Mercury 2.8 Diesel, 4.2 Diesel Maintance Manual
2.8 and 4.2 Diesel
Sterndrive Models
OPERATION &
MAINTENANCE
MANUAL
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to
ensure operating ease and durability.
With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this manual.
The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Name / function:
John Pfeifer, President,
Mercury Marine
Read This Manual Thoroughly
IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a
demonstration of actual starting and operating procedures.
Notice
Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the
8M0113987 1215 eng
International Hazard Symbol !, may be used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions
while performing the service, plus common sense operation, are major accident prevention measures.
WARNING
!
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.
NOTE: Indicates information that helps in the understanding of a particular step or action.
IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard,
and the safety of all occupants aboard. We strongly recommend that the operator read this Operation and Maintenance
Manual and thoroughly understand the operational instructions for the power package and all related accessories before
the boat is used.
WARNING
!
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth
defects or other reproductive harm.
2.8 and 4.2 Diesel Sterndrive Models
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine
power package. When contacting Mercury Marine about service, always specify model and serial numbers.
Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury
Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to
change specifications or designs without notice and without incurring obligation.
© 2016 Mercury Marine
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth
in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of
damages, and other related information. Please review this important information.
Copyright and Trademark Information
© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
Identification Records
Please record the following applicable information:
MerCruiser
Engine Model and Horsepower Engine Serial Number
Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
Transmission Model (Inboard) Gear Ratio Transmission Serial Number
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
Exhaust Gas Emissions Certification Number (Europe Only)
TABLE OF CONTENTS
Section 1 - Getting to Know Your Power Package
Identification............................................................................... 2
Serial Number Decal........................................................... 2
Engine Data Label.............................................................. 2
Bravo Sterndrive Serial Number and Identification............. 3
Bravo Transom Serial Number........................................... 3
Features And Controls............................................................... 4
Audio Warning System....................................................... 4
Switches............................................................................. 4
Lanyard Stop Switch........................................................... 5
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition.............................................. 6
Instrumentation................................................................... 6
VesselView..................................................................... 6
SmartCraft Speedometer, Tachometer, and Digital
Gauges........................................................................... 7
System Link Digital Gauges........................................... 7
Emergency Stop Switch...................................................... 8
Section 2 - On the Water
Safe Boating Recommendations............................................. 18
Carbon Monoxide Exposure.................................................... 19
Be Alert To Carbon Monoxide Poisoning........................... 19
Stay Clear of Exhaust Areas.............................................. 19
Good Ventilation ................................................................ 19
Poor Ventilation ................................................................. 20
Important Operation Information.............................................. 20
Launching......................................................................... 20
Duty Cycle Rating Requirements...................................... 20
High‑Output Rating........................................................... 20
Operation Chart................................................................ 21
Freezing Temperature and Cold Weather Operation....... 21
Drain Plug and Bilge Pump............................................... 22
Trailering the Boat............................................................ 22
Starting, Shifting, and Stopping............................................... 22
Before Starting the Engine................................................ 22
Important Information – SmartStart................................... 22
Starting a Cold Engine...................................................... 22
Engine Warm‑Up.............................................................. 23
Starting a Warm Engine.................................................... 23
Shifting.............................................................................. 24
Engine Shut Down (Stopping).......................................... 24
Starting the Engine After Stopped While in Gear............. 24
Protecting People in the Water................................................ 24
While You Are Cruising................................................ 24
Remote Controls................................................................. 8
Panel Mount Features.................................................... 9
Console Mount Features................................................ 9
Power Trim....................................................................... 10
Single‑Engine Trim and Trailer..................................... 11
Dual‑Engine Trim and Trailer....................................... 11
Trim without Key............................................................... 11
Overload Protection—Upper Engine Circuit Breaker
Panel................................................................................. 11
Overload Protection—Port Side Power Distribution
Box.................................................................................... 12
Vessel Integration Panel (VIP) Overload Protection......... 13
Power Trim and MerCathode Overload Protection........... 13
Engine Guardian System.................................................. 14
SeaCore Equipped Drives....................................................... 14
SeaCore Components and Castings................................ 14
Stainless Steel Fasteners................................................. 14
While Boat Is Stationary............................................... 24
High‑Speed and High‑Performance.................................. 25
Passenger Safety In Pontoon Boats and Deck Boats...... 25
Boats Having An Open Front Deck.............................. 25
Boats With Front‑Mounted, Raised Pedestal Fishing
Seats............................................................................ 25
Wave and Wake Jumping........................................................ 25
Impact with Underwater Hazards............................................. 26
Sterndrive Impact Protection.............................................. 26
Conditions Affecting Operation................................................ 27
Weight Distribution (Passengers and Gear) Inside the
Boat.................................................................................. 27
Bottom of Boat.................................................................. 27
Cavitation.......................................................................... 27
Ventilation......................................................................... 27
Elevation and Climate....................................................... 27
Propeller Selection............................................................ 28
Getting Started......................................................................... 28
Initial Break‑In Procedure................................................. 28
Sterndrive 10‑Hour Break‑In Period (New or With
Replacement Gears)......................................................... 28
Engine Break‑In................................................................ 28
