6.2 Inboard Mpi DTS: Operation & Maintenance Manual

6.
2 Inboard
MPI DTS
O P ERAT I O N &
MAI NT ENANCE
MANUAL
www.mercurymarine.com.au www.mercurymarine.com www.brunswick-marine.com

41-71 Bessemer Drive P.O. Box 1939 Parc Industriel de Petit-Rechain
Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA B-4800 Verviers, Belgium
© Mercury Marine. All rights reserved. 90-8M0119292 MAY 2015

Printed in U.S.A.
8M0119292 516 eng
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to
ensure operating ease and durability.
With proper care and maintenance, you will 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 and Maintenance 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 products. We sincerely hope your boating will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Name / function:
John Pfeifer, President,
Mercury Marine
Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a
demonstration of actual starting and operating procedures.
Notice
Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the
6.2 Inboard MPI DTS

International Hazard Symbol ! , may be used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly or carelessly. 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.
! 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.
IMPORTANT: 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 and Maintenance
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.
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine
power package. When contacting Mercury Marine about service, always specify model and serial numbers.
© 2016 Mercury Marine
Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury
Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to
change specifications or designs without notice and without incurring obligation.
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 Manual included with the product. The Warranty Manual 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.
Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
Identification Records
Please record the following applicable information:
MerCruiser
Engine Model and Horsepower Engine Serial Number
Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
Transmission Model (Inboard) Gear Ratio Transmission Serial Number
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
Exhaust Gas Emissions Certification Number (Europe Only)

TABLE OF CONTENTS
Section 1 - Getting to Know Your Power Package

Adaptive Speed Control (ASC).................................................. 2 Adjustment...................................................................... 8
Identification............................................................................... 2 Special Digital Throttle and Shift (DTS) Features............... 8
Engine Serial Number......................................................... 2 Dock............................................................................... 9
Transmissions..................................................................... 3 Throttle Only................................................................... 9
ZF Marine Transmissions............................................... 3 1 Lever.......................................................................... 10
Lanyard Stop Switch.................................................................. 3 Sync.............................................................................. 10
Keep the Lanyard Stop Switch and Lanyard Cord in Good Transfer (Boats equipped with dual helms).................. 11
Operating Condition............................................................. 4 Helm Transfer................................................................... 11
Instrumentation.......................................................................... 4 Electrical System Overload Protection..................................... 11
VesselView........................................................................... 4 Visual and Audio Warning Systems......................................... 14
SmartCraft Digital Instruments............................................. 4 Service Engine Light and OBD‑M MIL Kit......................... 14
System Link Digital Instruments........................................... 5 Testing the OBD‑M Malfunction Indicator Lamp
Remote Controls (DTS Models)................................................. 5 (MIL)............................................................................. 14
Remote Controls................................................................. 5 Audio Warning System..................................................... 14
DTS Slim Binnacle Single Handle Console Features and Caution......................................................................... 15
Operation............................................................................ 6 Critical........................................................................... 15
Special Digital Throttle and Shift (DTS) Features........... 7 Nonconfigured Alarm–DTS Only.................................. 15
Dual‑Handle Electronic Remote Control (ERC)—Operation Testing the Audio Warning System.............................. 15
and Adjustment................................................................... 7 Guardian Strategy............................................................. 15
Operation........................................................................ 7
Section 2 - On the Water

Safe Boating Recommendations............................................. 18 High‑Speed and High‑Performance Operation........................ 22
Carbon Monoxide Exposure.................................................... 19 Passenger Safety in Pontoon Boats and Deck Boats.............. 22
Be Alert To Carbon Monoxide Poisoning........................... 19 Boats Having an Open Front Deck..................................... 23
Stay Clear of Exhaust Areas.............................................. 19 Boats With Front‑Mounted, Raised Pedestal Fishing Seats
Good Ventilation ................................................................ 19 ........................................................................................... 23
Poor Ventilation ................................................................. 20 Wave and Wake Jumping........................................................ 23
Basic Boat Operation (DTS Models)........................................ 20 Impact with Underwater Hazards............................................. 24
Launching and Boat Operation......................................... 20 Conditions Affecting Operation................................................ 24
Operation Chart............................................................ 20 Weight Distribution (Passengers and Gear) Inside the
Starting and Stopping the Engine..................................... 20 Boat.................................................................................. 24
Starting the Engine....................................................... 20 The Bottom of the Boat..................................................... 24
Stopping the Engine..................................................... 21 Cavitation.......................................................................... 25
Throttle Only Operation—DTS Models............................. 21 Ventilation......................................................................... 25
Freezing Temperature Operation..................................... 22 Elevation and Climate....................................................... 25
Drain Plug and Bilge Pump............................................... 22 Getting Started......................................................................... 25
Protecting People in the Water................................................ 22 20‑Hour Break‑In Period................................................... 25
While You Are Cruising...................................................... 22 After the Break‑In Period.................................................. 25
While Boat Is Stationary..................................................... 22 End of First Season Checkup........................................... 25
Section 3 - Specifications
Fuel Requirements................................................................... 28 Engine Oil................................................................................ 28
Fuel Ratings....................................................................... 28 6.2 MPI Inboard Engine Specifications.................................... 29
Using Reformulated (Oxygenated) Gasoline (USA Only).. 28 Fluid Specifications.................................................................. 30
Gasoline Containing Alcohol.............................................. 28 Engine............................................................................... 30
Bu16 Butanol Fuel Blends............................................ 28 Transmission.................................................................... 30
Methanol and Ethanol Fuel Blends............................... 28
90-8M0119292 eng MAY 2016 Page i

Section 4 - Maintenance
Owner/Operator Responsibilities............................................ 32 Changing.......................................................................... 38
Dealer Responsibilities........................................................... 32 Engine Coolant....................................................................... 38
Maintenance........................................................................... 32 Checking......................................................................... 38
Do‑It‑Yourself Maintenance Suggestions............................... 32 Filling............................................................................... 39
Inspection............................................................................... 33 Changing ........................................................................ 39
MerCruiser Gas Inboard Inspection and Maintenance Flame Arrestor........................................................................ 40
Schedule................................................................................. 33 Fuel System Maintenance...................................................... 41
Daily Checks..................................................................... 33 Fuel System.................................................................... 41
After Each Use.................................................................. 33 Fuel Line Inspection........................................................ 41
Weekly Checks................................................................. 33 Water‑Separating Fuel Filter........................................... 41
20 Hour Break In............................................................... 33 Filter Housing Removal............................................... 41
Annually or 100 Hours...................................................... 33 Draining the Filter Housing.......................................... 42
Three Years or 300 Hours................................................ 34 Fuel Filter Inspection................................................... 43
Five Years or 500 Hours................................................... 34 Filter Housing Installation............................................ 43
Engine Oil............................................................................... 34 Battery.................................................................................... 43
Checking......................................................................... 34 Multiple EFI Engine Battery Precautions......................... 43
Oil Level—Overfilled................................................... 35 Serpentine Drive Belt.............................................................. 44
Filling............................................................................... 35 Serpentine Drive Belt Routing......................................... 44
Engine Oil Drain Pump.................................................... 36 Serpentine Belt Failure Identification............................... 44
Changing the Oil Filter..................................................... 37 Checking......................................................................... 45
Transmission Fluid................................................................. 37 Replacing........................................................................ 46
Checking the Fluid Level Before Operation...................... 37 Flushing the Power Package—Models with a Flushing
Checking the Fluid Level When Hot................................. 38 Attachment ............................................................................ 46
Section 5 - Storage
Cold Weather or Extended Storage........................................ 52 Draining the Seawater System............................................... 54
Reformulated (Oxygenated) Gasolines (U.S.A. Only)..... 52 Draining the Raw Water.................................................. 54
Fuel Containing Alcohol.................................................. 52 Air Actuated Single‑Point Drain System (Closed Cooling,
Preparing Power Package for Storage—MPI Models..... 52 Inboard Models).............................................................. 54
Special Fuel Mix.......................................................... 53 Battery Storage....................................................................... 57
Engine and Fuel System Preparation......................... 53 Recommissioning the Power Package................................... 57
TowSport and Inboard Transmissions Extended
Storage............................................................................ 54
Section 6 - Troubleshooting
Diagnosing EFI Problems....................................................... 60 Excessive Engine Temperature...................................... 61
Diagnosing DTS Problems..................................................... 60 Insufficient Engine Temperature..................................... 61
Engine Guardian System........................................................ 60 Low Engine Oil Pressure................................................. 61
Troubleshooting Charts.......................................................... 60 Battery Will Not Recharge............................................... 62
Starter Motor Will Not Crank Engine, or Cranks Slowly.. 60 Remote Control Is Difficult to Move or Makes Unusual
Engine Will Not Start or Is Hard to Start.......................... 60 Sounds............................................................................ 62
Engine Runs Rough, Misses, or Backfires...................... 61 Steering Wheel Jerks or Is Difficult to Turn..................... 62
Poor Performance........................................................... 61
Section 7 - Customer Assistance Information

Owner Service Assistance...................................................... 64 Replacement Service Parts.............................................. 64
Local Repair Service......................................................... 64 Parts and Accessories Inquiries....................................... 64
Service Away From Home................................................ 64 Resolving a Problem......................................................... 64
Stolen Power Package..................................................... 64 Contact Information for Mercury Marine Customer Service
Attention Required After Submersion............................... 64 .......................................................................................... 65
Page ii 90-8M0119292 eng MAY 2016

Customer Service Literature.................................................... 65 Ordering Literature................................................................... 66
English Language.............................................................. 65 United States and Canada................................................. 66
Other Languages................................................................ 66 Outside the United States and Canada.............................. 66
Section 8 - Checklists
Predelivery Inspection (PDI).................................................... 68 Customer Delivery Inspection (CDI)........................................ 69
Section 9 - Maintenance Log

Scheduled Maintenance Log................................................... 72 Vessel Maintenance Notes...................................................... 73
90-8M0119292 eng MAY 2016 Page iii

Page iv 90-8M0119292 eng MAY 2016
Section 1 - Getting to Know Your Power Package 1

Table of Contents
Adaptive Speed Control (ASC)............................................... 2 Operation ................................................................. 7
Identification........................................................................... 2 Adjustment .............................................................. 8
Engine Serial Number...................................................... 2 Special Digital Throttle and Shift (DTS) Features............ 8
Transmissions.................................................................. 3 Dock ........................................................................ 9
ZF Marine Transmissions ........................................ 3 Throttle Only ............................................................ 9
Lanyard Stop Switch............................................................... 3 1 Lever .................................................................. 10
Keep the Lanyard Stop Switch and Lanyard Cord in Sync ...................................................................... 10
Good Operating Condition .............................................. 4 Transfer (Boats equipped with dual helms) ........... 11
Instrumentation....................................................................... 4 Helm Transfer................................................................ 11
VesselView ..................................................................... 4 Electrical System Overload Protection................................. 11
SmartCraft Digital Instruments ....................................... 4 Visual and Audio Warning Systems..................................... 14
System Link Digital Instruments ..................................... 5 Service Engine Light and OBD‑M MIL Kit...................... 14
Remote Controls (DTS Models)............................................. 5 Testing the OBD‑M Malfunction Indicator Lamp (MIL)
Remote Controls.............................................................. 5 .............................................................................. 14
DTS Slim Binnacle Single Handle Console Features and Audio Warning System.................................................. 14
Operation......................................................................... 6 Caution .................................................................. 15
Special Digital Throttle and Shift (DTS) Features Critical ................................................................... 15
................................................................................ 7 Nonconfigured Alarm–DTS Only ........................... 15
Dual‑Handle Electronic Remote Control (ERC)— Testing the Audio Warning System ....................... 15
Operation and Adjustment............................................... 7 Guardian Strategy.......................................................... 15
90-8M0119292 eng MAY 2016 Page 1

