Mercury D4.2L, D3.6L, D4.2L LD, D2.8L D-Tronic, bravo 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 Warranty Sections of this manual. The warranty state-
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.

CE344

WARNING

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

WARNING

CALIFORNIA

PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.

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.

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.

Diesel Engines - Bravo Models

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

Printed in U.S.A.

1999, Mercury Marine 90Ć860094990 1099

CA753

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

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

CONSUMER AFFAIRS DEPARTMENT

2

CD474

Identification Record

Please record the following information:

1

Engine Model and Horsepower

2

Transom Assembly Serial Number (Sterndrive)

3

Transmission Model (Inboard)

4

Propeller Number

5

Hull Identification Number (HIN)

6

Boat Manufacturer

7

Exhaust Gas Emissions Certificate Number (Europe Only)

Serial Numbers

Engine Serial Number

Gear Ratio Sterndrive Unit Serial Number

Gear Ratio Transmission Serial Number

Pitch Diameter

Purchase Date

Boat Model Length

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.

5

7

SERIAL NUMBER

BSO/SAV

1

2

7 (D-Tronic)

2

BRUNSWICK CORP.

FOND DU LAC,WIS.

54935 U.S.A.

1

71935

1

73929

BSO/SAV

1

7

4

74298

3

CD673

TABLE OF CONTENTS

Page

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

WELCOME! 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Record 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Warranty Information 6

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

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

Mercruiser Diesel Limited Warranty 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Read This Manual Thoroughly 13
General Information 14

Lanyard Stop Switch 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Emissions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wave And Wake Jumping 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impact With Underwater Hazards 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Boating Suggestions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting People In The Water 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed And High-Performance Boat Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conditions Affecting Operation 22

Weight Distribution 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cavitation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Selection 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How Elevation And Climate Affect Performance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Information 25

Operation and Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Freezing Temperature And Cold Weather Operation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Plug and Bilge Pump 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Impact Protection 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Launching and Boat Operation Care 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attention Required After Submersion 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailering Boat 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stolen Power Package 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Service Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do-It-Yourself Maintenance Suggestions 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosing EDI Problems (If So Equipped) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiple EDI Engine Battery Precautions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Break-In 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Unit 10-Hour Break-In Period 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Break-In Period 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End of First Season Checkup 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Hour Checkup 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 35

Quicksilver Instruments and Instrumentation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Overload Protection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MerCathode System 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Remote Controls 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Trim 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting, Shifting and Stopping - D3.6L, D4.2L and D4.2L LD 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Chart - D3.6L, D4.2L and D4.2L LD 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting, Shifting and Stopping - D2.8L D-Tronic and D4.2L D-Tronic 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Chart - D2.8L D-Tronic and D4.2L D-Tronic 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 57

Seacock 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seawater Strainer 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-Freeze/Coolant 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Requirements 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel Fuel In Cold Weather 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Oil 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Capacities 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 64

General Information 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Aids 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Schedules 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Maintenance 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Fluid Levels 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Fluids 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Filter Cleaning/Replacement 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Belts - All Engines, Except D3.6L Engines 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Belts - D3.6L Engines 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shift Cable 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Quicksilver Seawater Strainer 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Seawater Cooling System 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seawater Pump Impeller 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propellers (Bravo One and Two) 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corrosion And Corrosion Protection 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather or Extended Storage 107

Battery Winter Storage 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Package Layup 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Instructions 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Package Recommissioning 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 114
Owner Service Assistance 120

Local Repair Service 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Away From Home 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts And Accessories Inquiries 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resolving A Problem 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Marine Service Offices 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Service Literature 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordering Literature 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Owner’s Logbook 125

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

CD600

Warranty Policy

Mercruiser Diesel Limited Warranty

I. We warrant each new production MerCruiser Diesel Sterndrive Power Package, Inboard Engine and

Accessories attached thereto (hereafter referred to as “Product”), manufactured by MerCruiser
(hereafter referred to as the “Company”), to be free from defects in material and workmanship, but only
when the customer purchases or obtains predelivery service from a Dealer authorized by us to
distribute MerCruiser Product in the country in which the sale or predelivery service occurred. This
warranty shall apply only to pleasure craft and light-duty craft applications.

