Mercury 3.0L Carbureted Alpha User Manual

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Page 1

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3.0L Carbureted Alpha Models



Page 2

Identification Record

PLEASE RECORD THE FOLLOWING INFORMATION:

1. Engine Model and Horsepower

Engine Serial Number

2. Transom Assembly Serial Number

(Sterndrive)

Gear Ratio Sterndrive Unit Serial

Number

3. Transmission Model (Inboard)

Gear Ratio Transmission Serial

Number

4. Propeller Number

Pitch Diameter

5. Hull Identification Number (HIN)

Purchase Date

6. Boat Manufacturer

Boat Model Length

7. Exhaust Gas Emissions Certificate Number

The serial numbers are the manufacturer’s keys to numerous engineering details, which apply to your Mercury MerCruiser

 power package. When contacting your authorized

Mercury MerCruiser dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was

approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.

Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.

 2004, Mercury Marine

The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide, Thruster and Mercury Precision Parts.

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79684

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Page 3

0002.1

Welcome!

You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability.

With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water.

Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!

Mercury MerCruiser

0003

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 statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages and other related information. Please review this important information.

0217

Mercury Marine products are designed and manufactured to comply with our own high quality standards and applicable industry standards and regulations, as well as certain emissions regulations. At Mercury Marine every engine is operated and tested before it is boxed for shipment to ensure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations. All Mercury Marine product, sold as new, receives the applicable limited warranty coverage, whether the engine participated in one of the test programs described above or not.

Warranty

Sections of this manual. The warranty

Page 4

0004

Read This Manual Thoroughly

IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES.

NOTICE

Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol

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 - Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION - Hazards or unsafe practices which could result in minor personal injury or product or property damage.

WARNING

CAUTION

, may be used to alert the installer/user

0197.0

IMPORTANT: - Indicates information or instructions that are necessary for proper operation and/or maintenance.

WARNING

The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

WARNING

California Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Page 5

WARRANTY

Warranty Information 2. . . . . . . . . . . . . . . . . . . .

Owner Warranty Registration 2. . . . . . . . . . . .

United States And Canada Only 2. . . . . .

International Owner Registration 3. . . . . . . . .

Outside The United States

And Canada 3. . . . . . . . . . . . . . . . . . . . . . .

Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .

Mercury MerCruiser One Year Limited Warranty

(Gasoline Fueled Products Only) 4. . . . . . . .

What Is Covered 4. . . . . . . . . . . . . . . . . . . .

Duration Of Coverage 4. . . . . . . . . . . . . . .

Conditions That Must Be Met In Order

To Obtain Warranty Coverage 4. . . . . . . .

What Mercury Will Do 4. . . . . . . . . . . . . . .

How To Obtain Warranty Coverage 5. . . .

What Is Not Covered 5. . . . . . . . . . . . . . . .

Disclaimers And Limitations 5. . . . . . . . . .

California Emissions Limited Warranty 6. . . .

What Is Covered 6. . . . . . . . . . . . . . . . . . . .

Duration Of Coverage 6. . . . . . . . . . . . . . .

How To Obtain Warranty Coverage 6. . . .

What Mercury Will Do 7. . . . . . . . . . . . . . .

What Is Not Covered 7. . . . . . . . . . . . . . . .

Components Of The Emissions

Control System 8. . . . . . . . . . . . . . . . . . . . .

Disclaimers And Limitations 8. . . . . . . . . .

California Emission Control

Warranty Statement 9. . . . . . . . . . . . . . . . . . .

Your Warranty Rights

And Obligations 9. . . . . . . . . . . . . . . . . . . .

Manufacturer’s Warranty Coverage 9. . . .

Owner’s Warranty Responsibilities 9. . . .

3 Year Limited Warranty

Against Corrosion (Worldwide) 10. . . . . . . . .

What Is Covered 10. . . . . . . . . . . . . . . . . . .

Duration Of Coverage 10. . . . . . . . . . . . . .

Conditions That Must Be Met In Order

To Obtain Warranty Coverage 10. . . . . . .

What Mercury Will Do 10. . . . . . . . . . . . . .

How To Obtain Warranty Coverage 11. . . .

What Is Not Covered 11. . . . . . . . . . . . . . . .

Transferable Warranty 12. . . . . . . . . . . . . . . . . .

Direct Sale By Owner 12. . . . . . . . . . . . . . . . .

Mercury Product Protection Plan 12. . . . . . . .

United States And Canada Only 12. . . . . . . .

California Emission Certification Label 13. .

Star Label 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

One Star - Low Emission 13. . . . . . . . . . . .

Two Stars - Very Low Emission 13. . . . . .

Three Stars - Ultra Low Emission 13. . . .

Four Stars - Super Ultra

Low Emission 13. . . . . . . . . . . . . . . . . . . . .

GETTING TO KNOW YOUR POWER PACKAGE

Features And Controls 16. . . . . . . . . . . . . . . . .

Lanyard Stop Switch 16. . . . . . . . . . . . . . . . . .

Instrumentation 18. . . . . . . . . . . . . . . . . . . . . . .

Remote Controls 19. . . . . . . . . . . . . . . . . . . . .

Panel Mounted 19. . . . . . . . . . . . . . . . . . . .

Console Mounted 20. . . . . . . . . . . . . . . . . .

Power Trim 21. . . . . . . . . . . . . . . . . . . . . . . . . .

Single Engine Trim/Trailer 22. . . . . . . . . . .

Dual Engine Trim/Trailer 22. . . . . . . . . . . .

Electrical System Overload Protection 23. . .

Audio Warning System 25. . . . . . . . . . . . . . . .

Emissions Information 26. . . . . . . . . . . . . . . . .

Emission Control Information Label 26. . . . .

Owner Responsibility 26. . . . . . . . . . . . . . . . . .

Star Label 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

90-860168040 JANUARY 2004 Page i

Page 6

ON THE WATER

Safe Boating Suggestions 30. . . . . . . . . . . . . .

Be Alert To

Carbon Monoxide Poisoning 32. . . . . . . . . . .

Good Ventilation 33. . . . . . . . . . . . . . . . . . .

Poor Ventilation 33. . . . . . . . . . . . . . . . . . . .

Basic Boat Operation 34. . . . . . . . . . . . . . . . . . .

Launching And Boat Operation Care 34. . . .

Operation Chart 35. . . . . . . . . . . . . . . . . . . .

Starting And Stopping The Engine 36. . . . . .

Starting Engine After Stopped

While In Gear 37. . . . . . . . . . . . . . . . . . . . . . . .

Trailering The Boat 37. . . . . . . . . . . . . . . . . . .

Freezing Temperature Operation 37. . . . . . .

Drain Plug and Bilge Pump 37. . . . . . . . . . . .

Protecting People In The Water 38. . . . . . . . .

While You Are Cruising 38. . . . . . . . . . . . . . . .

While Boat Is Stationary 38. . . . . . . . . . . . . . .

Passenger Safety Message -

Pontoon And Deck Boats 39. . . . . . . . . . . . . .

Wave And Wake Jumping 40. . . . . . . . . . . . . . .

Impact With Underwater Hazards 41. . . . . . . .

Drive Unit Impact Protection 42. . . . . . . . . . .

Conditions Affecting Operation 42. . . . . . . . .