20‑Hour Break‑In Period...............................................28
After the 20‑Hour Break‑In Period................................ 29
End of First Season Checkup........................................... 29
Section 3 - Specifications
Fuel Requirements................................................................... 32
Diesel Fuel in Cold Weather.................................................... 32
Antifreeze/Coolant................................................................... 32
Engine Oil................................................................................ 33
Engine Specifications............................................................... 34
90-8M0113987 eng DECEMBER 2015 Page i
Fluid Specifications.................................................................. 34
Engine............................................................................... 34
2.8.................................................................................34
4.2.................................................................................34
Bravo Sterndrive Fluid Specifications—Diesel................. 34
Power‑Assisted Steering and Power Trim Fluids............ 35
Approved Power‑Assisted Steering Fluids.................. 35
Section 4 - Maintenance
Approved Power Trim Fluids....................................... 35
Approved Paints..................................................................... 35
Owner and Operator Responsibilities..................................... 38
Dealer Responsibilities........................................................... 38
Maintenance........................................................................... 38
Do‑It‑Yourself Maintenance Suggestions............................... 38
Inspection............................................................................... 38
Maintenance Schedules......................................................... 39
Routine Maintenance...................................................... 39
Scheduled Maintenance.................................................. 40
Engine Oil............................................................................... 41
Checking......................................................................... 41
Filling............................................................................... 41
Changing Oil and Filter.................................................... 42
Sterndrive Gear Lube............................................................. 43
Checking......................................................................... 44
Filling............................................................................... 44
Changing......................................................................... 45
Power Trim Fluid.................................................................... 47
Checking......................................................................... 47
Filling............................................................................... 48
Changing......................................................................... 49
Power‑Assisted Steering Fluid............................................... 49
Checking......................................................................... 49
Filling............................................................................... 50
Changing......................................................................... 50
Engine Coolant....................................................................... 50
Check Coolant................................................................. 50
Filling............................................................................... 50
Changing......................................................................... 51
2.8 Air Filter............................................................................ 51
Removal.......................................................................... 51
Inspection........................................................................ 52
Installation....................................................................... 52
4.2 Air Filter............................................................................ 53
Removal.......................................................................... 53
Inspection........................................................................ 53
Installation....................................................................... 54
Water‑Separating Fuel Filter.................................................. 54
Draining........................................................................... 55
Replacing........................................................................ 55
Filling............................................................................... 57
Fuel System............................................................................ 58
Priming............................................................................ 58
Filling (Bleeding).............................................................. 58
Fuel Tank Cleaning and Flushing.................................... 59
Seawater System................................................................... 59
Draining the Seawater System........................................ 59
Sterndrive Water Inlets Check......................................... 61
Checking the Seawater Pickups...................................... 62
Cleaning the Seawater Strainer, if Equipped.................. 62
Flushing the Seawater System—Sterndrive Models....... 64
With the Boat out of the Water.................................... 64
With the Boat in the Water.......................................... 66
Engine Seawater Pump Inspection................................. 67
Replacing the Engine Coolant in the Closed‑Cooling
System.................................................................................... 67
Draining the Closed‑Cooling System.............................. 67
Filling the Closed‑Cooling System.................................. 68
Corrosion Protection............................................................... 69
General Information......................................................... 69
Engine Corrosion Protection Components...................... 69
Removal...................................................................... 69
Cleaning and Inspection............................................. 70
Installation................................................................... 71
Sterndrive Corrosion Protection Components................. 72
Continuity Circuit—Bravo Sterndrive............................... 75
MerCathode..................................................................... 77
Boat Bottom Care............................................................ 78
Painting Your Power Package......................................... 78
Sterndrive Surface Care.................................................. 79
Lubrication.............................................................................. 79
Steering System.............................................................. 79
Throttle Cable.................................................................. 81
Shift Cable....................................................................... 81
Transom Assembly.......................................................... 82
Engine Coupler................................................................ 82
Driveshaft Extension Models........................................... 82
Sterndrive, Bellows, and Engine Alignment.................... 83
Maintaining Torques............................................................... 84
Bravo Gimbal Ring U‑bolt Nuts....................................... 84
Engine Mounts................................................................ 85
Propellers............................................................................... 85
Bravo Sterndrive Propeller Removal............................... 85
Bravo One Models...................................................... 86
Bravo Two Models...................................................... 86
Bravo Three Models.................................................... 87
Bravo Sterndrive Propeller Installation............................ 88
Bravo One Models...................................................... 88
Bravo Three................................................................ 89
Drive Belts.............................................................................. 90
