Mercury HP700 SCi User Manual

Thank You

for your purchase of 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 & 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.

Again, thank you for purchasing one of our Mercury Marine products. We sincerely hope your boating will be pleasant!

Mercury Racing, N7480 County Road "UU" Fond du Lac, WI 54935-9585

7406

Warranty Message

WARNING

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

The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.

Safety Alerts and Notices

Throughout this publication, dangers, warnings, cautions, and notices., accompanied by the international HAZARD symbol

, are used to alert the boat operator and technician to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe these safety alerts carefully.

These safety alerts alone can not eliminate the hazards they signal. Strict compliance to these special instructions when performing the service, and common sense operation are major accident prevention measures.

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

iii

NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Verado, Vazer, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, SmartCraft, VesselView, Quicksilver, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

TABLE OF CONTENTS

Warranty Information

Warranty Registration United States And Canada......................1

Transfer of Warranty....................................................................2

Mercury Racing Division One Year Limited Warranty.................2

Products Sold to Government Agencies......................................6

Warranty Against Corrosion (Worldwide)....................................6

Warranty Coverage and Exclusions for Mercury Racing Sterndrive

Products.......................................................................................7

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

.....................................................................................................8

General Information

Boater's Responsibilities............................................................13

Boat Horsepower Capacity........................................................13

High‑Speed and High‑Performance Boat Operation................. 14

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

Trailering Boat........................................................................... 15

Protecting People In The Water.................................................16

Exhaust Emissions.................................................................... 16

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

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

Safe Boating Suggestions......................................................... 21

Stolen Power Package.............................................................. 24

Specifications

Power Package Identification.................................................... 25

General Engine Specifications (HP700)....................................27

Engine Operating Limitations (HP700)......................................28

Fuel Requirements.................................................................... 28

Low Permeation Fuel Hose Requirement .................................30

Oil Recommendations............................................................... 31

Capacities..................................................................................32

Engine Break‑in.........................................................................33

After Break‑In Period.................................................................33

TABLE OF CONTENTS

Operation

Instrumentation..........................................................................34

Warning System........................................................................34

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

Remote Controls (Console Mounted Zero Effort)......................40

Power Trim................................................................................41

Starting, Shifting and Stopping..................................................46

Operation Chart.........................................................................48

Freezing Temperature Operation..............................................49

Drain Plug and Bilge Pump........................................................49

Launching And Boat Operation Care.........................................49

Conditions Affecting Operation

Weight Distribution.....................................................................50

Bottom Of Boat..........................................................................50

Cavitation...................................................................................50

Ventilation..................................................................................51

Propeller Selection.....................................................................51

Conditions That Lower Engine Performance.............................52

TABLE OF CONTENTS

vii

Maintenance

Servicing High Horsepower Engines.........................................53

Service Responsibilities.............................................................53

Replacement Service Parts.......................................................54

Do‑It‑Yourself Maintenance Suggestions..................................54

Maintenance Charts...................................................................56

Checking Fluid Levels................................................................61

Changing Fluids.........................................................................72

Lubrication Points......................................................................88

Sterndrive Cleaver Propeller Installation (NXT¹)........................89

Cleaver Propeller Installation (SSM)..........................................92

Flushing Cooling System...........................................................94

Seawater Pump Impeller Inspection..........................................94

Cleaning the Seawater (Raw Water) Section of the Engine Oil,

Power Steering, Fuel, and Transmission Coolers.....................95

Serpentine and Supercharger Drive Belts.................................98

Fuel Filters............................................................................... 101

Corrosion and Corrosion Protection........................................ 105

Battery..................................................................................... 108

Bottom of Boat......................................................................... 109

Inspection and Maintenance....................................................109

Attention Required After Submersion...................................... 110

Cold Weather or Extended Storage

Power Package Lay‑up............................................................111

Cooling System Draining Instructions......................................114

Battery Storage........................................................................118

Power Package Recommissioning.......................................... 118

TABLE OF CONTENTS

viii

Troubleshooting

Engine Will Not Crank .............................................................121

Engine Cranks But Will Not Start.............................................121

Engine Hard to Start, Runs Rough, Misses, and/or Backfires. 122

Poor Performance....................................................................122

Engine Coolant Temperature Too Low....................................122

Engine Coolant Temperature Too High................................... 123

Low Engine Oil Pressure.........................................................123

Power Trim Does Not Operate (Motor Doesn't Run)...............124

Battery Will Not Come Up On Charge.....................................124

Power Trim Does Not Operate (Motor Runs But Drive Unit Does

Not Move)................................................................................124

Electrical Analog Trim Gauge Malfunction...............................124

Remote Control Operates Hard, Binds, Has Excessive Free‑Play

or Makes Unusual Sounds.......................................................125

Steering Wheel Turns Hard or Jerky.......................................125

Seawater Pressure Is Below Specification..............................125

Owner Service Assistance

Local Repair Service................................................................126

Service Away from Home........................................................126

Parts and Accessories Inquiries..............................................126

Service Assistance..................................................................126

Mercury Mercruiser Service Offices.........................................127

Ordering Literature

United States and Canada.......................................................129

Outside The United States and Canada..................................129

Maintenance Log

Maintenance Log.....................................................................130

WARRANTY INFORMATION

Warranty Registration United States And Canada

Outside United States and Canada ‑ Check with your local distributor.

1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information. Mercury Marine Attn.: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax 920-929-5893

NOTE: Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States, should a safety recall notification under the Federal Safety Act be required.

2. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration.

IMPORTANT: Your warranty coverage begins at the time of sale, but warranty claims cannot be processed until the product is registered with Mercury Marine.

3. Upon processing the warranty registration, Mercury Marine will send the purchaser a Mercury Owner Resource Guide. The back page of this guide contains your warranty registration information and should be saved. If this registration verification is not received within 30 days, please contact your selling dealer immediately.

WARRANTY INFORMATION

Transfer of Warranty

The limited 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.

To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty registration department. In the United States and Canada, mail to:

Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 929 5893

Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail.

There is no charge for this service. For products purchased outside the United States and Canada,

contact the distributor in your country, or the Marine Power Service Center closest to you.

Mercury Racing Division One Year Limited Warranty

WHAT IS COVERED

Mercury Marine warrants its new products (and remanufactured products sold under the trade name "Pacemaker") to be free of defects in material and workmanship during the period described below.

WARRANTY INFORMATION

DURATION OF COVERAGE

This Limited Warranty provides coverage for one (1) year from either the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent purchaser upon proper re‑registration of the product.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

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

WHAT MERCURY WILL DO

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

WARRANTY INFORMATION

HOW TO OBTAIN WARRANTY COVERAGE

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

WARRANTY INFORMATION

WHAT IS NOT COVERED

This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part not manufactured or sold by us, operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operation and Maintenance Manual), alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system, or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the engine out of water, mounting the engine too high on the transom, or running the boat with the engine trimmed out too far. The commercial use of the product, defined as any work or employment related use of the product, or any income generating use of the product, even if such use is only occasional, will void the warranty. Use of the product for racing or other competitive activity, at any point, even by a prior owner of the product, voids the warranty. Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, tournament fees, club fees, prize money or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

WARRANTY INFORMATION

No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty.

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

Products Sold to Government Agencies

Contact the Mercury Racing Sales Department for a copy of the Government Agencies Warranty Packet Kit which explains the conditions required for government agencies to receive warranty when purchasing Mercury Racing Outboard or Sterndrive product.

Mercury Racing Sales Department N7840 County Road UU Fond du Lac, WI 54935 920-921-5330 Fax 920-921-6533

Warranty Against Corrosion (Worldwide)

IMPORTANT: Corrosion failure warranty is not available for this product.

WARRANTY INFORMATION

Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products

The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Mercury Racing Division Three Year Limited Warranty Against Corrosion Failure, the Mercury Racing Division 90 Day, 6 months and One Year Limited Warranties.

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 to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented.

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

GENERAL EXCLUSIONS FROM WARRANTY

1. Minor adjustments and tune‑ups, including checking, cleaning or adjusting spark plugs, ignition components, carburetor or EFI settings, filters, belts, controls, and checking lubrication made in connection with normal services.

2. Damage caused by lack of maintenance.

3. Haul‑out, launch, towing charges, and all related transportation charges and/or travel time, etc.

4. Additional service work requested by customer other than that necessary to satisfy the warranty obligation.

WARRANTY INFORMATION

5. 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 the 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).

6. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.

7. 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.

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

9. Water in the starter motor.

10.Starter motors and/or armatures or field coil assembly, which are burned, or where lead is thrown out of commutator because of excess cranking.

11.Valve or valve seat grinding required because of wear.

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Mercury Racing are pleased to explain the emission control system warranty on your 2009 sterndrive engine. In California, new sterndrive engines must be designed, built and equipped to meet the State’s stringent anti‑smog standards. Mercury Racing must warrant the emission control system on your sterndrive engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your sterndrive engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission‑related assemblies.

