Mercury 350 Mag MPI Horizon, 8.1 S Horizon Service Manual
Horizon Inboard Models
2001, Mercury Marine 90Ć861357002 101
0
CH30
Identification Record
PLEASE RECORD THE FOLLOWING INFORMATION:
1.
Engine Model and Horsepower
Engine Serial Number
2.
Transmission Model
Gear Ratio Transmission Serial Number
3.
Propeller Number
Pitch Diameter
4.
Hull Identification Number (HIN)
Purchase Date
5.
Boat Manufacturer
Boat Model Length
Serial Numbers
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.
2001, Mercury Marine
The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop, Mariner, Merc,
MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide, Thruster and MMPP.
CH34
21
3
71452
2
77618
2
1
3
2
1
CA859
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. W e 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!
Consumer Affairs Department
CA741
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty
are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is
covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important
disclaimers and limitations of damages, and other related information. Please review this important
information.
CC961
IMPORTANT: This manual contains basic Operation, Maintenance and Warranty information for your
Mercury MerCruiser power package. If you desire to perform some of the maintenance items on your
own, you should obtain a copy of the Service Manual for your particular power package. Information for
obtaining the Service Manual is located at the back of this manual.
2
Table of Contents
Page
Warranty Information 4
Owner Warranty Registration 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
International Owner Registration 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury MerCruiser Limited Warranty - Gasoline Engines 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury MerCruiser International Warranty - Gasoline Engines 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Year Limited Warranty Against Corrosion Failure 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read This Manual Thoroughly 12
General Information 13
Lanyard Stop Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Emissions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Boating Suggestions 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed And High-Performance Boat Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions Affecting Operation 18
Important Information 20
Operation And Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freezing Temperature Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Plug and Bilge Pump 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attention Required After Submersion 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stolen Power Package 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Service Parts 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance Suggestions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple EFI Engine Battery Precautions 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosing EFI Problems 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After Break-In Period 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End of First Season Checkup 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 26
Instrumentation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audio Warning System 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Controls 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Shifting And Stopping 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1L Engine Guardian Strategy 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation Chart 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 35
Crankcase Oil 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Page
Maintenance 38
Maintenance Aids 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Capacities 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Chart 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Levels 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Fluids 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Water Separating Fuel Filter 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Flame Arrestor and Related Components 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System – 350 MAG MPI Only 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System – 8.1 S Horizon Only 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serpentine Drive Belt 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 57
Power Package Lay Up 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Winter Storage 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 63
Owner Service Assistance 67
4
CA455
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.
5
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 W arranty 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.
• 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 law.
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.
6
CA860
Warranty Policies
Mercury MerCruiser Limited Warranty - Gasoline Engines
UNITED STATES AND CANADA ONLY
I. We warrant each new production (not those made for high performance purposes) Mercury
MerCruiser Sterndrive Power Package, Inboard Engine and accessories attached thereto, (hereafter
referred to as “Product”) to be free from defects in material and workmanship, but only when the
customer purchases or obtains predelivery service from a Dealer authorized by us to distribute
Mercury MerCruiser Product in the country in which the sale or predelivery service occurred.
II. This warranty shall become effective only upon our receipt of a completed Warranty Registration Card,
which shall identify the Product so registered by serial number. This warranty shall remain in effect
for a period of one (1) year from date of purchase.
III. Since this warranty applies to defects in material and workmanship, it does not apply to
normal worn parts, adjustments, tune-ups or to damage caused by: 1) Neglect, lack of
maintenance, accident, abnormal operation or improper installation or service; 2) Use of an
accessory or part not manufactured or sold by us; 3) Operation with fuels, oils or lubricants which are not suitable for use with the Product; 4) Participating in or preparing for
racing or other competitive activity or operating with a racing type lower unit; 5) Alteration
or removal of parts; or 6) Water entering engine cylinder/s through the exhaust system or
carburetor/s.