Adaptive Speed Control (ASC)

This power package utilizes Adaptive Speed Control (ASC) to maintain the engine RPM that is demanded at the remote
control, regardless of the load change. As an example of how ASC functions, when the operator steers the boat into a hard turn
or is navigating at a slow on‑plane speed in following seas when boat control is needed without a lot of speed, the propulsion
control module will automatically adjust the engine to maintain the RPM without the operator changing the position of the
remote control throttle handle. ASC allows the operator to keep both hands on the steering wheel, which is safer, and the
operator can focus on the boating experience.
Identification
The serial numbers are the manufacturer's keys to numerous engineering details which apply to your MerCruiser power
package. When contacting MerCruiser about service, always specify model and serial numbers.
Engine Serial Number

The serial number is located in two places on the engine. One is on the engine specification decal located on the engine cover,
and the other is secured to the starboard side of the engine block near the starter motor.
A quick reference code on the engine cover or heat exchanger can be used to access additional information about the engine
and safe boating practices.
Freshwater cooled
b a - Engine serial number decal
a b - Quick reference code
61322
Engine block location

a a - Engine serial number plate
b - Flywheel housing
c - Starter motor
b
39307
Page 2 90-8M0119292 eng MAY 2016

Transmissions
ZF Marine Transmissions
On the ZF Marine 63 series transmissions, the identification plate lists the gear ratio, serial number, and model.
58645
61400
Model 63A Model 63IV
Lanyard Stop Switch

A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as
may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.
A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.
ATTACH LANYARD
RUN
a - Lanyard cord clip
b b - Lanyard decal
OFF
c - Lanyard stop switch
a
c
53910
Accidental ejections, such as falling overboard, are more likely to occur in:
• Low‑sided 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
• Carelessness caused by consuming alcohol or drugs
• High‑speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long 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 at‑rest
condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is
made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the
operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying 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 its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.
90-8M0119292 eng MAY 2016 Page 3

Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an
emergency.
! 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.
Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition
Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard
cord. If the engine does not stop, have the switch repaired before operating the boat.
Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or
wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard
cords.
Instrumentation
VesselView
There are several VesselView products available. VesselView will display all engine information, fault codes, vessel
information, basic navigation data, and system information. When an operating system error or failure occurs, VesselView
displays an alarm message.
VesselView may also be connected to other vessel systems such as GPS, generators, and chartplotters. This vessel
integration allows the operator to monitor and control a wide range of vessel systems from a single display.
Refer to the VesselView operator's manual for more information.
61325
VesselView
SmartCraft Digital Instruments

The SmartCraft instrument package augments the VesselView display. The instrument package may include:
• Tachometer
• Speedometer
• Engine coolant temperature
• Engine oil pressure
• Battery voltage
Page 4 90-8M0119292 eng MAY 2016

• Fuel consumption
• Engine operating hours
SmartCraft tachometer and speedometer

a b a - Tachometer
b - Speedometer
c - LCD display
c
50400
The SmartCraft instrument package also aids in identifying fault codes associated with the engine audio warning system. The
SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.
For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the
system, refer to the manual provided with your gauge package.
System Link Digital Instruments

Some instrumentation packages include system link gauges that augment the information provided by VesselView or a
SmartCraft system tachometer and speedometer. The owner and operator should be familiar with all the instruments and their
functions on the boat. Have your boat dealer explain the gauges and normal readings that appear on your boat.
The following digital instruments may be included with your power package.
a b c d
37925
System Link digital gauges
Item Gauge Indicates

a Oil pressure gauge Engine oil pressure
b Voltmeter Battery voltage
c Water temperature gauge Engine operating temperature
d Fuel gauge Quantity of fuel in tank
Remote Controls (DTS Models)

Remote Controls
IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided
by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the
Mercury Precision Parts/Quicksilver Accessories Guide.
The digital throttle and shift (DTS) system required to operate this engine package provides start and stop functions, throttle
control, shift control, start in gear protection, and emergency lanyard stop functions. The DTS system works with specialized
helm components such as a command module kit and electronic remote control. Consult your dealer for a description and/or
demonstration of your remote control.
90-8M0119292 eng MAY 2016 Page 5

DTS Slim Binnacle Single Handle Console Features and Operation

1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from
neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from
neutral to the first detent for reverse gear. Continue pulling back to increase speed.
b a - Forward
b - Neutral
c - Reverse
a c
58646
2. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move the control
handle out of detent positions. Turning the screw clockwise will increase tension. Turning the screw counterclockwise will
decrease tension. Adjust to the desired tension.
3. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control
handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn the screw clockwise to
increase tension and counterclockwise to decrease tension. Adjust to the desired tension.
a - Caps (2)
b - Detent tension adjustment
c - Control handle tension adjustment
a
b c
52313
NOTE: The control handle tension and detent tension screws may require periodic maintenance adjustment.
Page 6 90-8M0119292 eng MAY 2016

Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers.
STOP/
START a
g N
f DOCK TRANSFER b
THROTTLE - ONLY c
e d
58648
Slim binnacle ERC
Item Control Function

Allows the operator to start or stop the engine without the use of the key switch. The key switch must be in
a Stop/Start
the run position for the start/stop switch to function.
b Transfer Allows boat control to be transferred to a different helm.
c Throttle‑only Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into gear.
d + Increases brightness settings for the CAN pad, VesselView, and SmartCraft gauges.
e – Decreases brightness settings for the CAN pad, VesselView, and SmartCraft gauges.
Reduces control lever operation throttle capacity to approximately 50% of normal control lever throttle
f Dock
demand.
Illuminates when the drive is in the neutral gear position. The lights flash when the engine is in throttle
g Neutral light
only mode.
Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment

Operation
The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from
neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from
the forward position to the neutral position to decrease speed and eventually stop. Pull the control handle back from neutral to
the first detent for reverse gear. Continue pulling the handle back to increase speed in reverse.
NOTE: In certain modes, the gear position is determined by the electronic shift control (ESC), not the position of the ERC
levers. When using the joystick or while in Skyhook, the computer controls the shifting in and out of gears even though the
handles are in neutral.
b a - Forward
b - Neutral
c - Reverse
c a
51902
90-8M0119292 eng MAY 2016 Page 7

The amount of force needed to move the handles and to move the handles through the detents is adjustable to help prevent
unwanted motion.
Adjustment
NOTE: The control handle tension and detent tension may require periodic maintenance using the adjustment screws.
To adjust the handle detent tension:
1. Remove the side cover plugs of the handle that needs adjustment.
2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.
3. Adjust to the tension desired.
To adjust handle tension:
1. Remove the side cover plugs of the handle that needs adjustment.
2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.
3. Adjust to the tension desired.
a - Detent tension adjustment screw

b - Handle tension adjustment screw
a b
51901
Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed
features can operate simultaneously.
h b
g c
f d
e
58650
Dual engine ERC
Page 8 90-8M0119292 eng MAY 2016

Item Control Function

Illuminate when the drive is in the neutral gear position. The lights flash when the engine is in throttle only
a Neutral lights
mode.
b Transfer Allows boat control to be transferred to a different helm. Refer to Helm Transfer.
Available with joystick operation and the control levers.
Joystick operation reduces throttle capacity to approximately 70% of normal joystick throttle demand.
c Dock
Control lever operation reduces throttle capacity to approximately 50% of normal control lever throttle
demand.
d + Increases brightness settings for the CAN pad, VesselView, and SmartCraft gauges.
e Throttle‑only Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into gear.
f – Decreases brightness settings for the CAN pad, VesselView, and SmartCraft gauges.
g 1 Lever Enables the throttle and shift functions of both engines to be controlled by the port lever.
h Sync Turns off or on the auto‑synchronization feature.
NOTE: Not all functions may be active.

Dock
Dock mode is available with joystick operation and remote control lever operation. Dock mode reduces throttle capacity to
approximately 70% of normal joystick throttle demand, allowing finer control of engine power in close quarter situations. If more
power is needed for vessel maneuvering when environmental conditions require more thrust, use the electronic remote control
levers.
51854
DOCK button
Throttle Only
NOTE: On vessels equipped with Axius, throttle only mode should be used to disable the joystick if the captain is not in
command at the helm. Placing the ERC in throttle only mode will avoid unintended gear engagement. The engines will turn
using the steering wheel or the joystick and the RPM of the engines can be increased while in the throttle only mode, but the
gear position will remain in neutral.
51855
THROTTLE ONLY button
To engage throttle only mode:

1. Place both ERC levers in neutral.
2. Press the THROTTLE ONLY button. The button light will turn on and the neutral lights will blink.
3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in
throttle only, but will remain in neutral.
4. The RPM of the engines can be increased.
90-8M0119292 eng MAY 2016 Page 9

5. Throttle only mode also affects the joystick. The engines will move and the RPM can be increased, but will remain in
neutral.
NOTE: Pressing the THROTTLE ONLY button while the ERC levers are not in the neutral position turns the button light off and
remains in throttle only mode. You must place the ERC levers into the neutral position to disengage throttle only mode.
To disengage throttle only mode:
1. Place both ERC levers into neutral. Throttle only will not disengage unless the ERC levers are in neutral.
2. Press the THROTTLE ONLY button. The button light will turn off.
3. The neutral lights stop flashing and remain illuminated. The joystick can now be used.
1 Lever
The joystick piloting system features the ability to command both engines with a single lever on a dual‑engine application. This
feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both
engines simultaneously. It has no affect on the joystick function. It is not the same as the system feature called Sync.
51856
1 LEVER button
To engage 1 Lever mode:

2. Press the 1 LEVER button. The button light will turn on.
3. Place the starboard ERC lever into gear.
4. When the handle is moved, the engines RPM and gear position is synchronized.
To disengage 1 Lever mode:
2. Press the 1 LEVER button. The button light turns off.
Sync
Sync is an automatic engine synchronization feature that is always on unless it is manually turned off. Sync monitors the
position of both ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard
engine's RPM. The SmartCraft system will automatically disengage sync after 95% of throttle position range to allow each
engine the ability to reach maximum available RPM. Sync cannot engage until the engines are at a minimum speed.
The indicator light on the SYNC button is on when both engines are on. The light is yellow at idle and 95% of throttle and when
the engines are not synchronized. The light turns red when the engines are synchronized.
51857
SYNC button
The RPM display of VesselView also shows an orange icon under the RPM numbers if the engines RPMs differ more than 10%
of each other, and the icon turns red when they are synchronized.
To disengage sync mode:
1. Place the ERC levers in any detent.
Page 10 90-8M0119292 eng MAY 2016