II. This warranty shall become effective upon the date of sale to the first purchaser or user of the Product.

The warranty period for Pleasure Craft applications is one (1) year from date of sale to the first
purchaser or user of the product. The warranty period for Light-Duty Craft applications is one (1) year
from date of sale to the first purchaser or user of the product, or the accumulation of 500 hours of engine
operation, whichever occurs first. For purposes of this warranty Pleasure Craft is defined as a
recreational planing craft used exclusively for pleasure and recreation. Light-Duty Craft is defined as
a planing hull vessel used in law enforcement, commercial, or professional entertainment activity, or
in an enterprise or venture in which revenue (in any amount) is generated directly or indirectly.
Light-Duty Craft is further defined as having an annual operating time not to exceed 500 hours,
Wide-Open-Throttle operation is limited to less that 10% of operating time, and continuous cruising
RPM is limited to at or less than 90% of Wide-Open-Throttle RPM. If the applicable law prohibits
limitation of warranty coverage to one (1) year, then the warranty shall be the minimum period required
by law. The unused period of the applicable warranty, i f a ny, is transferable to subsequent purchasers.

III. To validate the warranty, the “W arranty Registration Card”, included with each Product, must be prop-

erly completed by the selling dealer and forwarded immediately after the sale to Mercury Marine
(U.S.A. and Canada) or to a Marine Power International Branch, or Distributor Service Office (outside
the U.S.A. and Canada).

IV. Purchaser must provide proof of purchase and substantiate the original date of sale by presenting to

the dealer, authorized to service the Product, the original purchaser’s copy of the “Warranty
Registration Card” or the “Owner Warranty Registration Card”. If either of these items is not available,
purchaser must provide a copy of the original purchaser’s “Bill of Sale” (Sales Contract) for the Product
to be serviced. Warranty claims will not be accepted by the dealer until the original date of sale and
Product serial number can be verified.

V. It is a condition for the continuation of this warranty that the Product be taken to an authorized

MerCruiser Service Dealer, after 100 hours of engine operation, but not later than 150 hours, for
required checks and adjustments. A copy of the dealer service work order must be retained as
evidence of the completion of this requirement.

VI. Since this warranty applies to defects in material or workmanship, it does not apply to normal wear,

adjustments, tune-ups or to damage caused by: 1) Neglect, lack of maintenance, accident, abnormal
operation, improper installation or service; 2) Use of a propeller not properly suited to application/boat
load or, failure to follow instructions in applicable service and warranty information manuals or
operation and maintenance manual; 3) Use of an accessory or part not manufactured or sold by us;

4) Operation with fuels, oils, lubricants or coolants/coolant additives which are not suitable for use with
the Product or recommended by us; 5) Participating in or preparing for racing or other competitive
activity or operating with racing type lower unit; 6) Alteration or removal of parts; 7) Water entering
engine cylinder/s through the exhaust system or air intake system; 8) Use of product in a
full-displacement or semi-displacement hull vessel; or 9) Use or operation of the product in a manner
inconsistent with the “Recommended Operation/Duty Cycle” section of the Operation, Maintenance
and Warranty Manual.

8

MerCruiser Diesel Limited Warranty (continued from previous page)

VII. Reasonable access must be provided to the Product for warranty service. This warranty will not apply

to: 1) Haul-out, launch, towing and storage charges, telephone or rental charges of any type, inconve­nience, or loss of time or income, or other consequential damages; or 2) Removal and/or replacement
of boat partitions or material because of boat design for necessary access to the Product.

VIII. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer

authorized to service the Product. If purchaser cannot deliver Product to such authorized dealer, he
may give notice in writing to the Company (U.S.A. and Canada) or the nearest Marine Power Interna­tional Branch or Distributor Service Office (outside the U.S.A. and Canada). We shall then arrange f or
the inspection and repair, provided such service is covered under this warranty. Purchaser shall pay
for all related transportation charges and/or travel time. If the service is not covered by this warranty,
purchaser shall pay for all related labor and material, and any other expenses associated with that
service. Any Product or parts shipped by purchaser for inspection or repair must be shipped with trans­portation charges prepaid.

IX. Our sole and exclusive obligation under this warranty shall be limited to repairing a defective part or,

at our option, refunding the purchase price or replacing such part or parts with new or Mercury certified
remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in mate­rial or workmanship as covered by this warranty. The repair or replacement of parts, or the perfor­mance of service, under this warranty, does not extend the period of this warranty beyond its original
expiration date. We reserve the right to improve the design of any Product without assuming any ob­ligation to modify any Product previously manufactured.

X. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS

WARRANTY. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM
THIS WARRANTY. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY.
SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY
TO YOU.

XI. 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

CD622

Warranty Coverage and Exclusion

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 consumer sale is made in the country
to which distribution is authorized by us.

Should you have any questions concerning warranty coverage contact your authorized dealer. They will be
pleased to answer any questions that you may have.

WARRANTY DOES NOT APPLY TO THE FOLLOWING:

• Minor adjustments or checks, including checking fuel injection pump timing, cleaning fuel injectors, filters, or

adjusting belts, 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.

• Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal

engine condition which could result in a failure, condition responsible for noise should be corrected under the
warranty.

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

• Water entering the engine via the air filter or exhaust system or submersion. Also, water in the starter motor.

• Starter motors and/or armatures or field coil assembly, which are burned, or where lead is thrown out of com-

mutator because of excess cranking.

• Valve or valve seat grinding required because wear.

• Failure of any parts caused by lack of cooling water, which results from starting power package out of water,

foreign material blocking inlets or power package being mounted too high.

• Use of fuels and lubricants which are not suitable for use with or on the product. Refer to your Operation and

Maintenance Manual.

• Our limited warranty does not apply to any damage to our products caused by the installation or use of parts

and accessories which are not manufactured or sold by us. Failures which are not related to the use of those
parts or accessories, are covered under warranty, if they otherwise meet the terms of the limited warranty for
that product.

10

CE350

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 W arranty Registration Card and a copy of the bill of sale to show
proof of ownership. In the United States and Canada, mail to:

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

• A new Owner Warranty Registration Card will be issued with the new owner’s name and address. Registration

records will be changed on the factory computer registration file.

• There is no charge for this service.

Outside the United States and Canada, please contact the closest Mercury Marine Service Office, or the
closest distributor in your country, for the transferable warranty procedure that would apply to you.

11

CD594

THIS PAGE IS INTENTIONALLY BLANK

12

CD326

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 In -
ternational HAZARD Symbol
ular 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 partic-

!

WARNING

CAUTION

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.
We strongly recommend that other occupants be instructed on proper starting and operation
procedures so they will be prepared should they be required to operate the power package and boat
in an emergency.

WARNING

The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with
your MerCruiser unit. If your MerCruiser unit is equipped with an accessory not manufactured by
Mercury Marine, be sure to read the Operation and Maintenance Manual for the accessory before
operation. If you haven’t been supplied with such a manual, contact your dealer or the manufacturer
of the accessory to secure the applicable manual.

Electrical system components on this engine are not external ignition protected. DO NOT STORE OR
UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN
MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to
comply could result in fire, explosion and/or severe personal injury.

WARNING

13

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.

1

74608

14

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.

15

CA641

CA642

1

Courtesy of ABYC

2A

2B

3A

16

3B

Courtesy of ABYC

CA620

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

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

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

WARNING

Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon
monoxide in sufficient concentration can lead to unconsciousness, brain damage or death.

GOOD VENTILATION

Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

1 Example of desired air flow through the boat.

CA643

POOR VENTILATION

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

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

2 Examples of poor ventilation while boat is stationary:
A Running the engine when the boat is moored in a confined space.
B Mooring close to another boat that has its engine running.

3 Examples of poor ventilation while boat is moving:
A Running the boat with the trim angle of the bow too high.
B Running the boat with no forward hatches open (station wagon effect).

17

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.

18

CD604

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 (24 to 40 km/h).

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.

19

CA476

Safe Boating Suggestions

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

• Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating

safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary , (2) The Power Squad­ron, (3) The Red Cross and (4) your state or provincial boating law enforcement agency. Inquiries may be
made to the Boating Hotline, 1-800-368-5647 or the Boat U.S. Foundation information number

1-800-336-BOAT.
We strongly recommend that all powerboat operators attend one of these courses.
You should also review the NMMA Sources of Waterway Information booklet. It lists regional sources of safety,

cruising and local navigation and is available at no charge by writing to:
Sources of Waterway Information

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

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

are properly made.

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

boating:
(1) Approved fire extinguisher(s); paddle or oar.
(2) Signal devices: flashlight, rockets or flares, flag and whistle or horn.

(3) Spare propeller, thrust hubs and an appropriate wrench.
(4) Tools for necessary minor repairs; first aid kit and book.

