Mercury Bravo Three Maintance Manual
OPERATION &
MAINTENANCE MANUAL
7.4L
Bravo Three
1995, Brunswick Corporation 90-805718960 595
CA1
Identification Record
Please Record the Following Information
1.
Engine Model and Horsepower
2.
Engine Serial Number
3.
Transom Assembly Serial Number
4.
Stern Drive Unit Serial Number and Gear Ratio
5.
Propeller Number
6.
Propeller Pitch
7.
Hull Identification Number (HIN) Purchase Date
8.
Boat Manufacturer Boat Model Length
SERIAL NUMBERS
The serial numbers are the manufacturer’s keys to numerous engineering details
which apply to your MerCruiser power package. When contacting your Authorized
MerCruiser Dealer about service, always specify model and serial numbers.
The description and specifications contained herein were in effect at the time this
guide was approved for printing. Mercury Marine, whose policy is one of continuous
improvement, reserves the right to discontinue models at any time, or to change
specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
1995, Brunswick Corporation
The following are registered trademarks of Brunswick Corporation: Autoblend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury
Marine, Quicksilver, Ride-Guide, and Thruster.
0
CB2
1
3
ABC12345Z123
7
71350
71348
2
71352
3
2
1
7
4
4
2
5
71773
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-19 48-12345
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71360
1
CB390
Table Of Contents
Page
Welcome! 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read This Manual Thoroughly 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lanyard Stop Switch 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Boating Suggestions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed And High-Performance Boat Operation 11. . . . . . . . . . . . . . .
Conditions Affecting Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight Distribution 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Of Boat 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavitation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Elevation And Climate Affect Performance 15. . . . . . . . . . . . . . . .
Important Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation And Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freezing Temperature Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Impact Protection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attention Required After Submersion 18. . . . . . . . . . . . . . . . . . . . . . . . .
Trailering Boat 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Stolen Power Package 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Service Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance Suggestions 21. . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After Break-In Period 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrumentation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . .
Models With Mercathode System 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Controls (Panel Mounted) 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Controls (Console Mounted) 33. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Controls (Two Lever) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Shifting And Stopping 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation Chart 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Oil 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tune-Up Specifications 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Page
Maintenance 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Aids 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Chart 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Levels 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Fluids 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Separating Fuel Filter 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Sight Tube Inspection 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Pump Impeller Inspection 79. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Seawater (Raw Water) Section Of
Heat Exchanger And Oil/Power Steering
Cooler - Closed Cooling Models Only 81. . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion And Corrosion Protection 85. . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Maintenance 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Of Boat 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Maintenance 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Or Extended
Storage 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Package Lay Up 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Winter Storage 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Information 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
International Owner Registration 111. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercruiser Limited Warranty - Gasoline Engines 112. . . . . . . . . . . . . . .
Mercruiser International Warranty - Gasoline Engines 114. . . . . . . . . .
3 Year Limited Warranty Against
Corrosion Failure 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Coverage 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transferable Warranty 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Q-guard Product Protection Plan 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Owner Service Assistance 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Centers 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Service Literature 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance Parts 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Literature Order Form 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
CA165
Welcome!
Y ou 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 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 MerCruiser products. We sincerely
hope your boating will be pleasant!
Consumer Affairs Department
4
CA166
Read This Manual Thoroughly
IF YOU DON’T UNDERST AND 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
tions concerning a particular service or operation that may be haz-
ardous if performed incorrectly or carelessly. Observe them care-
fully.
These “Safety Alerts” alone cannot eliminate the hazards that they
signal. Strict compliance with these special instructions while performing the service, plus ”common sense” operation, are major accident prevention measures.
WARNING-Hazards or unsafe practices which could result in
severe personal injury or death.
, may be used to alert the installer/user to special instruc-
!
!
WARNING
!
CAUTION
CAUTION-Hazards or unsafe practices which could result in minor personal injury or product or property damage.
IMPORTANT: - Indicates information or instructions that are
necessary for proper operation and /or maintenance.
!
WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all
occupants aboard. We strongly recommend that the operator
read this Operation and Maintenance Manual and thoroughly
understand the operational instructions for the power package
and all related accessories before the boat is used.
5
CA280
Lanyard Stop Switch
2
1
74608
1 Some boats come equipped with a lanyard stop switch. A lanyard
stop switch can also be installed as an accessory . The purpose of this
switch is to turn off the engine ignition whenever the operator (when
attached to the lanyard) moves far enough away from the operator’s
position to activate the switch.
2 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 metal snap on the other end for
attaching to the operator. It 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 for any reason it is desired to have a shorter
functional lanyard, this may be accomplished by using up length in
the way the lanyard and clip are attached to the operator (such as
wrapping the lanyard around the operator’s wrist or leg) or by tying
a simple knot in the lanyard.
Read the Safety Warning on this page and the following page
before electing to install, use, or not to use such a switch.
!
WARNING
The following advantages and disadvantages of a lanyard stop
switch should be considered before electing to use, or not to
use, such a switch.
6
ADV ANTAGES: The purpose of a lanyard stop switch is to stop
the engine ignition whenever the operator (when attached to the
lanyard) moves far enough away from the operator’s position to
activate the switch. This would occur if the operator falls or
moves within the boat a sufficient distance from the operator’s
position. This type of accident is most likely in certain types of
boats such as low-sided boats, and high-performance boats,
It is also likely as a result of poor operating practices such as
sitting on the back of the seat at planing speeds, standing at
planing speeds, operating at high speeds in shallow or obstacle-infested waters, releasing your grip on a steering wheel
that is pulling in one direction, drinking and driving, or daring,
high-speed boat maneuvers.
DISADVANTAGES: Inadvertent activation of the switch is also
a possibility . This could cause any, or all, of the following potentially hazardous situations:
1. Loss of balance and falling forward of unstable boat passen-
gers - a particular concern in bow rider type boats.
2. Loss of power and directional control in heavy seas, strong
current or high winds.
3. Loss of control when docking.
While activation of the lanyard stop switch will result in immediate power shut-down, a boat can 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.
As we cannot possibly know of and advise the boating public
of all conceivable boat/motor types and/or poor operating practices, the final decision of whether to use a lanyard stop switch
rests with you, the owner/driver.
We strongly recommend that other occupants be instructed on
proper starting and operating procedures should they be required to operate the engine and boat in an emergency.
7
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.
Y ou 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
8
• Know signs of weather change and avoid foul weather and
rough-sea boating.
• Tell someone where you are going and when you expect to
return.
• Passenger boarding. Stop the engine whenever passengers are
boarding, unloading or are near the back (stern) of the boat. Just
shifting the drive unit into neutral is not sufficient.
• Use personal flotation devices. Federal Law requires that there
be a U. S. Coast Guard approved, wearable-type life jacket (personal flotation device), correctly sized and readily accessible for
every person on board, plus a throwable cushion or ring. We
strongly advise that everyone wear a life jacket at all times while
in the boat.
• Prepare other boat operators. Instruct at least one person on
board in the basics of starting and operating the engine and boat
handling in case the driver becomes disabled or falls overboard.
• Do not overload your boat. Most boats are rated and certified
for maximum load (weight) capacities (refer to your boat capacity
plate). 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 fishing seats, any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping,
unexpected loss of boat control or sudden boat movement could
cause a person to be thrown overboard or into the boat.
• Never be under the influence of alcohol or drugs while boat-
ing (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 “main-
tain 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.
9
• Never drive your boat directly behind a water skier in case
the skier falls. As an example, your boat traveling at 25 miles per
hour (40 km/hr) in 5 seconds will overtake a fallen skier who was
200 feet in front of you.
• Watch fallen skiers. When using your boat for water skiing or
similar activities, always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. The operator should always have the down skier in sight and never back up
to the skier or anyone in the water.
• Report accidents. Boat operators are required by law to file a
Boating Accident Report with their state boating law enforcement
agency when their boat is involved in certain boating accidents.