WARRANTY INFORMATION

Where a warrantable condition exists, Mercury Racing will repair your sterndrive engine at no cost to you, including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE:

Select emission‑related control parts from model year 2009 and later sterndrive engines are warranted for 3 years or 480 hours, whichever first occurs. Select mechanical emission‑related components are warranted for 3 years or 150 hours of operation, whichever first occurs.

OWNER’S WARRANTY RESPONSIBILITIES:

As the sterndrive engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Mercury Racing recommends that you retain all receipts covering maintenance on your sterndrive engine, but Mercury Racing cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

As the sterndrive engine owner, you should however be aware that Mercury Racing may deny you warranty coverage if your sterndrive engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your sterndrive engine to a Mercury Marine distribution center as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact Mercury Racing at 1‑920‑924‑2088.

COMPONENTS OF THE EMISSION CONTROL SYSTEM

1. Fuel Metering System a. Carburetor and internal parts (and/or pressure regulator or

fuel injection system) b. Air/fuel ratio feedback and control system c. Cold start enrichment system d. Intake valve(s)

2. Air Induction System

WARRANTY INFORMATION

a. Controlled hot air intake system b. Intake manifold c. Air filter d. Turbocharger system e. Heat riser valve and assembly

3. Ignition System a. Spark plugs b. Magneto or electronic ignition system c. Spark advance/retard system d. Ignition coil and/or control module e. Ignition wires

4. Lubrication System a. Oil pump and internal parts b. Oil injector(s) c. Oil meter

5. Positive Crankcase Ventilation (PCV) System a. PCV valve b. Oil filler cap

6. Exhaust Gas Recirculation (EGR) System a. EGR valve body and carburetor spacer if applicable b. EGR rate feedback and control system

7. Air Injection System a. Air pump or pulse valve b. Valves affecting distribution of flow c. Distribution manifold

8. Exhaust System

9. Catalyst or Thermal Reactor System a. Catalytic converter b. Thermal reactor c. Exhaust manifold d. Exhaust valve(s)

10.Miscellaneous Items Used in Above Systems

WARRANTY INFORMATION

a. Hoses, clamps, fittings, tubing, sealing gaskets or

devices, and mounting hardware b. Pulleys, belts and idlers c. Vacuum, temperature, check, and time sensitive valves

and switches d. Electronic Controls

STAR LABEL

Engines are labeled with one of the following star labels. The Symbol for Cleaner Marine Engines Means: Cleaner Air and Water ‑ for a healthier lifestyle and environment. Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil

than conventional carbureted two‑stroke engines, saving money and resources.

Longer Emission Warranty ‑ Protects consumer for worry free operation.

IMPORTANT: Although labeled as Two or Three Star, the engine(s) in this boat meet the requirements of the Air Resources Board's 2009 and later exhaust emission standards for High Performance Sterndrive and Inboard Marine Engines with power > 373 kW.

22531

One Star ‑ Low Emission

The One Star label identifies engines that meet the Air Resources Board's 2001 exhaust emissions standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

22532

Two Stars ‑ Very Low Emission

The Two Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards. Engines meeting these standards have 20% lower emissions than One Star ‑ Low Emission engines.

WARRANTY INFORMATION

22533

Three Stars ‑ Ultra Low Emission

The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines.

22534

Four Stars ‑ Super Ultra Low Emission

The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star ‑ Low Emission engines.

GENERAL INFORMATION

Boater's Responsibilities

The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the power package.

Be sure at least one additional person on board is instructed in the basics of starting and operating the power package, and boat handling in case the driver is unable to operate the boat.

Boat Horsepower Capacity

WARNING

Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating.

Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS)

XXX

MAXIMUM WEIGHT CAPACITY

XXX

26777

GENERAL INFORMATION

High‑Speed and High‑Performance Boat Operation

If your power package is to be used on 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/ power package combination. For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

Lanyard Stop Switch

The purpose of a lanyard stop switch 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. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.

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.

21629

a - Lanyard cord b - Lanyard stop switch

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).

GENERAL INFORMATION

WARNING

If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard.

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.

Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller.

• Loss of power and directional control in heavy seas, strong current or high winds.

• Loss of control when docking.

Trailering Boat

The boat can be trailered with the drive unit in up or down position. Adequate road clearance is required between road and gear housing skeg when trailering with the drive unit in down position.

If adequate road clearance is a problem, place drive unit in full up position.

GENERAL INFORMATION

Protecting People In The Water

WHILE YOU ARE CRUISING

It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.

21604

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 (even coasting) and the gear shift is in neutral, 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

WARNING

A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat.

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

Carbon monoxide is present in the exhaust fumes of all internal combustion engines. This includes 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.

GENERAL INFORMATION

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

WARNING

Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

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 enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

While Boat Is Stationary

21626

a - Running the engine when the boat is moored in a confined

space.

b - Mooring close to another boat that has its engine running.

GENERAL INFORMATION

While Boat is Moving

5449

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).

GOOD VENTILATION

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

5448

Wave And Wake Jumping

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

5450

GENERAL INFORMATION

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 veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

WARNING

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

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 to a nearly instantaneous stop and can send the occupants flying forward. The boat may also steer sharply to one side.

Impact With Underwater Hazards

IMPORTANT: Operating in shallow waters can severely damage the boat or power package. Maintain a minimum safe speed when operating the vessel in shallow waters or in areas with underwater obstacles.

GENERAL INFORMATION

Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which 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 to control the boat speed. Under these conditions, boat speed should be kept to a minimum planing speed 24 to 40 km/h (15 to 25 MPH)

7462

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

• Part of the sterndrive or the entire sterndrive could break loose and fly into the boat.

• The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants 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, or even out of the boat.

• Impact damage to the sterndrive and/or boat.

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

GENERAL INFORMATION

WARNING

Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts. If damage is present or suspected, the sterndrive 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, or water leaks.

Operating a damaged sterndrive could cause additional damage to other parts of the sterndrive, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

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.

Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible.

Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). If in doubt, contact your dealer or the boats manufacturer.

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:

• Approved fire extinguisher; paddle or oar.

• Signal devices: flashlight, rockets or flares, flag and whistle or horn.

• Spare propeller, thrust hubs and an appropriate wrench.

• Tools for necessary minor repairs; first aid kit and book.

GENERAL INFORMATION

• Anchor, extra anchor line; water‑proof storage containers.

• Manual bilge pump and extra drain plugs; compass and map or chart of area.

• Spare operating equipment; batteries, bulbs, fuses, etc.

• Transistor radio and 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.

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

4. Your state boating law enforcement agency

Direct all inquiries to the Boat U.S. Foundation information number 1‑800‑336‑BOAT (2626).

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.

Make sure everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the back of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat; or anywhere that an 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.

GENERAL INFORMATION

Never be under the influence of alcohol or drugs while boating (it is the law). Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly.

Know your boating area and avoid hazardous locations.

Prepare other boat operators. Instruct at least one other person on board in the basics of starting and operating the power package, and boat handling, in case the driver becomes disabled or falls overboard.

Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Just shifting the power package into neutral is not sufficient.

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 speed.

Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft.) in front of you in five seconds.

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 assist 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

4. There is complete loss of the boat

IMPORTANT: Seek further assistance from local law enforcement for a complete list of rules and regulations.

GENERAL INFORMATION

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 Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines.

SPECIFICATIONS

Power Package Identification

ENGINE IDENTIFICATION

Model: Displacement: Max WOT RPM: Spark Plugs: Spark Plug Gap:

Spark Timing: Fuel Octane:

Engine Oil:

Engine Coolant:

**see owner's manual

HP600 SCi 502 C.I.D.

4800 - 5200 NGK BPR6ES

0.035 Inch **non-adjustable

91 (R+M)/2 or 98 RON International

**Kendall GT-1

Dex-Cool ®

SERIAL NUMBERS

ENGINE

DRIVE

TRANSOM

SAE 20W50

10013

a - Engine identification placard

SPECIFICATIONS

DRIVE UNIT AND TRANSOM ASSEMBLY IDENTIFICATION

25175

a - Transom serial number b - NXT¹ serial number, drive

overall ratio and rotation

c - NXT¹/SSM drive rotation d - NXT¹/SSM serial number

and drive overall ratio

SERIAL NUMBERS RECORD

The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting your authorized Mercury Marine dealer about service, always specify model and serial numbers.

1. The engine serial number is printed on the placard located on the heat exchanger.

2. The Transom serial number is located on the starboard side of the outer transom assembly under the plastic transom cover.

3. NXT¹ - Drive rotation, overall ratio, and serial number are all located under the cover or tie bar plate on the top of the upper driveshaft housing.

4. NXT¹/SSM - The serial number is located on the starboard underside of the upper gear housing.

5. NXT¹/SSM - The gear ratio is stamped on the bolt head located next to the serial number label.

SPECIFICATIONS

6. NXT¹/SSM - The running rotation is stamped on the back of the gearcase strut.

Engine Model/Horsepower: ________________________

Engine Serial Number: ________________________

Transom Assembly Serial Number: ________________________

Sterndrive Serial Number & Gear Ratio: ________________________

Propeller Number & Pitch: _________________________

Running Rotation: _________________________

Hull Identification Number: _________________________

Boat Model & Length: _________________________

General Engine Specifications (HP700)

Crankshaft Horsepower

700 HP (522 kW)

Displacement 8.2 L (502 c.i.)

