Mercury Bravo One, Bravo Two, Bravo Three User Manual

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
ment 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.

CB785

Warranty

Sections of this manual. The warranty state-

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.

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.

Diesel Sterndrives - Bravo One/Two/Three

1999, Mercury Marine

The following are registered trademarks of Brunswick Corporation:
Autoblend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser,
Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.

Printed in U.S.A.

1999, Mercury Marine 90861181990 999

CA753

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 MerCruiser products. We sincerely hope your boating will be pleasant!
Consumer Affairs Department

2

CD446

1.

Identification Record

PLEASE RECORD THE FOLLOWING INFORMATION:

Engine Model and Horsepower

Engine Serial Number

2.
Transom Assembly Serial Number (Sterndrive)

Gear Ratio Sterndrive Unit Serial Number

3.
Transmission Model (Inboard)

Gear Ratio Transmission Serial Number

4.
Propeller Number Pitch Diameter

5.
Hull Identification Number (HIN) Purchase Date

6.
Boat Manufacturer

Boat Model Length

7.
Exhaust Gas Emissions Certificate Number (Europe Only)

CB783

Serial Numbers

The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your Mer­Cruiser
model and serial numbers.

 power package. When contacting your Authorized MerCruiser Dealer about service, always specify

2

76454

3

74849

3

CB786

TABLE OF CONTENTS

Page

Warranty Message 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welcome! 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial Numbers 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table Of Contents 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Information 6

Owner Warranty Registration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

International Owner Registration 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recreational Use Diesel Sterndrive Limited Warranty 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Coverage and Exclusion 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transferable Warranty 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Read This Manual Thoroughly 12
General Information 13

Lanyard Stop Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wave And Wake Jumping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impact With Underwater Hazards 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating With Low Water Inlets In Shallow Water 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Boating Suggestions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting People In The Water 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

While You Are Cruising 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Boat Is Stationary 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed And High-Performance Boat Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conditions Affecting Operation 19

Weight Distribution 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cavitation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Selection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How Elevation And Climate Affect Performance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Information 21

Operation and Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Unit 10-Hour Break-In Period 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End of First Season Checkup 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Freezing Temperature And Cold Weather Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Impact Protection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Plug and Bilge Pump 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailering Boat 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Launching And Boat Operation Care 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stolen Sterndrive Unit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do-It-Yourself Maintenance Suggestions 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 26

Remote Controls (Panel Mounted) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Controls (Console Mounted) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Controls (Two Lever) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shifting 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 35

4

Page

Maintenance 36

General Maintenance Information 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Aids 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Maintenance 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Drive Unit Oil 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim Pump Fluid 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Drive Unit Oil 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propellers (Bravo One and Two) 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propellers (Bravo Three) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corrosion And Corrosion Protection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather or Extended Storage 52

Sterndrive Unit Lay Up 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Unit Recommissioning 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 53

Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual Sounds 53. . . . . . . . .

Steering Wheel Turns Hard Or Jerky 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim Does Not Operate (Electric Motor Does Not Run) 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim Does Not Operate (Electric Motor Runs But Drive Unit Does Not Move) 53. . . . . . . . . . . . . . . . .

Owner Service Assistance 54

Local Repair Service 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Away From Home 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts And Accessories Inquiries 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resolving A Problem 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Marine Service Offices 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Service Literature 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Owner’s Logbook 57

5

CD54

Warranty Information

CD55

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 re-

turned 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.

6

CD56

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 distributors/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 im-

mediately 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 Registra-

tion 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 pro-

cessing, 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.

7

CD613

Recreational Use Diesel Sterndrive Limited Warranty

I. WHAT IS COVERED

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

II. DURATION OF COVERAGE

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

III. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

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

IV. WHAT MERCURY WILL DO

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

V. HOW TO OBTAIN WARRANTY COVERAGE

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

8

VI. WHAT IS NOT COVERED

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

VII. Expenses related to haul-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, in-

surance cov e r age, loan payments, loss of time, loss of income, or any other type of incidental or conse­quential damages are not covered by this warranty . Also, expenses associated with the removal and/
or replacement of boat partitions or material caused by boat design for access to the product are not
covered by this warranty.

VIII. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mer-

cury Marine to make any affirmation, representation or warranty regarding the product, other than
those contained in this limited warranty , and if made, shall not be enforceable against Mercury Marine.

IX. For additional information regarding events and circumstances covered by this warranty, and those

that are not, see the W arranty Coverage section of the Operation, Maintenance and Warranty Manual,
incorporated by reference into this warranty.

X. DISCLAIMERS AND LIMITATIONS

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

9

CD621

Warranty Coverage and Exclusions

The purpose of this section is to help eliminate some of the more common misunderstandings regarding warran­ty coverage. The following list 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 affect the
product are not covered.

Warranty is limited to defects in material or 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.

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 or checks, including controls, and checking lubrication made in connection with normal

services.

• Damage caused by neglect, lack of maintenance, accident, abnormal operation, improper installation or ser-

vice, 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, in-

convenience 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.

• Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.

• 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 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.

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CD618

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
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, Wl 54936-1939
Attn: Warranty Registration Department

• 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 Mercury Marine Service Office in your country,
or the factory branch or distributor closet to you, for the transferable warranty procedure that would ap­ply to you.

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CD614

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

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.

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

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

, may be used to alert the installer/user to special instructions concerning a

!

WARNING

CAUTION

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

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CA619

Lanyard Stop Switch

General Information

2

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 feet (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.

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74608

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.

13

CD543

Wave And Wake Jumping

Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is
done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly
when the boat re-enters the water.

The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may
cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants
to be thrown out of their seats or out of the boat.

There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow
of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface
and “submarine” for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants
flying forward. The boat may also steer sharply to one side.

WARNING

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

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CD544

Impact With Underwater Hazards

Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where
the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bot­tom. The most important thing you can do to help reduce injury or impact damage from striking a floating

or underwater object is control the boat speed. Under these conditions, boat speed should be kept to
a minimum planing speed of (15 to 25 MPH).

Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could
result in the following:

• The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occu-

pants to be thrown out of their seats or out of the boat.

• A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.

• Impact damage to the sterndrive and/or boat.

Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situa­tions is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters
known to have underwater obstacles.

After striking a submerged object, stop engine as soon as possible and inspect the sterndrive unit for any broken
or loose parts. If damage is present or suspected, the power package should be taken to an authorized dealer
for a thorough inspection and necessary repair.

The boat should also be checked for any hull fractures, transom fractures, water leaks.
Operating a damaged sterndrive could cause additional damage to other parts of the power package, or could

affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

WARNING

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

15

CA802

Operating With Low Water Inlets In Shallow Water

A

76363

75827

CAUTION

Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be
sucked into the water inlets restricting or shutting off the water supply to the engine.

Extreme care should be exercised when operating a boat equipped with low water inlets (A) while maneuvering
in shallow water. Also, avoid beaching the boat with the engine(s) running.

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CA281

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, wear-

able-type life jacket (personal flotation device), correctly sized and readily accessible for every person on

board, plus a throwable cushion or ring. W e 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). When in doubt, contact your dealer or the boats manufacturer. Know your boat’s

operating and loading limitations.

• 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 fish-

ing seats, any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unex-

pected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into

the boat.

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• 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 trav-

eling 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 boat-

ing 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.

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.

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