2. Press the SYNC button. The button light turns off.

To engage Sync mode, press the SYNC button at any time.
Transfer (Boats equipped with dual helms)
The TRANSFER button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on
boats equipped with dual helms. Refer to Helm Transfer.
51858
TRANSFER button
Helm Transfer
Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to
as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to
another helm.
! 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. One‑person helm transfer should only be
performed while engine is in neutral.
The helm transfer function allows the boat operator to select which helm is in control of the vessel. Before a transfer can be
initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position.
NOTE: If you attempt to transfer helm control when the ERC levers are not in neutral, a beep will sound and the helm transfer
will not succeed until the levers at the helms are moved to neutral and transfer is requested again.
Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer
procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the
helm transfer procedure. Ensure that other control and navigation inputs are performed after helm transfer is complete to avoid
setting fault codes.
NOTICE
The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects
nearby resulting in damage. Keep an adequate look out while performing the helm transfer.
To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items
or when near other vessels.
Electrical System Overload Protection

If an electrical system overload occurs, a fuse will fail or the circuit breaker will open. The cause must be found and corrected
before replacing the fuse or resetting the circuit breaker.
NOTE: In an emergency, when you must operate the engine and cannot locate the cause for the high current draw, 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. Contact your authorized dealer.
90-8M0119292 eng MAY 2016 Page 11

To access the circuit breaker and fuses, remove the outside engine cover. Pull the outside engine cover up to remove it from
the four rubber mount grommets.
58358
The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead.
55033
All of the engine protection fuses are located at the front of the engine. To access the fuses, disengage the fuse holders from
the electrical plate assembly.
b d b Mechanical engine, freshwater

a b c cooled shown, others similar
a - Oxygen sensor fuses (4)
b - Spare fuse
c - Engine and trim relays
e g d - Fuel injectors
f e - Alternator and fuel pump relay
f - Ignition coils
g - Malfunction indicator lamp
(MIL)
61447
Page 12 90-8M0119292 eng MAY 2016

d b e b DTS engine, freshwater cooled

a b
c shown, others similar
a - Oxygen sensor fuses (4)
b - Spare fuse
c - Engine and trim relays
f g h d - DTS helm power
e - Fuel injectors
f - Alternator and fuel pump relay
g - Ignition coils
h - Malfunction indicator lamp
(MIL)
61448
A 90‑amp fuse located near the flame arrestor, protects the engine power harness if an electrical overload occurs. The fuse is
translucent so it can be inspected if the fuse has failed and is open.
b a - 90‑amp fuse
a b - Hot stud
56871
A 15‑amp fuse located at the aft end of the engine, protects the accessory circuits.
c
a - Cover
a b b - 15‑amp fuse
c - Accessory harness
32206
90-8M0119292 eng MAY 2016 Page 13

This power package uses a clean power harness that is connected to the engine starting battery. This clean power harness
minimizes an excessive voltage drop to the engine and drive digital control electrical system. This harness is protected by a
5‑amp fuse and is located near the engine starting battery.
a - 5‑amp fuse
b - Positive battery terminal (harness lead with fuse)
c - Negative battery terminal
a b c
43608
Visual and Audio Warning Systems

Service Engine Light and OBD‑M MIL Kit
Boats powered by emissions control technology (ECT) catalyzed engines must be equipped with a SmartCraft‑enabled gauge
capable of displaying the service engine icon, or a dash‑mounted service engine light. Malfunction indicator lamp (MIL) kits
containing a dash‑mounted service engine light and a special harness that connects to the engine harness may be purchased
separately.
The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and
will remain illuminated while the OBD‑M fault is active.
47594
SC 1000 gauge and service engine light
Testing the OBD-M Malfunction Indicator Lamp (MIL)

1. Turn the ignition switch to the on position without cranking the engine.
2. The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning
correctly.
Audio Warning System

IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from
damage.
Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.
There are two warning horn states:
• Caution
• Critical
There is also an alarm that sounds if the helm has not been properly configured using the G3 service tool.
Page 14 90-8M0119292 eng MAY 2016

Caution
If a caution state is detected, the audio warning system will sound for six one‑second intervals.
ON ON ON ON ON ON
1 1 1 1 1 1
a - Horn (on or off)
a 1 1 1 1 1 b - Time (in seconds)
OFF OFF OFF OFF OFF OFF
b
33402
Critical
If a critical state is detected, the audio warning system sounds for six seconds and then turns off.
ON

a 6
b - Time (in seconds)
OFF
b 53403
Nonconfigured Alarm–DTS Only

If the helm has not been properly configured using the G3 service tool, the audio warning system will sound for five one‑second
intervals.
ON ON ON ON ON
1 1 1 1 1
a 1 1 1 1 b - Time (in seconds)
OFF OFF OFF OFF OFF
b 53402
Testing the Audio Warning System

1. Turn the key switch to the on position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
Guardian Strategy
The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM
detects a potential problem. Below are some examples of what Engine Guardian monitors:
• Oil pressure
• Engine overspeed
• Exhaust manifold temperature
• Transmission oil temperature
IMPORTANT: Engine Guardian can reduce power anywhere from 100% to idle, depending on the severity of the problem. If
forced to idle, boat speed might not respond to throttle operation.
The PCM stores the fault for diagnostics. For example, if the water inlet becomes partially blocked, Engine Guardian reduces
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 Guardian restores engine power to normal.
90-8M0119292 eng MAY 2016 Page 15

Notes:
Page 16 90-8M0119292 eng MAY 2016


Table of Contents
Safe Boating Recommendations.......................................... 18
Carbon Monoxide Exposure................................................. 19
High‑Speed and High‑Performance Operation..................... 22
Passenger Safety in Pontoon Boats and Deck Boats.......... 22
2
Be Alert To Carbon Monoxide Poisoning ..................... 19 Boats Having an Open Front Deck ............................... 23
Stay Clear of Exhaust Areas ........................................ 19 Boats With Front‑Mounted, Raised Pedestal Fishing
Good Ventilation .......................................................... 19 Seats ............................................................................ 23
Poor Ventilation ........................................................... 20 Wave and Wake Jumping..................................................... 23
Basic Boat Operation (DTS Models).................................... 20 Impact with Underwater Hazards......................................... 24
Launching and Boat Operation...................................... 20 Conditions Affecting Operation............................................. 24
Operation Chart ..................................................... 20 Weight Distribution (Passengers and Gear) Inside the
Starting and Stopping the Engine.................................. 20 Boat............................................................................... 24
Starting the Engine ................................................ 20 The Bottom of the Boat.................................................. 24
Stopping the Engine .............................................. 21 Cavitation....................................................................... 25
Throttle Only Operation—DTS Models.......................... 21 Ventilation...................................................................... 25
Freezing Temperature Operation.................................. 22 Elevation and Climate.................................................... 25
Drain Plug and Bilge Pump............................................ 22 Getting Started..................................................................... 25
Protecting People in the Water............................................. 22 20‑Hour Break‑In Period................................................ 25
While You Are Cruising ................................................ 22 After the Break‑In Period............................................... 25
While Boat Is Stationary ............................................... 22 End of First Season Checkup........................................ 25
90-8M0119292 eng MAY 2016 Page 17

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions
and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary,
the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For
more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
• Here are some suggestions of the types of safety equipment to carry when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench
First aid kit and instructions
Waterproof storage containers
Spare operating equipment, batteries, bulbs, and fuses
Compass and map or chart of the area
Personal flotation device (one per person onboard)
Watch for signs of weather change and avoid foul weather and rough‑sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive
unit into neutral is not sufficient.
Use personal flotation devices.
• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and
readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life
jacket at all times while in the boat.
Prepare other boat operators.
• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver
becomes disabled or falls overboard.
Do not overload your boat.
• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your
boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your
authorized Mercury Marine dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
• 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. Passengers should not sit or ride
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 operate a boat while under the influence of alcohol or drugs. It is the law.
• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
Page 18 90-8M0119292 eng MAY 2016

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 operator's 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.
• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.
Watch fallen skiers.
• When using your boat for waterskiing 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.
Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning
Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the
engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless,
but if you can smell or taste engine exhaust, you are inhaling CO.
Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include
headache, dizziness, drowsiness, and nausea.
! WARNING
Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage,
or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.
Stay Clear of Exhaust Areas
41127
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines
are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While
underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the
possibility of injury from the boat propeller.
Good Ventilation
Ventilate the passenger area, open side curtains or forward hatches to remove fumes.
Example of desired air flow through the boat:
43367
90-8M0119292 eng MAY 2016 Page 19

Poor Ventilation
Under certain running or wind 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 a running engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:
a a - Operating the engine when the boat

b is moored in a confined space
b - Mooring close to another boat that
has its engine operating
21626
2. Examples of poor ventilation while the boat is moving:
a a - Operating the boat with the

b
trim angle of the bow too
high
b - Operating the boat with no
forward hatches open
43368 (station wagon effect)
Basic Boat Operation (DTS Models)

Launching and Boat Operation
IMPORTANT: Install bilge drain plug prior to launching boat.
Operation Chart
Operation Chart
BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING
Observe all gauges to
Observe all gauges to
check condition of Turn ignition key to the
Install bilge drain plug. check condition of engine. If
engine. If not normal, "OFF" position.
not normal, stop engine.
stop engine.
Check for fuel, oil, water, Listen for the audio Turn battery switch to the
Open engine hatch.
fluid and exhaust leaks. alarm. "OFF" position.
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Operate bilge blowers. Check steering operation. Close seacock, if equipped.
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if equipped. Drain bilge.
Close the drain system.
Check the engine oil.
Perform all other checks specified by
your dealer and/or boatbuilder.
Listen for audio warning alarm to sound
when the ignition switch is in the "ON"
position.
Starting and Stopping the Engine

Starting the Engine
1. Check all items listed in the Operation Chart.
Page 20 90-8M0119292 eng MAY 2016

2. Place the remote control handle in neutral.
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: This power package is 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 PCM signals the engine to start. 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 the ignition key to the RUN position.
4. Turn the ignition key switch to the START position then release, or press 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 throttle only button and position the remote control handle or throttle lever to the 1/4 throttle position.
b. Turn the ignition key to START. Release the 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 the 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 the throttle to the 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 the engine has been operated
at high speed for a long period of time, allow the engine to cool at idle speed for 3–5 minutes.
2. The engine can be stopped by any one of the following four 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. Press the start/stop button, if equipped. The engine will stop and the control system will remain active.
c. 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.
d. 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.
Throttle Only Operation—DTS Models

NOTE: When operating in throttle only (neutral) mode, the DTS control system will not allow the engine speed to exceed 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.
90-8M0119292 eng MAY 2016 Page 21

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. Press 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.
Freezing Temperature Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze
damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty.
Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a
drain plug and/or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does
not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused
by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Protecting People in the Water

While You Are Cruising
It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.
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.
While Boat Is Stationary

! WARNING
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the water is near your boat.
Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat.
High‑Speed and High‑Performance Operation

If your boat is considered a high‑speed or high‑performance boat and you are unfamiliar with its operation, we recommend that
you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your
dealer or an operator experienced with your boat. For additional information, refer to Hi‑Performance Boat Operation booklet
(90‑849250R03) from your dealer, distributor, or Mercury Marine.
Passenger Safety in Pontoon Boats and Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats
other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a
large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the
boat. Falling over the front of the boat between the two pontoons will position them to be run over.
Page 22 90-8M0119292 eng MAY 2016