Cylinder arrangement V‑8

Bore 114 mm (4.47 in.)

Stroke 101.6 mm (4.0 in.)

Compression ratio 7.7:1

Supercharger 3.3 L Screw‑type compressor

Altenator 90 amp / 1278 watt

Battery requirements 750 CCA 950 MCA

Ignition type

PCM 03 Distributorless with sequential individual coils

Engine firing order 1 8 4 3 6 5 7 2

Spark plug type (NGK BPR6ES)

Spark plug gap 0.889 mm (0.035 in.)

Fuel system

Sequential Fuel Injection with mechanical and electric fuel pumps

1. Kilowatts/horsepower rating is in compliance with the SAE J1228/ISO 3046 Standard. Usable power will be reduced by gear losses.

SPECIFICATIONS

Engine Operating Limitations (HP700)

Maximum wide open throttle (W.O.T.) RPM 4800 ‑ 5300 RPM

Rev limit

5400 RPM

Idle RPM in gear 700 RPM

Idle RPM out of gear 750 RPM

Maximum fuel system flow rate 256 L/hr (68 gals/hr) at 5200 RPM

Fuel pressure at idle 4071 ‑ 421 kPa (59 ‑ 61 psi)

Fuel pressure at W.O.T. 462 ‑ 483 kPa (68 ‑ 72 psi)

Coolant thermostat is fully open at temperature

70° C (158° F)

Minimum water pressure supplied to the engine

207 kPa (30 psi) at 5200 RPM

Maximum water pressure supplied to the engine

290 kPa (42 psi) at 5200 RPM

Minimum oil pressure @ idle (Hot) 100 kPa (14.5 psi)

Minimum oil pressure at 5200 RPM (Hot) 379 ‑ 448 kPa (55 ‑ 65 psi)

Maximum oil temperature at 5200 RPM (Hot)

88° C (190° F)

Fuel Requirements

Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness.

WARNING

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation.

1. Engines are equipped with an ignition system that has a built‑in 5400 RPM rev limiter. Engine is performing normally if it will not exceed this RPM.

SPECIFICATIONS

NOTICE

The use of improper fuel can cause serious damage to the engine. Damage resulting from the use of improper fuel is considered engine misuse and is not covered under the limited warranty. Use only the recommended fuel in the engine.

OCTANE REQUIREMENTS (U.S./CANADA)

Engine FUEL TYPE

MINIMUM POSTED

OCTANE

HP700 SCi Unleaded

(R+M) ÷ 2 = 89 or RON =

95*

NOTE: *Research Octane Number

OCTANE REQUIREMENTS (OUTSIDE THE U.S./CANADA)

Engine

FUEL TYPE

MINIMUM POSTED

OCTANE

HP700 SCi

Unleaded

(R+M) ÷ 2 = 89 or RON

= 95*

NOTE: *Research Octane Number

USING REFORMULATED (OXYGENATED) FUELS (USA ONLY)

This type of fuel is required in certain areas of the U.S. The two types of oxygenates used in these fuels are alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section.

These reformulated fuels are acceptable for use in your Mercury engine.

1. Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the combustion chambers.

SPECIFICATIONS

FUEL CONTAINING ALCOHOL

If the fuel in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.

Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank.

The fuel system components on your Mercury engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boats fuel system components (fuel tanks, fuel lines, and fittings).

Fuel containing alcohol may increase:

• Corrosion of metal parts.

• Deterioration of rubber or plastic parts.

• Fuel permeation through rubber fuel lines.

• Starting and operating difficulties.

IMPORTANT: Operating a Mercury Marine engine with gasoline containing alcohol creates unique problems as a result of long storage periods common to a boat. Cars normally consume alcohol‑blend fuels before they absorb enough moisture to cause problems; however, boats often sit idle long enough for phase separation to occur. In addition, alcohol can wash protective oil films from internal components causing corrosion.

IMPORTANT: Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol‑free fuel be used where possible.

If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required.

Low Permeation Fuel Hose Requirement

Required for sterndrives manufactured for sale, sold, or offered for sale in the United States.

SPECIFICATIONS

• The Environmental Protection Agency (EPA) requires that any sterndrive manufactured after January 1, 2009 must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the engine.

• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑ marine fuel hose.

Oil Recommendations

ENGINE CRANKCASE OIL

Preferred Oils API Classification

Kendall GT‑1 Motor Oil 20W‑50 SJ, CF‑2, CH‑4

Oil Filter Should Always Be Changed With Oil

SUPERCHARGER GEARCASE OIL

Preferred Oils API Classification

Castrol Syntec Synthetic Motor Oil 5W‑50 SL, SJ, CF

IMPORTANT OIL PRACTICES

Do Not Use

• Straight weight oils

• Non‑detergent oils

• Oils containing solid additives

• Multi‑viscosity oils other than the ones recommended

• Low quality oils

Do Not Mix

• Different brands of oils, straight weight or multi‑viscosity

• Different weights of straight weight or different weights of multi‑viscosity oils.

SPECIFICATIONS

TEMPERATURE/OIL VISCOSITY CHART

Multi-viscosity

Oil

-20 0 +20 +40 +60 +80 +100 F

SJ, CF-2, CH-4

-20 -30 -10 +20 0 +30 +40 +10

Kendall 20W 50

9160

Capacities

Unit Capacity Fluid Type

Crankcase Oil Capacity with New

Filter

7.6 L (8.5 U.S. qts) Kendall Motor Oil 20W‑50

Supercharger Gearcase

177 ml ( 6 U.S. oz)

Castrol Syntec Synthetic Motor Oil

5W‑50

Closed Cooling System

Approximately 15

L (16 U.S. qts)

Dex‑Cool Extended Life Anitfreeze/

Coolant (50‑50 mix)

NXT¹ Drive Unit Capacity

4.0 L (4.25 U.S. qts)

High Performance Gear Lube

Six Drive Dry Sump Unit Oil Capacity

4.0 L (4.25 U.S. qts)

Torco MTF Gear Lube

Transom Input Shaft Bearing Housing (Driveline model)

0.47 L (0.5 U.S. qts)

High Performance Gear Lube

Transmission fluid capacity

Approximately 1.0

liter (1.1 U.S. qt.)

High Performance Gear Lube

1. Always use dipstick to determine exact quantity of oil required.

SPECIFICATIONS

Engine Break‑in

IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures.

5 Hr. Break‑in Procedure

• Allow engine to warm‑up for 30‑ 60 seconds.

• Do not exceed 3/4 throttle.

• Avoid full throttle acceleration from idle speed.

• Always vary throttle setting.

• Run engine the majority of time between 3000 ‑ 4500 RPM.

• Frequently check engine oil level. Add oil if needed. It is normal for oil consumption to be high during break‑in period.

After Break‑In Period

To help extend the life of your power package, Mercury Marine recommends the following:

After 5 hr. Break‑in

• 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.

• Do not advance the throttle until the engine runs smoothly at idle and water temperature reaches a minimum of 54 °C (130 °F). Do not operate at full throttle until the engine oil temperature reaches 60 °C (140 °F).

• Follow the maintenance schedule in this manual.

OPERATION

Instrumentation

It is important to monitor critical engine and boat functions while the boat is in operation.

Mercury Racing requires that the following critical engine functions be monitored:

• Oil pressure

• Engine RPM

• Oil temperature

• Water temperature

• System voltage

• Guardian fault messages

Warning System

The engine's warning system includes an audible alert consisting of a horn located in the helm harness, and the Engine Guardian system. Do not attempt to alter or disable the warning system in any way.

NOTICE

A continuous horn indicates a critical fault. Operating the engine during a critical fault can damage components. If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation.

ENGINE GUARDIAN SYSTEM

The Engine Guardian system monitors sensors on the engine for any early indications of problems. If a sensor indicates a fault, the system responds to the problem by emitting a continuous or intermittent horn and, depending on the type of fault, may reduce engine power to provide engine protection. If the boat is equipped with System View, a message will be given on the display screen in conjuction with the horn. Refer to the System View manual for details. When the key switch is turned "ON", the warning system's horn beeps once to verify horn operation.

Fault Type and Related Warning Signal

• Critical ‑ Steady horn

OPERATION

• Severe ‑ 5 beeps, each 3 seconds long

• Warning ‑ 3 beeps, each 1.5 seconds long

• Caution ‑ 2 beeps, each 1 second long

• To stop an activated horn warning, turn off the engine. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem as soon as possible.

• If on restart the beeping stops, the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault.

If the Propulsion Control Module (PCM) detects a fault signal from an engine sensor, it records a fault code. A Digital Diagnostic Terminal (DDT) or Computer Diagnostic System (CDS) is required to extract specific problem codes from the PCM.