Weight Distribution (Passengers And Gear)

Inside The Boat 42. . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 42. . . . . . . . . . . . . . . . . . . . . . .

Cavitation 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

Elevation And Climate 43. . . . . . . . . . . . . . . . .

Propeller Selection 44. . . . . . . . . . . . . . . . . . . .

Getting Started 45. . . . . . . . . . . . . . . . . . . . . . . . .

20-Hour Break-In Period 45. . . . . . . . . . . . . . .

After Break-In Period 45. . . . . . . . . . . . . . . . . .

End of First Season Checkup 45. . . . . . . . . .

Page ii 90-860168040 JANUARY 2004

Page 7

SPECIFICATIONS

Specifications 47. . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 48. . . . . . . . . . . . . . .

Fuel Ratings 48. . . . . . . . . . . . . . . . . . . . . . .

Using Reformulated (Oxygenated) Gasolines (USA Only) 48.

Gasolines Containing Alcohol 49. . . . . . . .

MAINTENANCE

Owner/Operator Responsibilities 54. . . . . . . .

Dealer Responsibilities 54. . . . . . . . . . . . . . . . .

Maintenance 55. . . . . . . . . . . . . . . . . . . . . . . . . . .

Do-It-Yourself

Maintenance Suggestions 56. . . . . . . . . . . . .

Inspection 57. . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Maintenance Chart 57. . . . . . . . . .

Routine Maintenance 57. . . . . . . . . . . . . . . . .

Scheduled Maintenance 58. . . . . . . . . . . . . . .

Maintenance Record 60. . . . . . . . . . . . . . . . . .

Engine Oil 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking 61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Oil and Filter 63. . . . . . . . . . . . . . . .

Quick Drain Oil 63. . . . . . . . . . . . . . . . . . . .

Engine Oil Pump 63. . . . . . . . . . . . . . . . . . .

All Models 64. . . . . . . . . . . . . . . . . . . . . . . . .

Power Steering Pump Fluid, If Equipped 65.

Checking 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Oil 66. . . . . . . . . . . . . . . . . . . . . . . . . .

Checking 66. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim Pump Fluid 69. . . . . . . . . . . . . . . . .

Checking 69. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing 69. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump Sight Tube Inspection 70. . . . . . .

3.0L Models 70. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 50. . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications 51. . . . . . . . . . . . . . . . .

Fluid Specifications 52. . . . . . . . . . . . . . . . . . .

3.0 Liter (181 cid) 52. . . . . . . . . . . . . . . . . .

Sterndrive Fluid Specifications 52. . . . . . . . .

Flame Arrestor

and Related Components 71. . . . . . . . . . . . . .

Cleaning 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positive Crankcase

Ventilation Valve (PCV) 72. . . . . . . . . . . . . . . .

Changing 72. . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 73. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Steering System 73. . . . . . . . . . . . . . .

Manual Steering System 74. . . . . . . . . . . . . . .

Throttle Cable 75. . . . . . . . . . . . . . . . . . . . . . . .

Shift Cable - Typical 75. . . . . . . . . . . . . . . . . . .

Engine Coupler 76. . . . . . . . . . . . . . . . . . . . . . .

Propellers 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alpha 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 77. . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 77. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 78. . . . . . . . . . . . . . . . . . . . . . . .

Drive Belts 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking 79. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing - Front Mount Models 80. . . . . . . .

Power Steering Pump

Drive Belt, If Equipped 80. . . . . . . . . . . . .

Alternator Belt 80. . . . . . . . . . . . . . . . . . . . .

Replacing - Side Mount Models 81. . . . . . . . .

Power Steering Pump

Drive Belt, If Equipped 81. . . . . . . . . . . . .

Alternator Belt 81. . . . . . . . . . . . . . . . . . . . .

Corrosion Protection 82. . . . . . . . . . . . . . . . . . .

Painting Your Power Package 85. . . . . . . . . .

Emissions (Europe Only) 86. . . . . . . . . . . . . . .

Sealed Carburetor Mixture Screws 86. . . . . .

Emissions Testing 86. . . . . . . . . . . . . . . . . . . .

Installing Test Probes 87. . . . . . . . . . . . . . . . .

90-860168040 JANUARY 2004 Page iii

Page 8

STORAGE

Cold Weather Or Extended Storage 90. . . . . .

Preparing Your Power Package

For Storage 90. . . . . . . . . . . . . . . . . . . . . . . . .

Battery 92. . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Instructions 93. . . . . . . . . . . . . . . . . . .

3.0L Single Point Drain 94. . . . . . . . . . . . . . . .

Draining Seawater Section of

Closed Cooled (Coolant) Models 96. . . . . . .

Sterndrive 99. . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

Troubleshooting Charts 108. . . . . . . . . . . . . . .

Starter Motor Will Not Crank Engine,

Or Cranks Slow 108. . . . . . . . . . . . . . . . . . . . .

Engine Will Not Start,

Or Is Hard To Start 108. . . . . . . . . . . . . . . . . .

Engine Runs Rough, Misses

And/Or Backfires 109. . . . . . . . . . . . . . . . . . . .

Poor Performance 109. . . . . . . . . . . . . . . . . . .

Excessive Engine Temperature 110. . . . . . . .

Insufficient Engine Temperature 110. . . . . . .

Low Engine Oil Pressure 110. . . . . . . . . . . . .

CUSTOMER ASSISTANCE INFORMATION

Clearing Clogged Blue Drain Hoses 100. . . .

Flushing The Power Package 102. . . . . . . . . .

Sterndrive Water Pickup 102. . . . . . . . . . . . . .

Flushing Attachments 102. . . . . . . . . . . . . .

Power Package Recommissioning 105. . . . .

Battery Will Not Come Up On Charge 111. . . Remote Control Operates Hard, Binds, Has Excessive Free-play

Or Makes Unusual Sounds 111. . . . . . . . . . . .

Steering Wheel Turns Hard Or Jerky 112. . . Power Trim Does Not Operate

(Motor Doesn’t Operate) 112. . . . . . . . . . . . .

Power Trim Does Not Operate (Motor Operates But Sterndrive Unit

Does Not Move) 112. . . . . . . . . . . . . . . . . . . .

Owner Service Assistance 114. . . . . . . . . . . . .

Local Repair Service 114. . . . . . . . . . . . . . . . .

Service Away From Home 114. . . . . . . . . . . .

Stolen Power Package 114. . . . . . . . . . . . . . .

Attention Required After Submersion 114. . .

Replacement Service Parts 115. . . . . . . . . . .

Parts And Accessories Inquiries 115. . . .

Resolving A Problem 116. . . . . . . . . . . . . . . . .

Mercury Marine Service Offices 117. . . . . . .

Customer Service Literature 118. . . . . . . . . . .

English Language 118. . . . . . . . . . . . . . . . . . .

Other Languages 118. . . . . . . . . . . . . . . . . . . .

Andre sprog 118. . . . . . . . . . . . . . . . . . . . . . . .

Andere talen 118. . . . . . . . . . . . . . . . . . . . . . . .

Muut kielet 118. . . . . . . . . . . . . . . . . . . . . . . . . .

Autres langues 119. . . . . . . . . . . . . . . . . . . . . .

Andere Sprachen 119. . . . . . . . . . . . . . . . . . . .

Altre lingue 119. . . . . . . . . . . . . . . . . . . . . . . . .