Serpentine Belt................................................................ 90
Inspection.................................................................... 90
Replacement............................................................... 91
Power‑Assisted Steering Pump Belt............................... 92
Inspection.................................................................... 92
Adjustment.................................................................. 92
Replacement............................................................... 93
Battery.................................................................................... 94
Battery Precautions for Multiple Engines.......................... 94
Section 5 - Storage
Cold Weather (Freezing Temperature), Seasonal Storage, and
Extended Storage................................................................... 98
Cold Weather (Freezing Temperature) Storage.............. 98
Page ii 90-8M0113987 eng DECEMBER 2015
Preparing Your Power Package for Seasonal or Extended
Storage............................................................................ 98
Seasonal Storage Instructions........................................ 99
Extended Storage Instructions...................................... 100
Battery............................................................................ 100 Recommissioning................................................................... 100
Section 6 - Troubleshooting
Diagnosing Electronically Controlled Fuel System
Problems................................................................................ 104
Troubleshooting Charts.......................................................... 104
Starter Motor Will Not Crank Engine, or Cranks Slow.... 104
Engine Will Not Start, or Is Hard to Start........................ 104
Engine Runs Rough, Misses, or Backfires..................... 104
Poor Performance........................................................... 104
Incorrect Engine Temperature........................................ 105
Low Engine Oil Pressure................................................ 105
Section 7 - Customer Assistance Information
Owner Service Assistance..................................................... 108
Local Repair Service........................................................ 108
Service Away From Home................................................108
Stolen Power Package..................................................... 108
Attention Required After Submersion............................... 108
Replacement Service Parts.............................................. 108
Parts and Accessories Inquiries................................. 108
Resolving a Problem........................................................ 108
Section 8 - Maintenance Log
Battery Will Not Charge.................................................. 105
Remote Control Operates Hard, Binds, Has Excessive
Free‑play, or Makes Unusual Sounds............................ 105
Steering Wheel Turns Hard or Jerky.............................. 106
Power Trim does not Operate (Electric Motor Operates but
Sterndrive does not Move).............................................. 106
Power Trim Does Not Operate (Electric Motor Does Not
Operate).......................................................................... 106
Contact Information for Mercury Marine Customer Service
......................................................................................... 109
Customer Service Literature.................................................. 109
English Language............................................................ 109
Other Languages..............................................................110
Ordering Literature................................................................. 110
United States and Canada............................................... 110
Outside the United States and Canada............................ 110
Scheduled Maintenance Log................................................. 112 Vessel Maintenance Notes.................................................... 113
90-8M0113987 eng DECEMBER 2015 Page iii
Page iv 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
Section 1 - Getting to Know Your Power Package
Table of Contents
Identification........................................................................... 2
Serial Number Decal........................................................2
Engine Data Label........................................................... 2
Bravo Sterndrive Serial Number and Identification.......... 3
Bravo Transom Serial Number........................................ 3
Features And Controls............................................................ 4
Audio Warning System.................................................... 4
Switches.......................................................................... 4
Lanyard Stop Switch........................................................ 5
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition ....................................... 6
Instrumentation................................................................ 6
VesselView .............................................................. 6
SmartCraft Speedometer, Tachometer, and Digital
Gauges .................................................................... 7
System Link Digital Gauges .................................... 7
Emergency Stop Switch...................................................8
1
Remote Controls.............................................................. 8
Panel Mount Features ............................................. 9
Console Mount Features ......................................... 9
Power Trim.................................................................... 10
Single‑Engine Trim and Trailer .............................. 11
Dual‑Engine Trim and Trailer ................................ 11
Trim without Key............................................................ 11
Overload Protection—Upper Engine Circuit Breaker
Panel..............................................................................11
Overload Protection—Port Side Power Distribution Box
....................................................................................... 12
Vessel Integration Panel (VIP) Overload Protection...... 13
Power Trim and MerCathode Overload Protection........ 13
Engine Guardian System............................................... 14
SeaCore Equipped Drives.................................................... 14
SeaCore Components and Castings............................. 14
Stainless Steel Fasteners.............................................. 14
90-8M0113987 eng DECEMBER 2015 Page 1
Section 1 - Getting to Know Your Power Package
MODEL..................................................... I4
DISPLACEMENT.................................. 2.8L
ENGINE ROTATION................................LH
MAX. W.O.T. RPM............................... 3800
IDLE RPM IN NEUTRAL...... 700 NON ADJ
Scan for
additional
engine
information
QR CODE
SPECIFICATIONS
BELT ROUTING
COLOR CODES
ENGINE OIL
DRIVE LUBE
COOLANT
PR STR FLUID
ENGINE SERIAL NUMBER
TRANSOM SERIAL NUMBER
DRIVE SERIAL NUMBER
54680
abcde
a
b
c
d
e
b
a
53340
Identification
The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power
package. When contacting Mercury Marine about service, always specify model and serial numbers.
Serial Number Decal
The serial number decal is located on top of the engine cover.
2.8 shown, 4.2 similar
a - Serial numbers
b - Engine specifications
c - Maintenance color codes
d - Quick reference code
e - Belt routing
Engine Data Label
A tamper‑resistant engine data label is affixed to the engine at the time of manufacture. It contains important information. Note
that the engine data label will not affect the fit, function, or performance of the engine and neither boatbuilders nor dealers may
remove the engine data label or the engine component it is affixed to before sale. If modifications are necessary or the engine
data label is damaged, contact Mercury Marine about the availability of a replacement.
The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission
levels to exceed their predetermined factory specifications.
Engine data label example
a - Engine weight
b - Engine power rating
c - Maximum engine speed (RPM)
d - Engine serial number
e - Abbreviated engine description
Page 2 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
33533
44426
Transom Serial No.
53651
Bravo Sterndrive Serial Number and Identification
The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side
of the sterndrive.
