - Maintenance
2. Apply a liberal coat of one of the following lubricants to the propeller shaft.
Tube Ref No.
34 94 95
Description Special Lubricant 101 Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon
3. Align splines and place propeller on propeller shaft. 4. Install and torque the propeller nut. Check propeller at least every 20 hours of operation and retorque as needed.
Description Forward propeller nut Nm 136 lbin. lbft 100
5. Slide aft thrust hub onto propeller shaft, with tapered side toward propeller hub (toward end of shaft). 6. Align splines and place propeller on propeller shaft. 7. Install and torque the propeller nut. Check propeller at least every 20 hours of operation and retorque as needed.
Description Aft propeller nut Nm 81 lbin. lbft 60
8. Install the propeller shaft anode over the propeller shaft nut. 9. Place the flat washer onto the propeller shaft anode screw. 10. Place the star washer onto the propeller shaft anode screw. 11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw.
c d
5303
12. Secure the propeller shaft anode to the propeller shaft using the propeller shaft anode screw and washers. Torque the screw.
Page 86
Section 5 - Maintenance
Description Propeller shaft anode screw 38 mm (0.312518 x 1.5 in.) long Nm 27 llbin. lbft 20
a b d b
a f c e
6116
f
6117
c
Without a seawater pump d - Alternator pulley e - Seawater pump pulley f - Power steering pump pulley
With a seawater pump a - Idler pulley b - Water circulating pump pulley c - Crankshaft pulley
Checking
1. Inspect the drive belt for proper tension and for the following: Excessive wear Cracks
NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are NOT acceptable. Fraying Glazed surfaces Proper tension 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys.
mc75130-1
Section 5 - Maintenance
NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys. 1. Loosen the 16 mm (5/8 in.) locking nut on the adjustment stud. 2. Turn the adjustment stud and loosen the belt. 3. If a new serpentine drive belt is required, remove the old belt and install a new belt onto the pulleys. 4. Put a wrench on the adjustment stud 16 mm (5/8 in.) locking nut. 5. Use a 8 mm (5/16 in.) socket and tighten adjusting the stud to adjust the belt deflection. 6. Using one of the 2 methods following, check for correct deflection. a. Push down with moderate thumb pressure on the longest stretch of belt. Proper deflection is 13 mm (1/2 in.). b. Attach the Kent Moore Belt Tension Gauge to the belt. The gauge has different ranges for new and used belts.
a
14980
b - Serpentine belt
7. While holding the adjustment stud at the correct belt tension, tighten the 16 mm (5/8 in.) locking nut.
6119
8. Operate the engine for a short period of time and recheck the belt adjustment.
Page 88
IDE
NEWTONE
NT PATE918 2.83
W TO
R GU COLO for
Section 5 - Maintenance
Corrosion Protection
Corrosion Information
Whenever two or more dissimilar metals are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90881813003).
Page 89
Section 5 - Maintenance
Description Location Figure
MerCathode System
The MerCathode electrode is mounted to the underside of the gimbal housing. The MerCathode controler is mounted on the engine or on the boat transom. The controler harness connects to the electrode harness.
20340
Located in front of the propeller, between the front side of the propeller and the gear housing.
20343
Page 90
Section 5 - Maintenance
Reference Electrode 9176675T 1
Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential.
9188
2. Clean the entire power package. External surfaces that have become bare should be repainted with the recommended primer and spray paint at recommended intervals.
Description Mercury Light Gray Primer Mercury Phantom Black Painted surfaces Part Number 92802878 52 92802878Q 1
Antifouling Paint
IMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty. You may apply antifouling paint to the boat hull and boat transom but you must observe the following precautions: IMPORTANT: Do not paint or pressurewash the anodes or the MerCathode System reference electrode and anode. Doing so will render them ineffective as inhibitors of galvanic corrosion.
Page 91
Section 5 - Maintenance
IMPORTANT: If antifouling protection is required for the boat hull or boat transom, you can use copperbased paint if it is not prohibited by law. If you are using copper based antifouling paint, observe the following precaution: Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (11/2 in.) UNPAINTED area on transom of the boat around these items.
b
8107
NOTE: Sterndrive and transom assembly can be painted with a good marine paint or an antifouling paint that DOES NOT contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, the MerCathode system or items specified by the boat manufacturer.
NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or highpressure washers to clean the MerCathode assembly.
Page 92
Section 5 - Maintenance
Do not powerwash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosion.
b
21563
a - Reference electrode
b - Anode plate
g b
21083
abcd-
Standard Bravo sterndrive Sacrificial trim cylinder anode e - Stainless steel hoses Sacrificial anodic plate f - Ground wire between the gimbal housing and trim cylinder Steering lever ground wire g - Ground wire between the gimbal Ground wire between the gimbal ring and gimbal housing ring and bell housing
We recommend the following maintenance items to help keep your sterndrive corrosionfree: Maintain a complete paint covering on the sterndrive. Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tinbased antifouling paint or its equivalent on or near aluminum surfaces below the waterline. If bare metal is showing, apply 2 coats paint.
Page 93
Section 5 - Maintenance
Description Mercury Phantom Black Where used Bare metal Part number 92 8028781
Inspect the sacrificial trim tab or anode plate if equipped, at regular intervals and replace it before it is half gone. If a stainless steel propeller is installed, additional anodes or a MerCathode System will be required. Inspect the propeller shaft for fishing line, which can cause corrosion on a stainless steel shaft. Remove the propeller at least every 60 days and lubricate the propeller shaft. Do not use lubricants containing graphite on or near the aluminum in saltwater. Do not paint trim tabs or the mounting surface.
FLUSHING ATTACHMENTS
c
21514
21515
Flushing attachments for dual water pickup a - Flushing device b - Hose attachment
Flushing attachments for side water pickup c - Dual water pickup flush gearcase seal kit
Page 94
Section 5 - Maintenance
Flushing Device 9144357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.
9192
91881150K 1
Blocks off the front water inlet holes on the dual water inlet gearcases.
9194
STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).
5752
5773
NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results.
NOTICE
Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine. Keep the seacock closed until starting the engine. 1. On seawater cooled models: Proceed to Step 4. or Step 5. 2. On models with the sterndrive seawater inlet blocked, supply water to the sterndrive and to the engine. See Alternative Water Pickups.
Page 95
Section 5 - Maintenance
3. On models using the sterndrive seawater inlet and a throughhull or throughtransom alternative water pickup, supply water to only the sterndrive by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet Yfitting. a. If equipped with a seacock, close the seacock in the hose from the alternative water pickup. b. If not equipped with a seacock, disconnect the hose from the alternative water pickup and plug both ends. c. If there is not a hose running to the transom, refer to Alternative Water Pickups. 4. If flushing the cooling system with the boat in the water: a. Raise sterndrive to trailer position. b. Install the appropriate flushing attachment over the water inlet holes in the gear housing. c. Lower sterndrive to full down (in) position. 5. If flushing the cooling system with the boat out of the water: a. Lower sterndrive to full down (in) position.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the antiventilation plate. Remove propeller. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 6. Connect hose between flushing attachment and water source. 7. With sterndrive in normal operating position, open the water source fully. 8. Place the remote control in the neutral idle speed position and start engine. b. c.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. 9. Depress the throttleonly button and slowly advance the throttle until the engine reaches 1300 RPM ( 100 RPM). 10. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. 12. Slowly return throttle to idle speed position. 13. Stop engine. 14. Shut off water and remove flushing attachment. 15. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine.
Page 96
Section 5 - Maintenance
16. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.
ALTERNATIVE WATER PICKUPS IMPORTANT: Two water sources are needed for this procedure. NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. IMPORTANT: Models with the sterndrive water inlet blocked off at the gimbal housing and using a throughhull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation. 1. If flushing the cooling system with the boat in the water: a. Raise sterndrive to trailer position. b. Install the appropriate flushing attachment over the water inlet holes in the gear housing. c. Lower sterndrive unit to full down (in) position. 2. If flushing the cooling system with the boat out of the water: a. Lower sterndrive to full down (in) position.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the antiventilation plate. Remove propeller. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 3. Connect hose between flushing attachment and water source. 4. Close the seacock, if equipped, to prevent water from siphoning into the engine or boat. 5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine or boat. b. c.
6147
6. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.