Andre språk 119. . . . . . . . . . . . . . . . . . . . . . . . .

Outros Idiomas 119. . . . . . . . . . . . . . . . . . . . . .

Otros idiomas 119. . . . . . . . . . . . . . . . . . . . . . .

Andra språk 119. . . . . . . . . . . . . . . . . . . . . . . . .

  119. . . . . . . . . . . . . . . . . . . . . .

Ordering Literature 120. . . . . . . . . . . . . . . . . . . .

United States and Canada 120. . . . . . . . . . . .

Outside The United States

and Canada 120. . . . . . . . . . . . . . . . . . . . . . . .

Page iv 90-860168040 JANUARY 2004

Page 9

NOTES:

90-860168040 JANUARY 2004 Page v

Page 10

NOTES:

Page vi 90-860168040 JANUARY 2004

Page 11

Table of Contents

WARRANTY

Warranty Information 2. . . . . . . . . . . . . . . . . . . .

Owner Warranty Registration 2. . . . . . . . . . . .

United States And Canada Only 2. . . . . .

International Owner Registration 3. . . . . . . . .

Outside The United States

And Canada 3. . . . . . . . . . . . . . . . . . . . . . .

Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .

Mercury MerCruiser One Year Limited Warranty

(Gasoline Fueled Products Only) 4. . . . . . . .

What Is Covered 4. . . . . . . . . . . . . . . . . . . .

Duration Of Coverage 4. . . . . . . . . . . . . . .

Conditions That Must Be Met In Order

To Obtain Warranty Coverage 4. . . . . . . .

What Mercury Will Do 4. . . . . . . . . . . . . . .

How To Obtain Warranty Coverage 5. . . .

What Is Not Covered 5. . . . . . . . . . . . . . . .

Disclaimers And Limitations 5. . . . . . . . . .

California Emissions Limited Warranty 6. . . .

What Is Covered 6. . . . . . . . . . . . . . . . . . . .

Duration Of Coverage 6. . . . . . . . . . . . . . .

How To Obtain Warranty Coverage 6. . . .

What Mercury Will Do 7. . . . . . . . . . . . . . .

What Is Not Covered 7. . . . . . . . . . . . . . . .

Components Of The Emissions

Control System 8. . . . . . . . . . . . . . . . . . . . .

Disclaimers And Limitations 8. . . . . . . . . .

California Emission Control

Warranty Statement 9. . . . . . . . . . . . . . . . . . .

Your Warranty Rights

And Obligations 9. . . . . . . . . . . . . . . . . . . .

Manufacturer’s Warranty Coverage 9. . . .

Owner’s Warranty Responsibilities 9. . . .

3 Year Limited Warranty

Against Corrosion (Worldwide) 10. . . . . . . . .

What Is Covered 10. . . . . . . . . . . . . . . . . . .

Duration Of Coverage 10. . . . . . . . . . . . . .

Conditions That Must Be Met In Order

To Obtain Warranty Coverage 10. . . . . . .

What Mercury Will Do 10. . . . . . . . . . . . . .

How To Obtain Warranty Coverage 11. . . .

What Is Not Covered 11. . . . . . . . . . . . . . . .

Transferable Warranty 12. . . . . . . . . . . . . . . . . .

Direct Sale By Owner 12. . . . . . . . . . . . . . . . .

Mercury Product Protection Plan 12. . . . . . . .

United States And Canada Only 12. . . . . . . .

California Emission Certification Label 13. .

Star Label 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

One Star - Low Emission 13. . . . . . . . . . . .

Two Stars - Very Low Emission 13. . . . . .

Three Stars - Ultra Low Emission 13. . . .

Four Stars - Super Ultra

Low Emission 13. . . . . . . . . . . . . . . . . . . . .

90-860168040 JANUARY 2004 Page 1

Page 12

WARRANTY

0005

Warranty Information

Owner Warranty Registration

UNITED STATES AND CANADA ONLY

• It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product.

• It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address. The dealer also certifies that you are the original purchaser and user of the product.

• Upon receipt of the Warranty Registration Card at the factory, you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification. It must be presented to the servicing dealer should warranty service be required. Warranty claims will not be accepted without presentation of this card.

• A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed. Should your product need service during this period, present the temporary registration card to the dealer. He will attach it to your warranty claim form.

• Because of your selling dealer’s continuing personal interest in your satisfaction, the product should be returned to him for warranty service.

• If your plastic card is not received within 30 days from date of new product sale, please contact your selling dealer.

• The product warranty is not effective until the product is registered at the factory.

• NOTICE: Registration lists must be maintained by factory and dealer on marine

products sold in the United States, should notification under the Federal Boat Safety Act be required.

• You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser’s warranty registration department. Your dealer can also process this change of information.

Mercury Marine

Attn: Warranty Registration Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54935-1939

Phone: 920-929-5054

Fax: 920-929-5893

Page 2 90-860168040 JANUARY 2004

Page 13

International Owner Registration

OUTSIDE THE UNITED STATES AND CANADA

• It is important that your selling dealer fills out the Warranty Registration Card

completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.

• The Warranty Registration Card identifies your name and address, product model

and serial number(s), date of sale, type of use and the selling distributor’s/dealer ’s code number, name and address. The distributor/dealer also certifies that you are the original purchaser and user of the product.

• A copy of the Warranty Registration Card, designated as the “Purchaser’s Copy”,

MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer. This card represents your factory registration identification, and should be retained by you for future use when required. Should you ever require warranty service on this product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form(s).

• In some countries, the Marine Power Service Center will issue you a permanent

(plastic) Warranty Registration Card within 30 days after receiving the “Factory Copy” of the Warranty Registration Card from your distributor/dealer. If you receive a plastic Warranty Registration Card, you may discard the “Purchaser’s Copy” that you received from the distributor/dealer when you purchased the product. Ask your distributor/dealer if this plastic card program applies to you.

WARRANTY

• For further information concerning the Warranty Registration Card and its

relationship to Warranty Claim processing, refer to the “International Warranty.” Refer to “Table of Contents.”

IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by l a w. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your dealer/distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.

90-860168040 JANUARY 2004 Page 3

Page 14

WARRANTY

0006

Warranty Policies

Mercury MerCruiser One Year Limited Warranty (Gasoline Fueled Products Only)

WHAT IS COVERED

Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.

DURATION OF COVERAGE

This Limited Warranty provides coverage for either one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. Commercial users of these products receive warranty coverage of either one (1) year from the date of first retail sale, or the accumulation of 500 hours of operation, whichever occurs first. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re-registration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use, or subsequent change of use from recreational to commercial (unless properly re-registered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to obtain warranty coverage. Mercury Marine reserves the right to make any warranty coverage contingent upon proof of proper maintenance.

WHAT MERCURY WILL DO

Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

Page 4 90-860168040 JANUARY 2004

Page 15

HOW TO OBTAIN WARRANTY COVERAGE

The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury . We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage.

WHAT IS NOT COVERED

This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part which damages the Mercury product and was not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operation and Maintenance Manual), alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the engine out of water, mounting the engine too high on the transom, or running the boat with the engine trimmed out too far. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

WARRANTY

Expenses related to haul-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.

DISCLAIMERS AND LIMITATIONS

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.