A boating accident must be reported if (1) there is loss of life or
probable loss of life, (2) there is personal injury requiring medical
treatment beyond first aid, (3) there is damage to boats or other
property where the damage value exceeds $500.00 or (4) there
is complete loss of the boat. Seek further assistance from local
law enforcement.
10
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.
CA283
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
90-86168--3) from your dealer, distributor, or Mercury Marine.
11
CA7
Conditions Affecting
Operation
Weight Distribution
Positioning of weight (passengers and gear) inside the boat has the
following effects:
Shifting weight to rear (stern) will:
• Generally increases speed and engine RPM.
• At extremes can cause boat to porpoise.
• Causes bow to bounce in choppy water.
• Increases danger of following wave splashing into boat when
coming off plane.
Shifting weight to front (bow) will:
• Improve ease of planing.
• Improve rough water ride.
• At extremes, can cause boat to veer back and forth (bow steer).
CA8
Bottom Of Boat
T o maintain maximum speed, the following conditions of the boat bottom should be observed.
A. Clean, free of barnacles and marine growth.
B. Free of distortion; nearly flat where it contacts the water.
C. Straight and smooth, fore and aft.
Marine vegetation may accumulate when boat is docked. This
growth must be removed before operation; it may clog water inlets
and cause engine to overheat.
12
CA9
Cavitation
Cavitation occurs when water flow cannot follow the contour of a
fast-moving underwater object, such as a gear housing or propeller.
Cavitation permits the propeller to speed up, but the boat speed to
reduce. Cavitation can seriously erode the surface of the gear housing or propeller. Common causes of cavitation are:
A. Weeds or other debris snagged on propeller or gear housing.
B. Bent propeller blade or damaged gear housing skeg.
C. Raised burrs or sharp edges on propeller or gear housing.
CA10
Ventilation
Ventilation is caused by surface air or exhaust gases which are introduced around the propeller resulting in propeller speedup and a reduction in boat speed. Excessive ventilation is annoying and usually
caused by:
A. Drive unit trimmed out too far.
B. A missing propeller diffuser ring.
C. A damaged propeller or gear housing, which allows exhaust
gases to escape between propeller and gear housing.
D. Drive unit installed too high on transom.
CA294
Propeller Selection
IMPORTANT: Installed propeller must allow engine to run at
its specified maximum wide-open-throttle revolutions per
minute (RPM). Use an accurate service tachometer to verify
engine operating RPM.
It is the responsibility of the boat manufacturer and/or the selling
dealer to equip the power package with the correct propeller(s). Specified engine wide-open-throttle (WOT) and operating RPM range
are listed in “SPECIFICATIONS”.
13
IMPORT ANT : The engines covered in this manual are equipped
with an RPM rev-limiter that is set to an upper (or limited) RPM
amount. This limit is slightly above the normal operating range
of the engine and is designed to help prevent damage from excessive engine RPM. Once the RPM drop into the recommended
operating RPM range normal engine operation resumes.
Select a propeller that will allow the engine power package to operate
at or near the top end of the recommended wide-open-throttle operating RPM range with a normal load. High RPM, caused by an excessive trim angle, should not be used in determining correct propeller
selection.
If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause higher than normal wear
and/or damage. Generally , there is a 200-300 RPM change between
propeller pitches.
After initial propeller selection, the following common problems may
require that the propeller be changed to a lower pitch:
• Warmer weather and greater humidity cause an RPM loss.
• Operating in a higher elevation causes an RPM loss.
• Operating with a damaged propeller or dirty boat bottom causes
an RPM loss.
• Operating with increased load ( additional passengers, pulling
skiers, etc.)
For better acceleration, such as is needed for water skiing, use the
next lower pitch propeller. However, do not operate at full throttle
when using the lower pitch propeller but not pulling skiers.
14
CA12
How Elevation And Climate Affect Performance
Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity , barometric pressure and temperature do have a noticeable effect on the
density of air. Heat and humidity thin the air. This condition can become particularly annoying when the propeller testing was done on
a cool, dry day . Then later; on a hot, sultry day, the boat doesn’t seem
to have the same performance.