WARNING SYSTEM TABLE

The following table is divided into four columns. The Possible Cause column lists items that could be initiating the fault. The Horn column lists the type of audible alert that will be given if a fault is detected. If the boat is equipped with System View, the Monitor Display column indicates whether or not a message will be given on the screen. The Guardian Activated and Engine Power Reduced column indicates if the PCM will reduce engine power or force the engine into an idle based on the severity of the problem. The table lists only the possible problem areas and not specific error codes or messages recorded by the PCM.

Possible Cause

Horn

Monitor Display

Guardian

Activated and

Engine Power

Reduced

PCM Error Steady Horn Yes Forced Idle

Battery charging

high or low

Steady Horn Yes Yes

Low Seawater

Pressure

Steady Horn Yes Yes

Low Oil Pressure Steady Horn Yes Yes

Engine Overspeed Steady Horn Yes No

OPERATION

Possible Cause Horn

Monitor Display

Guardian

Activated and

Engine Power

Reduced

Charge

Temperature

Overheat

Steady Horn Yes Yes

MAP Sensor Error Steady Horn Yes No

Oil Temperature

High

Steady Horn Yes No

Coil Pack Failure 5 Beeps‑3 Sec. Long Yes No

Fuel Injector Failure 5 Beeps‑3 Sec. Long Yes No

Fuel Pump Failure 5 Beeps‑3 Sec. Long Yes No

Idle Air Control

Failure

5 Beeps‑3 Sec. Long Yes No

Guardian Invoked 3 Beeps‑1.5 Sec. Long Yes No

Coolant Overheat 3 Beeps‑1.5 Sec. Long Yes Yes

Knock Sensor 3 Beeps‑1.5 Sec. Long Yes Yes

Charge

Temperature Sensor

Failure

3 Beeps‑1.5 Sec. Long Yes No

Oil Temperature

Sensor Failure

3 Beeps‑1.5 Sec. Long Yes No

Cam Sensor 3 Beeps‑1.5 Sec. Long Yes No

Oil Pressure Sensor

Failure

3 Beeps‑1.5 Sec. Long Yes Yes

Fuel Pressure

Sensor Failure

3 Beeps‑1.5 Sec. Long Yes No

Block Pressure

Sensor Failure

3 Beeps‑1.5 Sec. Long Yes No

Charge

Temperature Sensor

Failure

3 Beeps‑1.5 Sec. Long Yes No

Coolant

Temperature Sensor

3 Beeps‑1.5 Sec. Long Yes No

Throttle Position

Sensor

3 Beeps‑1.5 Sec. Long Yes Yes

Low Battery Voltage 2 Beeps‑1 Sec. Long Yes No

OPERATION

Possible Cause Horn

Monitor Display

Guardian

Activated and

Engine Power

Reduced

Low Drive Lube

2 Beeps‑1 Sec. Long Yes No

Electrical System Overload Protection

If an electrical overload occurs, a fuse or circuit breaker opens. Locate and correct the problem before replacing the fuse or resetting the circuit breaker.

A circuit breaker protects the engine wiring harness and instrumentation power lead. Reset by pushing the reset button.

7764

a - Reset button

In an emergency, if you cannot locate and correct the cause of the high current draw, and you must operate the engine, perform the following:

1. Turn off or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker.

2. If the breaker remains open, electrical overload is still present. Inspect the electrical system.

1. This message refers to Transmission Fluid Overheat. Check the transmission fluid level if this message is displayed.

OPERATION

3. A 15 amp fuse, located on the engine's electrical panel, protects the keyswitch power. Check for an open fuse if the key is turned to "START" and nothing happens (and circuit breaker is not tripped).

10138

a - Ignition switch "I" terminal lead

4. The power trim pump is internally protected from thermal overload. If it overheats, it will shut off, allowing itself to cool and then reset. However, it is recommended that the power trim system be installed with additional overload protection. Therefore, the power trim may be protected from overload by a 110 amp fuse in the power supply to the pump and a 20 amp in‑line fuse to the switch power.

5. A 110 amp fuse is located on the starter.

10309

a - Positive (+) battery cable b - 110 amp fuse c - Starter

OPERATION

6. Eight fuses are located at the upper rear of the engine in two fuse holders (four fuses in each holder).

10310

a - Fuse holders (2)

OPERATION

Fuse Holder ‑ C24 Fuse Holder ‑ C25

(1) ‑ 5 amp ‑ RED to RED/GRN Hour meter

(5) ‑ 25 amp ‑ RED/BLK to RED/PNK Fuel pump

(2) ‑ 15 amp ‑ RED/PPL to RED Accessories, Trim switch, Key switch, CAN

(6) ‑ 20 amp ‑ RED/GRN to RED/BLU Main power relay energizing power, ground through PCM

(3) ‑ 2 amp ‑ RED/ORN to RED Diagnostics

(7) ‑ 20 amp ‑ RED/GRN to RED/YEL Coil power

(4) ‑ 15 amp ‑ YEL to YEL/PPL Spare pin K/CAN

(8) ‑ 20 amp ‑ RED/GRN to RED/WHT Fuel injector power

Remote Controls (Console Mounted Zero Effort)

1. Control the throttle by moving the longer control lever(s) or, to increase speed, push the control lever forward. Detents give the movement of the lever a notched, precise feel. The detents also help hold the lever at the desired engine RPM to reduce operator fatigue.

NOTICE

Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running can cause misalign the clutch, preventing proper shifting. Always shift the gearcase into gear when the engine is operating at idle. If you must shift while the engine is not operating, rotate the propeller shaft in the appropriate direction during shifting.

OPERATION

2. Control shifting by moving the shorter control lever(s). This control shifts the unit into gear with full lever movement. Move the lever forward to engage the forward gear. Move lever backward to engage reverse gear. Place the lever in the center position to shift to neutral. Shifting should occur only with the engine at idle speed. Always move to the desired gear position with a quick, firm motion. The control handle should be adjusted by your dealer to engage forward, reverse, and neutral when the lever is at the appropriate detent.

4090

a - Throttle control lever b - Shift control lever c - Power trim switch

3. See Power Trim section for detailed power trim operating procedures.

Power Trim

Power Trim allows the operator to adjust the drive angle while underway to provide the ideal boat angle for varying load and water conditions.

IMPORTANT: Each boat manufacturer has the option as to how the power trim will function on their particular boat. The boat owner/operator must be aware of how the power trim functions before operating the boat.

OPERATION

In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3° to 5° angle to the water.

7418

a - Boat bottom at 3° to 5° angle with water

Trimming Drive Unit Up/Out Can:

• Generally increase top speed.

• Increase clearance over submerged objects or a shallow bottom.

• Cause the boat to accelerate and plane off slower.

• In excess, cause boat porpoising (bouncing) or propeller ventilation.

7419

OPERATION

Trimming Drive Unit Down/In Can:

7420

• Help the boat accelerate and plane off quicker.

• Generally improve the ride in choppy water.

• In most cases, reduce boat speed.

• Lower the bow of some boats to a point at which they begin to "plow". This is called "bow steering" or "over steering" and can result in an unexpected turn in either direction when a turn is attempted or if a significant wave is encountered.

POWER TRIM OPERATION

Dual Engine Console Mount Remote Control (Two Button Version)

NOTICE

If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems. If using an external tie bar, raise and lower all drives together as a unit.

IMPORTANT:

Holding the trailer button depressed after the drive unit reaches the end of its travel will cause an internal circuit breaker to open. Release the button and allow the pump to cool for one minute. The circuit breaker will reset and power trim operation can be resumed.

OPERATION

7867

OPERATION

1 - Control - Used to control both drive units from the

handle. Press up on the button(s) to trim drive unit up or out. Press down on button(s) to trim drive unit down or in.

2 - Trailer Button - Press button until drive unit reaches

desired height to prevent the drive units from contacting the ground while the boat is being trailered.

3 -

Three Button Trim Control (Trim Adjustment Switches) - With a single integral trim button in the handle

to control two drive units simultaneously, these two switches control the fine tune adjustment of each drive unit. Using these fine tune switches, set each drive unit to the desired trim angle. Then use the single trim switch in the handle to control the trim of both drive units simultaneously.

Zero Effort Control with Integral Trim Switch

NOTICE

OPERATION

NOTE: The word trim is usually considered the first 20° up/out movement from vertical position.

7868

a - Trailering and trimming up/out position - Press (top) up/

out portion of switch until drive unit reaches desired trim/ trailering position.

b - Trim drive unit in/down position - Press (bottom) in/down

portion of switch until drive unit reaches desired trim position.

Starting, Shifting and Stopping

WARNING

Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes.

NEW ENGINES OR ENGINES COMING OUT OF STORAGE

See Power Package Recommissioning.

OPERATION

IMPORTANT: Observe the following:

• Do not start the engine without supplying water to the seawater pickup pump (to prevent pump or engine damage).

• Do not operate the starter motor continuously for more than 30 seconds.

• Never shift the drive unit unless the engine is at idle RPM.