90-860168040 JANUARY 2004 Page 5

Page 16

WARRANTY

218.0

California Emissions Limited Warranty

The California Air Resources Board has promulgated air emissions regulations for inboard and sterndrive engines. The regulations apply to all inboard and sterndrive engines that were manufactured for the 2003 model year those regulations, provides this limited warranty for the emission control systems (see the components of the emission control system listed following), and further warrants that the inboard or sterndrive engine was designed, built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. For information regarding the limited warranty for the non-emissions related components of the inboard or sterndrive engine, please see the limited warranty statement for your engine.

WHAT IS COVERED

and later. Mercury Marine, in compliance with

Mercury Marine warrants the components of the emissions control systems (see the components of the emission control system listed following) of its new, 2003 model year and later California certified inboard and sterndrive engines, registered2 to a California resident, to be free from defects in material or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved). Damage to other engine components caused by the failure of a warranted part will also be repaired under warranty.

DURATION OF COVERAGE

This limited warranty provides coverage for the components of the emissions control systems of new 2003-2008 model year either the date the product is first sold, or first put into service, whichever occurs first. Emission related normal maintenance items such as spark plugs and filters, that are on the warranted parts list (see following) are warranted up to their first required replacement interval only. (See Maintenance Schedule). The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent purchaser. (See instructions on transfer of warranty).

HOW TO OBTAIN WARRANTY COVERAGE

inboard and sterndrive engines for 2 years from

The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. W arranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair. Purchaser in that case shall pay f or all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury.

Page 6 90-860168040 JANUARY 2004

Page 17

WHAT MERCURY WILL DO

Mercury Marine’s sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified re–manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

WHAT IS NOT COVERED

This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide–open–throttle RPM range (see Specifications), operation of the product in a manner inconsistent with the recommended operation procedures, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for use with the product (see Specifications section), alteration or removal of parts, or water entering the engine through the fuel intake, air intake or exhaust system. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

Expenses related to haul–out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

WARRANTY

Non–warranty maintenance, replacement, or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual. The use of non–Mercury parts for non–warranty maintenance or repairs will not be grounds for disallowing other warranty work. The use of add–on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a non–exempted add–on or modified part will not be covered.

Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

Your dealer will register your engine for warranty coverage for you. The warranty registration process is not related in any way to the process of obtaining a license, title or registration from state boating authorities. You should ask your dealer to update your warranty registration information to reflect a change of address or a transfer of ownership. (This change may be made at any time.) See the Warranty Registration section of your manual or your dealer for more information.

90-860168040 JANUARY 2004 Page 7

Page 18

WARRANTY

COMPONENTS OF THE EMISSIONS CONTROL SYSTEM

1. Fuel Metering System a. Carburetor and internal parts (and/or pressure regulator or fuel injection system) b. Intake valve(s)

2. Air Induction System a. Intake manifold

3. Ignition System a. Spark plugs b. Electronic ignition system c. Ignition coil and/or control module d. Ignition wires

4. Positive Crankcase Ventilation (PCV) System a. PCV Valve b. Oil filler cap

5. Exhaust System a. Exhaust manifold b. Exhaust elbow c. Intermediate exhaust elbow d. Lower exhaust pipe e. Tailpipe f. Exhaust valve

6. Miscellaneous Items Used in Above Systems a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware. b. Pulleys, belts, and idlers. c. Vacuum, temperature, check and time sensitive valves and switches d. Electronic controls.

DISCLAIMERS AND LIMITATIONS

If you have any questions regarding your warranty rights and responsibilities, refer to Owner Service Assistance for contact information.

Page 8 90-860168040 JANUARY 2004

Page 19

California Emission Control Warranty Statement

YOUR WARRANTY RIGHTS AND OBLIGATIONS

WARRANTY

The California Air Resources Board is pleased to explain the emission control system warranty on your 2003 model year inboard and sterndrive engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Mercury Marine must warrant the emission control system on your inboard or sterndrive engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your inboard or sterndrive engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Mercury Marine will repair your inboard or sterndrive engine at no cost to you; including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

For 2003-2008 spark-ignition inboard and sterndrive marine engines: Select emission control parts from model year

for 2 years. If any emission-related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Marine.

OWNER’S WARRANTY RESPONSIBILITIES

As the inboard or sterndrive engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Mercury Marine recommends that you retain all receipts covering maintenance on your inboard or sterndrive engine, but Mercury Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

and later inboard or sterndrive engine. In California, new

2003-2008 inboard and sterndrive engines are warranted

As the inboard or sterndrive engine owner, you should however be aware that Mercury Marine may deny you warranty coverage if your inboard or sterndrive engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, refer to Owner Service Assistance for contact information.

90-860168040 JANUARY 2004 Page 9

Page 20

WARRANTY

0007

3 Year Limited Warranty Against Corrosion (Worldwide)

WHAT IS COVERED

Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

DURATION OF COVERAGE

This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair and replacement of parts, or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to subsequent (noncommercial use) purchaser upon proper re-registration of the product.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat, and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants, and touch-up of nicks and scratches) in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance.

WHAT MERCURY WILL DO

Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

Page 10 90-860168040 JANUARY 2004

Page 21

HOW TO OBTAIN WARRANTY COVERAGE

WHAT IS NOT COVERED

This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by the Customer); products used in a commercial application. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of warranty period, even if the product is only occasionally used for such purposes.

WARRANTY

90-860168040 JANUARY 2004 Page 11

Page 22

WARRANTY

0008

Transferable Warranty

The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.

Direct Sale By Owner

• The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to:

• A new Owner Warranty Registration Card will be issued with the new owner’s name and address. Registration records will be changed on the factory computer registration file.

Mercury Marine

Attn: Warranty Registration Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54935-1939

• There is no charge for this service.

Outside the Uni t ed States and Canada, please contact the distributor in your country, or the Marine Power International Service Center closest to you, for the transferable warranty procedure that would apply to you.

0009

Mercury Product Protection Plan

United States And Canada Only

(Certain performance products, triple engine installations, and commercial applications are excluded.)

The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty.

The optional Mercury Product Protection Plan is the only Factory Plan available for your engine.

Two, three or four - year term plans can be purchased up to 12 months after the original engine registration date.

See your participating Mercury MerCruiser dealer for complete program details.

Page 12 90-860168040 JANUARY 2004

Page 23

219.01

California Emission Certification Label

Star Label

Your boat is labeled on the hull with one of the following star labels. The Symbol for Cleaner Marine Engines Means: Cleaner Air and Water - for a healthier lifestyle and environment. Better Fuel Economy - burns up to 30-40 percent less gas and oil than conventional

carbureted two–stroke engines, saving money and resources. Longer Emission Warranty - Protects consumer for worry free operation.

ONE STAR - LOW EMISSION

The one-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are

mc79569

equivalent to the U.S. EPA’s 2006 standards for marine engines.

WARRANTY

TWO STARS - VERY LOW EMISSION

The two-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions

mc79570

that One Star - Low-Emission engines.

THREE STARS - ULTRA LOW EMISSION

The three-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have

mc79571

65% lower emissions than One Star - Low Emission engines.

FOUR STARS - SUPER ULTRA LOW EMISSION

The Four Star label identifies engines that meet the Air Resources Board’s Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower

mc79572

emissions than One Star - Low Emission engines.