Although some performance can be regained by dropping to a lower
pitch propeller, the basic problem still exists. In some cases, a gear
ratio change to more reduction is possible and very beneficial.
Summer conditions of high temperature, low barometric pressure
and high humidity all combine to reduce the engine power. This, in
turn, is reflected in decreased boat speeds, as much as 2 or 3 miles
per hour in some cases. Nothing will regain this speed for the boater,
but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine running on a hot, humid, summer day , may encounter a loss of
as much as 14% of the horsepower it would produce on a dry , brisk
spring or fall day . With the drop in available horsepower , this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended RPM. This will result in further loss
of horsepower at the propeller with another decrease in boat speed.
This secondary loss, however, can be somewhat regained by switching to a lower-pitch propeller that allows the engine to again run at
recommended RPM.
For boaters to realize optimum engine performance under changing
weather conditions, it is essential that the engine be propped to allow
it to operate at or near the top end of the recommended maximum
RPM range at wide-open-throttle with a normal boat load.
Not only does this allow the engine to develop full power, but equally
important is the fact that the engine also will be operating in an RPM
range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine.
15
CA13
Important Information
Operation And Maintenance
OWNER/OPERATOR RESPONSIBILITIES
It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance instructions are complied
with for safe operation and to return the unit to an Authorized MerCruiser Dealer for a periodic checkup.
Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects
in workmanship or material within the terms of the warranty . Individual operating habits and usage contribute to the need for maintenance
service.
Proper maintenance and care of your power package will assure optimum performance and dependability , and will keep your overall operating expenses at a minimum. See your Authorized MerCruiser
Dealer for service aids.
CA14
DEALER RESPONSIBILITIES
In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as:
• Make sure that the boat is properly equipped.
• Prior to delivery , make certain that the MerCruiser power package
and other equipment are in proper operating condition.
• Make all necessary adjustments for maximum efficiency.
• Familiarize the customer with the on-board equipment.
• Explain and demonstrate the operation of the power package and
boat.
• At the time of delivery , the dealer should provide you with a copy
of a Predelivery Inspection Checklist.
• Your selling dealer should fill out the Warranty Registration Card
completely and mail it to the factory immediately upon sale of the
new product.
16
CA15
Freezing Temperature Operation
IMPORT ANT : It boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Refer to “COLD WEATHER or EXTENDED STORAGE” for draining instructions.
CA17
Drive Unit Impact Protection
The Power Trim hydraulic system is designed to provide impact protection for drive unit. If a submerged object is struck while boat is
moving forward, the hydraulic system will cushion the kickup of drive
unit as it clears the object, reducing damage to unit. After drive unit
has cleared object, the hydraulic system allows drive unit to return
to original operating position, preventing loss of steering control and
engine overspeed.
Use extreme caution when operating in shallow water or where underwater objects are known to be present. Use extreme care to prevent striking submerged object while operating in REVERSE. No impact protection is provided in REVERSE.
If drive unit should strike a submerged object, stop engine as soon
as possible and inspect drive unit for damage. If damage is present
or suspected, boat should be taken to an Authorized MerCruiser
Dealer for thorough inspection and necessary repair. Operating a
damaged drive unit could cause additional damage to other parts of
drive unit, or could affect control of boat. If continued running is necessary, do so at greatly reduced speeds.
IMPORT ANT: Impact protection system cannot be designed to
ensure total protection from impact damage under all conditions.
17
CA18
Attention Required After Submersion
• Before recovery, contact a MerCruiser Dealer.
• After recovery, immediate service by an Authorized MerCruiser
Dealer is required to prevent serious damage to power package.
CA19
Trailering Boat
Boat can be trailered with drive unit in “up” or “down” position. Adequate road clearance is required between road and gear housing
skeg when trailering with drive unit in “down” position.
If adequate road clearance is a problem, place drive unit in full trailer
position and support with an optional trailer kit which is available from
your Authorized MerCruiser Dealer.
18
CA20
Launching And Boat Operation Care
!