IV. Reasonable access must be provided to the Product for warranty service. This warranty will
not apply to: 1) Haul-out, launch, towing and storage charges; telephone or rental charges
of any type, inconvenience, or loss of time or income; or other consequential damages; or
2) Removal and/or replacement of boat partitions or material because of boat design for necessary
access to the Product.
V. Claim shall be made under this warranty by delivering the Product for inspection to a Mercury
MerCruiser dealer authorized to service the Purchaser’s product. If purchaser cannot deliver Product
to such authorized dealer, he may give notice in writing to the Company. We shall then arrange for the
inspection and repair, provided such service is covered under this warranty. Purchaser shall pay for
all related transportation charges and/or travel time. If the service is not covered by this warranty
purchaser shall pay for all related labor and material and any other expenses associated with that
service. Any Product or parts shipped by purchaser for inspection or repair must be shipped with
transportation charges prepaid. The Warranty Registration Card is the only valid registration
identification and must be presented at the time warranty service is required. Warranty claims will not
be accepted without presentation of the Warranty Registration Card.
VI. Our sole and exclusive obligation under this Warranty shall be limited to repairing a defective part, or
at our option, refunding the purchase price or replacing such part or parts with new or Mercury certified
remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in
material or workmanship as covered by this Warranty. We reserve the right to improve the design of
any Product without assuming any obligation to modify any Product previously manufactured.
VII. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS
WARRANTY. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM
THIS WARRANTY. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY.
SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY
TO YOU.
VIII. This warranty gives you specific legal rights, and you may also have other legal rights which vary from
state to state.
7
Mercury MerCruiser International Warranty Gasoline Engines
OUTSIDE THE UNITED STATES AND CANADA
I. We warrant each new production (not those made for high performance purposes) Mercury MerCruiser
Sterndrive Power Package, Inboard Engine and accessories attached thereto, (hereafter referred to
as “Product”) to be free from defects in material and workmanship, but only when the customer purchases or obtains predelivery service from a Dealer authorized by us to distribute Mercury MerCruiser
Product in the country in which the sale or predelivery service occurred. This warranty shall remain in
effect for a period of one (1) year from date of purchase.
II. Since this warranty applies to defects in material and workmanship, it does not apply to normal worn
parts, adjustments, tune-ups or to damage caused by: 1) Neglect, lack of maintenance, accident, abnormal operation or improper installation or service; 2) Use of an accessory or part not manufactured
or sold by us: 3) Operation with fuels, oils or lubricants which are not suitable for use with the Product:
4) Participating in or preparing for racing or other competitive activity or operating with a racing type
lower unit: or 5) Alteration or removal of parts or 6) Water entering engine cylinder/s through exhaust
system or carburetor/s.
III. Reasonable access must be provided to the Product for warranty service. This warranty will
not apply to: 1) Haul-out, launch, towing and storage charges, telephone or rental charges of
any type, inconvenience, or loss of time or income or other consequential damages or 2) Removal
and/or replacement of boat partitions or material because of boat design for necessary access
to the Product.
IV. Claim shall be made under this warranty by delivering the Product for inspection to a Mercury Mer-
Cruiser dealer authorized to service the Product. If purchaser cannot deliver Product to such authorized dealer , he may give notice in writing to the Marine Power Service Center or distributor. The Marine
Power Service Center or distributor shall then arrange for the inspection and repair , provided such service is covered under this warranty Purchaser shall pay for all related transportation charges and/or
travel time. If the service is not covered by this warranty purchaser shall pay for all related labor and
material, and any other expenses associated with that service. Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid.
V. Purchaser must provide “proof of purchase” and substantiate “date of purchase” by presenting the
“Purchaser’s Copy” of the “Warranty Registration Card” or the plastic “Warranty Registration Card” to
the dealer authorized to service the Product. lf either of these items is not available purchaser must
provide a copy of the original “Bill of Sale” (Sales Contract) for the Product to be serviced. Warranty
claims will not be accepted until adequate “proof of purchase” is presented by purchaser and “date of
purchase” has been substantiated.