Bravo sterndrive information on ground plate
The serial number is also stamped on the driveshaft housing behind the back cover. This is used as a permanent reference for
authorized MerCruiser dealers.
Bravo sterndrive serial number stamping
Bravo Transom Serial Number
The Bravo transom serial number is stamped in the transom assembly decal.
90-8M0113987 eng DECEMBER 2015 Page 3
Section 1 - Getting to Know Your Power Package
44425
38160
The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser
dealers.
Serial number location on gimbal housing
Features And Controls
Audio Warning System
Your power package is equipped with an audio warning system. The audio warning system monitors critical components and
informs the operator when a malfunction has occurred. The warning system is not capable of protecting the power package
from damage caused by a malfunction.
When an electronic control system detects a recordable malfunction, the audio warning system will sound to alert the operator.
The duration and type of horn sound depend upon the nature of the fault condition. In the case of any horn sounding, the user
should refer to the helm displays to understand the specific situation.
For the operator to view the fault code of the malfunction indicated and any recommended actions, the power package must be
equipped with a gauge package that supports the warning system and can display fault codes.
The following instruments have screens that display fault codes:
• VesselView
• SmartCraft System Tachometer
• SmartCraft System Speedometer
NOTICE
The sound from an audio warning horn indicates that a critical fault malfunction has occurred. Operating a power package
with a critical fault can damage components. If the audio warning horn emits a sound, do not continue operations unless
avoiding a hazardous situation.
If the audio warning sounds, stop the engine immediately if you are not in a hazardous situation. Investigate the cause and
correct it, if possible. If you cannot determine the cause, consult an authorized repair facility.
Switches
Four position key switch
Page 4 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
28082
OFF
ON
38277
c
a
b
53910
OFF
RUN
ATTACH LANYARD
•
"OFF" In the "OFF" position, all electrical circuits are off. The engine will not operate with the key switch in the "OFF"
position.
•
"ACC" In the "ACC" position, any accessory connections to the electrical circuits can be operated. The engine will not
operate with the key switch in the "ACC" position.
•
"ON" In the "ON" position, all electrical circuits and instrumentation receive power. The engine can be started with an
optional start stop switch.
•
"START" Turn the key to the start position and release to start the engine.
NOTE: The key can only be removed with the key switch in the "OFF" position.
Dual engine start-stop switch
A start‑stop switch is optional equipment. The start‑stop switch works in conjunction with the key switch. There is one start‑stop
switch for each engine. Each button on a multi‑engine start‑stop switch functions independently. The key switch must be in the
run position to start a stopped engine with the the start‑stop switch. Pressing a start‑stop switch button when an engine is
running will shut down the corresponding engine.
Typical bilge blower toggle switch
Operates the bilge blower, if equipped
Lanyard Stop Switch
A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as
may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.
A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.
a - Lanyard cord clip
b - Lanyard decal
c - Lanyard stop switch
Accidental ejections, such as falling overboard, are more likely to occur in:
90-8M0113987 eng DECEMBER 2015 Page 5
Section 1 - Getting to Know Your Power Package
• Low‑sided sport boats
• Bass boats
• High‑performance boats
Accidental ejections can also occur from:
• Poor operating practices
• Sitting on the seat or gunwale at planing speeds
• Standing at planing speeds
• Operating at planing speeds in shallow or obstacle‑infested waters
• Releasing your grip on the steering wheel
• Carelessness caused by consuming alcohol or drugs
• High‑speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long when stretched out, with an element on one end made
to be inserted into the switch, and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest
condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is
made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the
operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying a knot in
the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance,
depending upon its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.
Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an
emergency.
WARNING
!
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the stop switch using a lanyard.
Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of
the following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the
front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.
• Loss of power and directional control in heavy seas, strong current, or high winds.
• Loss of control when docking.
WARNING
!
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition
Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard
cord. If the engine does not stop, have the switch repaired before operating the boat.
Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or
wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard
cords.
Instrumentation
VesselView
Your power package may be connected to a SmartCraft VesselView display. VesselView 7 is a comprehensive boat
information center that can display information for up to four gasoline or diesel engines. It continuously monitors and reports
basic operating data including detailed information such as seawater temperature and depth, trim status, boat speed and
steering angle, and the status of fuel, oil, water, and waste tanks.
VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible device to provide
up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.
Page 6 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
52421
a
b
c
c
50400
VesselView 4 and 7 are equipped with a micro SD card port that allows an authorized OEM or dealership to import the
personality configuration. It can also be use by the owner to import pictures or graphics. When more than one VesselView is
used, either as a triple or quad‑engine application for multiple helms, the same mico SD card can be used to download those
configurations.
VesselView
Refer to your VesselView operations manual for detailed instructions on how to operate this display.
SmartCraft Speedometer, Tachometer, and Digital Gauges
The SmartCraft instrument package augments the information provided by VesselView. The instrument package may display:
• Engine RPM
• Boat speed
• Coolant temperature
• Oil pressure
• Battery voltage
• Fuel consumption
• Engine operating hours
SmartCraft tachometer and speedometer
a - Tachometer
b - Speedometer
c - LCD display
The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system.
The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.