Boats Having an Open Front Deck

No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence
or enclosure.
Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their
legs caught by a wave and pulled into the water.
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.
Boats With Front‑Mounted, Raised Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats
designated for traveling at faster speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.
mc79557-1
Wave and Wake Jumping

! WARNING
Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave
or wake jumping whenever possible.
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.
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.
90-8M0119292 eng MAY 2016 Page 23

Impact with Underwater Hazards

Reduce speed and proceed with caution whenever you're driving a boat in shallow water or in areas where the waters are
suspected of having underwater obstacles that could be struck by the underwater drive components, rudder, or the boat
bottom.
7576
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
24–40 km/h (15–25 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.
Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to rear (stern):
• Generally increases speed and engine RPM
• Causes bow to bounce in choppy water
• Increases danger of following wave splashing into the boat when coming off plane
• At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
• Improves ease of planing
• Improves rough water ride
• At extremes, can cause the boat to veer back and forth (bow steer)
The Bottom of the Boat

To maintain maximum speed, the boat bottom should be:
• 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.
Page 24 90-8M0119292 eng MAY 2016

Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast‑moving 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 speed‑up
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
Elevation and Climate

Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by:
• Higher elevations
• Higher temperatures
• Low barometric pressures
• High humidity
For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to
allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your
normal boating weather conditions.
In most cases, recommended RPM can be achieved by changing to a lower pitch propeller.
Getting Started
20‑Hour Break‑In Period
IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil
consumption and maximum engine performance. During this break‑in 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 (five 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 break‑in period.
After the Break‑In Period

To help extend the life of your Mercury MerCruiser power package, follow these recommendations:
• Ensure that the propeller allows the engine to operate at or near the top of the specified wide‑open throttle (WOT) RPM
range. Refer to Specifications and Maintenance.
• Operate the engine at 3/4 throttle or lower. Refrain from prolonged operation at WOT RPM.
• At 25 hours of operation, change the transmission fluid. Models equipped with a transmission filter must also have the filter
changed at this time.
End of First Season Checkup

At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform
scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact
your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
90-8M0119292 eng MAY 2016 Page 25

Notes:
Page 26 90-8M0119292 eng MAY 2016

Table of Contents
Fuel Requirements............................................................... 28 Methanol and Ethanol Fuel Blends ....................... 28
Fuel Ratings ................................................................. 28 Engine Oil............................................................................. 28
Using Reformulated (Oxygenated) Gasoline (USA Only) 6.2 MPI Inboard Engine Specifications................................. 29
3
...................................................................................... 28 Fluid Specifications............................................................... 30
Gasoline Containing Alcohol ........................................ 28 Engine............................................................................ 30
Bu16 Butanol Fuel Blends ..................................... 28 Transmission................................................................. 30
90-8M0119292 eng MAY 2016 Page 27

Fuel Requirements
NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.
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 will not be covered under the limited warranty.
Fuel Ratings
Mercury MerCruiser engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following
specifications:
USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for all models. Premium gasoline 91 (R+M)/2
octane is also acceptable for all models. Do not use leaded gasoline.
Outside USA and Canada ‑ A posted pump octane rating of 91 RON, minimum, for all models. Premium gasoline (95 RON) is
also acceptable for all models. Do not use leaded gasoline.
Using Reformulated (Oxygenated) Gasoline (USA Only)

Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The
only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Gasoline Containing Alcohol

Bu16 Butanol Fuel Blends
Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable
substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system
components (fuel tanks, fuel lines, and fittings).
Methanol and Ethanol Fuel Blends
IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or
ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol.
Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines,
and fittings).
Be aware that gasoline containing methanol or ethanol may cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through the rubber fuel lines
• Likelihood of phase separation (water and alcohol separating from the gasoline in the fuel tank)
! 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.
IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of
inspection for leaks and abnormalities.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline
in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause
trouble; boats often sit idle long enough for phase separation to take place. Internal corrosion may occur during storage if
alcohol has washed protective oil films from internal components.
Engine Oil
For optimum engine performance and maximum protection, use the following oil:
Application Recommended Oil

All MerCruiser engines Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst Compatible rated
IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for noncatalyzed engines. Some
marine‑grade lubricants contain high levels of phosphorus. Although these high‑phosphorus lubricants may allow 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.
Page 28 90-8M0119292 eng MAY 2016

If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of
recommendation.
1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible.
IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.
2. Other recognized brands of NMMA FC‑W Catalyst Compatible rated 4‑cycle oil.
3. Other recognized brands of NMMA FC‑W rated 4‑cycle oils.
4. A good‑grade, straight‑weight detergent automotive oil according to the last row of the operating chart below.
NOTE: We do not recommend nondetergent oils, multi‑viscosity oils (other than as specified), non‑FC‑W rated synthetic oils,
low‑quality oils, or oils that contain solid additives.
Use the following information for selecting the type of oil according to the order of preference.
Mercury/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W Catalyst Compatible rated 4-cycle oil
ORDER OF PREFERENCE
Mercury/Quicksilver 25W-40 Mineral NMMA FC-W Catalyst Compatible rated 4-cycle oil
Other recognized brands of NMMA FC-W Catalyst Compatible rated 4-cycle oil
Other recognized brands of NMMA FC-W rated 4-cycle oil
SAE40W
SAE30W
SAE 20W
0° C 10° C
(32° F) (50° F) 53574
AIR TEMPERATURE
6.2 MPI Inboard Engine Specifications

NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power.
All measurements are taken with the engine at normal operating temperature.
RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures.
Oil pressure must be checked with the engine at normal operating temperature.
NOTE: Oil pressure specifications are for reference and may vary.
IMPORTANT: Do not mix spark plug types in an engine. All spark plugs should have the same part number.
90-8M0119292 eng MAY 2016 Page 29

224 kW (300 hp)

Crankshaft power
261 kW (350 hp)
Displacement 6.2 L (377 cid)
Hot 72 A
Alternator amperage
Cold 65 A
WOT operating range 5000–5400
Rev limiter 5550
RPM
Idle in neutral 625 (not adjustable)
Idle in gear 650 (not adjustable)
At 2000 RPM 124 kPa (18 psi)
Minimum oil pressure
At idle 41 kPa (6 psi)
Standard cooling 60 °C (140 °F)
Thermostat
Closed cooling 77 °C (170 °F)
Firing order 1‑8‑4‑3‑6‑5‑7‑2
Minimum battery rating* All models 800 CCA, 1000 MCA, 190 Ah
Spark plug type Factory installed NGK (BPR5EFS‑13)
Spark plug gap 1.3 mm (0.051 in.)
Emission control technology, heated oxygen sensor
ECT
Emission control system (HO2S), catalyst
EC Electronic engine control
*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are
the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do
not meet Mercury Marine battery requirements.
Fluid Specifications
Engine
IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required.
All Models Capacity Fluid Type

Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA
6.2L engine oil (with filter) 4.7 L (5 US qt)
FC‑W®
6.2L seawater cooling system
26.5 L (28 US qt) Propylene glycol and purified water
(winterization use only)
Mercury Extended Life Coolant Antifreeze or extended‑life
6.2L closed‑cooling system 17 L (17.9 US qt)
ethylene glycol 5/100 antifreeze mixed 50/50 with purified water
Transmission
Model Capacity Fluid Type
63A 4.3 L (4.5 US qt) Dexron III Automatic
63IV 4.4 L (4.6 US qt) Transmission Fluid
Page 30 90-8M0119292 eng MAY 2016

Table of Contents
Owner/Operator Responsibilities.......................................... 32 Changing ...................................................................... 38
Dealer Responsibilities......................................................... 32 Engine Coolant..................................................................... 38
Maintenance......................................................................... 32 Checking........................................................................ 38
Do‑It‑Yourself Maintenance Suggestions............................. 32 Filling............................................................................. 39
Inspection............................................................................. 33 Changing ...................................................................... 39
MerCruiser Gas Inboard Inspection and Maintenance Flame Arrestor...................................................................... 40
Schedule............................................................................... 33 Fuel System Maintenance.................................................... 41
Daily Checks ................................................................. 33 Fuel System................................................................... 41
4
After Each Use ............................................................. 33 Fuel Line Inspection....................................................... 41
Weekly Checks ............................................................. 33 Water‑Separating Fuel Filter.......................................... 41
20 Hour Break In .......................................................... 33 Filter Housing Removal ......................................... 41
Annually or 100 Hours .................................................. 33 Draining the Filter Housing .................................... 42
Three Years or 300 Hours ............................................ 34 Fuel Filter Inspection ............................................. 43
Five Years or 500 Hours ............................................... 34 Filter Housing Installation ...................................... 43
Engine Oil............................................................................. 34 Battery.................................................................................. 43
Checking........................................................................ 34 Multiple EFI Engine Battery Precautions....................... 43
Oil Level—Overfilled .............................................. 35 Serpentine Drive Belt............................................................ 44
Filling............................................................................. 35 Serpentine Drive Belt Routing....................................... 44
Engine Oil Drain Pump.................................................. 36 Serpentine Belt Failure Identification............................. 44
Changing the Oil Filter................................................... 37 Checking........................................................................ 45
Transmission Fluid............................................................... 37 Replacing....................................................................... 46
Checking the Fluid Level Before Operation .................. 37 Flushing the Power Package—Models with a Flushing
Checking the Fluid Level When Hot ............................. 38 Attachment .......................................................................... 46
90-8M0119292 eng MAY 2016 Page 31

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 the complete listing of all scheduled maintenance to be performed. Some
items should be performed only by an authorized Mercury MerCruiser dealer only. 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.
Maintenance Point Color Codes

Yellow Engine Oil
Red ATF (Transmission)
Orange Coolant
Blue Raw Water Flush
Do‑It‑Yourself Maintenance Suggestions

Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery.
Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the
untrained mechanic.
If you are one of those persons who likes to do it yourself, here are some suggestions for you.
• Do not attempt any repairs unless you are aware of the Cautions, Warnings, and procedures required. Your safety is our
concern.
• If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual
outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't
understand. Do not attempt repairs if you do not understand the procedures.
• There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs unless you
have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would
charge you.
Page 32 90-8M0119292 eng MAY 2016

• Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must
reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer
immediately upon having a problem. It may be a very simple adjustment to correct the problem.
• Do not telephone the dealer, service office, or the factory to attempt for them to diagnose a problem or to request the repair
procedure. It is difficult for them to diagnose a problem over the telephone.
Your authorized dealer is there to service your power package. They have qualified factory trained mechanics.
It is recommended you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the
fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating
season when you want trouble free boating pleasure.
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.
MerCruiser Gas Inboard Inspection and Maintenance Schedule

Daily Checks
• Check the engine oil level
• Check the transmission fluid level
• Check the lanyard stop switch
After Each Use

• Flush the engine with fresh water, brackish or saltwater use only
Weekly Checks
• Check the seawater inlets for marine growth
• Clean the seawater strainer, if equipped
• Check the coolant level, if equipped
• Check the transmission fluid level
20 Hour Break In
• Change the transmission fluid and filter—ZF requirement to maintain warranty—dealer item
Annually or 100 Hours