90-860168040 JANUARY 2004 Page 13

Page 24

WARRANTY

NOTES:

Page 14 90-860168040 JANUARY 2004

Page 25

GETTING TO KNOW YOUR POWER PACKAGE

Table of Contents

GETTING TO KNOW YOUR POWER PACKAGE

Features And Controls 16. . . . . . . . . . . . . . . . .

Lanyard Stop Switch 16. . . . . . . . . . . . . . . . . .

Instrumentation 18. . . . . . . . . . . . . . . . . . . . . . .

Remote Controls 19. . . . . . . . . . . . . . . . . . . . .

Panel Mounted 19. . . . . . . . . . . . . . . . . . . .

Console Mounted 20. . . . . . . . . . . . . . . . . .

Power Trim 21. . . . . . . . . . . . . . . . . . . . . . . . . .

Single Engine Trim/Trailer 22. . . . . . . . . . .

Dual Engine Trim/Trailer 22. . . . . . . . . . . .

Electrical System Overload Protection 23. . .

Audio Warning System 25. . . . . . . . . . . . . . . .

Emissions Information 26. . . . . . . . . . . . . . . . .

Emission Control Information Label 26. . . . .

Owner Responsibility 26. . . . . . . . . . . . . . . . . .

Star Label 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

90-860168040 JANUARY 2004 Page 15

Page 26

GETTING TO KNOW YOUR POWER PACKAGE

0010

Features And Controls

0011

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator’s position (as in accidental ejection from the operator’s position).

74608

a-Stop switch b-Lanyard c-Clips to the operator

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 that is pulling in one direction

• consuming alcohol or drugs

• high speed boating maneuvers

Some remote control units are equipped with a lanyard stop switch, if your remote control is not equipped with a lanyard stop switch one can be installed on the dashboard or side adjacent to th e operator’s position. The lanyard is a cord usually 4-5 ft (1.2-1.5 m) 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 it as short as possible to minimize the likelihood of entanglement with nearby objects. It stretches to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator’s position. To shorten the lanyard, wrap it around the operator’s wrist or leg, or tie a knot in the lanyard.

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Page 27

GETTING TO KNOW YOUR POWER PACKAGE

Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. H o w ever, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat would when under power.

We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).

WARNING

Avoid contact with the boat hull and propeller from accidental ejection. Personal injury or death could occur. Always properly connect both ends of the lanyard stop switch.

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 gear case or propeller.

• Loss of power and directional control in heavy seas, strong current or high winds.

• Loss of control when docking.

WARNING

Avoid abrupt deceleration of the boat from lanyard stop switch activation. Boat damage and personal injury or death could occur. NEVER leave the operator’s station with the engine operating and in gear.

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Page 28

GETTING TO KNOW YOUR POWER PACKAGE

0012.2

Instrumentation

The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.

a b c d e

f g h i j

70514

70519

70515 70516

70521

a-Speedometer b-Tachometer c-Oil pressure gauge d-Battery meter e-Water temperature gauge

70522

f-Fuel gauge g-Hour meter h-Bilge blower switch

i-Ignition switch j-Power trim gauge

70517

70523

Speedometer: Indicates boat speed. Tachometer: Indicates engine rpm. Oil Pressure Gauge: Indicates engine oil pressure. Battery Meter: Indicates battery voltage. Water Temperature Gauge: Indicates engine operating temperature.

70518

70520

Fuel Gauge: Indicates quantity of fuel in tank. Hour Meter: Records engine operating time. Bilge Blower Switch: Operates bilge blower. Ignition Switch: Allows operator to start and stop engine. Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in). Sterndrive

Models only.

Page 18 90-860168040 JANUARY 2004

Page 29

0014

Remote Controls

Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.

0015.02

PANEL MOUNTED

GETTING TO KNOW YOUR POWER PACKAGE

a-Neutral lock button b-Throttle only button c-Lanyard stop switch d-Control handle throttle friction screw e-Control handle

f-Trim / tilt button

77019

Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed IN to move the control handle out of NEUTRAL.

Throttle Onl y Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.

Lanyard Stop Switch - Turns the ignition OFF whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.

Control Handle Throttle Friction Screw - This screw (located behind the bezel cover) can be adjusted to increase or decrease the tension on the control handle. This will help prevent slipping of the remote control handle. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear. Continue pushing forward to increase speed. Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear and continue pushing back to increase speed.

Trim/Tilt Button - Refer to Power Trim.

90-860168040 JANUARY 2004 Page 19

Page 30

GETTING TO KNOW YOUR POWER PACKAGE

0242.00

CONSOLE MOUNTED

mc79503

a-Throttle only button b-Control handles c-Power Trim switch d-Trailer switch

Throttle Onl y Button - Allows engine throttle advancement without shifting the engine. This

is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.

Control Handle Tension Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed to adjust). This will help prevent slipping of the remote control handle. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

Control Handles - Operation of the the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear and continue pushing forward to increase speed. Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear and continue pushing back to increase speed.

79690

Power Trim Switch - See Power Trim section for detailed power trim operating procedures. Trailer S w itch - Used to raise drive unit for trailering, launching, beaching or shallow water

operation. On the single remote control handle units, the trailering mode begins with the second click or when the Power Trim/ T railer Switch is pressed all the way UP. See Power Trim for detailed trailer switch operation.

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Page 31

0169.02

Power Trim

GETTING TO KNOW YOUR POWER PACKAGE

Power Trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system Trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, and low speed operation (below 1200 rpm engine speed), shallow water operation.

CAUTION

Never trim the sterndrive unit UP/OUT using TRAILER switch while boat is underway at engine speeds above 1200 rpm. Use extreme caution when operating with sterndrive unit raised. Severe damage to the sterndrive unit may result if unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 rpm.

For best performance trim the sterndrive unit so that the boat bottom is at a 3-5 degreeangle to the water.

3 - 5

mc79528

Trimming sterndrive unit UP/OUT can:

• Generally increase top speed

• Increase clearance over submerged objects or a shallow bottom

• Cause boat to accelerate and plane off slower

• In excess, cause boat porpoising (bouncing) or propeller ventilation

• Cause engine overheating if trimmed UP/OUT to a point where any cooling water

intake holes are above the water line

90-860168040 JANUARY 2004 Page 21

mc79529

Page 32

GETTING TO KNOW YOUR POWER PACKAGE

Trimming sterndrive unit DOWN/IN can:

• Help the boat accelerate and plane off quicker

• Generally improve the ride in choppy water

• In most cases, reduce boat speed

• If in excess, lower the bow of some boats to a point at which they begin to plow with

their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.

0170

SINGLE ENGINE TRIM/TRAILER

mc79530

Single engine applications will have a button that can be pressed to trim the sterndrive unit up or down.

To raise the sterndrive unit for trailering, beaching, launching and low speed (below 1200 rpm), shallow water operation push the trim button to raise the sterndrive unit to the full UP/OUT position.

Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.

0171

DUAL ENGINE TRIM/TRAILER

Avoid tw i s t i n g o r b i n d i n g dual engine tie bars. Damage to the tie bar and sterndrives could occur. ALWAYS raise or lower the sterndrive units evenly.

Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit.

Some controls also have a trailer button that trims the drives to a position suitable for trailer purposes only.

CAUTION

Page 22 90-860168040 JANUARY 2004

Page 33

0018.04

Electrical System Overload Protection

If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing the fuse or resetting the circuit breaker.

NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker . If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your authorized Mercury MerCruiser dealer.