(5) Anchor and extra anchor line; water-proof storage containers.
(6) Manual bilge pump and extra drain plugs; compass and map or chart of area.
(7) Spare operating equipment; batteries, bulbs, fuses, etc.
(8) Transistor radio
(9) Drinking water

• Know signs of weather change and avoid foul weather and rough-sea boating.

• Tell someone where you are going and when you expect to return.

• Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back

(stern) of the boat. Just shifting the drive unit into neutral is not sufficient.

• Use personal flotation devices. Federal Law requires that there be a U.S. Coast Guard approved, wear-

able-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.

20

• 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.

21

CA7

Conditions Affecting Operation

Weight Distribution

Positioning of weight (passengers and gear) inside the boat has the following effects:
A. 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.

B. Shifting weight to front (bow) will:

• Improve ease of planing on some boats.

• Improve rough water ride.

• At extremes, can cause boat to veer back and forth (bow steer).

CA8

Bottom Of Boat

To 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.

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 t o 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 skew.
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.

22

CD670

Propeller Selection

IMPORTANT: Installed propeller must allow engine to run at the upper end of the specified throttle
operating revolutions per minute (rpm) range, with a normal load aboard the boat. 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 below and
in “Specifications.”

IMPORTANT: The engines covered in this manual, depending upon the model, are equipped with either
a governor or a device that limits engine rpm. Be sure that propeller being used does not allow engine
to run against the governor or limiter, as a significant loss in performance will result.

Engine rpm Limits

MCM Model Engine Specified Operating Rpm Range

Rpm Governor or Limiter Setting

(Begins At: )

D3.6L 3600-3800 3830± 20
D4.2L 3400-3600 3630± 20

D4.2L LD 3400-3600 3650± 50
D2.8L D-Tronic
D4.2L D-Tronic

3600-3800 3875± 50

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 specified range, the propeller must be changed to prevent loss of perfor­mance and possible engine damage. On the other hand, operating an engine above the specified operating rpm
range will cause higher than normal wear and/or damage. Generally , there is a 200 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 (not as significant on D-Tronic models).

• Operating in a higher elevation causes an rpm loss (not as significant on D-Tronic models).

• 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.

23

CD476

How Elevation And Climate Affect Performance

NOTE: Engines equipped with EDI (D-Tronic engines) reduce the effects of changes in elevation and climate
by automatically adjusting fuel flow for weather conditions and elevation. EDI engines however, do not compen­sate for increased loading or hull conditions.

Generally, elevation has a very noticeable ef fect 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 an engine is propped out on a cool, dry day in spring and later, on
a hot, sultry day in August, doesn’t have its old zip.

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.

24

CD5

Important Information

CD598

Operation and Maintenance

RECOMMENDED OPERATION / DUTY CYCLE

It is the operator’s responsibility to operate within the following specified operational capability, or duty cycle, as
applicable to engine and installation:

PLEASURE DUTY RATING

• Engine Specified Operating rpm Range

Model

D4.2L and D4.2L LD 3400-3600
D3.6L, D2.8L D-Tronic, D4.2L D-Tronic 3600-3800

Rpm

• Wide-Open-Throttle operation is limited to short periods of time.

LIGHT DUTY RATING

• Engine Specified Operating rpm Range

Model

D4.2L and D4.2L LD 3400-3600
D3.6L, D2.8L D-Tronic, D4.2L D-Tronic 3600-3800

Rpm

• Wide-Open-Throttle operation is limited to less that 10% of operating time.

• Continuous cruising rpm is limited to at or less than 90% of Wide-Open-Throttle rpm.

• Annual operating time is not to exceed 500 hours.

NOTE:

Pleasure duty rating

applies to recreational planing craft used exclusively for pleasure and recreation.

Light duty rating
stated above). Examples of Light Duty applications include, but are not limited to: search and rescue craft, fast
patrol boats, fire boats, dive boats, and limited season fishing boats such as sport-fish charter boats. Application
to common commercial crafts having full-displacement or semi-displacement hulls exceeds the recommended
operational capability, or duty cycle.

IMPORTANT: Damage caused by improper application or failure to operate within the operational
capability, or duty cycle, will not be covered by the MerCruiser Diesel Limited Warranty.

applies to planing boats where the use of full rated power at maximum rated RPM is limited (as

25

CD478

OWNER/OPERATOR RESPONSIBILITIES

It is the operator’s responsibility to perform all safety checks, ensure that all lubrication and maintenance instruc­tions are complied with for safe operation, and 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.