VI. Our sole and exclusive obligation under this Warranty shall be limited to repairing a defective part or
AT OUR OPTION, refunding the purchase price or replacing such part or parts with new or Mercury
certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects
in material or workmanship as covered by this Warranty. We reserve the right to improve the design
of any Product without assuming any obligation to modify any Product previously manufactured.
VII. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WAR-
RANTY. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS
WARRANTY. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY. SOME
COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS
OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU.
VIII. This warranty gives you specific legal rights, and you may also have other legal rights which vary from
country to country.
MARINE POWER INTERNATIONAL
Division of Brunswick Corporation
Fond du Lac, Wisconsin 54935 U.S.A.
8
CA861
3 Year Limited Warranty Against
Corrosion Failure
(Applicable In The United States, Canada And Australia)
I. We warrant parts and assemblies of each 1988 and newer production Mercury MerCruiser (Product)
sold with a one year limited Product warranty or the Bravo and TRS Drive Units on performance
Products that have a 90 day limited warranty rendered inoperative as a direct result of corrosion,
provided the following simple precautionary steps which are specified in Owner’s Manuals have been
taken:
1. Specified maintenance procedures (such as replacement of sacrificial anodes, specified lubrication
and touch-up of nicks and scratches) have been implemented on a timely basis.
2. Recommended corrosion prevention devices have been employed (details below).
II. This warranty shall become effective upon receipt of a completed standard Product warranty
registration card and shall remain effective for a period of three years from the date of purchase.
III. This warranty does not cover: (1) electrical system corrosion; (2) corrosion resulting from damage,
abuse or improper service; (3) corrosion to accessories, instruments, steering systems; (4) damage
due to marine growth; (5) Product sold with less than a one year limited Product warranty except for
Bravo and TRS Drive Units; nor (6) Product used in commercial application.
IV. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS
WARRANTY. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM
THIS WARRANTY. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY.
SOME STATES (OR COUNTRIES) DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY
TO YOU.
V. This warranty gives you specific legal rights, and you may also have other legal rights which vary from
state to state (or country to country).
VI. Other details of this warranty are contained in paragraphs IV, V and VI of the (United States and
Canada) Product Warranty, and paragraphs III, IV, V and VI of the (International) Product Warranty,
contained in this manual, which paragraphs are incorporated herein by reference.
Mercury Marine products are built using the most advanced corrosion protection process available. This
manufacturing system, complemented by dealer and customer participation in an anti-corrosion preventive
maintenance program, provides protection against repair costs incurred by the effects of marine corrosion.
OWNER’S RESPONSIBILITY
Protection against certain types of corrosion damage must be provided by using such systems as the Quicksilver
MerCathode System and/or Galvanic Isolator. These certain types of corrosion damage are: damage due to
stray electrical currents (on-shore power connections, nearby boats, submerged metal), or improper application
of copper base anti-fouling paint.
If anti-fouling protection is required, Tri-Butyl-Tin-Adipate (TBTA) base anti-fouling paints are recommended on
Mercury MerCruiser boating applications. In areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law,
copper base paints can be used on the boat hull and transom. Do not apply paint to the Mercury MerCruiser drive
unit or transom assembly. In addition, care must be taken to avoid an electrical interconnection between the
Mercury MerCruiser Product and the paint. Corrosion damage that results from the improper application of
copper base paint will not be covered by this limited warranty.
TRANSFER OF WARRANTY
This Limited Warranty is transferable to subsequent purchasers for the remainder of the unused portion of the
3-year limited corrosion warranty.
9
CA458
Warranty Coverage
The purpose of this section is to help eliminate some of the more common misunderstandings regarding
warranty coverage. The table explains some of the types of services that are not covered by warranty.
Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in
material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that af fect
the product are not covered.
Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country
to which distribution is authorized by us.
Should you have any questions concerning warranty coverage, contact your authorized dealer. They will be
pleased to answer any questions that you may have.
Warranty Does Not Apply To The Following:
• Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs, ignition components,
carburetor settings, filters, belts, controls, and checking lubrication made in connection with normal services.
• Damage caused by neglect, lack of maintenance, accident, abnormal operation or improper installation or
service, or freezing temperatures.
• Haul-out, launch, towing charges; removal and/or replacement of boat partitions or material because of boat
design for necessary access to the product; all related transportation charges and/or travel time, etc.
Reasonable access must be provided to the product for warranty service. Customer must deliver product to
an Authorized Dealer.
• Additional service work requested by customer other than that necessary to satisfy the warranty obligation.
• Labor performed by other than an Authorized Dealer may be covered only under following circumstances:
When performed on emergency basis (providing there are no Authorized Dealers in area who can perform
the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the
work performed at this facility).
• All incidental and/or consequential damages (storage charges, telephone or rental charges of any type,
inconvenience or loss of time or income) are the owner’s responsibility.
• Use of other than Quicksilver replacement parts when making warranty repairs.
• Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s responsibility unless loss
or contamination of same is caused by product failure that would be eligible for warranty consideration.
• Participating in or preparing for racing or other competitive activity.
• Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal
engine condition which could result in a failure, condition responsible for noise should be corrected under the
warranty.
• Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.
• Water entering the engine via the carburetor or exhaust system or submersion. Also water in the starter motor.
• Starter motors and/or armatures or field coil assembly, which are burned, or where lead is thrown out of
commutator because of excess cranking.
• Valve or valve seat grinding required because of wear.
• Failure of any parts caused by lack of cooling water, which results from starting power package out of water,
foreign material blocking inlets or power package being mounted too high.
• Use of fuels and lubricants which are not suitable for use with or on the product.
• Our limited warranty does not apply to any damage to our products caused by the installation or use of parts
and accessories which are not manufactured or sold by us. Failures which are not related to the use of those
parts or accessories, are covered under warranty , if they otherwise meet the terms of the limited warranty for
that product.
10
CA459
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:
Mercury Marine
Attn: Warranty Registration Department
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
• 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.
• There is no charge for this service.
Outside the United 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.
CA862
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.
11
CA961
THIS PAGE IS INTENTIONALLY BLANK
12
CA755
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 , may be used to alert the installer/user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly or carelessly. 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
WARNING-Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
CAUTION-Hazards or unsafe practices which could result in minor personal injury or product or
property damage.
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.
13
CC942
General Information
CA619
Lanyard Stop Switch
74608
2
1
The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from
the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote
control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed on the dashboard
or side adjacent to the operator’s position.
The lanyard is a cord usually between 4 and 5 ft (1220 and 1524 mm) in length when stretched out with an
element on one end made to be inserted into the switch and a snap (2) on the other end for attaching to the
operator. The lanyard is coiled to make its at-rest condition as short as possible so as to minimize the likelihood
of lanyard entanglement with nearby objects. It is made as long as it is in its stretched condition to minimize the
likelihood of accidental activation should the operator choose to move around in an area close to the normal
operator’s position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator’s wrist or leg,
or tie a knot in the lanyard.
IMPORTANT: The purpose of a lanyard stop switch is to stop the engine when the operator moves far
enough away from the operator’s position to activate the switch. This would occur if the operator
accidentally falls overboard or moves within the boat a sufficient distance from the operator’s position.
Accidental ejections and falls overboard are more likely to occur in certain types of boats such as low
sided sport boats or bass boats, and high-performance boats. Accidental ejections and falls overboard
are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating
at planing speeds in shallow or obstacle-infested waters, releasing your grip on a steering wheel that
is pulling in one direction, drinking alcohol or consuming drugs, or daring, high-speed boat maneuvers.