CAUTION
During launching from a trailer , if the unloading ramp is steep
or the trailer bed must be tilted, the boat may enter the water rapidly and at a steep angle. This may force water through the exhaust system into the cylinders. The more weight on the transom, the more likely this is to occur.
Slowing down rapidly or stopping suddenly may cause a following wave to “swamp” the transom. In this instance, water may
enter the cylinders through the exhaust system.
When backing up rapidly, the same situation may occur as
stated in the preceding paragraph.
In any of these situations, water entering the engine could cause severe damage to internal parts. Refer to “Attention Required After
Submersion”.
CA21
Stolen Power Package
If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to
whom the recovery is to be reported. This “Stolen Motor” information
is placed into a file at Mercury Marine to aid authorities and dealers
in recovery of stolen motors.
19
CA22
Replacement Service Parts
!
WARNING
Electrical, ignition and fuel system components on MerCruiser
gasoline power packages are designed and manufactured to
comply with U.S. Coast Guard rules and regulations to minimize
risks of fire or explosion.
Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations,
could result in a fire or explosion hazard and should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed
and tightened. If not, any electrical or ignition component would
permit sparks to ignite fuel vapors from fuel system leaks, if
they existed.
Marine engines are expected to operate at or near full–throttle for
most of their life. They are also expected to operate in both fresh and
saltwater environments. These conditions require numerous special
parts. Care should be exercised when replacing marine engine parts
as specifications are quite different from those of the standard automotive engine.
For example, one of the most important, and probably the least suspected special replacement part, is the cylinder head gasket. Since
saltwater is highly corrosive, the steel-type automotive head gasket
cannot be used. A marine engine head gasket uses special materials
to resist corrosive action.
Since marine engines must be capable of running at or near maximum RPM much of the time, special valve springs, valve lifters, pistons, bearings, camshafts and other heavy-duty moving parts are required for long life and peak performance.
These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance.
20
CA23
Do-It-Yourself Maintenance Suggestions
If you are one of those persons who likes to do-it-yourself, here are
some suggestions for you.
• Present-day marine equipment, such as your MerCruiser power
package, are highly technical pieces of machinery . Electronic ignition and special carburetion provide greater fuel economies, but
also are more complex for the untrained mechanic.
• Do not attempt any repairs which are not covered in this manual
unless you are aware of the precautions (“Cautions” and “Warnings”) and procedures required. Your safety is of our concern.
• If you attempt to service the product yourself, we suggest you or-
der the service manual for that model. The service manual outlines the correct procedures to follow. It is written for the trained
mechanic, so there may be procedures you don’t understand. Do
not attempt repairs if you do not understand the procedures.
• There are special tools and equipment that are required to per-
form some repairs. Do not attempt these repairs unless you have
these special tools and/or equipment. You can cause damage to
the product in excess of the cost a dealer would charge you.
• Also, if you partially disassemble an engine or drive assembly and
are unable to repair it, the dealer’s mechanic must reassemble the
components and test to determine the problem. This will cost you
more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem.
• Do not telephone the dealer, service office or the factory to at-
tempt for them to diagnose a problem or request the repair procedure. It is difficult for them to diagnose a problem over the telephone. A doctor can’t and won’t diagnose your illness by
telephone; he must examine you personally, just as a mechanic
must examine your power package.
• Your Authorized Dealer is there to service your power package.
He has qualified factory-trained mechanics.
It is recommended you have the dealer do periodic maintenance
checks on your power package. Have him winterize it in the fall and
service it before the boating season. This will reduce the possibility
of any problems occurring during your boating season when you
want trouble-free boating pleasure.
21
CA24
20-Hour Break-In Period
IMPORTANT: The first 20 hours of operation is the engine
break-in period. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. During this break-in period, the following rules must be observed:
• Do not operate below 1500 RPM for extended periods of time for
first 10 hours. Shift into gear as soon as possible after starting and
advance throttle above 1500 RPM if conditions permit safe op-
eration.
• Do not operate at one speed consistently for extended periods.
• Do not exceed 3/4 throttle during first 10 hours. During next 10
hours, occasional operation at full throttle is permissible (5 minutes at a time maximum).