For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the
system, refer to the manual provided with your gauge package.
System Link Digital Gauges
Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft
tachometer and speedometer. The owner and operator should be familiar with all the instruments and their functions on the
boat. Have your boat dealer explain the gauges and normal readings that appear on your boat.
90-8M0113987 eng DECEMBER 2015 Page 7
Section 1 - Getting to Know Your Power Package
abc
d
37925
35308
The following types of digital gauges may be included with your power package.
System Link digital gauges
Item Gauge Indicates
a Oil pressure gauge Engine oil pressure
b Voltmeter Battery voltage
c Water temperature gauge Engine operating temperature
d Fuel gauge Quantity of fuel in tank
Emergency Stop Switch
An emergency stop (E‑stop) switch is used to turn off the engines in an emergency situation, such as a person overboard or a
tangled propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. If the boat is
equipped with an E‑stop switch, the E‑stop switch turns off all of the engines.
Typical E-stop switch
Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance
depending upon the velocity and degree of any turn at shutdown. 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 recommend instructing other occupants on proper starting and operating procedures should they need to operate the
engine in an emergency.
Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the
following potentially hazardous situations:
• Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could
be ejected over the bow and possibly struck by the propulsion or steering components.
• The operator can lose power and directional control in heavy seas, strong current, or high winds.
• The operator can lose control of the vessel when docking.
Restarting an engine using the key switch or start button after an E‑stop shutdown without first turning the key switch to the off
position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous
situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some
fault codes are still being displayed, contact your authorized Mercury Diesel repair facility.
Remote Controls
Your boat may be equipped with 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.
Page 8 90-8M0113987 eng DECEMBER 2015
Panel Mount Features
Section 1 - Getting to Know Your Power Package
a
f
b
e
a - Neutral lock button
b - Throttle‑only button
c - Lanyard stop switch
d - Control handle tension adjustment screw
e - Control handle
f - Trim and tilt button
c
d
mc77019-1
Neutral lock button. Prevents accidental shift and throttle engagement. The neutral lock button must be pushed into move the
control handle out of neutral.
Throttle‑only button. Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle‑only button can be depressed only when the remote control handle is in the
neutral position, and should only be used to assist in starting the engine.
Lanyard stop switch. Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away
from the operator's position to activate the switch. See Lanyard Stop Switch for information on the use of this switch.
Control handle. The shift and throttle are controlled by the movement of the control handle. Push the control handle forward
from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the
control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to
increase speed.
Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote
control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.
Trim (tilt) button. See Power Trim.
Console Mount Features
b
b
c
d
a
a
Throttle‑only button. Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle‑only button can be depressed only when the remote control handle is in the
neutral position.
c
d
mc79503-1
a - Throttle‑only button
b - Control handle
c - Power trim switch
d - Trailer switch
90-8M0113987 eng DECEMBER 2015 Page 9
Section 1 - Getting to Know Your Power Package
Control handles. The shift and throttle are controlled by the movement of the control handle. Push the control handle forward
from neutral with a quick, firm motion to the first detent for forward gear and continue pushing forward to increase speed. Pull
the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to
increase speed.
Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote
control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.
Power trim switch. See the Power Trim section for detailed power trim operating procedures.
Trailer switch. Used to raise the sterndrive for trailering, launching, beaching, or shallow water operation. See Power Trim for
detailed trailer switch operation.
Power Trim
Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load
and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive for trailering, beaching,
launching, low‑speed (below 1200 RPM engine speed), and shallow water operation.
WARNING
!
Excessive trim can cause serious injury or death at high speeds, and single‑ram trim systems do not provide a trim‑out
limiting device or trim indicator. Use caution when trimming with a single‑ram trim system and never trim out beyond the unit's
side support flanges while the boat is underway or at engine speeds above 1200 RPM.
For best performance, trim the sterndrive so that the boat bottom is at a 3–5° angle to the water.
3 - 5
mc79528
Trimming the sterndrive up (out) can:
• Generally increase top speed
• Increase clearance over submerged objects or a shallow bottom
• Cause the boat to accelerate and plane off slower
• In excess, cause boat porpoising (bouncing) or propeller ventilation
• Cause engine overheating if trimmed up (out) to a point where any cooling water intake holes are above the water line
mc78529
Trimming the sterndrive down (in) can:
• Help the boat accelerate and plane off quicker
• Generally improve the ride in choppy water
• In most cases, reduce boat speed
Page 10 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
• If excessively trimmed down (in), may lower the bows of some boats to a point at which they begin to plow with their bow in
the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any
turn is attempted or if a significant wave is encountered.
mc79530
Single-Engine Trim and Trailer
Single‑engine applications have a button that can be pressed to trim the sterndrive up (out) or down (in).
To raise the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM), and shallow water operation, push the
trim button to raise the sterndrive 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.
NOTE: The Engine Control Module (ECM) limits the extent to which the sterndrive can be trimmed up (out) when engine speed
is above 1200 RPM.
Dual-Engine Trim and Trailer
NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering
systems. If using an external tie bar, raise and lower all drives together as a unit.
Dual‑engine applications may have a single integral button to operate both sterndrives simultaneously or may have separate
buttons for each sterndrive.