While activation of the lanyard stop switch will stop the engine immediately , a boat will continue to coast for some
distance depending upon the velocity and degree of any turn at shut-down. However, the boat will not complete
a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat
would when under power.
We strongly recommend that other occupants be instructed on proper starting and operating procedures should
they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).
WARNING
Should the operator fall out of the boat, the possibility of serious injury or death from being run over
by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both
ends of the stop switch lanyard to the stop switch and the operator.
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:
1 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.
2 Loss of power and directional control in heavy seas, strong current or high winds.
3 Loss of control when docking.
WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop
switch activation. The boat operator should never leave the operator’s station without first
disconnecting the stop switch lanyard from the operator.
14
CC670
Courtesy of ABYC
2A
2B
3A
3B
1
15
CA620
Exhaust Emissions
Be Alert To Carbon Monoxide Poisoning
Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards,
stern drives 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 the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage or death.
GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches to remove fumes.
1 Example of desired air flow through the boat.
CA643
POOR VENTILATION
Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with
insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your
boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an unclosed area of a
stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon
monoxide.
2 Examples of poor ventilation while boat is stationary:
A Running the engine when the boat is moored in a confined space.
B Mooring close to another boat that has its engine running.
3 Examples of poor ventilation while boat is moving:
A Running the boat with the trim angle of the bow too high.
B Running the boat with no forward hatches open (station wagon effect).
16
CA476
Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations
and restrictions, and consider the following suggestions.
• Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating
safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2) The Power
Squadron, (3) The Red Cross and (4) your state or provincial boating law enforcement agency. Inquiries may
be made to the Boating Hotline, 1-800-368-5647 or the Boat U.S. Foundation information number
1-800-336-BOAT.
We strongly recommend that all powerboat operators attend one of these courses.
You should also review the NMMA Sources of Waterway 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 suggestions of the types of safety equipment to carry when
boating:
1 Approved fire extinguisher(s); paddle or oar.
2 Signal devices: flashlight, rockets or flares, flag and whistle or horn.
3 Spare propeller, thrust hubs and an appropriate wrench.
4 Tools for necessary minor repairs; first aid kit and book.
5 Anchor and extra anchor line; water-proof storage containers.
6 Manual bilge pump and extra drain plugs; compass and map or chart of area.
7 Spare operating equipment; batteries, bulbs, fuses, etc.
8 Transistor radio.
9 Drinking water.
• Know 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. Just 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 dealer or the boats manufacturer.
17
• Make sure everyone in the boat is properly seated. Don’t allow anyone to sit or ride on any part of the boat
that was not intended for such use. This includes backs of seats, gunwales, transom, bow, decks, raised
fishing seats, 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. See that all passengers have a proper seat and are in it before any boat movement.
• Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment
and greatly reduce your ability to react quickly.
• Know your boating area and avoid hazardous locations.
• Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing).”
The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats
should block the operators view when operating the boat above idle or planing transition speed. Watch “the
other guy,” 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 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front
of you.
• 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 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.
CA282
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) and the drive unit is in neutral position, 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
Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near
your boat.
WARNING
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 moving gear case,
or any solid device rigidly attached to a moving boat or gear case.
18
CC828
High-Speed And High-Performance Boat Operation
If your boat is considered a high-speed or high-performance boat with which you are unfamiliar, we recommend
that you never operate it at its high speed capability without first requesting an initial orientation and
familiarization demonstration ride with your dealer or an operator experienced with your boat. For additional
information, obtain a copy of our Hi-Performance Boat Operation booklet (Part Number 90-849250--1) from your
dealer, distributor, or Mercury Marine.
CA958
Conditions Affecting Operation
Weight Distribution (Passengers And Gear) Inside The Boat
Shifting weight to rear (stern):
• Generally increases speed and engine rpm.
• At extremes, can cause boat to porpoise.
• Causes bow to bounce in choppy water.
• Increases danger of waves splashing into boat when coming off plane.