Perform the following as appropriate:

Check all items listed in Operation Chart.

Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner's manual.

Place the drive unit in full the down/in position.

Place the control handle in neutral.

COLD OR WARM ENGINE

EFI engines require no throttle advance to start. The boat can be operated after the engine has started and is idling smoothly.

NOTE: Engines that have not been started for extended periods or have had fuel filter changes may not stay running on the first few initial attempts to start. Do not advance the throttle to keep the engine running. Continue to restart the engine until it idles smoothly which means the fuel system is primed. Allow the engine to warm up to 54 °C (130 °F) before advancing the throttle. Do not operate at full throttle until the engine reaches an oil temperature of 60 °C (140 °F).

FLOODED ENGINE

Move control/throttle lever to half throttle. Be prepared to decrease engine speed to 1000 ‑ 1500 RPM as soon as engine starts.

STARTING PROCEDURE

1. Turn the key switch to "START." Release the key when the engine starts and allow the switch to return to the "RUN" position.

2. Check the oil pressure gauge immediately after the engine starts. If oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause.

OPERATION

3. If the engine is cold, make sure the engine is idling smoothly before operating the boat.

4. After the engine has warmed up, check the water temperature gauge to ensure that the engine temperature is not abnormally high. If it is, stop the engine immediately and determine cause.

5. Ensure that the charging system is functioning correctly.

6. Observe the power package for fuel, oil, water, and exhaust leaks.

Operation Chart

Before Starting

Open the engine hatch.

Turn battery switch "ON," if equipped.

Operate bilge blowers, if equipped.

Open fuel shut off valve.

Open seacock, if equipped.

Perform all other checks specified by your dealer and/or boat builder.

After Starting

Observe all gauges to check condition of engine. If not normal, stop engine.

Check for fuel, oil, water, fluid and exhaust leaks, etc.

Check shift and throttle control operation.

Check steering operation.

While Underway

Observe all gauges to monitor engine condition.

After Stopping

Shift to neutral. Turn ignition key "OFF."

Turn battery switch "OFF," if equipped.

Close fuel valve.

Close seacock.

OPERATION

Flush cooling system if in saltwater area.

Freezing Temperature Operation

IMPORTANT: If boat is operated in freezing temperatures, ensure that closed coolant is rated for the temperature range in which it is to be used. The seawater section of the engine must be drained after use to prevent freezing. Damage caused by freezing is not covered by Mercury Racing's Limited Warranty.

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. Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty.

The bilge drain can be used to change crankcase oil. Refer to the Maintenance section.

Launching And Boat Operation Care

NOTICE

Some boating maneuvers can introduce water into the engine through the exhaust system, causing severe engine damage. Be careful when unloading a boat from its trailer, slowing down rapidly, backing up rapidly, and stopping suddenly.

In any of the situations described in the preceding caution

, water entering the engine could cause severe damage to internal parts. Refer to Attention Required After Submersion in the General Information section of this manual.

CONDITIONS AFFECTING OPERATION

Weight Distribution

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

Shifting weight to rear (stern) may:

• Increase speed and engine RPM.

• Cause the boat to porpoise.

• Cause the bow to bounce in choppy water.

• Increase the danger of a following wave splashing into the boat when coming off plane.

Shifting weight to front (bow) may:

• Improve ease of planing.

• Improve rough water ride.

• Cause the boat to veer back and forth (bow steer).

Bottom Of Boat

To maintain maximum speed, ensure that the bottom of the boat is:

• Clean and free of barnacles and marine growth.

• Free of distortion and nearly flat where it contacts the water.

• Straight and smooth both fore and aft.

Marine vegetation may accumulate when the boat is docked, clogging water inlets and causing the engine to overheat. This growth must be removed before operation.

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:

• Weeds or other debris snagged on propeller or gear housing.

• Bent propeller blade or damaged gear housing skeg.

• Raised burrs or sharp edges on propeller or gear housing.

CONDITIONS AFFECTING OPERATION

Ventilation

Ventilation occurs when surface air or exhaust gases surround the propeller, causing propeller speed‑up (slippage) and a decrease in boat speed. Excessive ventilation is annoying and usually caused by:

• A drive unit trimmed out too far.

• A damaged propeller or gear housing, allowing exhaust gases to escape between propeller and gear housing.

• A drive unit installed too high on the transom.

Propeller Selection

IMPORTANT: Choosing the correct propeller allows the engine to run at its specified maximum wide‑open‑throttle RPM. Use an accurate service tachometer to verify engine operating RPM.

It is the boat manufacturer and/or the selling dealer's responsibility to equip the power package with the correct propeller(s). Specified engine wide‑open‑throttle (WOT) and operating RPM range are listed in Specifications.

IMPORTANT: All Mercury Racing engines have a RPM rev‑limiter that is set to an upper (or limited) RPM. 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 drops into the recommended operating RPM range, normal engine operation resumes.

Select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to Specifications).

If full throttle operation is below the recommended range, change the propeller to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating RPM range causes higher than normal wear or damage. Generally, there is a 200 ‑ 300 RPM change between propeller pitches.

RPM loss may require changing to a lower pitch propeller due to the following conditions:

• Operating in warmer weather and greater humidity.

CONDITIONS AFFECTING OPERATION

• Operating in a higher elevation.

• Operating with a damaged propeller or dirty boat bottom.

• Operating with increased load (additional passengers, pulling skiers, etc.).

Conditions That Lower Engine Performance

The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems.

• Above sea level elevations

• High temperature.

• Low barometric pressure.

• High humidity.

The conditions listed above reduce air density to the engine which in turn reduces the following:

• Boost pressure on supercharged engines

• Horsepower and torque throughout the RPM range

• Peak RPM

• Cranking compression

EXAMPLE: An engine running at an elevation of 2,438 m (8,000 ft) will have over a 30% power loss while engine power on a hot and humid day can be reduced by as much as 14%. These losses apply to both normally aspirated and supercharged engines.

Compensating for power robbing conditions:

• Switch to a lower pitch propeller.

• Change the gear ratio.

Some boat performance can be regained by dropping to a lower pitch propeller, but engine performance will remain lower. In some cases, a gear ratio reduction may be more beneficial. To optimize engine performance, prop the engine to allow it to allow operation at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load.

Other advantages to propeller or gear ratio changes:

• Reduces the possibility of detonation.

• Enhances overall reliability and durability of the engine.

MAINTENANCE

Servicing High Horsepower Engines

All high performance engines require frequent maintenance and inspection schedules due to the extreme duty cycles and related stress these products endure. Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastrophic engine failure and increased owner expense.

Service Responsibilities

OWNER/OPERATOR RESPONSIBILITIES

It is the owner/operator's responsibility to perform the following:

• Perform all safety checks.

• Make sure lubrication and maintenance instructions are complied with for safe operation.

• Return the unit to an authorized Mercury Marine dealer for a periodic checkup.

• Perform normal maintenance service using authorized replacement parts.

Proper maintenance and care of your power package will ensure optimum performance and dependability, and will keep your overall operating expenses at a minimum. See your authorized Mercury Marine dealer for service aids.

DEALER RESPONSIBILITIES

In general, a dealer's responsibilities to the customer include pre‑delivery inspection and preparation. These include:

• Completing a Warranty Registration Card provided with the product and mailing it to the factory or by using the electronic registration system provided by Mercury Marine for the selling dealer.

• Properly equipping the boat.

• Making certain that the Mercury Marine power package and other equipment are in proper operating condition prior to delivery.

• Making all necessary adjustments for maximum efficiency.

• Familiarizing the customer with the on‑board equipment.

MAINTENANCE

• Explaining and demonstrating the operation of the power package and boat.

• Providing the customer with a copy of a Pre-delivery Inspection Checklist prior to delivery.

Replacement Service Parts

WARNING

Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.

Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in 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 Mercury Marine engines to provide long life and dependable performance.

Do‑It‑Yourself Maintenance Suggestions

If you are one of those persons who likes to do‑it‑yourself, here are some suggestions for you.

MAINTENANCE

• Present‑day marine equipment, such as your Mercury Marine power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but are more complex for the untrained mechanic.

• Do not attempt any repairs that 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. This 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.

• Special tools and equipment may be 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 for the repair.

• If you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must re‑assemble 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 Mercury Marine dealer is there to service your power package. They have qualified factory‑trained mechanics.

Mercury Marine recommends that 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.

MAINTENANCE

IMPORTANT: Refer to the Maintenance Charts (on following pages) for a complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner/operator, while others should be performed by an authorized Mercury Marine dealer. Before attempting maintenance or repair procedures not covered in this manual, Mercury Marine recommends purchasing a Mercury Marine Service Manual.

Maintenance Charts

ENGINE & TRANSMISSION MAINTENANCE CHART

NOTE: The following maintenance charts should be used as a guideline. Depending on the type of boat, optional equipment, the application and/or conditions of use, it may be required that the maintenance intervals be modified. Work closely with your authorized Mercury Marine dealer to develop a specific maintenance schedule designed for your application.