• Check the battery condition and connections—dealer item
• Lubricate the propeller shaft splines
• Check the torque of the propeller nut
• Clean the gauges and check wire connection—dealer item
• Touch up any paint nicks and spray the power package with Corrosion Guard
• Change the engine oil and filter
• Change transmission fluid and filter—dealer item
• Check the closed cooling fluid level and concentration for freeze protection, if equipped
• Replace the water‑separating fuel filter
• Check the crankcase vent—8.2L only
• Check the IAC muffler—8.2L only
• Clean the flame arrestor—8.2L only
• 6.2L MIE models, inspect the exhaust system. If the power package is equipped with water shutters, verify they are not
missing or worn—dealer item.
• Inspect the condition of the accessory drive belt—dealer item
• Replace the PCV valve
• Spray the power package with Corrosion Guard
90-8M0119292 eng MAY 2016 Page 33

• Inspect anodes, if equipped
Three Years or 300 Hours

• Inspect the spark plugs and spark plug wires1.
• Clean the flame arrestor and crankcase vent hoses
• Check the engine mount fasteners for tightness and tighten to the specified torque—dealer item
• Check the electrical system for loose, damaged, or corroded fasteners—dealer item
• Check the exhaust and cooling system hose clamps for tightness. Inspect for damage or leaks—dealer item.
• Inspect and clean seawater side of closed cooling system, if equipped—dealer item
• Clean, inspect, and test the closed cooling pressure cap, if equipped—dealer item
• Inspect seawater pump. Replace worn components—dealer item.
• Inboard models, inspect the exhaust system. If the power package is equipped with water shutters, verify they are not
missing or damaged—dealer item.
• Replace the vent valve on each exhaust elbow, port and starboard, if equipped—dealer item
• TowSport models, check the neutral position on manual shift transmission. Adjust the control cable if necessary—dealer
item.2.
Five Years or 500 Hours

• Replace the antifreeze—replace the antifreeze every two years if not using extended life antifreeze—dealer item
Engine Oil
Checking
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.
1. With the engine warm but not running, wait five minutes to allow the oil to drain into the oil pan.
2. Remove the dipstick, wipe it clean, and install it fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.
Remove the dipstick.
58400
V-drive model shown
1. Inspect the condition of the spark plugs and spark plug wires. Replace as necessary. If the condition of these components is satisfactory at the time of inspection, repeat the inspection every
100 hours or once a year, whichever occurs first.
2. After the three year or 300 hour inspection, repeat the inspection every 100 hours or once a year, whichever occurs first.
Page 34 90-8M0119292 eng MAY 2016

58402
In-line drive model shown
3. Inspect the dipstick for the oil level reading. The oil should be between the ADD mark and the FULL or OK range mark on
the dipstick. Install the dipstick into the dipstick tube. If the oil level is low, refer to Filling.
Oil Level—Overfilled
IMPORTANT: Do not overfill the engine with oil. An overfilled crankcase can cause a fluctuation or drop in oil pressure and
rocker arm clatter, and result in a loss of engine performance.
An overfilled crankcase (oil level too high) can cause a fluctuation or drop in oil pressure, and rocker arm clatter. This condition
results in the engine crankshaft splashing and agitating the oil, causing it to foam (become aerated). The aerated oil causes the
hydraulic valve lifters to bleed down. This results in rocker arm clatter and loss of engine performance.
Care must be taken when checking the engine oil level. The oil level must be maintained between the ADD mark and the FULL
or OK range mark on the dipstick.
Filling
IMPORTANT: Do not overfill the engine with oil. Always use the dipstick to determine the exact quantity of oil or fluid required.
1. Remove oil fill cap.
58405
V-drive model shown
90-8M0119292 eng MAY 2016 Page 35

58404
In-line dive model shown
2. Add the specified engine oil to bring the level up to, but not over, the FULL or OK range mark on the dipstick. Check the oil
level.
3. Replace the fill cap.

Engine oil (with filter) 4.7 L (5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W
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 - Oil pump
b - Dipstick tube
c - Oil drain hose
a
c
b
mc70571-1
4. Insert the hose end of the crankcase oil pump onto an appropriate container and use the handle to pump until the
crankcase is empty.
5. Remove the pump.
6. Install the dipstick.
Page 36 90-8M0119292 eng MAY 2016

Changing the Oil Filter

1. Use a shop towel to capture oil that may spill. Remove and discard the oil filter.
58410
V-drive model shown
58411
In-line drive model shown
2. Clean up any residual oil that may be on the oil filter mount.
3. Apply engine oil to the sealing ring on the new filter.
4. Install and tighten the oil filter securely following the filter manufacturer's instructions. Do not overtighten.
5. Remove the oil fill cap.
6. Add the required amount of the recommended oil to bring the level up to the bottom of the OK range on the dipstick.
7. With the boat at rest in the water, repeat steps 5, and 6 if necessary.
NOTE: Adding 0.95 L (1 US qt) of engine oil raises the level from the ADD mark to the top of the OK range.

Engine oil (with filter) 4.7 L (5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W
8. Start the engine and operate for three minutes while checking for leaks.
9. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.
10. Use the dipstick to check the level of the oil. Add oil if necessary.
Transmission Fluid
Checking the Fluid Level Before Operation
IMPORTANT: Always check the fluid level before starting and operating.
90-8M0119292 eng MAY 2016 Page 37

1. Remove the dipstick and wipe it with a clean towel.
61380
63IV shown, others similar
2. Insert the dipstick without turning it in.

3. Remove the dipstick and observe the fluid level on the dipstick. The fluid level must be between the minimum and
maximum marks. Add fluid if necessary, but do not overfill.
4. Install the dipstick and tighten the T‑handle securely. Do not overtighten.
Checking the Fluid Level When Hot

The process for checking the fluid level when hot is the same as checking the fluid level before operation.
Changing
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. Allow the engine to cool down to the ambient air temperature.

2. Remove the cap from the heat exchanger and observe the fluid level.
61326
Heat exchanger cap
3. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, verify that there
is fluid in the coolant recovery bottle. If the recovery bottle is empty, contact your authorized Mercury MerCruiser dealer.
4. Install the cap onto the heat exchanger.
IMPORTANT: When installing the cap, be sure to tighten it until it seats on the filler neck.
5. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.
Page 38 90-8M0119292 eng MAY 2016

6. The coolant level should be between the ADD and FULL marks.
6102
7. Add the specified fluid as necessary.
Tube Ref No. Description Where Used Part No.
122 Extended Life Antifreeze/Coolant Closed Cooling System 92-877770K1
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
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 the engine is at normal operating temperature.
1. Remove the fill cap from the coolant recovery bottle. Inspect the gasket and replace if necessary.
IMPORTANT: Coolant flows at a high rate of speed in this closed cooling system. Higher idle speeds can trap air in the
system and make purge procedures more difficult. Operate at idle when filling the system or purging air.
2. Fill to the full mark with the specified coolant.
122 Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1
3. Check the antifreeze concentration for adequate freeze protection and correct if necessary. Refer to the Specifications
section.
4. Install the fill cap to the coolant recovery bottle.
Changing
Contact your authorized Mercury MerCruiser dealer.
90-8M0119292 eng MAY 2016 Page 39

Flame Arrestor
! WARNING
Fuel is flammable and explosive. Ensure that 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.
1. There are two engine covers you must remove to access the flame arrestor:
a. Pull the outside engine cover up to remove it from the four rubber mount grommets.
b. Carefully guide the cover past the O2 sensors.
58808
c. Lift up on the front of the second cover to disengage the cover from the front grommets. Pull the cover towards the
front of the vessel to remove it from the two rear grommets.
b a - Front grommets
b b b - Rear grommets
a a
58810
2. Loosen the clamp securing the flame arrestor and remove the flame arrestor.
Flame arrestor
a - Clamp securing the flame arrestor
b - Flame arrestor
a
61328
Page 40 90-8M0119292 eng MAY 2016

3. Cut the cable tie securing the crankcase vent hose to the flame arrestor and gently pull the vent hose off the flame arrestor.
61330
Crankcase vent hose
4. Clean the flame arrestor with warm water and a mild detergent.
5. Inspect the flame arrestor for holes, cracks, or deterioration. Replace if necessary.
6. Allow the flame arrestor to air dry completely before use.
7. Install the vent hose and secure with a cable tie.
8. Install the flame arrestor and tighten the flame arrestor clamp to the specified torque.
Description Nm lb‑in. lb‑ft

Flame arrestor clamp nut 6.2 55 –
9. Install the engine covers.
Fuel System Maintenance

Fuel System
! WARNING
IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately. Material used to contain
spilled fuel must be disposed of in an approved receptacle.
Before servicing any part of the fuel system:
1. Stop engine and disconnect the battery.
2. Perform fuel system service in a well‑ventilated area.
3. Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection

Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these
conditions are found, the fuel line must be replaced.
Water‑Separating Fuel Filter

The water‑separating fuel filter is a low‑pressure filter that removes debris and water before the fuel reaches the high‑pressure
fuel pump. It is best to service the water‑separating fuel filter when the engine is cold or after the engine has not run for several
hours. Although the engine may not have run for hours, high ambient air temperatures can cause the fuel system to become
pressurized. The amount of pressure within the system is dependent on the type of fuel system installed on the vessel.
Refer to the Scheduled Maintenance for the proper maintenance interval.
Filter Housing Removal
1. Verify the ignition key switch is off and remove the key.
2. Disconnect the batteries.
3. Locate the water‑separating fuel filter on the starboard front side of the engine.
4. Remove the red service cap.
90-8M0119292 eng MAY 2016 Page 41

5. Place a rag or towel around the fuel filter housing to prevent the fuel from leaking or spraying.
6. Use the fuel filter removal/installation tool or the shaft of a screwdriver between the lugs on the filter cover and turn the fuel
filter cover counterclockwise to loosen it. Do not remove the cover.
Fuel Filter Removal/Installation Tool 91‑896661
Aids in the removal and installation of the fuel filter cap assembly.
24896
7. Slide the filter housing up to release it from the bracket. The fuel hoses have enough slack to remove the filter housing
from the bracket.
c a - Bracket retainers
b - Filter cover
b c - Red service cap
61359
Draining the Filter Housing

! WARNING
Tip the filter housing and remove the filter cover to drain the fluid into an approved container. Dispose of the fuel according to
local regulations.
61360
Page 42 90-8M0119292 eng MAY 2016

Fuel Filter Inspection

The fuel filter is an important component in the fuel delivery system and should be inspected for debris or degradation every
100 hours of operation. Replace the fuel filter when necessary.
Filter Housing Installation
1. Place the filter housing mounting tabs into the slots on the bracket and push down on the filter housing to slide the
mounting tabs into the lock position.
2. Lubricate the filter O‑ring seals with clean oil.
3. Install the filter and tighten the cover securely.
4. Install the red service cap.
5. Connect the battery cables.
6. Turn the ignition key to the ON or RUN position. Do not start the engine.
7. Inspect the filter housing and hoses for leaking fuel.
IMPORTANT: Inspect for leaking fuel before starting the engine.
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.
Multiple EFI Engine Battery Precautions

Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is
mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for
both batteries. Normally, the other engine's alternator will not be required to supply any charging current.
EFI electronic control module (ECM): The ECM requires a stable voltage source. During multiple engine operation, an
onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may go below the ECMs
minimum required voltage. Also, the alternator on the other engine may now start charging. This could cause a voltage spike in
the engine's electrical system.
In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself,
and the engine will operate normally. The ECM shuts off and resets itself so quickly that the engine may only seem to have an
ignition miss.
Batteries: Boats with multiengine EFI power packages require each engine be connected to its own battery. This ensures that
the engine's ECM has a stable voltage source.
Battery switches: Battery switches should always be positioned so each engine is operating off of its own battery. Do not
operate engines with switches in both or all position. In an emergency, another engine's battery can be used to start an engine
with a dead battery.
Battery isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should
not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this
purpose.
Generators: The generator's battery should be considered another engine's battery.
90-8M0119292 eng MAY 2016 Page 43

Serpentine Drive Belt

Serpentine Drive Belt Routing
! WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition
key before adjusting tension or inspecting belts.
a With a seawater pump

a - Alternator pulley
f b - Water circulating pump pulley
c - Crankshaft pulley
b d - Seawater pump pulley
e - Belt tensioner
f - Idler pulley
e
c
55041
Serpentine Belt Failure Identification

Appearance Description Cause Solution
Abrasion Replace the belt and

Belt is in contact with an object.
Each side of the belt appears inspect for contact with an
Can be caused by improper belt
shiny or glazed. Severe object. Verify the belt
tension or tensioner failure.
condition: Fabric is exposed. tensioner is functioning.
40791
Pilling There are a number of causes When pilling leads to belt

Belt material is sheared off from including lack of tension, noise or excess vibration,
the ribs and builds up in the belt misalignment, worn pulleys, or a the belt should be
grooves. combination of these factors. replaced.
40794
The belt life has been

severely limited and
Improper belt installation is a should be replaced
Improper install
common cause of premature immediately. Ensure all
The belt ribs begin separating
failure. One of the outermost belt ribs of the replacement
from the joined strands. If left
ribs is placed outside the pulley belt fit into the pulley
unattended, the cover will often
groove, causing a belt rib to run grooves. Run the engine.
separate, causing the belt to
without a supporting or aligning Then, with the engine off
unravel.
pulley groove. and battery disconnected,
40795 inspect the belt for proper
installation.
Page 44 90-8M0119292 eng MAY 2016

Appearance Description Cause Solution
Misalignment
Sidewalls of the belt may appear
glazed or the edge‑cord may Pulley misalignment. Misalignment
Replace the belt and verify
become frayed and the ribs are forces the belt to kink or twist while
the alignment of the pulley.
removed. A noticeable noise running, causing premature wear.
may result. In severe cases, the
belt can jump off the pulley.
40796
Chunk‑out Chunk‑out can happen when

Pieces or chunks of rubber several cracks in one area move
Replace the belt
material have broken off the belt. parallel to the cord line. Heat, age,
immediately.
When chunk‑out has occurred, a and stress are the primary
belt can fail at any moment. contributors.
40797
Uneven rib wear

Belt shows damage to the side A foreign object in the pulley can Replace the belt and
with the possibility of breaks in cause uneven wear and cut into the inspect all pulleys for
the tensile cord or jagged edged belt. foreign objects or damage.
ribs.
40799
Continuous exposure to high

temperatures, the stress of bending
around the pulley leads to cracking.
Cracking
Cracks begin on the ribs and grow Replace the belt
Small visible cracks along the
into the cord line. If three or more immediately.
length of a rib or ribs.
cracks appear in a three‑inch
section of a belt, eighty percent of
40800
the life is gone.
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.
Checking
Inspect the drive belt for:
• Proper belt tension deflection
• Excessive wear
• Cracks
• Fraying
• Glazed surfaces
• Proper tension
Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys.
Description
Deflection 13 mm (1/2 in.)
90-8M0119292 eng MAY 2016 Page 45

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.
21062
Replacing
IMPORTANT: If the belt is removed and is found to be in acceptable condition to use, you must install it in the same direction of
rotation as before.
NOTE: All power packages have a decal on the front of the engine. The decal shows the serpentine belt routing. Refer to the
decal when installing the serpentine belt.
The belt tensioner operates within the limits of movement provided by the cast stops when the belt length and geometry are
correct. If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length.
Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the
tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist.
! CAUTION
Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.
Relieve the spring tension slowly.
1. Use a breaker bar and appropriate socket to relieve the tensioner. Rotate the tensioner counterclockwise away from the
belt until it stops.
2. Remove the belt from the idler pulley and slowly relieve the tension on the breaker bar.
Standard cooling shown, closed cooling similar

a - Belt tensioner
54989
3. Inspect the belt for damage and replace as necessary.
4. Route the belt according to the diagram on the decal.
5. Carefully release the tensioner and ensure that the belt stays positioned properly.
6. Check the belt tension.
NOTE: Proper tension is a measurement of deflection with moderate thumb pressure on the belt at the location that has
the longest distance between two pulleys.
Description
Deflection 13 mm (½ in.)
Flushing the Power Package—Models with a Flushing Attachment

NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications. Flushing is recommended after
each outing for best results.
Page 46 90-8M0119292 eng MAY 2016

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. Close the seacock, if equipped.
For visual clarity, the seacock shown is not installed

c a - Hose fitting to engine
b - Seacock
c - Handle (closed position)
d - To water source pickup attachment
a b d
18510
2. If the boat is not equipped with a seacock, disconnect the water hose from the water pickup and plug both ends to prevent
water from entering the boat.
3. Remove the quick‑connect fitting from the parts bag supplied with the engine.
4. Attach the quick‑connect fitting to a water hose.
a a - Quick‑connect fitting (water hose end)

b
b - Water hose
18487
5. Snap the quick‑connect fitting with the water hose into the flush socket on the engine.
a - Water hose
b - Quick‑connect fitting (water hose end)
a
c - Flush socket
18489
6. Open the water source of the water hose to a full flow.

7. Place the remote control in neutral idle speed position and start the engine.
8. Operate the engine at idle speed in neutral gear. Do not exceed 1200 RPM.
9. Monitor the engine temperature while operating the engine.
10. Flush the engine for 5–10 minutes or until the discharge water is clear.
11. Shut off the engine.
12. Turn off the water source.
90-8M0119292 eng MAY 2016 Page 47

13. Disconnect the quick‑connect fitting and water hose from the flush socket on the engine by pressing the release button on
the flush socket.
a - Quick‑connect fitting (water hose end)

a b - Flush socket release button
18488
14. Remove the quick‑connect fitting from the water hose.
a a - Quick‑connect fitting (water hose end)

b
b - Water hose
18487
15. Retain the quick‑connect 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 quick‑connect 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.
a Quick-connect fitting stored in the boat

a - Quick‑connect fitting (water hose end)
25900
16. Insert the dust cover in the flush socket on the engine.
a Dust cover installed in the flush socket

a - Dust cover
b - Flush socket
b
18490
Page 48 90-8M0119292 eng MAY 2016

17. Remove the plugs from the water hose and connect to the fittings. Tighten the hose clamps securely.
18. Open the seacock, if equipped.
IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If the unit is to
be stored out of the water, open the seacock.
90-8M0119292 eng MAY 2016 Page 49

Notes:
Page 50 90-8M0119292 eng MAY 2016

Section 5 - Storage
Section 5 - Storage
Table of Contents
Cold Weather or Extended Storage...................................... 52 Draining the Seawater System............................................. 54
Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 52 Draining the Raw Water................................................. 54
Fuel Containing Alcohol................................................. 52 Air Actuated Single‑Point Drain System (Closed Cooling,
Preparing Power Package for Storage—MPI Models.... 52 Inboard Models)............................................................. 54
Special Fuel Mix .................................................... 53 Battery Storage..................................................................... 57
Engine and Fuel System Preparation .................... 53 Recommissioning the Power Package................................. 57
TowSport and Inboard Transmissions Extended Storage
....................................................................................... 54
90-8M0119292 eng MAY 2016 Page 51

Section 5 - Storage
Cold Weather or Extended Storage

Reformulated (Oxygenated) Gasolines (U.S.A. Only)
This type of gasoline is required throughout most of the U.S.A. There are two types of oxygenates used in fuels: alcohol
(ethanol) or ether (MTBE or ETBE). Gasoline containing ethanol is especially subject to absorbing atmospheric moisture,
forming gums or solids, or it may separate into a layer of fuel floating on top of a layer of water and alcohol. To reduce the
potential for separation, storage should be in containers that prevent oxidation or water vapors mixing. If ethanol is used in the
gasoline in your area, refer to Fuel Containing Alcohol.
Fuels for your Mercury Marine engine may contain up to 10% of ethanol or ether.
Fuel Containing Alcohol

Fuels containing either methanol (methyl alcohol) or ethanol (ethyl alcohol) may cause certain adverse effects. These adverse
effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a
separation (phase) of the water/alcohol from the gasoline in the fuel tank.
The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do
not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations
on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may
cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through rubber fuel lines
• Starting and operating difficulties
! 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, only alcohol‑free gasoline should be used. If only fuel containing
alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is
required.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for
long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol‑blend
fuels normally are consumed before they can absorb enough moisture to cause problems. Conversely, boats may not be used
for days, weeks, or months, 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.
IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury
MerCruiser dealer. Damage caused by freezing temperatures is not covered by the Mercury MerCruiser Limited Warranty.
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 freezing temperatures. 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 manufacturer's instructions, be used
in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure 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.
Preparing Power Package for Storage—MPI Models

Multipoint fuel injection (MPI) systems must have a special mix of fuel, stabilizer, and lubricant, completely fill the fuel delivery
system. This fuel mix stabilizes the fuel and lubricates the fuel pumps, fuel pressure regulator, fuel injectors and, reduces
internal oxidation of the fuel system metal components.
IMPORTANT: This special fuel mix can be used on Mercury Marine catalyzed gasoline engines.
Page 52 90-8M0119292 eng MAY 2016

Section 5 - Storage
Special Fuel Mix

! WARNING
! WARNING
1. Fill a 23 liter (6 US gal) remote fuel tank with 19 L (5 US gal) regular unleaded 87 octane (90 RON) gasoline.
2. Pour into the remote fuel tank 1.89 L (2 US qt) of Premium Plus 2‑Cycle TC‑W3 Outboard Oil and 29.5 ml (1 oz) of
Mercury Quickstor Fuel Stabilizer.