Page 97
Section 5 - Maintenance
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 7. With sterndrive in normal operating position, open the water source fully. 8. Place the remote control in neutral idle speed position and start engine.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. 9. Slowly advance throttle until engine reaches 1300 RPM (+/100 RPM). 10. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. 12. Slowly return throttle to idle speed position. 13. Stop engine. 14. Shut off the water and remove flushing attachments. 15. If the boat is out of the water: Install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp securely. 16. If the boat is in the water: Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the antiventilation plate. IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends. 1. Remove the boat from the water.
Page 98
Section 5 - Maintenance
c a b
For visual clarity, the secock shown is not installed a - Hose fitting to engine c - Handle (closed position) b - Seacock d - To water source pickup attachment 3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive. 4. Ensure that the inlet water hose from the sterndrive to the engine is connected. 5. Remove the quickconnect fitting from the parts bag supplied with the engine. 6. Attach the quickconnect fitting to a water hose.
18510
18487
b - Water hose
Page 99
Section 5 - Maintenance
7. Snap the quickconnect fitting with the water hose into the flush socket on the engine.
a b
18489
c - Flush socket
8. Open the water source of the water hose to a full flow. 9. Allow the water to flush the sterndrive for 30 seconds. 10. Place the remote control in neutral idle speed position and start engine.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 11. Operate the engine at idle speed in neutral gear. Do not exceed 1200 RPM. 12. Monitor the engine temperature while operating the engine. 13. Flush the engine for 5 to 10 minutes or until discharge water is clear. 14. Shut off the engine. 15. Allow the water to flush the sterndrive for 10 seconds. 16. Turn off the water source.
Page 100
Section 5 - Maintenance
17. Disconnect the quickconnect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket.
a b
18488
18487
b - Water hose
19. Retain the quickconnect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access. IMPORTANT: Do not store the quickconnect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty.
25900
Quickconnect fitting stored in the boat a - Quickconnect fitting (water hose end)
Page 101
Section 5 - Maintenance
20. Insert the dust cover in the flush socket on the engine.
a b
18490
Dust cover installed in the flush socket a - Dust cover b - Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock. 21. Open the seacock, if equipped, or reconnect the alternative water inlet source prior to operating the engine.
Page 102
Section 6 - Storage
Section 6 - Storage
Table of Contents
Cold Weather or Extended Storage.................. 104 Preparing Power Package for Storage........104 Engine and Fuel System Preparation . . 105 Draining the Seawater System......................... 106 Drain System Identification.........................107 Air Actuated Single Point Drain System ............................................................. 107 Manual Single Point Drain System ....... 107 Three Point Manual Drain System ....... 108 Multi-Point Drain (MPD) System .......... 108 Air-Actuated Single-Point Drain System.....109 Boat in the Water ................................. 109 Boat out of the Water ........................... 111 Manual Single Point Drain System..............114 Boat in the Water ................................. 114 Boat out of the Water ........................... 115 Three Point Manual Drain System..............116 Boat in the Water ................................. 116 Boat out of the Water ........................... 117 Multi-Point Drain (MPD) System.................118 Boat out of the Water ........................... 118 Boat in the Water ................................. 120 Battery Storage................................................. 122 Power Package Recommissioning................... 122
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Section 6 - Storage
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.
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Section 6 - Storage
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged. 9. Ensure that the sterndrive vent holes and water drain holes and passages are unobstructed and open (refer to Draining Instructions). 10. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position. 11. Store boat with drive unit in full down/in position. 12. Store the battery according to the manufacturer's instructions.
! WARNING
Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately.
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package. 1. In a 23 L (6 U.S. gal.) remote fuel tank mix: a. 19 L (5 U.S. gal) regular unleaded 87 octane (90 RON) gasoline b. 1.89 L (2 U.S. qts.) Premium Plus 2Cycle TCW3 Outboard Oil c. 150 mL (5 ounces) Fuel System Treatment and Stabilizer or 30 mL (1 ounce) Fuel System Treatment and Stabilizer Concentrate
Tube Ref No.
115 124
Description Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer
2. Allow the engine to cool down. IMPORTANT: Immediately wipe up any fuel spills or sprays.
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Section 6 - Storage
3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off valve. 4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting. IMPORTANT: Supply cooling water to the engine. 5. Start and operate the engine at 1300 rpm for 5 minutes. 6. After specified operating time is complete, slowly return throttle to idle rpm and shut engine off. IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the engines fuel system to become completely dry. 7. Replace the water separating fuel filter element. Refer to Section 5 for proper procedure.
! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining. Do not operate the engine with the drain system open. IMPORTANT: Only drain the seawater section of the closedcooling system. IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system. Your power package is equipped with a drain system. Refer to Drain System Identification to determine which instructions apply to your power package. IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.
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Section 6 - Storage
c a b c a b d d
6124 6125
Closed Cooled Models a - Blue drain plug location b - Blue air pump
a b c
d d
Scorpion Models a - Blue air pump b - Air manifold c - Green indicators d - Blue drain plug locations
21125
a b
6128
a - Blue handle
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Section 6 - Storage
a
a - Blue drain plug
a
6126
b a
93235672
b a
10226
M110050
6129
b a
6130
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Section 6 - Storage
6131
b
a - Actuator fitting b - Green indicators c - Manual release valve
8293
6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.
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Section 6 - Storage
7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system.
c a b c a b d d
6124 6125
Closed Cooled Models a - Blue drain plug location b - Blue air pump
a b c
d d
Scorpion Models a - Blue air pump b - Air manifold c - Green indicators d - Blue drain plug locations
21125
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Section 6 - Storage
8. Verify that water is draining from each opening. If not, use the Three Point Manual Drain System instructions.
a
a - Port side drain location
6133
9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended. 10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow engine to start. 11. Reinstall the blue drain plug in the thermostat housing or heat exchanger. 12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
a
6135
a - Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
BOAT OUT OF THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Place the boat on a lever surface to ensure complete draining of system. 2. Remove the air pump from the engine.
90-899883180 OCTOBER 2007 Page 111
Section 6 - Storage
3. Ensure that the lever on top of the pump is flush with the handle (horizontal). 4. Install the air pump on the actuator fitting. 5. Pull lever on air pump (vertical) to lock pump on the fitting.
b
a - Actuator fitting b - Green indicators c - Manual release valve
8293
6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.
c a b c a b d d
6124 6125
Closed Cooled Models a - Blue drain plug location b - Blue air pump
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Section 6 - Storage
a b c
d d
Scorpion Models a - Blue air pump b - Air manifold c - Green indicators d - Blue drain plug locations
21125
7. Verify that water is draining from each opening. If not, use the Three Point Manual Drain System instructions.
a
a - Port side drain location
6133
8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended. 9. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump. Do not allow engine to start. 10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
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Section 6 - Storage
12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
a
6135
a - Green indicators
b a
6136
a - Blue handle
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Section 6 - Storage
4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.
b a
a - Drain location orange or red
6137
5. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. 6. Reinstall the blue drain plug in the thermostat housing. 7. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle as this will create new threads. 8. Open the seacock (if equipped) or unplug and reconnect the water inlet hose prior to operating the engine.
BOAT OUT OF THE WATER 1. Place the boat on a level surface to ensure complete draining of system. 2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not overtighten the handle as this will create new threads.
6141
a - Blue handle
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Section 6 - Storage
3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.
b a
a - Drain location orange or red
6137
4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained. 5. Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug. The handle is fully seated when no red is visible. Do not overtighten handle as this will create new threads.
6138
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Section 6 - Storage
3. To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds.
6139
a - Blue drain plug location 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
a
a - Blue drain plugs
6140
5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained. 7. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 8. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain plugs. 9. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
BOAT OUT OF THE WATER NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 1. Place the boat on a level surface to ensure complete draining of the system.
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Section 6 - Storage
2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side).
a
6142
a - Blue drain plug 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained. 5. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 6. Prior to launching the boat or starting the engine, close the drain system by installing the three blue drain plugs.
b a
93235672
b a
10226
M110050
6129
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Section 6 - Storage
c.
a
6143
6144
6131
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Section 6 - Storage
3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses.
a
6145
b
a - Hose clamps b - Blue drain plugs 4. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 5. After the cooling system has been drained completely, install the drain plugs, reconnect the hoses, and tighten all hose clamps securely.