Interval Task

Check prior to every use and every 3

hours of operation

Engine Crankcase Oil ‑ Check level

Seawater Filter ‑ Check for debris or leakage

Power Steering Fluid ‑ Check level

Transmission Fluid ‑ Check level

Supercharger ‑ Check oil level in sight‑glass

Fuel Pump Sight Tube ‑ Ensure that no fuel is present. Vapor or condensation is acceptable

After every use in salty, brackish, or

mineral‑laden water

Flush the seawater section of the cooling system

Initial break‑in at 25 hours of operation

Change the fuel filter ‑ At recommended intervals thereafter

MAINTENANCE

Interval Task

Every 25 hours of operation or once

every 30 days, whichever occurs first

Battery ‑ Check water level and inspect for corrosion or damage

Inspect external water pickups ‑ Check for marine growth or debris

Sea Pump/Fuel Pump ‑ Check the oil level and inspect for fuel contamination

Engine Oil and Filter ‑ Change

Check the engine coolant level

Saltwater use: Every 50 hours of

operation or 60 days, whichever

occurs first

Power Package Exterior Surfaces ‑ Spray with rust preventive

Every 50 hours or once a year,

whichever occurs first

Perform all 25 hour maintenance items

Serpentine and Supercharger Belts ‑ Inspect condition and check tension

Cooling System Hoses and Clamps ‑ Inspect for damage and deterioration. Check clamps for tightness

Electrical System ‑ Check for loose or damaged wiring

Continuity Circuit ‑ Check components for loose connections, broken or frayed wires

Shift and Throttle Cable and Linkage ‑ Lubricate and inspect for loose, damaged or missing parts

Engine Exhaust System ‑ Inspect for damage, deterioration and restrictions. Check clamps for tightness

Water Separator Filter ‑ Inspect (If Installed on boat)

Driveshaft U‑joints and Slip Yoke ‑ Lubricate (drive‑line models)

Freshwater use: Twice a year

Power Package Exterior Surfaces ‑ Spray with rust preventative

MAINTENANCE

Interval Task

Every 100 hours of operation or once

a year, whichever occurs first

Perform all 25 hour and 50 hour maintenance items

Supercharger ‑ Change oil

Power Package Exterior Surfaces ‑ Clean and paint

Engine Cylinder Compression ‑ Check

Engine and Power Steering Oil Coolers ‑ Clean the seawater sections

Positive Crankcase Ventilation (PCV) Valve ‑ Replace

Flame Arrestor and Crankcase Ventilation Hose ‑ Inspect, clean or replace

Engine Alignment ‑ Check

Exhaust ‑ Check for signs of water leakage

Exhaust System Internal and External Shutters ‑ Inspect

Change transmission fluid

Every 100 hours of operation or

recommissioning after storage

Peform 25, 50, and 100 hour maintenance items

Fuel filters ‑ Replace

Every 100 hours of operation or once

a season or whenever insufficient

seawater flow is suspected causing

the operating temperature to exceed

normal

Seawater Pick‑up Pump ‑ Disassemble and inspect

Every 200 hours of operation

Peform 25, 50, and 100 hour maintenance items

Ignition System ‑ Clean and inspect condition. Check electrode gap or replace spark plugs as needed

Change power steering system filter(s)

Every 5 years

Flush the closed cooling system and refresh coolant

1. Severe duty requires more frequent service

MAINTENANCE

DRY SUMP NXT¹ DRIVE SCHEDULED MAINTENANCE

Interval Task

Check prior to use and every 3 hours

of operation.

Drive, Transom, and Propeller ‑ Inspect.

Lower Gear Housing Oil ‑ Check level.

Power Trim Pump Oil ‑ Check level and for any water contamination. Replace if necessary.

Anodes ‑ Inspect for erosion.

Gear Housing Water Pickups ‑ Check for marine growth or debris.

Initial break‑in at 25 hours. Lower Gear Housing Oil ‑ Change

Every 25 hours of operation or every

90 days, whichever occurs first.

Tie‑bar Mounting Bracket Nuts ‑ Inspect and tighten to specifications as needed.

Propeller Shaft ‑ Lubricate.

Propeller Nut ‑ Retighten.

Anodes ‑ Inspect for erosion.

Sterndrive ‑ Inspect, clean, and spray with rust preventative.

Every 50 hours of operation.

Perform 25 Hour Maintenance Items.

Sterndrive Unit Input Splines (Internal and External) ‑ Lubricate with Optimol Paste White T Grease.

Drive Mounting Nuts ‑ Tighten to 136 Nm (100 lb. ft.)

Drive Input Shaft ‑ Lubricate.

Steering System ‑ Inspect for loose, damaged or missing parts. Lubricate the steering cylinder pivot points.

Every 100 hours of operation or

every 120 days, whichever occurs

first.

Peform 25 and 50 Hour Maintenance Items.

Drive Unit Bellows and Clamps ‑ Inspect.

Inspect all rotating and reciprocating components for wear. Replace the components as needed.

Every 100 hours of operation

Lower Gear Housing Oil ‑ Change

Driveline Support Housing ‑ Change the oil.

MAINTENANCE

Interval Task

Every 200 hours of operation or once

a year, whichever occurs first.

Peform 25, 50, and 100 Hour Maintenance Items.

Engine Alignment ‑ Check.

Propeller Shaft Bearing ‑ Inspect by measuring shaft deflection.

Every rebuild

Lower Gear Housing ‑ Oil and filter change

NXT¹/SSM DRIVE MAINTENANCE SCHEDULE

Interval

Task

Check prior to use and every 3 hours of

operation.

Drive, Transom, and Propeller ‑ Inspect.

Lower Gear Housing Oil ‑ Check level.

Power Trim Pump Oil ‑ Check level and for any water contamination. Replace if necessary.

Anodes ‑ Inspect for erosion.

Initial break‑in at 25 hours. Drive ‑ Change Oil and filter

Every 25 hours of operation or every 90

days, whichever occurs first.

Tie‑bar Mounting Bracket Nuts ‑ Inspect and tighten to specifications as needed.

Propeller Shaft ‑ Lubricate.

Propeller Nut ‑ Retighten.

Anodes ‑ Inspect for erosion.

Sterndrive ‑ Inspect, clean, and spray with rust preventative.

MAINTENANCE

Interval Task

Every 50 hours of operation.

Perform 25 Hour Maintenance Items.

Drive Mounting Nuts ‑ Tighten to 136 Nm (100 lb. ft.)

Steering System ‑ Inspect for loose, damaged or missing parts. Lubricate the steering cylinder pivot points.

Every 100 hours of operation or annually, whichever occurs first

Peform 25 and 50 Hour Maintenance Items.

Drive Unit Bellows and Clamps ‑ Inspect.

Sterndrive Unit Input Splines (Internal and External) ‑ Lubricate with Optimol Paste White T Grease.

Drive Input Shaft U‑joints ‑ Lubricate.

Drive ‑ Change Oil

Transom Input Shaft Bearing Housing ‑ Change the oil.

Every 200 hours of operation or once a

year, whichever occurs first.

Peform 25, 50, and 100 Hour Maintenance Items.

Engine Alignment ‑ Check.

Propeller Shaft Bearing ‑ Inspect by measuring shaft deflection.

Every 200 hours of operation

Drive ‑ Change oil and filter

Every rebuild Drive ‑ Change oil and filter

Checking Fluid Levels

CHECKING CRANKCASE OIL

IMPORTANT: Check the engine crankcase oil at the intervals specified in the Maintenance Chart.

NOTE: Oil consumption is greatly dependant on engine speed. Consumption is highest at wide‑open‑throttle and decreases substantially as engine speed is reduced. It is common for big block, high‑performance engines to use up to one quart of oil in one to five hours, if the engine is operated continuously at the upper end of the RPM range.

1. Severe duty requires more frequent service

MAINTENANCE

1. Stop the engine.

2. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water or at the approximate angle that it would be if setting in the water.

3. Remove the dipstick, wipe it clean, and re‑install it all the way into the dipstick tube.

4. Remove the dipstick and check the oil level. The oil level must be between the "OK RANGE" and the "ADD" marks.

5. If the oil level is at or below the "ADD" mark, remove the oil filler cap (port or starboard). Add enough oil to bring the level into the "OK RANGE" on the dipstick. Do not overfill.

IMPORTANT: Do not overfill the crankcase with oil.

ADD

OK RANGE

9987

a - Oil level dipstick b - Crankcase oil filler cap

Tube Ref No. Description Where Used Part No.

Kendall GT-1 SAE 20W50

Engine crankcase Obtain Locally

MAINTENANCE

CHECKING SUPERCHARGER GEARCASE OIL

IMPORTANT: A sight glass is located in the front gearcase cover of the supercharger. The oil should be covering approximately half of the sight glass. If the oil level increases, decreases, or changes to an abnormal color, there may be an internal problem with the supercharger. Contact your authorized Mercury Marine dealer.

1. Stop the engine.

2. Allow approximately 5 minutes for the oil in the supercharger case to settle and the sight‑glass to clear.

3. Visually inspect the level and quality of the oil in the sight glass gage. The oil should be covering approximately half of the sight glass.