Premium Plus 2-Cycle TC-W3
115 Fuel system 92-858026K01
Outboard Oil
124 Quickstor Fuel Stabilizer Fuel system 92-8M0047932
3. Install the remote fuel tank cap and ensure the added ingredients are thoroughly mixed with the fuel.
Engine and Fuel System Preparation
! WARNING
! WARNING
NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.
1. Check the antifreeze concentration where applicable. Refer to the Specifications section.
2. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks
and proceed with the following:
a. Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add
a sufficient amount of Mercury Quickstor Fuel Stabilizer to treat the gasoline. Follow the instructions on the container.
b. Vessels using fuel containing alcohol—drain the fuel tanks as low as possible and add a sufficient amount of Mercury
Quickstor Fuel Stabilizer to treat the remaining gasoline. Follow the instructions on the container.
3. Flush the cooling system. Refer to the Maintenance section.
4. Supply cooling water to the engine. Refer to the Maintenance section.
5. Close the fuel shut off valve, if equipped, or disconnect and plug the boat fuel tank hose.
6. Connect the remote fuel tank with the special fuel mix to the fuel inlet fitting.
7. Start the engine and run the engine at 1300 RPM for five minutes. This is usually enough time for the special fuel mix to
circulate through the fuel system. Check to ensure there are no oil leaks. Shut the engine off.
IMPORTANT: Do not allow the engine to run out of fuel.
8. Disconnect the special fuel mix hose from the inlet fitting. Connect the boat fuel tank hose to the inlet fitting. Open the fuel
shut off valve, if equipped.
9. Change the oil and oil filter.
10. Replace the water separating fuel filter element where applicable.
11. Drain the engine seawater cooling system. Refer to Draining the Seawater System.
90-8M0119292 eng MAY 2016 Page 53

Section 5 - 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 freezing temperatures. 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.
12. Fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect the engine
to the lowest temperature to which it will be exposed during freezing temperatures or extended storage. This will also
prevent the formation of exfoliating rust in the cooling system passages.
13. Store the battery according to the manufacturer's instructions.
TowSport and Inboard Transmissions Extended Storage

TowSport and Inboard power package transmissions require the fluid and applicable filter be replaced after 300 hours of
operation or once a year, whichever comes first. It is recommended before the power package will be stored for an extended
time, that the transmission fluid and applicable filter be replaced.
Draining the Seawater System

Draining the Raw Water
! 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 raw water section of the closed cooling system. Raw water is sometimes referred to as seawater.
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system.
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 raw water section of the cooling system during freezing temperatures or for extended storage. Ensure 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.
Air Actuated Single‑Point Drain System (Closed Cooling, Inboard Models)

The following instructions apply to draining procedures performed on engines in vessels that are in the water. For vessels that
are not in the water, you do not need to close the seacock (if equipped) or remove and plug the water inlet hose.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Remove the blue plug from the heat exchanger.
3. Remove the cap from the air actuated valve assembly.
a - Blue plug
b b - Cap
55099
4. Ensure that the lever on top of the air pump is flush with the handle (horizontal).
5. Install the air pump on the actuator fitting.
Page 54 90-8M0119292 eng MAY 2016

Section 5 - Storage
6. Pull the lever on the air pump (vertical) to lock the pump onto the fitting.
c e a- Actuator fitting
b- Green indicators
c- Manual release valve
d- Air pump
e- Lever (locking)
a
d
8293
b
7. Pump air into the system until both green indicators extend out of the actuator assembly.
8. Check to ensure water drains out of the distribution housing.
IMPORTANT: If water does not drain from the distribution housing when both green indicators are extended, remove the
blue plug on the distribution housing.
a - Distribution housing water drain

b - Blue plug
b
a
55101
9. Check to ensure water drains out of the seawater pump housing.
IMPORTANT: If water does not drain from the seawater pump housing when both green indicators are extended, remove
the blue plugs on the seawater pump housing.
a - Seawater pump housing water drain

b - Blue plugs
56033
90-8M0119292 eng MAY 2016 Page 55

Section 5 - Storage
10. There are power packages that require specific drain plugs removed because the engine angle is greater than the air
actuated drain system allows for proper draining of the system. Remove the blue plugs shown in the following illustrations.
58423
Port side view
58765
Starboard side view
11. Allow the system to drain for a minimum of ten minutes. Pump air as necessary to keep the green indicators extended.
12. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow the
engine to start.
IMPORTANT: This engine has an automatic start function controlled by the PCM. The start function can be terminated by
turning the key to the OFF position.
13. After the water has drained from the engine, install the blue plugs on the distribution housing and seawater pump if they
were removed and tighten securely.
14. Push the locking lever down on the air pump and remove the pump from the air actuator assembly. Install the cap on the
fitting.
15. Install the blue plug on the heat exchanger and tighten securely.
16. The drain system should remain open while transporting the boat or while performing other maintenance. This helps
ensure that all water is drained.
Page 56 90-8M0119292 eng MAY 2016

Section 5 - Storage
17. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
a - Green indicators
a
6135
18. Open the seacock, if equipped, or unplug and connect the water inlet hose prior to 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.
Recommissioning the Power Package

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.
! 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 the 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 Operation Chart.
NOTICE
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.
90-8M0119292 eng MAY 2016 Page 57

Section 5 - Storage
Notes:
Page 58 90-8M0119292 eng MAY 2016

Table of Contents
Diagnosing EFI Problems..................................................... 60 Poor Performance.......................................................... 61
Diagnosing DTS Problems................................................... 60 Excessive Engine Temperature..................................... 61
Engine Guardian System...................................................... 60 Insufficient Engine Temperature.................................... 61
Troubleshooting Charts........................................................ 60 Low Engine Oil Pressure............................................... 61
Starter Motor Will Not Crank Engine, or Cranks Slowly Battery Will Not Recharge............................................. 62
....................................................................................... 60 Remote Control Is Difficult to Move or Makes Unusual
Engine Will Not Start or Is Hard to Start........................ 60 Sounds........................................................................... 62
Engine Runs Rough, Misses, or Backfires.................... 61 Steering Wheel Jerks or Is Difficult to Turn................... 62
90-8M0119292 eng MAY 2016 Page 59

Diagnosing EFI Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on electronic fuel injection
(EFI) systems. The engine control module (ECM) on these engines has the ability to detect some problems with the system
when they occur, and store a Trouble Code in the ECMs memory. This code can then be read later by a service technician
using a special diagnostic tool.
Diagnosing DTS Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift
(DTS) systems. The engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect
some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory. This code can then be
read later by a service technician using a special diagnostic tool.
Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. The system will
respond to a problem by emitting a continuous beep and/or reducing engine power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The horn will turn off when throttle speed is within the allowable
limit. Consult an authorized Mercury MerCruiser dealer for assistance.
Troubleshooting Charts
Starter Motor Will Not Crank Engine, or Cranks Slowly
Possible Cause Remedy
Battery switch turned off. Turn the switch on.
Remote control not in neutral position. Position the control lever in neutral.
Check and reset the main power circuit breaker or replace the fuse. Check the
Open circuit breaker or fuse. 5‑amp fuse on the power harness connected to the battery, and replace if
necessary.
Loose or dirty electrical connections or Check all electrical connections and wires (especially battery cables). Clean
damaged wiring. and tighten all faulty connections.
Bad battery or low battery voltage. Test the battery and charge if necessary; replace if bad.
Lanyard stop switch activated. Check the lanyard stop switch.
Engine Will Not Start or Is Hard to Start

Lanyard stop switch activated. Check the lanyard stop switch.
Improper starting procedure. Read the starting procedure.
Insufficient fuel supply. Fill fuel tank or open valve.
Faulty ignition system component. Service the ignition system.
Clogged fuel filter. Replace fuel filter.
Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to remove
Fuel line or tank vent line kinked or clogged.
obstruction.
Faulty wire connections. Check wire connections.
EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer.
Page 60 90-8M0119292 eng MAY 2016

Engine Runs Rough, Misses, or Backfires

Clogged fuel filter. Replace filter.
Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to remove
Kinked or clogged fuel line or fuel tank vent line.
obstruction.
Flame arrestor dirty. Clean the flame arrestor.
Faulty ignition system component. Service ignition system.
Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer.
Poor Performance
Throttle not fully open. Inspect the throttle cable and linkages for proper operation.
Damaged or improper propeller. Replace the propeller.
Excessive bilge water. Drain and check for cause of entry.
Boat overloaded or load improperly distributed. Reduce load or redistribute load more evenly.
Flame arrestor dirty. Clean the flame arrestor.
Boat bottom fouled or damaged. Clean or repair as necessary.
Ignition problem. See Engine Runs Rough, Misses, or Backfires.
Engine overheating. See Excessive Engine Temperature.
Excessive Engine Temperature

Water inlet or seacock closed. Open.
Drive belt loose or in poor condition. Replace or adjust belt.
Seawater pickups or sea strainer obstructed. Remove obstruction.
Faulty thermostat. Replace.
Check for cause of low coolant level and repair. Fill system with
Coolant level (if equipped) low in closed cooling section.
proper coolant solution.
Clean heat exchanger, engine oil cooler, and transmission oil
Heat exchanger or fluid cooler plugged with foreign material.
cooler (if equipped).
Loss of pressure in closed cooling section. Check for leaks. Clean, inspect, and test pressure cap.
Faulty seawater pickup pump. Repair.
Seawater discharge restricted or plugged. Clean exhaust elbows.
Insufficient Engine Temperature

Faulty thermostat. Replace.
Low Engine Oil Pressure

Insufficient oil in crankcase. Check and add oil.
Excessive oil in crankcase (causing it to Check and remove required amount of oil. Check for cause of excessive oil
become aerated). (improper filling).
Change oil and oil filter, using correct grade and viscosity oil. Determine
Diluted or improper viscosity oil.
cause for dilution (excessive idling).
90-8M0119292 eng MAY 2016 Page 61

Battery Will Not Recharge

Excessive current draw from battery. Turn off nonessential accessories.
Alternator drive belt loose or in poor condition. Replace and/or adjust.
Unacceptable battery condition. Test battery, replace if necessary.
Check all associated electrical connections and wires (especially
Loose or dirty electrical connections or damaged
battery cables). Clean and tighten faulty connections. Repair or
wiring.
replace damaged wiring.
Faulty alternator. Test alternator output, replace if necessary.
Remote Control Is Difficult to Move or Makes Unusual Sounds

Incorrect friction adjustment. Change friction adjustment.
Incorrect detent adjustment. Change detent adjustment.
Friction pad in the remote control worn. Replace the remote control.
Steering Wheel Jerks or Is Difficult to Turn

Insufficient lubrication on steering components. Lubricate.
Check all parts and fasteners if any are loose or missing, see authorized
Loose or missing steering fasteners or parts.
Mercury MerCruiser dealer immediately.
Page 62 90-8M0119292 eng MAY 2016


Table of Contents
Owner Service Assistance.................................................... 64 Contact Information for Mercury Marine Customer
Local Repair Service .................................................... 64 Service ......................................................................... 65
Service Away From Home ............................................ 64 Customer Service Literature................................................. 65
Stolen Power Package ................................................. 64 English Language ......................................................... 65
Attention Required After Submersion ........................... 64 Other Languages .......................................................... 66
Replacement Service Parts .......................................... 64 Ordering Literature............................................................... 66
Parts and Accessories Inquiries ................................... 64 United States and Canada ........................................... 66
Resolving a Problem .................................................... 64 Outside the United States and Canada ........................ 66
90-8M0119292 eng MAY 2016 Page 63

Owner Service Assistance

Local Repair Service
If you need service for your Mercury MerCruiser‑powered boat, take it to your authorized dealer. Only authorized dealers
specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your engine.
NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser
sterndrives and inboards.
Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. If, for any reason,
you cannot obtain service, contact the nearest regional service center. Outside the United States and Canada, contact the
nearest Marine Power International service center.
Stolen Power Package

If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers
and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities
and dealers in recovery of stolen power packages.
Attention Required After Submersion