BOAT IN THE WATER 1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2. Remove the blue drain plugs from the following locations. If necessary, clean out the drain holes using a stiff piece of wire. Do so until the entire system is drained. a. Port and starboard side of cylinder block b. Bottom of exhaust manifolds
b a
93235672
b a
10226
M110050
6129
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Section 6 - Storage
c.
a
6143
6144
6131
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Section 6 - Storage
3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses.
a
6145
b
a - Hose clamps b - Blue drain plugs 4. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 5. Before launching the boat or starting the engine, close the drain system by installing the blue drain plugs. 6. Open the seacock, if equipped, or unplug and reconnect the water inlet hose before operating the engine.
Battery Storage
Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for storage.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative () battery cable first and connect it last. 2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect cables. Tighten each cable clamp securely when connecting. 3. Coat the terminal connections with a battery terminal anticorrosion agent. 4. Perform all the checks in the before starting column of the Operation Chart.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly. 6. Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks. 7. Inspect the steering system, shift and throttle control for proper operation.
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Section 7 - Troubleshooting
Section 7 - Troubleshooting
Table of Contents
Diagnosing EFI Problems................................. 124 Diagnosing DTS Problems............................... 124 Engine Guardian System.................................. 124 Starter Motor Will Not Crank Engine, Or Cranks Slow.................................................................. 124 Engine Will Not Start or Is Hard to Start........... 125 Engine Runs Rough, Misses, or Backfires....... 125 Poor Performance............................................. 125 Excessive Engine Temperature........................ 125 Insufficient Engine Temperature....................... 126 Low Engine Oil Pressure.................................. 126 Battery Will Not Recharge................................ 126 Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds....................... 127 Steering Wheel Jerks or Is Difficult to Turn...... 127 Power Trim Does Not Operate (Motor Does Not Operate)............................................................ 127 Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move)....................... 127
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Section 7 - Troubleshooting
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Section 7 - Troubleshooting
Poor Performance
Possible Cause Throttle not fully open. Damaged or improper propeller. Excessive bilge water. Boat overloaded or load improperly distributed. Flame arrestor dirty. Boat bottom fouled or damaged. Ignition problem. Engine overheating. EFI System fault Replace the propeller. Drain and check for cause of entry. Reduce load or redistribute load more evenly. Clean the flame arrestor. Clean or repair as necessary. See Engine Runs Rough, Misses or Backfires. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser dealer. Remedy Inspect the throttle cable and linkages for proper operation.
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Section 7 - Troubleshooting
Possible Cause Drive belt loose or in poor condition. Seawater pickups or sea strainer obstructed. Faulty thermostat. Coolant level (if equipped) low in closed cooling section. Replace or adjust belt. Remove obstruction. Replace. Check for cause of low coolant level and repair. Fill system with proper coolant solution. Remedy
Heat Exchanger or Fluid Cooler plugged with foreign Clean Heat Exchanger, Engine Oil Cooler, and material Transmission Oil Cooler (if equipped). Loss of pressure in closed cooling section. Faulty seawater pickup pump. Seawater discharge restricted or plugged. Check for leaks. Clean, inspect and test pressure cap. Repair. Clean exhaust elbows.
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Section 7 - Troubleshooting
Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds
Possible Cause Insufficient lubrication on shift and throttle linkage fasteners. Obstruction in shift or throttle linkages. Loose or missing shift and throttle linkages. Lubricate. Remove obstruction. Check all throttle linkages. If any are loose or missing, see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer replace cable if damaged beyond repair. Remedy
Insufficient lubrication on steering components. Lubricate. Loose or missing steering fasteners or parts. Contaminated power steering fluid.
Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move)
Possible Cause Trim pump oil level low. Drive unit binding in gimbal ring. Fill pump with oil. Check for obstruction. Remedy
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Section 7 - Troubleshooting
Notes:
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Page 129
NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser sterndrives and inboards.
Page 130
PARTS AND ACCESSORIES INQUIRIES Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has the necessary information to order parts and accessories for you if they are not in stock. Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring on parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.
Resolving a Problem
Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need additional assistance: 1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem. 2. If your question, concern, or problem cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems. The following information will be needed by the Service Office: Your name and address Daytime telephone number Model and serial numbers for your power package The name and address of your dealership Nature of problem Mercury Marine Service Offices are listed on the next page.
(32) (87) 32 32 11
(32) (87) 31 19 65
Page 131
Ordering Literature
Before ordering literature, please have the following information about your power package available: Model Serial Number Horsepower Year built
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