• Avoid full throttle acceleration from IDLE speed.
• Do not operate at full throttle until engine reaches normal operat-
ing temperature.
• Frequently check crankcase oil level. Add oil if needed. It is nor-
mal for oil consumption to be high during break-in period.
• After 20-hour break-in period, drain crankcase oil and replace oil
filter (see MAINTENANCE). Fill crankcase with correct oil (see
SPECIFICATIONS).
CA211
After Break-In Period
T o help extend the life of your MerCruiser power package, the following recommendations should be considered;
• Use a propeller that allows the engine to operate at or near the top
of the maximum RPM range (See “Specifications” section) when
at full throttle with a normal boat load.
• Operation at 3/4 throttle setting or lower is recommended. Refrain
from prolonged operation at maximum (full throttle) RPM.
22
CB270
20-Hour Checkup
After first 20 hours of operation, an Authorized MerCruiser Dealer
should be contacted for the following maintenance. The boat owner
is responsible for any charges.
• Change crankcase oil and filter.
• Retorque intake manifold to
35 lb.ft. (48 N·m).
• Check all fluid levels.
• Cooling System: Inspect all hoses for damage and deterioration;
check all hose clamps for adequate tightness.
• Check carburetor adjustment.
• Inspect ignition system and timing.
• Check for loose, missing or damaged parts.
• Check shift and throttle cable adjustments, and lubricate and in-
spect for loose, damaged or missing parts.
• Steering System: Lubricate and inspect for loose, damaged or
missing parts.
• Inspect all drive belts.
• Check engine alignment. Include proper lubrication of U-joint and
splined shaft.
• Inspect Complete Engine Exhaust System (Externally) for dam-
age and deterioration; check all hose clamps for adequate tightness.
• Retorque gimbal ring clamping screws to 50-55 lb. ft. (67-74 N⋅m).
• Check that both front engine mount locknuts are tightened se-
curely. Then, check to ensure that tab washers are bent down
over adjusting nuts.
• Check that rear engine mounts are torqued to
35-40 lb.ft. (47-54 N
⋅m).
23
CA26
1
10
9
70514
70523
70522
2
70515
3
4
5
70516
70517
70518
8
24
70521
7
70520
6
70519
CA27
Operation
Instrumentation
The following is a brief explanation of instrumentation typically found
on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety
of instrumentation and manufacturers, you should have your boat
dealer explain the particular gauges and normal readings that will appear on your style gauges.
1 Speedometer: Indicates boat speed.
2 Tachometer: Indicates engine RPM.
3 Oil Pressure Gauge: Indicates engine oil pressure.
4 Battery Meter: Indicates battery voltage.
5 Water Temperature Gauge: Indicates engine operating tempera-
ture.
6 Fuel Gauge: Indicates fuel tank volume.
7 Power Trim Gauge: Indicates drive unit angle (trim up/out and
down/in).
8 Hour Meter: Records engine running time.
9 Bilge Blower Switch: Must be operated for five minutes before
starting engine, to ventilate bilge.
10Ignition Switch: Allows operator to start and stop engine.
25
CB218
705161A
26
1B
1C
70518
71987
CB200
Audio Warning System
Y our MerCruiser power package is equipped with an Audio W arning
System.
1 The audio warning system buzzer will sound if one of the following
occur:
A Insufficient Oil Pressure
B Excessive Engine Temperature
C Insufficient Drive Lubricant
NOTE: To provide a test of the system, the audio warning buzzer will
sound when the ignition switch is first turned to the run position, prior
to cranking the engine. Once the engine starts, the buzzer should
stop.
!
CAUTION
Avoid engine damage. Do not operate engine once the buzzer
has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION.
The Audio Warning System will not protect the engine from
damage. It is designed to warn the operator that a problem has
occurred.
When the buzzer sounds with the engine running, stop engine immediately . Investigate cause and correct it, if possible. If cause cannot be determined, consult your Authorized MerCruiser Dealer.
27
CB125
1
71466
4
2
70525
70527
28
71773
5
70528
3
70526
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