1. Before recovery, contact an authorized Mercury MerCruiser dealer.
2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of
serious engine damage.
Replacement Service Parts

! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both
fresh and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine
engine parts because specifications are different from those of the standard automotive engine. For example, one of the most
important special replacement parts is the cylinder head gasket. Marine engines cannot use steel‑type automotive head
gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.
Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve
springs, valve lifters, pistons, bearings, camshafts, and other heavy‑duty moving parts.
Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.
Parts and Accessories Inquiries

Direct any questions concerning genuine Mercury Precision Parts or Quicksilver Marine Parts and Accessories to a local
authorized dealer. Dealers have the proper systems to order parts and accessories, if they are not in stock. Engine model and
serial number are required to order correct parts.
Resolving a Problem
Satisfaction with your Mercury MerCruiser product is 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 a 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 Customer Service:
• Your name and address
• Daytime telephone number
• Model and serial numbers for your power package
• The name and address of your dealership
Page 64 90-8M0119292 eng MAY 2016

• Nature of the problem
Contact Information for Mercury Marine Customer Service

For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.
United States, Canada

English +1 920 929 5040 Mercury Marine
Telephone
Français +1 905 636 4751 W6250 Pioneer Road
English +1 920 929 5893 P.O. Box 1939
Fax Fond du Lac, WI 54936-1939
Français +1 905 636 1704
Website www.mercurymarine.com
Australia, Pacific
Telephone +61 3 9791 5822 Brunswick Asia Pacific Group
41–71 Bessemer Drive
Fax +61 3 9706 7228 Dandenong South, Victoria 3175
Australia
Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe
Parc Industriel de Petit-Rechain
Fax +32 87 31 19 65 B-4800 Verviers,
Belgium
Mexico, Central America, South America, Caribbean

Telephone +1 954 744 3500 Mercury Marine
11650 Interchange Circle North
Fax +1 954 744 3535 Miramar, FL 33025
U.S.A.
Japan
Telephone +072 233 8888 Kisaka Co., Ltd.
4-130 Kannabecho Sakai-shi Sakai-ku
Fax +072 233 8833 5900984 Osaka,
Japan
Asia, Singapore
Telephone +65 65466160 Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
Fax +65 65467789 29 Loyang Drive
Singapore, 508944
Customer Service Literature

English Language
English language publications are available from:
Mercury Marine
Attn: Publications Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for
further information.
When ordering be sure to:
• List your product, model, year, and serial numbers.
• Check the literature and quantities you want.
• Enclose full remittance in check or money order (NO COD).
90-8M0119292 eng MAY 2016 Page 65

Other Languages
To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine
Power International Service Center for information. A list of part numbers for other languages is provided with your power
package.
Ordering Literature
Before ordering literature, have the following information about your power package available:
Model Serial Number

Horsepower Year
United States and Canada

For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:
Mercury Marine
Telephone Fax Mail
Mercury Marine
(920) 929‑5110 (920) 929‑4894 Attn: Publications Department
(USA only) (USA only) P.O. Box 1939
Outside the United States and Canada

Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular
power package.
Mercury Marine
Submit the following Attn: Publications Department
order form with payment W6250 Pioneer Road
to: P.O. Box 1939
Ship To: (Copy this form and print or type–This is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country
Quantity Item Stock Number Price Total

. .
. .
. .
. .
. .
Total Due .
Page 66 90-8M0119292 eng MAY 2016

Table of Contents
Predelivery Inspection (PDI)................................................. 68 Customer Delivery Inspection (CDI)..................................... 69
90-8M0119292 eng MAY 2016 Page 67

Predelivery Inspection (PDI)

IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use
the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual.
Perform these tasks before the Customer Delivery Inspection (CDI).
Check/
N/A Item
Adjust
⃞ ⃞ Service bulletin updates or repairs completed
⃞ Drain plug installed and drain valves closed
⃞ ⃞ Seawater inlet valve open
⃞ Engine mounts tight
⃞ ⃞ Engine alignment
⃞ ⃞ Drive unit fasteners tightened to specifications
⃞ ⃞ Power trim cylinders fasteners tight
⃞ Battery of proper rating, fully charged, secured, with protective covers in place
⃞ All electrical connections tight
⃞ Exhaust system hose clamps tight
⃞ All fuel connections tight
⃞ Correct propeller selected, installed, and tightened to specifications
⃞ Throttle, shift, and steering system fasteners tightened to specifications
⃞ ⃞ Test OBDM warning system and MIL (light) operation (EC models only)
⃞ Steering operation throughout range
⃞ Throttle plates open and close completely
⃞ Crankcase oil level
⃞ ⃞ Power trim oil level
⃞ ⃞ Sterndrive unit oil level
⃞ ⃞ Power steering fluid level
⃞ ⃞ Closed cooling fluid level
⃞ ⃞ Transmission fluid level
⃞ ⃞ V‑engines: serpentine belt tension
⃞ ⃞ Alternator belt tension (3.0L)
⃞ ⃞ Power steering pump belt tension (3.0L)
⃞ ⃞ SmartCraft gauges calibrated, if equipped
⃞ ⃞ Warning system operation
⃞ ⃞ Trim limit switch operation
Page 68 90-8M0119292 eng MAY 2016

Predelivery Inspection Checklist, Continued
Check/
N/A Item
Adjust
On‑the‑Water Test
⃞ ⃞ Engine alignment (Inboard models only)
⃞ Starter neutral safety switch operation
⃞ E‑stop switch/lanyard stop switch operation (all helms)
⃞ Seawater pump operation
⃞ Operation of instruments
⃞ Fuel, oil, and water leaks
⃞ Exhaust leaks
⃞ Ignition timing
⃞ Forward, neutral, and reverse gear operation
⃞ Steering operation throughout range
⃞ Acceleration from idle RPM is normal
⃞ WOT________ RPM within specification (in forward gear)
⃞ ⃞ EC models: run two full operating cycles (key on/off) to WOT with engine at normal operating temperature
while monitoring engine with G3 CDS to verify engine goes into closed‑loop engine control.
⃞ ⃞ Power trim operation
⃞ ⃞ Boat handling
After On‑the‑Water Test
⃞ Propeller nut tightened to specification
⃞ Fuel, oil, coolant, water, and fluid leaks
⃞ Oil and fluid levels
⃞ Apply Quicksilver Corrosion Guard to engine package
⃞ Operation, Maintenance & Warranty manual in boat
If Boat Is Registered to a Resident of California
⃞ ⃞ CARB hang tag in boat
⃞ ⃞ CARB decal properly affixed to boat hull
Customer Delivery Inspection (CDI)

IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use
the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual.
Perform these tasks after the Predelivery Inspection (PDI).
This inspection must take place in the presence of the customer.
N/A Completed Item

⃞ Operation and Maintenance manual—provide and review with customer. Emphasize the importance of safety
warnings and Mercury engine testing procedures.
⃞ Approve the external appearance of the product (paint, cowl, decals, etc.)
⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services.
⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only)
Operation of equipment—explain and demonstrate:
⃞ E‑stop switch/lanyard stop switch operation (all helms)
⃞ Cause and effect of steering torque or pull; instruct on using a firm steering grip; explain boat spin‑out and
how to trim for neutral steering
⃞ ⃞ U.S. Coast Guard capacity plate
⃞ Proper seating
⃞ Importance of personal flotation devices (PFDs or life vests) and throwable PFDs (throw cushions)
⃞ ⃞ Functions of SmartCraft accessories (if applicable)
⃞ Off‑season storage and maintenance schedule
⃞ Engine (starting, stopping, shifting, using throttle)
⃞ Boat (lights, battery switch location, fuses/breakers)
⃞ ⃞ Trailer (if applicable)
90-8M0119292 eng MAY 2016 Page 69

N/A Completed Item
Registration:
⃞ Complete and submit warranty registration—provide the customer with a copy
Page 70 90-8M0119292 eng MAY 2016


Table of Contents
Scheduled Maintenance Log................................................ 72 Vessel Maintenance Notes................................................... 73
90-8M0119292 eng MAY 2016 Page 71

Scheduled Maintenance Log

100 Hours
Actual Hours
Service Notes
Dealer Name Signature Date
200 Hours
Actual Hours
Service Notes
300 Hours
Actual Hours
Service Notes
400 Hours
Actual Hours
Service Notes
500 Hours
Actual Hours
Service Notes
600 Hours
Actual Hours
Service Notes
Page 72 90-8M0119292 eng MAY 2016

Vessel Maintenance Notes

Record all general maintenance performed on your power package here. Save all work orders and receipts.
Engine
Date Maintenance Completed Servicing Dealer
Hours
90-8M0119292 eng MAY 2016 Page 73

6.2 Inboard
MPI DTS
O P ERAT I O N &
MAI NT ENANCE
MANUAL
www.mercurymarine.com.au www.mercurymarine.com www.brunswick-marine.com

41-71 Bessemer Drive P.O. Box 1939 Parc Industriel de Petit-Rechain
Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA B-4800 Verviers, Belgium
© Mercury Marine. All rights reserved. 90-8M0119292 MAY 2015

Printed in U.S.A.

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www.mercurymarine.com.au www.mercurymarine.com www.brunswick-marine.com

© Mercury Marine. All rights reserved. 90-8M0119292 MAY 2015

Read This Manual Thoroughly

6.2 Inboard MPI DTS

IMPORTANT: Identifies information essential to the successful completion of the task.

Copyright and Trademark Information

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

Section 1 - Getting to Know Your Power Package

Section 2 - On the Water

90-8M0119292 eng MAY 2016 Page i

Section 7 - Customer Assistance Information

Page ii 90-8M0119292 eng MAY 2016

Section 9 - Maintenance Log

90-8M0119292 eng MAY 2016 Page iii

Section 1 - Getting to Know Your Power Package 1

90-8M0119292 eng MAY 2016 Page 1

Adaptive Speed Control (ASC)

Engine Serial Number

Engine block location

Page 2 90-8M0119292 eng MAY 2016

Model 63A Model 63IV

Lanyard Stop Switch

90-8M0119292 eng MAY 2016 Page 3

SmartCraft Digital Instruments

Page 4 90-8M0119292 eng MAY 2016

SmartCraft tachometer and speedometer

System Link Digital Instruments

System Link digital gauges

Item Gauge Indicates

Remote Controls (DTS Models)

90-8M0119292 eng MAY 2016 Page 5

DTS Slim Binnacle Single Handle Console Features and Operation

Page 6 90-8M0119292 eng MAY 2016

Special Digital Throttle and Shift (DTS) Features

Slim binnacle ERC

Item Control Function

Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment

90-8M0119292 eng MAY 2016 Page 7

a - Detent tension adjustment screw

Special Digital Throttle and Shift (DTS) Features

Dual engine ERC

Page 8 90-8M0119292 eng MAY 2016

Item Control Function

NOTE: Not all functions may be active.

THROTTLE ONLY button

To engage throttle only mode:

90-8M0119292 eng MAY 2016 Page 9

To engage 1 Lever mode:

Page 10 90-8M0119292 eng MAY 2016

2. Press the SYNC button. The button light turns off.

Electrical System Overload Protection

90-8M0119292 eng MAY 2016 Page 11

b d b Mechanical engine, freshwater

Page 12 90-8M0119292 eng MAY 2016