1. A red circuit breaker provides protection for engine wiring harness and the instrumentation power lead. Reset by pushing the “RESET” button IN.

GETTING TO KNOW YOUR POWER PACKAGE

79689

2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs.

79702

3. A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the START position and nothing happens (and circuit breaker is not tripped).

90-860168040 JANUARY 2004 Page 23

70525

Page 34

GETTING TO KNOW YOUR POWER PACKAGE

0172.04

4. The Power Trim System is protected from overload by a 110 amp fuse and a 20 amp in-line fuse on the power trim pump.

5. The Quicksilver Three-Button Power Trim Control Panel is further protected by a 20 amp in-line fuse.

79779

70527

Page 24 90-860168040 JANUARY 2004

Page 35

0020.05

Audio Warning System

Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.

GETTING TO KNOW YOUR POWER PACKAGE

70516

Oil pressure gauge Engine temperature gauge Sterndrive oil reservoir

The audio warning system will sound with a continuous horn if one of the following occurs:

• Engine oil pressure too low

• Engine temperature too hot

The audio warning system will sound with an intermittent horn if the following occurs:

• Sterndrive oil level too low

Operation of the engine after the audio warning system alarm has sounded could result in damage to the power package. Do NOT operate engine once the alarm has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION.

If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If cause cannot be determined, consult your authorized Mercury MerCruiser dealer.

0128

TESTING THE AUDIO WARNING SYSTEM

1. Turn the ignition switch to the ON position without cranking the engine.

70518

CAUTION

79682

2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.

90-860168040 JANUARY 2004 Page 25

Page 36

GETTING TO KNOW YOUR POWER PACKAGE

0220.01

Emissions Information

Emission Control Information Label

A tamper-resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, FEL (emission level), date of manufacture (month, year), and the engine displacement. Please note that the low emissions certification will not affect the fit, function, or performance of the engines. Boat builders and Dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER’S MANUAL FOR MAINTENANCE SPECIFICA TIONS AND ADJUSTMENTS SERIAL # OMXXXXXXXX FAMILY XXXXX_XXXXXX FEL. XX.X g/kW-hr

EMISSION CONTROL INFORMATION

D.O.M. JAN. 2003 DISP X.XL

79706

“SERIAL#” - Engine Serial Number “FAMILY” - Engine Family “FEL.” - Family Emission Limit “D.O.M.” - Date of Manufacture “DISP” - Piston Displacement

Owner Responsibility

The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.

Page 26 90-860168040 JANUARY 2004

Page 37

0221.01

Star Label

GETTING TO KNOW YOUR POWER PACKAGE

Beginning January 1, 2003, one 3-Star label will be included with each factory-certified MerCruiser engine.

All Mercury MerCruiser engines (500 hp and below) will have a 3-Star Ultra Low Emission rating. The 3-Star label identifies that these engines meet the California Air Resources Board’s Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions that One Star - Low Emission engines.

The 3-Star label will be affixed on the left side of the hull as shown.

a-Recommended decal location b-Secondary decal location

ONE STAR - LOW EMISSION

mc79569

equivalent to the U.S. EPA’s 2006 standards for marine engines.

TWO STARS - VERY LOW EMISSION

mc79570

that One Star - Low-Emission engines.

mc79531

THREE STARS - ULTRA LOW EMISSION

mc79571

FOUR STARS - SUPER ULTRA LOW EMISSION

mc79572

90-860168040 JANUARY 2004 Page 27

Page 38

GETTING TO KNOW YOUR POWER PACKAGE

NOTES:

Page 28 90-860168040 JANUARY 2004

Page 39

Table of Contents

ON THE WATER

Safe Boating Suggestions 30. . . . . . . . . . . . . .

Be Alert To

Carbon Monoxide Poisoning 32. . . . . . . . . . .

Good Ventilation 33. . . . . . . . . . . . . . . . . . .

Poor Ventilation 33. . . . . . . . . . . . . . . . . . . .

Basic Boat Operation 34. . . . . . . . . . . . . . . . . . .

Launching And Boat Operation Care 34. . . .

Operation Chart 35. . . . . . . . . . . . . . . . . . . .

Starting And Stopping The Engine 36. . . . . .

Starting Engine After Stopped

While In Gear 37. . . . . . . . . . . . . . . . . . . . . . . .

Trailering The Boat 37. . . . . . . . . . . . . . . . . . .

Freezing Temperature Operation 37. . . . . . .

Drain Plug and Bilge Pump 37. . . . . . . . . . . .

Protecting People In The Water 38. . . . . . . . .

While You Are Cruising 38. . . . . . . . . . . . . . . .

While Boat Is Stationary 38. . . . . . . . . . . . . . .

Passenger Safety Message -

Pontoon And Deck Boats 39. . . . . . . . . . . . . .

Wave And Wake Jumping 40. . . . . . . . . . . . . . .

Impact With Underwater Hazards 41. . . . . . . .

Drive Unit Impact Protection 42. . . . . . . . . . .

Conditions Affecting Operation 42. . . . . . . . .

Weight Distribution (Passengers And Gear)

Inside The Boat 42. . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 42. . . . . . . . . . . . . . . . . . . . . . .

Cavitation 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

Elevation And Climate 43. . . . . . . . . . . . . . . . .

Propeller Selection 44. . . . . . . . . . . . . . . . . . . .

Getting Started 45. . . . . . . . . . . . . . . . . . . . . . . . .

20-Hour Break-In Period 45. . . . . . . . . . . . . . .

After Break-In Period 45. . . . . . . . . . . . . . . . . .

End of First Season Checkup 45. . . . . . . . . .

90-860168040 JANUARY 2004 Page 29

Page 40

ON THE WATER

0022

Safe Boating Suggestions

In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and also consider the following suggestions.

• Know and obey all nautical rules and laws of the waterways.

Mercury MerCruiser strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency. Inquiries may be made to the Boating Hotline at 1-800-368-5647 or the Boat U.S. Foundation at 1-800-336-BOAT.

Y ou should also review the NMMA Sources of W aterway Information booklet. It lists regional sources of safety, cruising and local navigation and is available at no charge by writing to:

Sources of Waterway Information National Marine Manufacturers Association 410 N. Michigan Avenue Chicago, IL 60611 U.S.A.

• Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.

• Check safety equipment on board. Here are some suggestions of the types of safety equipment to carry when boating:

Approved fire extinguishers Paddle or oar Signal devices: flashlight, rockets or

flares, flag and whistle or horn

Spare propeller, thrust hubs and an

appropriate wrench Tools necessary for minor repairs First aid kit and instructions Anchor and extra anchor line Water-proof storage containers Manual bilge pump and extra drain

plugs

Spare operating equipment, batteries,

bulbs and fuses Drinking water Compass and map or chart of the area Transistor radio

Page 30 90-860168040 JANUARY 2004

Page 41

ON THE WATER

• 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, wearable-type life jacket (personal flotation device), correctly sized and readily accessible for every person on board, 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 on board 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 capacity plate). Know your boat’s operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser 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; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

• Never be under the influence of alcohol or drugs while boating (it is the law).

They impair your judgment and greatly reduce your ability to react quickly.

90-860168040 JANUARY 2004 Page 31

Page 42

ON THE WATER

• Know your boating area and avoid hazardous locations.