CAUTION

Except on the D-Tronic models, the injection pump lever Wide-Open-Throttle (W.O.T.) Stop Screw
adjusts the engine speed governor, and is factory set and sealed. Readjusting the governed speed and
operating above the specified RPM will cause extensive engine damage and/or failure. Removal of the
seal and/or readjustment of the governed speed is considered misuse of engine, and resulting
damages will not be covered by the limited warranty.

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 operat-

ing 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.

• Y our selling dealer should fill out the Warranty Registration Card completely and mail it to the factory (branch

or distributor) immediately upon sale of the new product.

26

CE8

Freezing Temperature And Cold Weather Operation

IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to
prevent freezing damage to power package. Refer to the following and to “Cold Weather or Extended
Storage” for related information and draining instructions.

CAUTION

Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or
immediately after cold weather use, if the possibility of freezing temperatures exist. Failure to comply
may result in trapped water causing freeze and/or corrosion damage to engine.

In order to operate the engine in temperatures of 32° F (0° C) or lower, observe the following instructions:

• At the end of each daily operation, COMPLETELY drain seawater section of cooling system to protect against

damage by freezing.

• At the end of each daily operation, drain water from water separator, if equipped. Fill fuel tank at end of daily

operation to prevent condensation.

• Use required permanent-type antifreeze solution to protect components against damage by freezing.

• Be sure to use proper cold weather lubrication oil, and be sure 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 optimum condition.

• At temperatures of –4° F (–20° C) and below, it is recommended that you use a coolant heater to improve

cold starting.

• If operating in arctic temperatures of –20°F (–29°C) or lower, consult your dealer for information about spe-

cial cold weather equipment and precautions.

CA408

Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally
equipped with a drain plug and/or a bilge pump. It is very important to check these items on a regular basis to
ensure that the water level does not rise to come in contact with your power package. Components on your
engine will be damaged if submerged. Damage caused by submersion is not covered by the MerCruiser Limited
Warranty.

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 kick-up 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 over speed.

Use extreme caution when operating in shallow water or where underwater objects are known to be present.
Use extreme care to prevent striking submerged objects 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.

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

27

CA20

Launching and Boat Operation Care

CAUTION

During launching from a trailer, i f 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
causing water to enter the cylinders through the exhaust system causing severe engine damage.

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”.

CA409

Attention Required After Submersion

• Before recovery, contact an Authorized 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 skew 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.

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.

CE9

Replacement Service Parts

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.

Since marine engines must be capable of running at or near maximum RPM much of the time, special pistons,
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.

28

CA772

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 fuel delivery systems 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 order 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 perform 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 attempt for them to diagnose a problem or request

the repair procedure. It is difficult for them to diagnose a problem over the telephone.

• Your Authorized Dealer is there to service your power package. They have qualified factory-trained

mechanics.

It is recommended you have the dealer do periodic maintenance checks on your power package. Have them
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.

29

CD329

Diagnosing EDI Problems (If So Equipped)

Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on Electronic Diesel
Injection (EDI) Systems. The Electronic Control Module (ECM) on these engines have the ability to detect some
problems with the system when they occur, and store a “Trouble Code” in the ECM’s memory. This code can
then be read later by a service technician using a special diagnostic tool.

CE335

Multiple EDI Engine Battery Precautions

SITUATION
Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the

alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all
of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply
any charging current.

EDI Electronic Control Module (ECM): The ECM requires a stable voltage source. During multiple engine op­eration, an onboard electrical device may cause a sudden drain of voltage at the engine’s battery. The voltage
may go below the ECM’s minimum required voltage. Also, the alternator on the other engine may now start
charging. This could cause a voltage spike in the engine’s electrical system.

In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM
will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine
just appears to have an ignition miss.

Recommendations
Batteries: Boats with multi-engine EDI power packages require each engine be connected to its own battery.

This ensures that the engine’s Electronic Control Module (ECM) has a stable voltage source.
Battery Switches: Battery switches should always be positioned so each engine is running off its own battery.

DO NOT operate engines with switches in BOTH or ALL position. In an emergency, another engine’s battery can
be used to start an engine with a dead battery.

Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the
boat. Isolators should not be used to charge the battery of another engine in the boat unless the type of isolator
is specifically designed for this purpose.

Generators: The generator ’s battery should be considered in the same manner as another engine’s battery.

30