7356

a - Sight glass

CHECKING POWER STEERING PUMP FLUID

IMPORTANT: If fluid is not visible in the reservoir, contact your authorized Mercury Marine dealer.

1. Stop the engine and turn the drive unit to the straight ahead position.

NOTE: Multiple engine applications may have only one common reservoir, that is common to all of the engines, or that fills the adjacent engine's reservoir. The full reservoir will not have a dipstick, check the fluid level at the other engine's reservoir or the common reservoir for all engines.

MAINTENANCE

2. Remove the fill cap/dipstick and observe the level. The oil level must be between the lower and upper marks.

3. Add power steering fluid if required to bring the oil level up to the full mark on the cap/dipstick.

21834

a - Reservoir cap b - Add fluid mark

c - Full fluid mark

Tube Ref

No.

Description Where Used Part No.

114

Power Trim and Steering Fluid

Power steering pump 92-858074K01

4. Install the cap/dipstick.

CHECKING FUEL PUMP SIGHT TUBE

NOTE: The mechanical fuel pump has a clear plastic tube connected to the back of the fuel pump, which is routed to the throttle body of the supercharger. If the mechanical fuel pump's internal diaphragm ruptures, fuel is by‑passed into the plastic tube. This indicates that the fuel pump needs replacement.

MAINTENANCE

NOTE: Vapor or condensation can occur in the tube and is acceptable.

16981

a - Fuel pump sight tube (routed from pump, past the intake

manifold, and into the throttle body)

CHECKING SEAWATER/FUEL PUMP OIL

IMPORTANT: Change the oil at specified intervals. Refer to the Maintenance Chart for specific requirements. Use only High Performance Gear Lube in the pump.

1. Remove the fill screw and check the oil level.

MAINTENANCE

2. Oil should be up to the bottom of the fill hole. A low oil level indicates that there is an internal problem, and that you should contact your authorized Mercury Marine dealer for appropriate service. Do not operate engine if this oil level is low.

10073

a - Oil level screw

Tube Ref

No.

Description Where Used Part No.

High Performance Gear Lubricant

Seawater/fuel pump 92-858064K01

CHECKING ENGINE COOLANT

CAUTION

A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.

IMPORTANT: Check engine coolant before starting the engine.

MAINTENANCE

1. Check the coolant level in the coolant reservoir when the engine is cold. Coolant should be at the "COLD FULL" line marked on the front of the reservoir or to the top of the raised bosses on the back of the reservoir. Add specified coolant by turning the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.

COLD FILL

10140

122

a - Coolant reservoir cap b - Cold full decal on the front of the reservoir c - Cold full raised bosses on the back of the reservoir

Tube Ref

No.

Description Where Used Part No.

122

Extended Life Antifreeze/Coolant

Closed cooling

system

92-877770K1

2. If coolant is low, inspect the coolant recovery system for leaks.

3. Inspect the cap for damage and replace if necessary.

CHECKING POWER TRIM PUMP FLUID

IMPORTANT: Check oil level with sterndrive unit in the full down/ in position.

MAINTENANCE

1. Place the sterndrive unit in the full down/in position.

2. Check the fluid level in the trim pump reservoir. The level should be between the "MIN" and "MAX" level marks on the reservoir.

3. If necessary, remove the fill cap and add Power Trim and Steering Fluid until the level in the reservoir reaches the "MIN" level mark. It is acceptable to fill the reservoir beyond the "MIN" level mark, but do not overfill past the "MAX" level mark.

114

15033

Tube Ref

No.

Description Where Used Part No.

114

Power Trim and Steering Fluid

Trim pump reservoir 92-858074K01

4. Raise the sterndrive unit two or three times to bleed air out of the system. The fluid level may drop. Add more Power Trim and Steering Fluid if necessary, but do not overfill past the "MAX" level mark.

5. Replace the fill cap.

MAINTENANCE

CHECKING TRANSOM INPUT SHAFT BEARING HOUSING (DRIVE-LINE MODELS ONLY)

1. Remove the level indication (middle) pipe plug from the input shaft housing. Gear lube level should be to the bottom of the hole. If not, remove the pipe plug from the top of the input shaft housing.

2. Fill the input shaft housing through the top pipe plug hole with High Performance Gear Lube until gear lube flows from the middle pipe plug hole (do not overfill).

3. Install the pipe plugs into the input shaft housing and tighten securely.

21730

a - Fill hole b - Check level here c - Drain

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Transom input shaft

bearing housing

92-858064K01

MAINTENANCE

CHECKING NXT¹ DRIVE UNIT GEAR LUBE

1. Remove the upper vent plug from the gearcase. The gear lube level should be to the bottom of the vent plug hole with the propeller shaft level.

2. If gear lube level is low, add High Performance Gear Lube until gear lube comes out of the vent plug opening.

3. Install the vent plug.

21707

a - Vent plug opening b - Level propeller shaft

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Drive uinit 92-858064K01

CHECKING SIX DRIVE UNIT GEAR LUBE

1. Remove the upper vent plug from the gearcase. The gear lube level should be to the bottom of the vent plug hole with the propeller shaft level.

2. If gear lube level is low, add Torco MTF Gear Lube until gear lube comes out of the vent plug opening.

MAINTENANCE

3. Install the vent plug.

7429

150

a - Vent Plug b - Fill/Drain Plug

Tube Ref

No.

Description Where Used Part No.

150

Torco MTF Gear Oil

VI Drive Gear

Housing

92-849684 1

CHECKING TRANSMISSION FLUID LEVEL

IMPORTANT: Wait at least 30 minutes before checking the transmission fluid level to avoid inaccurate readings.

1. Remove the transmission dipstick and check the fluid level.

MAINTENANCE

2. Remove the fill plug and add High Performance Gear Lube as necessary to bring the fluid level within the cross‑hatched area above the "ADD" mark on the dipstick.

21710

a - Dipstick b - Fill plug c - ADD mark

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Transmission 92-858064K01

Changing Fluids

CHANGING CRANKCASE OIL AND FILTER (BOAT IN THE WATER)

NOTICE

Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

MAINTENANCE

IMPORTANT: Change oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended motor oil (see

Specifications

NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum (approximately 1/4 turn). Then turn the filter back clockwise until the oil filter seal makes light contact with the housing (approximately an 1/8 turn) to prevent unwanted oil leakage. Let the oil drain back into the system for 15 minutes prior to complete removal of the filter.

10449

a - Crankcase oil filter

1. With the engine at normal operating temperature, remove the dipstick.

2. Install a crankcase oil pump onto the dipstick tube.

MAINTENANCE

3. Insert the hose end of the crankcase oil pump into an appropriate container and pump out the oil until the crankcase is empty.

10460

a - Crankcase oil pump b - Crankcase oil pump hose

4. Remove the crankcase oil pump.

5. Place a container below the oil filter.

6. Remove the oil filter from the adaptor and discard the old oil filter and old sealing ring.

7. Coat the sealing ring on the new filter with new motor oil and install the new sealing ring and filter.

MAINTENANCE

8. Tighten the filter securely by hand. Do not overtighten.

25262

a - Oil filter sealing ring

9. Remove the oil filler cap (port or starboard).

10.Add enough oil to bring the oil level into the "OK RANGE" on the dipstick; approximately 8 L (8.5 qts.).

IMPORTANT: Engine crankcase capacity is 8 L (8.5 qts.). However, due to possible incomplete oil pump out, always use the dipstick to confirm proper oil level and prevent overfilling.

10152

a - Crankcase oil fill cap

Tube Ref

No.

Description Where Used Part No.

Kendall GT-1 SAE 20W50

Engine crankcase Obtain Locally

MAINTENANCE

11.Start the engine and check for proper oil pressure. Allow the engine to idle for one minute and verify that no oil is leaking.

12.Shut off the engine.

13.Wait a few minutes for the engine oil to return to the crankcase and then check the oil level. If the oil level is low, add enough oil to bring it within the "OK RANGE" on the dipstick. Do not overfill.

CHANGING CRANKCASE OIL AND FILTER (BOAT OUT OF THE WATER)

WARNING

Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury.

NOTICE

Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.

NOTICE

IMPORTANT:

Use only recommended motor oil, see

Specifications.

Change oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up. See the boat owner's manual for information on connecting a water supply to the boat's external water pickup.

MAINTENANCE

1. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up.

2. Open the water tap to supply enough flow to the sea pump so that suction created by the sea pump, does not collapse the supply hose.

3. Place the remote control in neutral position and start the engine. Operate the engine at idle speed, in neutral, until the engine reaches normal operating temperature.

4. Stop the engine and shut off the water.

10449

a - Crankcase oil filter

MAINTENANCE

5. Remove the bilge plug. The oil drain hose is tethered to the plug.

6150

a - Bilge drain plug b - Tether c - Oil drain plug

d - Bilge drain flange e - Oil drain hose

6. Pull the oil drain hose through the bilge drain flange.

7. Place an appropriate container directly under the oil drain hose.

8. Using two wrenches, separate the oil drain hose plug from the oil drain hose and allow crankcase oil to drain until empty.