• Be alert. The operator of the boat is responsible by law to “maintain a proper lookout

by sight and hearing.” The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when operating the boat above idle or planing transition speed. Watch out for others, the water and your wake.

• Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 25 MPH (40 km/h) will overtake a fallen skier who was 61 m (200 ft) in front of you in 5 seconds.

• Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator’s side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

• Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if (1) there is loss of life or probable loss of life, (2) there is personal injury requiring medical treatment beyond first aid, (3) there is damage to boats or other property where the damage value exceeds $500.00 or (4) there is complete loss of the boat. Seek further assistance from local law enforcement.

0023

Be Alert To Carbon Monoxide Poisoning

Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.

Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness and nausea.

WARNING

Avoid prolonged exposure to carbon monoxide. Carbon monoxide poisoning can lead to unconsciousness, brain damage or death. Ensure that the boat, while at rest or underway, is well ventilated.

Page 32 90-860168040 JANUARY 2004

Page 43

0024.01

GOOD VENTILATION

Ventilate the passenger area by opening the side curtains or forward hatches to remove fumes.

ON THE WATER

0025.01

POOR VENTILATION

Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide.

mc79553

Courtesy of ABYC

Example of desired air flow through the boat

mc79554

Example of poor ventilation while a boat is stationary:

a-Operating the engine when the boat is moored in a confined space. b-Mooring close to another boat with its engine operating.

Courtesy of ABYC

Example of poor ventilation while a boat is moving:

a-Operating the boat with the trim angle of the bow too high. b-Operating the boat with no forward hatches open (station wagon effect).

90-860168040 JANUARY 2004 Page 33

mc79556

Courtesy of ABYC

Page 44

ON THE WATER

0026

Basic Boat Operation

0027.1

Launching And Boat Operation Care

To avoid possible ingestion of water that can damage engine components:

• Do NOT turn the ignition key off when the engine is above idle speed.  When launching your boat from a steep ramp, enter the water slowly.

• Do NOT use the lanyard stop switch to shut off the engine above idle speed.

• When coming off plane, if a large following wave may roll over the boat’s

transom, apply a short, light burst of throttle to minimize the wave action against the stern of the boat.

• Do NOT come off plane quickly, shift into reverse, and shut off engine.

IMPORTANT: Install the bilge drain plug prior to launching the boat.

CAUTION

Page 34 90-860168040 JANUARY 2004

Page 45

0028.05

OPERATION CHART

ON THE WATER

Operation Chart

BEFORE STARTING

Install bilge drain plug.

Open engine hatch.

Turn battery switch ON.

Operate bilge blowers.

Open fuel shut off valve.

Close the drain system.

Place sterndrive unit in full DOWN/IN position.

Perform all other checks specified by your dealer and/or boat builder.

AFTER STARTING

Observe all gauges to check condition of engine. If not normal, stop engine.

Check for fuel, oil, water, fluid and exhaust leaks.

Check shift and throttle control operation.

Check steering operation.

WHILE UNDERWAY

Observe all gauges to check condition of engine. If not normal, stop engine.

Listen for the audio alarm.

AFTER STOPPING

Turn ignition key to OFF position.

Turn battery switch to OFF position.

Close fuel shut off valve.

Flush cooling system if in saltwater.

Drain bilge.

Listen for Audio Warning Alarm to sound when the ignition switch is in the ON position.

90-860168040 JANUARY 2004 Page 35

Page 46

ON THE WATER

0029.03

Starting And Stopping The Engine

NOTE: Only perform those functions applicable to your power package.

1. Check all items listed in Operation Chart.

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

Explosive gasoline fumes collect in the engine compartment. Avoid injury or property damage, operate the bilge blower for at least five minutes prior to starting the engine. If the boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine.

2. Push the THROTTLE ONLY button and position the remote control handle / throttle lever setting as follows:

a. For Cold Engine Starts (an engine that has not been started for 1 or more days),

move the remote control handle / throttle lever to full throttle, then return to about 1/4 throttle. In extreme cold it may be necessary to pump lever more than once.

CAUTION

WARNING

b. For Warm Engine Starts (an engine that has been running within the last few hours),

move the remote control handle / throttle lever to 1/4 throttle position.

c. For Flooded Engine Starts, move the remote control handle / throttle lever to full

throttle. Be prepared to decrease engine speed to 1000-1500 rpm as soon as the engine starts.

IMPORTANT: Do not operate starter motor continuously for more than 30 seconds.

3. Turn ignition key to START. Release key when engine starts and allow switch to return to ON position. If the engine does not start in 10-15 seconds, repeat Step 2.

4. Operate engine for 1 or 2 minutes at fast IDLE (1000-1500 rpm) or until engine temperature reaches 60-71 degrees C (140-160 degrees F).

5. Inspect the power package for fuel, oil, water and exhaust leaks.

6. To shift into gear, move the remote control handle with a firm, quick motion forward to shift to FORWARD gear, or backward to shift to REVERSE. After shifting the drive unit, advance the throttle to the desired setting.

7. Move the remote control handle to NEUTRAL and allow the engine to slow to IDLE speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at IDLE speed for 3 to 5 minutes.

8. Turn ignition key to the OFF position.

Page 36 90-860168040 JANUARY 2004

Page 47

0173

Starting Engine After Stopped While In Gear

IMPORT ANT: A void stopping the engine if the sterndrive unit is in gear. If the engine does stop, refer to the following procedure:

1. Push and pull repeatedly on the remote control handle until handle returns to the

NEUTRAL/IDLE position. This may take several tries if the power package was operating above idle rpm when the engine stopped.

2. After the handle returns to the NEUTRAL/IDLE position, resume normal starting

procedures.

0174

Trailering The Boat

Your boat can be trailered with the sterndrive unit in THE UP or DOWN position. Adequate clearance is required between the road and sterndrive when transporting.

If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer.

0030

Freezing Temperature Operation

ON THE WATER

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

0031

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.

covered by Mercury MerCruiser Limited Warranty.

90-860168040 JANUARY 2004 Page 37

Page 48

ON THE WATER

0032

Protecting People In The Water

While You Are Cruising

It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed.

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 (coasting) in NEUTRAL/IDLE, 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

Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a gear case or any solid device rigidly attached to a moving boat or gear case.

WARNING

Shift into the NEUTRAL/IDLE position and shut off the engine before allowing people to swim or be in the water near your boat.

Page 38 90-860168040 JANUARY 2004

Page 49

0131.02

Passenger Safety Message - Pontoon And Deck Boats

WARNING

Avoid serious injury or death from falling over the front end of a pontoon or deck boat and coming in contact with the boat hull or propeller. Stay back from the front end of the deck and remain seated while the boat is in motion.

Whenever the boat is in motion, observe the location of all the 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 the result of 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 boat. Falling over the front of the boat between the two pontoons will position them to come into contact with the drive unit.

1. Boats having an open front deck:

a. No o ne s hould e ver b e o n t he d eck i n f ront o f t he f ence w hile t he b oat i s i n m otion. K eep

all passengers behind the front fence or enclosure.

b. 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.

ON THE WATER

mc79555

Incorrect Correct

2. Boats with front-mounted, raised pedestal fishing seats:

a. These 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.

b. Any unexpected sudden reduction in boat speed could result in the elevated

passenger falling over the front of the boat.

mc79557

Incorrect Correct

90-860168040 JANUARY 2004 Page 39

Page 50

ON THE WATER

0034.01

Wave And Wake Jumping

Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.