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.
Trim without Key
!
CAUTION
The Trim Without Key mode allows trim operation after the ignition key switch is turned off. To avoid injury or product
damage, do not attempt any engine‑ or sterndrive‑related repairs or maintenance until performing the Wide Open Throttle
Reverse operation to end the Trim Without Key mode.
Trim without key allows trim operation for up to 15 minutes after the ignition key switch is turned off. On multi‑engine
applications, the trim without key time is managed separately for each engine.
The trim without key period may be ended at any time by moving the control handle to Wide Open Throttle Reverse with the
key off.
Overload Protection—Upper Engine Circuit Breaker Panel
If an electrical overload occurs, a fuse will burn out (blow) or a circuit breaker will trip open. Find and correct the cause for the
electrical overload 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 the 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 Mercury Diesel authorized repair facility.
90-8M0113987 eng DECEMBER 2015 Page 11
Section 1 - Getting to Know Your Power Package
a
b
c
f
23245
d
e
a
b
Circuit breakers provide protection for the engine electrical system. The circuit breaker panel is located beneath a small access
panel in the engine cover on top of the engine.
Typical engine cover with access panel
a - Engine cover
b - Circuit breakers
After finding and correcting the cause of the overload, reset the circuit breaker by pressing the reset button.
Circuit breakers viewed from the port side of the engine
Reference Circuit breaker rating Protection Location on fuse panel
a 20 A Key unswitched power to helm Lower left
b 10 A Switched power to ECM Upper left
c 10 A Key switch to ECM Middle left
d 15 A Switched power to ECM Middle right
e 15 A ECM switched power to SIM Upper right
f 5 A Power—diagnostic connector Lower right
Overload Protection—Port Side Power Distribution Box
If an electrical overload occurs, a fuse will burn out (blow) or a circuit breaker will trip open. Find and correct the cause for the
electrical overload 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 the accessories connected to the engine and instrumentation wiring. The circuit breaker
should automatically reset. If the breaker remains open, the electrical overload has not been eliminated. Further checks must
be made on the electrical system. Contact your Mercury Diesel authorized repair facility.
Circuit breakers provide protection for the engine electrical system as indicated. The circuit breaker panel is located within a
power distribution box mounted on the engine control module.
Page 12 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
37254
50465
a
b
c
After finding and correcting the cause of the overload, connect the starting battery and turn the ignition switch to the run
position. The circuit breaker should automatically reset. If a circuit breaker fails to reset, contact your Mercury Diesel authorized
repair facility
Port Side Power Distribution Box
Circuit Protection Circuit Breaker Rating
Key unswitched power to helm 20 A
Switched power to ECM 10 A
Key switch to ECM 10 A
Switched power to ECM 15 A
ECM switched power to SIM 15 A
Power—diagnostic connector 5 A
Vessel Integration Panel (VIP) Overload Protection
A vessel integration panel (VIP) is typically mounted in the engine compartment. The VIP contains three circuit breakers that
help protect system wiring.
a - Helm circuit breaker (10 A)
b - Gear circuit breaker (15 A)
c - SIM/Vessel circuit breaker (10 A)
Power Trim and MerCathode Overload Protection
If an electrical overload on the electrical system occurs, a fuse will open (blow). Find and correct the cause before replacing the
fuse.
NOTE: If you must operate the engine in an emergency, turn off and disconnect all accessories from the engine and
instrumentation wiring in an attempt to isolate the electrical overload or excessive current draw. Replace the fuse. If the fuse
burns out, the electrical overload has not been eliminated and further checks must be made on the electrical system. Contact
your Mercury Diesel authorized repair facility.
90-8M0113987 eng DECEMBER 2015 Page 13
Section 1 - Getting to Know Your Power Package
a
c
50534
b
1. 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.
a - 20‑amp in‑line fuse holder
b - 110‑amp fuse
a
b
2. The MerCathode system has a fuse connected to the positive (+) terminal on the controller. If the fuse is open (blown), the
system will not operate, resulting in a loss of corrosion protection. Replace the fuse with one of the same amp rating.
a - MerCathode
b - Red/purple wire
c - Fuse
9208
Engine Guardian System
The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian
is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected.
The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to
provide engine protection.
If Engine Guardian has been activated, reduce the engine speed. The problem will need to be identified and corrected. The
system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will
reset the Engine Guardian system. If the Engine Guardian system has determined the reset has not corrected the problem,
Engine Guardian will remain activated, limiting the throttle. The problem must be identified and corrected before Engine
Guardian will allow the engine to reach a normal operating RPM.
SeaCore Equipped Drives
SeaCore Components and Castings
Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular
aluminum castings with special coatings. Do not replace SeaCore components with non‑SeaCore. Use only the specified
Mercury MerCruiser SeaCore components and castings on these power packages.
Stainless Steel Fasteners
SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in saltwater
environments.
Page 14 90-8M0113987 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction,
improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads.
Apply lubricant 2‑4‑C with PTFE or an equivalent, on the threads of stainless steel fasteners during installation to avoid galling.
Lubricate at least the first 8 mm (1/4 in.) of the threads before installation.
Tube Ref No. Description Where Used Part No.