Shifting weight to front (bow):
• Improves ease of planing.
• Improves rough water ride.
• At extremes, can cause boat to veer back and forth (bow steer).
CA959
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 boat is docked. This growth must be removed before operation; it may
clog water inlets and cause engine to overheat.
19
CC1027
Propeller Selection
IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide open
throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating
rpm.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the
correct propeller. Refer to Specifications for engine WOT and operating rpm range.
IMPORTANT: The engines covered in this manual are equipped with an rpm rev-limiter that is set to an
upper (or limited) rpm amount. This limit is slightly above the normal operating range of the engine and
is designed to help prevent damage from excessive engine rpm. Once the rpm drop into the
recommended operating rpm range normal engine operation resumes.
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 damaged propeller or dirty boat bottom causes a loss of rpm.
• Operating with increased load (additional passengers, pulling skiers) causes a loss of rpm.
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate
at full throttle when using the lower pitch propeller but not pulling skiers.
20
CA960
How Elevation And Climate Affect Performance
Elevation has a very noticeable effect on the wide open throttle power of an engine. Since air gets thinner as
elevation increases, the engine begins to starve for air . Humidity, barometric pressure and temperature do have
a noticeable effect on the density of air. Heat and humidity thin the air. This condition can become particularly
annoying when the propeller testing was done on a cool, dry day. Then later; on a hot, sultry day, the boat doesn’t
seem to have the same performance.
Although some performance can be regained by dropping to a lower pitch propeller , the basic problem still exists.
In some cases, a gear ratio change to more reduction is possible and very beneficial.
Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the
engine power. This, in turn, is reflected in decreased boat speeds, as much as 2 or 3 miles per hour in some
cases. Nothing will regain this speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine running on a hot, humid, summer day,
may encounter a loss of as much as 14% of the horsepower it would produce on a dry , brisk spring or fall day.
With the drop in available horsepower, this propeller will, in effect, become too large. Consequently , the engine
operates at less than its recommended rpm. This will result in further loss of horsepower at the propeller with
another decrease in boat speed. This secondary loss, however, can be somewhat regained by switching to a
lower-pitch propeller that allows the engine to again run at recommended rpm.
For boaters to realize optimum engine performance under changing weather conditions, it is essential that the
engine be propped to allow it to operate at or near the top end of the recommended maximum rpm range at WOT
with a normal boat load.
Not only does this allow the engine to develop full power, but equally important is the fact that the engine also
will be operating in an rpm range that discourages detonation. This, of course, enhances overall reliability and
durability of the engine.
CA863
Important Information
Operation And Maintenance
OWNER/OPERATOR RESPONSIBILITIES
It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance
instructions are complied with for safe operation and to return the unit to an Authorized Mercury MerCruiser
Dealer for a periodic checkup.
Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such,
are not considered defects in workmanship or material within the terms of the warranty. Individual operating
habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your power package will assure optimum performance and dependability, an d
will keep your overall operating expenses at a minimum. See your Authorized Mercury MerCruiser Dealer for
service aids.
21
CA864
DEALER RESPONSIBILITIES
In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as:
• Make sure that the boat is properly equipped.
• Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper
operating condition.
• Make all necessary adjustments for maximum efficiency.
• Familiarize the customer with the on-board equipment.
• Explain and demonstrate the operation of the power package and boat.
• At the time of delivery, the dealer should provide you with a copy of a Predelivery Inspection Checklist.
• Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory
immediately upon sale of the new product.
CA865
Freezing Temperature Operation
IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to
prevent freezing damage to power package. Damage caused by freezing IS NOT
covered by Mercury
MerCruiser Limited Warranty.
CA867
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 rise to come in 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.
CA869
Attention Required After Submersion
• Before recovery, contact an Authorized Mercury MerCruiser Dealer.
• After recovery , immediate service by an Authorized Mercury MerCruiser Dealer is required to prevent serious
damage to power package.
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