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 re-enters 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.

mc79675

WARNING

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.

Page 40 90-860168040 JANUARY 2004

Page 51

0035.02

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.

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:

ON THE WATER

mc79680

• 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

Avoid serious injury or death from loss of boat control. Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts. Have the power package thoroughly inspected and any necessary repairs made.

90-860168040 JANUARY 2004 Page 41

Page 52

ON THE WATER

0132

Drive Unit Impact Protection

The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit. After the sterndrive unit has cleared the object, the hydraulic system allows the sterndrive unit to return to its original operating position, preventing loss of steering control and engine overspeed.

Use extreme caution when operating in shallow water or where underwater objects are known to be present. No impact protection is provided in REVERSE, use extreme care to prevent striking submerged objects while operating in REVERSE.

IMPORTANT: Impact protection system cannot be designed to ensure total protection from impact damage under all conditions.

0036

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)

0037

Bottom Of 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 42 90-860168040 JANUARY 2004

Page 53

0038

Cavitation

0134

Ventilation

ON THE WATER

Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or a propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. 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 is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speedup and a reduction in boat speed. Excessive ventilation is annoying and 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

0039

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, performance can be regained by changing to a lower pitch propeller.

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ON THE WATER

0040.01

Propeller Selection

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. Refer to

Propellers

Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating rpm range with a normal load.

If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch.

• Warmer weather and greater humidity cause a loss of rpm.

• Operating in a higher elevation causes a loss of rpm.

• Operating with a dirty boat bottom causes a loss of rpm.

• Operating with increased load (additional passengers, pulling skiers) causes a loss

of rpm.

(90-8614492)

Everything You Need To Know About

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle when using the lower pitch propeller, but not pulling skiers.

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0042

Getting Started

0041

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 (5 minutes at a time maximum).

• Avoid full throttle acceleration from IDLE speed.

• Do NOT operate at full throttle until the engine reaches normal operating

temperature.

ON THE WATER

• Frequently check engine oil level. Add oil as needed. It is normal for oil consumption

to be high during the break-in period.

0043.1

After Break-In Period

To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered;

• Ensure that propeller allows the engine to operate at or near the top of the specified

WOT rpm range (Refer to Specifications) when at full throttle with a normal boat load.

• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged

operation at WOT rpm.

• Change the oil and oil filter. Refer to Maintenance.

0044

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.

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ON THE WATER

NOTES:

Page 46 90-860168040 JANUARY 2004

Page 57

Table of Contents

SPECIFICATIONS

Specifications 47. . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 48. . . . . . . . . . . . . . .

Fuel Ratings 48. . . . . . . . . . . . . . . . . . . . . . .

Using Reformulated (Oxygenated) Gasolines (USA Only) 48.

Gasolines Containing Alcohol 49. . . . . . . .

Engine Oil 50. . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications 51. . . . . . . . . . . . . . . . .

Fluid Specifications 52. . . . . . . . . . . . . . . . . . .

3.0 Liter (181 cid) 52. . . . . . . . . . . . . . . . . .

Sterndrive Fluid Specifications 52. . . . . . . . .

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SPECIFICATIONS

0045

Specifications

Fuel Recommendations

IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.

FUEL RATINGS

Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications:

USA and Canada

- having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium

gasoline [92 (R+M)/2 Octane] is also acceptable. DO NOT use leaded gasoline.

Outside USA and Canada

- having a posted pump Octane Rating of 90 RON minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.

0046

USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)

This type of gasoline is required in certain areas of the USA. The two types of oxygenates used in these fuels is Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol.

These Reformulated Gasolines are acceptable for use in your Mercury MerCruiser engine.

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0047

GASOLINES CONTAINING ALCOHOL

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. 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 of the water/alcohol from the gasoline in the fuel tank.

The fuel system components on your Mercury MerCruiser 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 boats 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

SPECIFICATIONS

WARNING

FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel components should be inspected for leakage, softening, hardening, swelling or corrosion. Any sign of leakage or deterioration requires replacement before further engine operation.

Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol-free gasoline be used where possible. 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 MerCruiser 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 trouble, but boats often sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components.

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SPECIFICATIONS

0048.01

Engine Oil

To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of MerCruiser 4-cycle 25W40 Engine Oil. This oil is a special blend of 25-weight and 40-weight oils for marine engines. If not available, a good grade, straight weight, detergent automotive oil of correct viscosity, with an API classification of SJ, CF-2, CH-4 may be used.

In those areas where MerCruiser 4-cycle 25W40 Engine Oil or a recommended straight weight oil are not available, a multi-viscosity 20W40 or, a less preferable choice, 20W50, with API service ratings of SJ, CF-2, CH-4 may be used.

IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than MerCruiser 4-cycle 25W40 Engine Oil or a good quality 20W40 or 20W50), synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended.

The chart below is a guide to engine oil selection.

MerCruiser 4-cycle 25W40 Engine Oil

SAE 40W

SAE 20W

SAE 30W

32° F 0

° C

AIR TEMPERATURE

50 10

° F ° C

75796

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0049

Engine Specifications

0237.00

Horsepower Kilowatts

Models 3.0L

135 101

SPECIFICATIONS

Displacement

3.0 liter

(181 cid)

Specified WOT rpm

range Idle rpm in

NEUTRAL

Minimum oil pressure @ 2000 rpm

Minimum oil pressure @ Idle

4400-4800

700

207-414 kPa

(30-60 psi)

28 kPa (4 psi)

Thermostat 71 degrees C (160 degrees F) Timing @ idle 2 degrees ATDC Firing order 1-3-4-2 Electrical system 12-volt negative (–) ground Alternator rating - hot

operating amps Alternator rating -

cold operating amps

65 amps

72 amps

Recommended battery rating

375 cca, 475 mca, or 90 Ah

(minimum) Spark plug type AC-MR43LTS Spark plug gap 1.1 mm (0.045 in.)

1 Performance obtained and corrected in accordance with SAE J1228 Crankshaft Power.

Measured using an accurate service tachometer, with engine at normal operating temperature.

Oil pressure must be checked with engine at normal operating temperature.

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SPECIFICATIONS

Closed cooling

0051.02

Fluid Specifications

IMPORTANT: All capacities are approximate fluid measures.

0238.00

3.0 LITER (181 CID)

IMPORT ANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines).

Engine oil (with filter)

Seawater cooling system

system

All models

Capacity

liters

(U.S. qts)

3.8 (4)

9 (8.5)

Fluid type Part number

MerCruiser 4-cycle 25W40

Engine Oil

Plumbing Antifreeze

(Propylene Glycol and

Purified Water)

Extended Life

Coolant/Antifreeze

Extended Life Ethylene

Glycol 5/100

Antifreeze/Coolant mixed

50/50 with Purified Water

92-802837A1

92-851901

92-877770K1

Obtain Locally

Always use the dipstick to determine the exact quantity of oil or fluid required.

Seawater Cooling System capacity information is for winterization use only.

0135.03

Sterndrive Fluid Specifications

NOTE: Oil capacity includes Drive Lube Monitor.

Model

Alpha One 1892 (64)

Capacity

ml (oz)

Fluid type Part number

High Performance Gear

Lube

92-802854A1

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