95
2-4-C with PTFE Threads of stainless steel fasteners 92-802859A 1
90-8M0113987 eng DECEMBER 2015 Page 15
Section 1 - Getting to Know Your Power Package
Notes:
Page 16 90-8M0113987 eng DECEMBER 2015
Table of Contents
Section 2 - On the Water
Section 2 - On the Water
Safe Boating Recommendations.......................................... 18
Carbon Monoxide Exposure................................................. 19
Be Alert To Carbon Monoxide Poisoning ..................... 19
Stay Clear of Exhaust Areas ........................................ 19
Good Ventilation .......................................................... 19
Poor Ventilation ........................................................... 20
Important Operation Information........................................... 20
Launching...................................................................... 20
Duty Cycle Rating Requirements...................................20
High‑Output Rating........................................................ 20
Operation Chart............................................................. 21
Freezing Temperature and Cold Weather Operation.... 21
Drain Plug and Bilge Pump............................................22
Trailering the Boat......................................................... 22
Starting, Shifting, and Stopping............................................ 22
Before Starting the Engine.............................................22
Important Information – SmartStart................................22
Starting a Cold Engine................................................... 22
Engine Warm‑Up........................................................... 23
Starting a Warm Engine.................................................23
Shifting........................................................................... 24
Engine Shut Down (Stopping)....................................... 24
Starting the Engine After Stopped While in Gear.......... 24
Protecting People in the Water............................................. 24
While You Are Cruising ......................................... 24
While Boat Is Stationary ........................................ 24
High‑Speed and High‑Performance...............................25
Passenger Safety In Pontoon Boats and Deck Boats... 25
Boats Having An Open Front Deck ....................... 25
Boats With Front‑Mounted, Raised Pedestal Fishing
Seats ..................................................................... 25
Wave and Wake Jumping..................................................... 25
Impact with Underwater Hazards......................................... 26
Sterndrive Impact Protection ........................................ 26
Conditions Affecting Operation............................................. 27
Weight Distribution (Passengers and Gear) Inside the
Boat............................................................................... 27
Bottom of Boat............................................................... 27
Cavitation....................................................................... 27
Ventilation...................................................................... 27
Elevation and Climate.................................................... 27
Propeller Selection.........................................................28
Getting Started..................................................................... 28
Initial Break‑In Procedure.............................................. 28
Sterndrive 10‑Hour Break‑In Period (New or With
Replacement Gears)......................................................28
Engine Break‑In............................................................. 28
20‑Hour Break‑In Period ....................................... 28
After the 20‑Hour Break‑In Period ......................... 29
End of First Season Checkup........................................ 29
2
90-8M0113987 eng DECEMBER 2015 Page 17
Section 2 - On the Water
Safe Boating Recommendations
To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions
and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary,
the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For
more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
• Here are some suggestions of the types of safety equipment to carry when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench
First aid kit and instructions
Waterproof storage containers
Spare operating equipment, batteries, bulbs, and fuses
Compass and map or chart of the area
Personal flotation device (one per person onboard)
Watch for signs of weather change and avoid foul weather and rough‑sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive
unit into neutral is not sufficient.
Use personal flotation devices.
• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and
readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life
jacket at all times while in the boat.
Prepare other boat operators.
• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver
becomes disabled or falls overboard.
Do not overload your boat.
• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your
boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your
authorized Mercury Marine dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of
seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride
anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat
movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat
and are in it before any boat movement.
Never operate a boat while under the influence of alcohol or drugs. It is the law.
• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
Page 18 90-8M0113987 eng DECEMBER 2015
Section 2 - On the Water
43367
Be alert.
• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have
an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when
the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.
Never drive your boat directly behind a water skier.
• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.
Watch fallen skiers.
• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the
boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to
the skier or anyone in the water.
Report accidents.
• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when
their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable
loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other
property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from
local law enforcement.
Carbon Monoxide Exposure
Be Alert To Carbon Monoxide Poisoning
Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the
engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless,
but if you can smell or taste engine exhaust, you are inhaling CO.
Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include
headache, dizziness, drowsiness, and nausea.
WARNING
!
Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage,
or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.
Stay Clear of Exhaust Areas
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines
are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While
underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the
possibility of injury from the boat propeller.
Good Ventilation
Ventilate the passenger area, open side curtains or forward hatches to remove fumes.
Example of desired air flow through the boat:
90-8M0113987 eng DECEMBER 2015 Page 19
Section 2 - On the Water
21626
a
b
a
b
43368
Poor Ventilation
Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient
ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that
contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:
a - Operating the engine when the boat
is moored in a confined space
b - Mooring close to another boat that
has its engine operating
2. Examples of poor ventilation while the 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)
Important Operation Information
Launching
IMPORTANT: Install the bilge drain plug before launching the boat.
Duty Cycle Rating Requirements
IMPORTANT: Damage caused by incorrect application or failure to operate the power package within the specified operating
parameters will not be covered by the Mercury Marine Limited Warranty.
Mercury Diesel engines must be used in applications that meet the operation specifications indicated by a Mercury Diesel
product application engineer. The power package must be equipped with a gear ratio and propeller that allows the engine to
operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do
not meet specified operational parameters is not approved.
High‑Output Rating
A High‑output rating applies to pleasure (nonrevenue generating) applications that operate 500 hours or less per year, where
full power is limited to one (1) hour out of every eight (8) hours of operation. Reduced power operation must be at or below
cruise speed (RPM). Cruise speed is dependant on the engine's maximum rated speed (RPM).
Page 20 90-8M0113987 eng DECEMBER 2015
Section 2 - On the Water
Operation Chart
Starting Procedure After Starting While Underway Stopping and Shut Down
Open the engine hatch. Air
out the bilge completely.
Turn the battery switch on, if
equipped.
Turn on and run the engine
compartment bilge blower, if
equipped, for five minutes.
Check for leaks: fuel, oil,
water, fluid, etc.
Open the fuel shut‑off valve,
if equipped.
Open the seacock, if
equipped.
Prime the fuel injection
system, if necessary.
Turn the key switch to
"START" position. Release
the key when the engine
starts.
Warm‑up the engine at a
fast idle‑RPM for several
minutes.
Observe all instrumentation to
monitor the condition of the
engine. If not normal, stop the
engine.
Check for fuel, oil, water, fluid,
and exhaust leaks, etc.
Check shift and throttle control
operation.
Check steering operation.
Frequently review all
instrumentation to monitor
engine condition.
Listen for the audio alarm.
Shift the remote control lever
to the neutral position.
Run the engine at idle‑RPM
for several minutes to allow
the turbocharger and engine
to cool.
Turn the key switch to "OFF"
position.
Turn the battery switch off, if
equipped.
Close the fuel shut‑off valve, if
equipped.
Close the seacock, if
equipped.
Flush the seawater cooling
circuit, if operating in
saltwater, brackish water, or
polluted water.
Freezing Temperature and Cold Weather Operation
IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freezing damage to
the power package. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE:
the seacock or unplug and connect the water inlet hose before starting the engine.
In order to operate the engine in temperatures of 0° C (32° F) or lower, observe the following instructions:
• At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage
• At the end of each daily operation, drain the water from the water separator, if equipped. Fill the fuel tank at the end of daily
• Use the required permanent‑type antifreeze solution to protect components against damage by freezing.
• Use proper cold weather lubrication oil; ensure that the crankcase contains a sufficient amount.
• Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in
• At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting.
• If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for
Refer to Section 6 for cold weather or extended storage related information.
As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
by freezing.
operation to prevent condensation.
optimum condition.
information about special cold weather equipment and precautions.
90-8M0113987 eng DECEMBER 2015 Page 21
Section 2 - On the Water
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 or a bilge pump. It is 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 Marine Limited Warranty.
Trailering the Boat
Your boat can be trailered with the sterndrive in the up (out) or down (in) position. Adequate clearance is required between the
road and sterndrive when transporting.
If adequate road clearance is a problem, place the sterndrive in full trailer position and support it with an optional trailer kit,
which is available from your Mercury Marine authorized repair facility.
Starting, Shifting, and Stopping
WARNING
!
Vapors can ignite and cause an explosion, resulting in engine damage or severe personal injury. Do not use volatile starting
aids such as ether, propane, or gasoline in the engine air intake system.
WARNING
!
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
Before Starting the Engine
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
IMPORTANT: Observe the following before starting:
• If running the engine with the boat out of the water, provide water to both the engine and sterndrive seawater pickup
pumps. Refer to Section 5—Flushing the Seawater System.
• Trim the sterndrive to the full down (in) position.
•
Ensure that the engine crankcase is filled to the correct level with the specified engine oil. Refer to Section 4:
Specifications—Engine Oil.
• Ensure all electrical connections are secure.
•
Check all items listed in Section 5—Maintenance Schedules and the Operation Chart.
• Perform any other necessary procedures as indicated by your dealer or Mercury Diesel authorized repair facility.
Important Information – SmartStart
IMPORTANT: This power package is equipped with SmartStart. SmartStart performs all appropriate starting operations upon
initial start switch actuation. To begin the SmartStart sequence, turn the ignition key switch to the "START" position and
release, or turn the ignition key switch to the run position and press and release the start/stop switch, if equipped.
SmartStart controls the starting process automatically. When the start switch is actuated, the system signals the engine's
electronic controller to start the engine. The starter will receive power until the engine starts and will time out after a few
seconds, or when the engine reaches 400 RPM. Attempting to start the engine with the engine running will turn the engine off.
Starting a Cold Engine
WARNING
!
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the water is near your boat.
NOTE: Check the fluid levels before starting the engine. Refer to
IMPORTANT: Mercury Marine DTS and Axius models are equipped with SmartStart. SmartStart features push and release
starting. The PCM completely controls the starting process after it receives a start command from the ignition key or start
button. The starting process will time‑out if the engine does not start after a few seconds or when cranking speed reaches 400
RPM. Attempting to start the engine with the engine already running will turn the engine off.
1. Turn on and run the engine compartment bilge blower (if equipped) for five minutes. Or, open the engine hatch to air out
the bilge before attempting to start the engine.
Page 22 90-8M0113987 eng DECEMBER 2015
Section 5—Maintenance Schedule
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