9. Place a container below the oil filter.

10.Remove the oil filter from the adaptor and discard the old oil filter and sealing ring.

MAINTENANCE

11.Coat the sealing ring on the new filter with new motor oil. Install the sealing ring and filter. Tighten the filter securely by hand. Do not overtighten.

25262

a - Oil filter sealing ring

12.Using two wrenches, connect the oil drain hose plug to the oil drain hose and place it back into the boat.

13.Tighten the bilge drain plug.

14.Remove the oil filler cap (port or starboard). Add oil to bring the oil level into the "OK RANGE" on the dipstick; approximately 8 L (8.5 qts.).

IMPORTANT: Engine crankcase capacity is 8 L (8.5 qts.). However, always use the dipstick to confirm proper oil level.

10152

a - Crankcase oil filler cap

MAINTENANCE

Tube Ref

No.

Description Where Used Part No.

Kendall GT-1 SAE 20W50

Engine crankcase Obtain Locally

15.Turn on the water supply hose to the water pick‑up.

16.Start the engine and check for proper oil pressure. Allow the engine to idle for one minute and verify that no oil is leaking.

17.Shut off the engine and the water to the water pick‑up attachment.

18.Wait a few minutes for the engine oil to return to the crankcase and then check the oil level. If the oil level is low, add enough oil to bring it within the "OK RANGE" on the dipstick. Do not overfill.

19.Remove the external water supply.

CHANGING SUPERCHARGER GEARCASE OIL

IMPORTANT: Change the supercharger oil when the engine and supercharger are warm from operation. Warm oil flows more freely, carrying away more impurities. Use only the recommended oil in the supercharger, see

Specifications.

If the oil level in the sight‑glass has increased, decreased, or changed to an abnormal color, there may be an internal problem with the supercharger. Contact your authorized Mercury Marine dealer.

1. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up.

2. Open the water tap to supply enough flow to the sea pump so that suction created by the sea pump, does not collapse the supply hose.

3. Place the remote control in neutral position and start the engine. Operate the engine at idle speed, in neutral, until the engine reaches normal operating temperature.

4. Stop the engine and shut off the water.

5. Remove the fill plug from the top of the supercharger gearcase.

6. Place a suitable container under the drain plug in the bottom of the supercharger gearcase.

MAINTENANCE

7. Remove the drain plug and drain the oil.

8. Clean and inspect the plug O‑rings, the gearcase fill and drain hole threads, and the plug threads.

9. Install the drain plug in the gearcase and tighten to specifications.

10.Fill the gearcase through the top fill hole with approximately 177 milliliters (6 oz.) of oil. The oil should cover half of the sight‑glass in the gearcase.

11.Install the fill plug and tighten to specifications.

10567

a - Drain plug b - Sight‑glass c - Fill plug

Description Nm lb. in. lb. ft.

Fill and drain plugs, supercharger gearcase

13.5 10

Tube Ref No. Description Where Used Part No.

Castrol Syntec 5W-50 Synthetic Oil

Supercharger

gearcase

Obtain Locally

MAINTENANCE

CHANGING ENGINE COOLANT

Contact your authorized Mercury Marine dealer.

CHANGING TRANSMISSION OIL

1. Remove the bilge plug and pull the drain hose through the transom.

2. Using two wrenches, separate the drain plug from the hose.

6150

a - Bilge plug b - Tether c - Drain plug

d - Flange e - Drain hose

3. Reinstall the drain and bilge plug after draining the fluid.

4. Remove the fill plug and add High Performance Gear Lube as necessary to bring the fluid level within the cross‑hatched area above the "ADD" mark on the dipstick (approximately 1 Liter (1.1 U.S. quarts).

21710

a - Dipstick b - Fill plug c - "ADD" mark

MAINTENANCE

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Transmission 92-858064K01

Capacity Fluid Type

Transmission 1 Liter (1.1 Qts.) High Performance Gear Lubricant

CHANGING NXT¹ DRIVE UNIT GEAR LUBE

1. Remove propeller, position drive unit so propeller shaft is level.

21733

a - Oil level hole b - Level

2. Remove the water pick‑up.

21209

a - Fasteners

b - Water pick‑up

3. Remove the tab washer.

MAINTENANCE

4. Remove fill/drain screw and vent screw from gear housing and drain the gear lube.

IMPORTANT: If any water drained, or if gear lube appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser Dealer.

21210

a - Tab washer b - Fill/drain screw

5. Fill the drive unit, through the fill/drain hole, with High Performance Gear Lube until a stream of lubricant flows from gear oil level hole.

MAINTENANCE

6. Install vent screw and remove tube from fill/drain hole. Quickly install the fill/drain screw. Tighten securely.

21733

a - Oil level hole b - Level

7. Install tab washer.

21210

a - Tab washer

b - Fill/drain screw

MAINTENANCE

8. Install water pick‑up and tighten fasteners to specification.

21209

a - Fasteners b - Water pick‑up

Description Nm lb. in. lb. ft.

Water pick‑up fasteners 3.4 30

9. Install propeller.

10.Check oil level after first test trial. Refill if necessary.

CHANGING SIX DRIVE UNIT GEAR LUBE

IMPORTANT: Use only Torco MTF Gear Oil in the drive unit.

1. Remove the propeller and place the drive unit where the propeller shaft is level.

2. Remove the fill/drain screw, sealing washer, vent screw, and sealing washer from the gear housing.

IMPORTANT: If any water drained, or if gear lube appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser Dealer.

MAINTENANCE

3. Fill the drive unit through the fill/drain hole with Torco MTF Gear Oil until an air‑free stream of lubricant flows from the gear oil level hole of gear housing.

7429

150

a - Top vent screw b - Fill/drain screw

Tube Ref

No.

Description Where Used Part No.

150

Torco MTF Gear Oil

VI Drive gear

housing

92-849684 1

IMPORTANT: If the filter was replaced, rotate the propeller shaft at least 80 full revolutions to fill the filter cavity with oil. Recheck the fluid level and add fluid as necessary.

4. Install vent screw and washer and remove tube from fill/drain hole. Quickly install the sealing washer and the fill/drain screw. Tighten securely.

5. Check oil level after first test trial. Add fluid if necessary.

CHANGING TRANSOM INPUT SHAFT BEARING HOUSING GEAR LUBE (DRIVE-LINE MODELS)

1. Remove the drain plug and drain the oil.

2. Install the drain plug and tighten securely.

3. Remove the plug from the fill hole.

MAINTENANCE

4. Remove the plug from the fill level hole.

5. Pour High Performance Gear lube into the fill hole until fluid starts to come from the fill level hole.

6. Install both plugs and tighten securely.

21730

a - Fill hole b - Fill level c - Drain

Lubrication Points

Lubricate pivot points with SAE 25W40 motor oil:

• Shift cable.

MAINTENANCE

• Throttle linkage and cable ‑ Lubricate cable and swivels.

10305

a - Lubrication points

Tube Ref No. Description Where Used Part No.

MerCruiser 4-cycle 25W40 Engine Oil

Pivot points 92-858048K01

Sterndrive Cleaver Propeller Installation (NXT¹)

IMPORTANT: Ensure that the propeller direction of rotation matches the propeller shaft direction of rotation.

WARNING

Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

MAINTENANCE

IMPORTANT: Propeller damage can occur if there is not enough space between the propeller tips. Multi‑engine configurations require a minimum distance of 25.4 mm (1 in.) gap between propeller tips to prevent damage to the propellers and other equipment.

21685

a - Nylon Nut b - Jam nut c - Washer d - Adaptor (Mercury Racing

sterndrive cleaver propeller)

e - Bushing f - Retaining ring

1. Install the adaptor into the propeller, as shown.

MAINTENANCE

2. Install the bushing and secure with the retaining ring as shown.

21686

a - Propeller b - Adaptor

c - Bushing d - Retaining ring

3. Coat the propeller shaft splines with Anti‑Corrosion Grease.

4. Install the propeller/adaptor assembly to the propeller shaft.

21685

a - Nylon nut b - Jam nut c - Washer d - Adaptor

e - Bushing f - Retaining ring (installed

in propeller)

Tube Ref

No.

Description Where Used Part No.

Anti-Corrosion Grease

Propeller shaft

splines

92-802867Q 1

MAINTENANCE

5. Place a wooden block between the blades and the anti‑ventilation plate to prevent the propeller from turning. Tighten the jam nut to specification and install the nylon nut and tighten to specification.

Description Nm lb. in. lb. ft.

Nylon nut, Jam nut 136 100

6. After initial use, retighten the propeller to specification and check after every 20 hours of operation.

Cleaver Propeller Installation (SSM)

1. Lubricate the propeller shaft splines with a specified grease.

2. Install the propeller onto the shaft.

3. Install the washer.

4. Install the propeller nut and tighten to the specified torque.

Mercury HP700 SCi User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual