Mercury mercruiser User Manual

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NOTE: The following applies to CE marked products only.

Declaration of Conformance – Mercury MerCruiser

This sterndrive or inboard engine when installed in accordance to Mercury MerCruisers’ instructions complies with the requirements of the following directives by meeting the associated standards, as amended:

Recreational Craft Directive 94/25/EC; 2003/44/EC

Applicable Requirement Standards Applied

Owner’s manual (A.2.5) ISO 10240

Openings in Hull, Deck and superstructure (A.3.4) ISO 9093-1; ISO 9093-2

Handling characteristics (A.4) ISO 8665

Inboard Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO 10133

Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469

Electrical System (A.5.3) ISO 10133; ISO 8846

Steering system (A.5.4)

Exhaust emission requirements (B.2) ISO 8178

Owner’s manual (B.4) ISO 8665

Noise emission levels (C.1) ISO 14509

Ignition-protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031

Applicable portions of: ISO 10592, ISO 8848 and ABYC P-17

Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions requirements of the directive mentioned above. This engine must not be put into service until the recreational craft in which it is to be installed has been declared in conformity, if so required, with the relevant provision of the directive.

Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC

Generic emission standard EN 50081-1

Generic immunity standard EN 50082-1

Vehicles, boats and internal combustion engine driven devices - Radio disturbance characteristics

Electrostatic discharge testing EN 61000-6-2; EN 61000-4-2; EN61000-4-3

The notified body responsible for surveillance of the quality system under Full Quality Assurance Module H of Directive 2003/44/EC is:

Det Norske Veritas Norway Notified Body Number: 0575

This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.

SAE J551 (CISPR 12)

President - Mercury Marine, Fond du Lac, WI USA

Patrick C. Mackey

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Regulatory contact: Engineering - Regulatory MerCruiser 3003 N. Perkins Rd Stillwater, Oklahoma 74075 USA (405) 377-1200

Identification Record

Please record the following information:

Engine Model and Horsepower Engine Serial Number

Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number

Welcome

The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers.

The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.

Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, 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.

You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability.

With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

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

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

Mercury MerCruiser

Warranty Message

The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty 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.

Mercury Marine products are designed and manufactured to comply with our own high quality standards, applicable industry standards and regulations, as well as certain emissions regulations. At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations. All Mercury Marine product, sold as new, receives the applicable limited warranty coverage, whether the engine participated in one of the test programs described above or not.

Read This Manual Thoroughly

IMPORTANT: If you don’t understand any portion of this manual, contact your dealer for a demonstration of actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, WARNINGS and CAUTIONS,

accompanied by the International Hazard Symbol user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while performing the service, plus common sense operation, are major accident prevention measures.

WARNING—indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices.

WARNING

CAUTION

, may be used to alert the installer/

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

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WARNING

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

WARNING

California Proposition 65 Warning

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

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TABLE OF CONTENTS

Section 1 - Warranty

Transfer Of Warranty...............................................2

Warranty Registration United States And Canada..2 Warranty Registration Outside The United States And

Canada....................................................................2

Mercury, MerCruiser Limited Warranty United States, Canada and Europe (Gasoline Fueled Products

Only)........................................................................3

Section 2 - Getting to Know Your Power Package

Lanyard Stop Switch..............................................12

Instrumentation......................................................13

System View.....................................................13

Digital Gauges..................................................14

Analog Gauges.................................................14

Remote Controls (Non-DTS Models).....................15

Remote Controls............................................15

Panel Mount Features..................................15

Console Mount Features..............................16

Zero Effort Features.......................................17

Remote Controls (DTS Models)............................17

Remote Controls............................................17

Panel Mount Features....................................18

Console Mount Features - Single Engine.......19

Slim Binnacle Console Mount Features - Single

Engine............................................................20

Console Mount Features- Dual Engine..........21

Synchronizing Dual Engines..........................22

Mercury MerCruiser Limited Warranty (Confederation

of Independent States, Middle-East, and Africa......5

3 Year Limited Warranty Against Corrosion

(Worldwide).............................................................6

Warranty Coverage And Exclusions........................7

General Exclusions From Warranty....................8

Dual Helm Station Transfer............................22

Synchronizing Dual Helms Prior To Station

Transfer........................................................23

Zero Effort Features.......................................23

Power Trim............................................................24

Single Engine Trim/Trailer............................25

Dual Engine Trim/Trailer..............................25

Trim without Key.............................................25

Trim Delta.......................................................26

Electrical System Overload Protection..................26

Audio Warning System..........................................28

Testing The Audio Warning System.................29

Engine Guardian Strategy.....................................29

Warning Horn Signals............................................29

Emissions Information...........................................30

Emission Control Information Label...............30

Owner Responsibility...................................31

Star Label.......................................................31

Safe Boating Suggestions.....................................34

Be Alert To Carbon Monoxide Poisoning..............35

Good Ventilation...............................................36

Poor Ventilation ...............................................36

Basic Boat Operation (Non-DTS Models)..............36

Launching and Boat Operation.......................36

Operation Chart............................................37

Starting and Stopping the Engine...................37

Starting the Engine.......................................37

Stopping the Engine.....................................38

Starting Engine After Stopped While In Gear. 38

Throttle Only Operation..................................38

Trailering the Boat..........................................38

Freezing Temperature Operation...................39

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Section 3 - On The Water

Drain Plug and Bilge Pump............................39

Basic Boat Operation (DTS Models).....................39

Launching and Boat Operation.......................39

Operation Chart............................................39

Starting and Stopping the Engine...................40

Starting the Engine.......................................40

Stopping the Engine.....................................41

Throttle Only Operation..................................41

Trailering the Boat..........................................42

Freezing Temperature Operation...................42

Drain Plug and Bilge Pump............................42

Protecting People In The Water............................42

While You Are Cruising.....................................42

While Boat Is Stationary...................................42

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High-Speed And High-Performance Boat

Operation..............................................................43

Passenger Safety In Pontoon Boats And Deck

Boats.................................................................... 43

Boats Having An Open Front Deck..................43

Boats With Front-Mounted, Raised Pedestal

Fishing Seats...................................................43

Wave And Wake Jumping....................................44

Impact With Underwater Hazards........................ 44

Drive Unit Impact Protection............................45

Operating With Low Water Inlets In Shallow

Water....................................................................45

Section 4 - Specifications

Conditions Affecting Operation.............................46

Weight Distribution (Passengers and Gear)

Inside the Boat.............................................. 46

Bottom Of Boat..............................................46

Cavitation...................................................... 46

Ventilation..................................................... 46

Elevation And Climate...................................47

Propeller Selection........................................47

Getting Started..................................................... 47

20-Hour Break-In Period............................... 47

After Break-In Period.....................................48

End of First Season Checkup....................... 48

Fuel Requirements...............................................50

Fuel Ratings.....................................................50

Using Reformulated (Oxygenated) Gasolines

(USA Only).......................................................50

Gasolines Containing Alcohol..........................50

Section 5 - Maintenance

Owner/Operator Responsibilities..........................56

Dealer Responsibilities.........................................56

Maintenance.........................................................56

Do It Yourself Maintenance Suggestions............. 57

Inspection.............................................................57

Maintenance Schedule - Sterndrive Models.........58

Routine Maintenance.......................................58

Each Day Start............................................58

Each Day End.............................................58

Weekly........................................................ 58

Every Two Months or 50 Hours.................. 58

Scheduled Maintenance..................................58

After the initial 20 Hour Break-in Period......58

Every 100 Hours or Annually (Whichever

Occurs First)............................................... 58

Every 200 Hours or 3 Years........................59

Every 300 Hours or 3 Years........................59

Every 5 Years............................................. 59

Maintenance Log..................................................59

Engine Oil.............................................................60

Checking..........................................................60

Filling............................................................... 60

Changing Oil and Filter....................................61

Easy Engine Oil Drain System....................61

Engine Oil Drain Pump............................... 62

Changing Filter............................................62

Power Steering Fluid............................................63

Checking..........................................................63

Engine Oil.............................................................51

Engine Specifications...........................................52

Fluid Specifications.............................................. 52

Sterndrives.......................................................52

Engine..............................................................52

Filling............................................................... 64

Changing......................................................... 64

Engine Coolant.....................................................64

Checking..........................................................64

Filling............................................................... 65

Changing ........................................................ 65

Drive Unit Oil........................................................ 65

Checking..........................................................65

Filling............................................................... 66

Changing......................................................... 67

Power Trim Fluid.................................................. 69

Checking..........................................................69

Filling............................................................... 69

Changing......................................................... 69

Cleaning The Flame Arrestor............................... 70

Cleaning The IAC Muffler.....................................70

Changing Water Separating Fuel Filter................71

Lubrication............................................................73

Steering System............................................73

Throttle Cable................................................75

Shift Cable - Typical......................................75

Sterndrive Unit and Transom Assembly........76

Sterndrive U-joint Shaft Splines And O-rings

(Sterndrive Unit Removed)............................76

Engine Coupler............................................. 76

Engine Coupler............................................. 77

Driveshaft Extension Models.........................78

Propellers............................................................. 78

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Page 7

Propeller Repair.............................................78

Bravo One Propeller Removal........................78

Bravo One Propeller Installation.....................79

Bravo Two Propeller Removal........................80

Bravo Two Propeller Installation.....................80

Bravo Three Propeller Removal.....................81

Bravo Three Propeller Installation..................82

Serpentine Drive Belt.............................................84

Checking...........................................................84

Section 6 - Storage

Replacing..........................................................85

Flushing the Power Package.................................86

Flushing Attachments.......................................87

Sterndrive Water Pickups.................................87

Alternative Water Pickups.................................89

Battery...................................................................90

Multiple EFI Engine Battery Precautions........91

Corrosion Protection..............................................92

Painting Your Power Package..........................96

Cold Weather or Extended Storage.....................100

Preparing Power Package for Storage.........100

Engine and Fuel System Preparation........101

Draining the Seawater System............................101

Drain System Identification...........................102

Air Actuated Single Point Drain System.....102

Manual Drain System.................................103

Air Actuated Single Point Drain System.......103

Section 7 - Troubleshooting

Diagnosing EFI Problems....................................112

Diagnosing DTS Problems..................................112

Engine Guardian System.....................................112

Starter Motor Will Not Crank Engine, Or Cranks

Slow.....................................................................112

Engine Will Not Start Or Is Hard To Start............112

Engine Runs Rough, Misses And/Or Backfires...113

Poor Performance...............................................113

Excessive Engine Temperature...........................113

Insufficient Engine Temperature..........................114

Boat in the Water.......................................103

Boat out of the Water.................................105

Manual Drain System...................................107

Boat in the Water.......................................107

Boat out of the Water.................................108

Draining the Sterndrive.................................108

Battery Storage....................................................109

Power Package Recommissioning......................109

Low Engine Oil Pressure.....................................114

Battery Will Not Come Up On Charge.................114

Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual Sounds 114

Steering Wheel Turns Hard Or Jerky..................114

Power Trim Does Not Operate (Motor Does Not

Operate)..............................................................115

Power Trim Does Not Operate (Motor Operates But

Sterndrive Unit Does Not Move)..........................115

Section 8 - Customer Assistance Information

Owner Service Assistance...................................118

Local Repair Service.......................................118

Service Away From Home..............................118

Stolen Power Package...................................118

Attention Required After Submersion.............118

Replacement Service Parts............................118

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Parts And Accessories Inquiries................119

Resolving A Problem......................................119

Mercury Marine Service Offices......................119

Ordering Literature..............................................120

United States and Canada..............................120

Outside The United States and Canada.........120

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Section 1 - Warranty

Table of Contents

Transfer Of Warranty............................................ 2

Warranty Registration United States And Canada

.............................................................................. 2

Warranty Registration Outside The United States

And Canada.......................................................... 2

Mercury, MerCruiser Limited Warranty United States, Canada and Europe (Gasoline Fueled

Products Only)...................................................... 3

Mercury MerCruiser Limited Warranty (Confederation of Independent States, Middle-East,

and Africa.............................................................. 5

3 Year Limited Warranty Against Corrosion

(Worldwide)........................................................... 6

Warranty Coverage And Exclusions..................... 7

General Exclusions From Warranty ............... 8

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Section 1 - Warranty

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 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.

Warranty Registration United States And Canada

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 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. To be eligible for warranty coverage, the product must be registered with Mercury Marine. 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.

3. Upon processing the warranty registration, Mercury Marine will send registration verification by mail to the purchaser of the product. If this registration verification is not received within 30 days, please contact your selling dealer immediately. Warranty coverage is not effective until your product is registered with Mercury Marine.

Warranty Registration Outside The United States And Canada

1. It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.

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Section 1 - Warranty

2. The Warranty Registration Card identifies your name and address, product model and

serial numbers, date of sale, type of use and the selling distributor's/dealer's code number, name and address. The distributor/dealer also certifies that you are the original purchaser and user of the product.

3. A copy of the Warranty Registration Card, designated as the Purchaser's Copy, MUST

be given to you immediately after the card has been completely filled out by the selling distributor/dealer. This card represents your factory registration identification, and should be retained by you for future use when required. Should you ever require warranty service on this product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms.

4. In some countries, the Marine Power Service Center will issue you a permanent

(plastic) Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor/dealer. If you receive a plastic Warranty Registration Card, you may discard the Purchaser's Copy that you received from the distributor/dealer when you purchased the product. Ask your distributor/dealer if this plastic card program applies to you.

IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your dealer/distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.

5. For further information concerning the Warranty Registration Card and its relationship

to Warranty Claim processing, refer to the International Warranty.

Mercury, MerCruiser Limited Warranty United States, Canada and Europe (Gasoline Fueled Products Only)

WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in

material and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for either two (2)

years from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. Commercial users of these products receive warranty coverage of either one (1) year from the date of first retail sale, or the accumulation of 500 hours of operation, whichever occurs first. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re– registration of the product. Unexpired warrant coverage cannot be transferred either to or from a commercial use customer.

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Section 1 - Warranty

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. 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 future warranty coverage contingent on 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 remanufactured 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.

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.

WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation 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 which damages the Mercury Product and was not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operation and Maintenance Manual), alteration or removal of parts, or 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.. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

Expenses related to haul out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

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.

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Section 1 - Warranty

DISCLAIMERS AND LIMITATIONS:

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME 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.

Mercury MerCruiser Limited Warranty (Confederation of Independent States, Middle-East, and Africa

WHAT IS COVERED: Mercury Marine warrants its products to be free of defects in material

and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for either one (1)

year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. Commercial users of these products receive warranty coverage for either one (1) year from the date of first retail sale, or the accumulation of 500 hours of operation, whichever occurs first. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re-registration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer.

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. 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 on proof of proper maintenance.

90-864839060 MAY 2006 Page 5

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Section 1 - Warranty

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 laborand 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.

WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation 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, jet pump impellers and liners, 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, or 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 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.

Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

DISCLAIMERS AND LIMITATIONS:

3 Year Limited Warranty Against Corrosion (Worldwide)

WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury

Racing, Sport Jet, M2 Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

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Section 1 - Warranty

DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three

(3) years from either the date the product is first sold, 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 subsequent (non-commercial use) 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. Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat, and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants, and touch-up of nicks and scratches) 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 corroded 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.

WHAT IS NOT COVERED: This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by customer); products used in a commercial application. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes.

Warranty Coverage And Exclusions

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 Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited Outboard Warranty.

90-864839060 MAY 2006 Page 7

Page 16

Section 1 - Warranty

Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered.

Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.

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

General Exclusions From Warranty

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

2. Factory installed jet drive units - Specific parts excluded from the warranty are: The jet drive impeller and jet drive liner damaged by impact or wear, and water damaged drive shaft bearings as a result of improper maintenance.

3. Damage caused by neglect, lack of maintenance, accident, abnormal operation or improper installation or service.

4. Haul out, launch, towing charges, removal and/or replacement of boat partitions or material because of boat design for necessary access to the product, all related transportation charges and/or travel time, etc. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an authorized dealer.

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

6. 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).

7. All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility.

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

9. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

10. Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit.

11. 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.

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

13. Water entering engine through the fuel intake, air intake or exhaust system or submersion.

14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high or trimmed too far out.

Page 8 90-864839060 MAY 2006

Page 17

Section 1 - Warranty

15. Use of fuels and lubricants which are not suitable for use with or on the product. Refer

to the Maintenance section.

16. Our limited warranty does not apply to any damage to our products caused by the

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

90-864839060 MAY 2006 Page 9

Page 18

Section 1 - Warranty

Notes:

Page 10 90-864839060 MAY 2006

Page 19

Section 2 - Getting to Know Your Power Package

Table of Contents

Section 2 - Getting to Know Your Power Package

Lanyard Stop Switch........................................... 12

Instrumentation................................................... 13

System View ................................................ 13

Digital Gauges .............................................. 14

Analog Gauges ............................................ 14

Remote Controls (Non-DTS Models).................. 15

Remote Controls...........................................15

Panel Mount Features ............................ 15

Console Mount Features ........................ 16

Zero Effort Features......................................17

Remote Controls (DTS Models).......................... 17

Remote Controls...........................................17

Panel Mount Features...................................18

Console Mount Features - Single Engine.....19

Slim Binnacle Console Mount Features - Single

Engine...........................................................20

Console Mount Features- Dual Engine.........21

Synchronizing Dual Engines.........................22

Dual Helm Station Transfer...........................22

Synchronizing Dual Helms Prior To Station

Transfer .................................................. 23

Zero Effort Features......................................23

Power Trim......................................................... 24

Single Engine Trim/Trailer ...................... 25

Dual Engine Trim/Trailer ........................ 25

Trim without Key...........................................25

Trim Delta......................................................26

Electrical System Overload Protection............... 26

Audio Warning System....................................... 28

Testing The Audio Warning System ............. 29

Engine Guardian Strategy.................................. 29

Warning Horn Signals......................................... 29

Emissions Information........................................ 30

Emission Control Information Label..............30

Owner Responsibility ............................. 31

Star Label......................................................31

90-864839060 MAY 2006 Page 11

Page 20

Section 2 - Getting to Know Your Power Package

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position).

RUN

74608

a - Stop switch b - Lanyard

Accidental ejections, such as falling overboard, are more likely to occur in:

• low sided sport boats

• bass boats

• high performance boats Accidental ejections can also occur from:

• poor operating practices

• sitting on the seat or gunwale at planing speeds

• standing at planing speeds

• operating at planing speeds in shallow or obstacle infested waters

• releasing your grip on the steering wheel that is pulling in one direction

• consuming alcohol or drugs

• high speed boating maneuvers The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when

stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at-rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched-out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or tie a knot in the lanyard.

Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).

c - Clips to the operator

Avoid contact with the boat hull and propeller from accidental ejection. Personal injury or death could occur. Always properly connect both ends of the lanyard stop switch.

Page 12 90-864839060 MAY 2006

WARNING

Page 21

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

• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.

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

• Loss of control when docking.

Avoid abrupt deceleration of the boat from lanyard stop switch activation. Boat damage and personal injury or death could occur. Never leave the operator's station with the engine operating and in gear.

Instrumentation

System View

Section 2 - Getting to Know Your Power Package

WARNING

Sm a rt Craf t

SELECT

System View

HOME

5650

Your power package may be connected to the Mercury SC5000 SmartCraft System View display. The display monitors and reports information ranging from basic operating data to engine alarm data.

The SC5000 System View Display is a comprehensive boat information center. System View allows the boat operator to receive a wealth of critical operational information, displayed clearly and instantly at the helm on the LCD display. The System View continuously monitors and reports information ranging from basic operating data to detailed vessel environment information. System View displays water temperature and depth, engine trim status, boat speed, steering angle, system preventive maintenance reminders and systems diagnostics. System View also can be fully integrated with the boat's GPS, if equipped, to provide up to the minute location, course, speed, and fuel-to-destination information.

When a problem is detected with the engine or system, the System View will alert the operator to the potential problem by displaying the alarm message in the information window, located at the bottom of the view screen.

If the problem can cause immediate engine damage, the Engine Guardian System will respond to the problem by limiting engine power. Immediately reduce throttle speed to idle. Refer to the System View Operation Manual for further explanation of the problem and the correct action to take.

90-864839060 MAY 2006 Page 13

Page 22

Section 2 - Getting to Know Your Power Package

OIL

C H

TEMP

R P M

X 1000

MPH

KPH

100

120

110

10 16

BATT

FUEL

CRUISELOG

0 0 0 0

TRIM

14671

Digital Gauges

A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, battery voltage, fuel consumption and engine operating hours.

The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems.

Refer to the manual with your gauge package for the warning functions monitored and basic operation of the SmartCraft Instrument package.

Analog Gauges

The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.

a - Speedometer b - Tachometer c - Oil pressure gauge d - Voltmeter e - Water temperature gauge

f - Fuel gauge g - Hour meter h - Bilge blower switch i - Ignition switch j - Power trim gauge

Speedometer: Indicates boat speed. Tachometer: Indicates engine RPM. Oil Pressure Gauge: Indicates engine oil pressure. Voltmeter: Indicates battery voltage. Water Temperature Gauge: Indicates engine operating temperature. Fuel Gauge: Indicates quantity of fuel in tank. Hour meter: Records engine operating time. Bilge Blower Switch: Operates bilge blower.

Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in).

Ignition Switch: Allows operator to start and stop engine.

Page 14 90-864839060 MAY 2006

Page 23

Remote Controls (Non-DTS Models)

Remote Controls

Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.

PANEL MOUNT FEATURES

Section 2 - Getting to Know Your Power Package

mc77019-1

a - Neutral lock button b - Throttle only button c - Lanyard stop switch

Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock

button must be pushed into move the control handle out of neutral. Throttle Only Button - Allows engine throttle advancement without shifting the engine.

This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position, and should only be used to assist in starting the engine.

Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.

Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed.

Control Handle Tension Adjustment Screw - (not visible) This screw is used to adjust the effort required to move the remote control handle. Refer to instructions provided with remote control for complete adjustment instructions.

Trim/Tilt Button - Refer to Power Trim.

d - Control handle tension adjustment

screw

e - Control handle f - Trim/tilt button

90-864839060 MAY 2006 Page 15

Page 24

Section 2 - Getting to Know Your Power Package

CONSOLE MOUNT FEATURES

a - Throttle Only Button b - Control Handle

Throttle Only Button - Allows engine throttle advancement without shifting the engine.

This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.

Control Handles - Operation of the the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to increase speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed.

Power Trim Switch - See Power Trim section for detailed power trim operating procedures.

Trailer Switch - Used to raise drive unit for trailering, launching, beaching or shallow water operation. See Power Trim for detailed trailer switch operation.

c - Power Trim Switch d - Trailer Switch

mc79503-1

Page 16 90-864839060 MAY 2006

Page 25

Zero Effort Features

Section 2 - Getting to Know Your Power Package

a - Shift ever b - Throttle lever

Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into

reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position.

Throttle Lever - Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.

Trim/Tilt Switch - Refer to Power Trim.

5656

c - Trim/tilt switch

Remote Controls (DTS Models)

Remote Controls

IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

The Digital Throttle and Shift System (DTS) required to operate this engine package provides start and stop functions, throttle control, shift control, start in gear protection, and emergency lanyard stop functions. The DTS system works with specialized helm components such as a command module kit and electronic remote control. Consult your dealer for a description and/or demonstration of your remote control.

90-864839060 MAY 2006 Page 17

Page 26

Section 2 - Getting to Know Your Power Package

Panel Mount Features

3409

a - Lanyard stop switch b - Control handle c - Shift lock d - Trim/tilt switch e - Throttle only button f - Start/stop button g - Detent tension adjustment screw h - Control handle friction adjustment screw

Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the

lanyard) moves far enough away from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.

Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.

Shift Lock - Pressing the shift lock allows the engine to shift. The shift lock must always be pressed when moving the control handle out of the neutral position.

Trim/Tilt Switch (if equipped) - Refer to Power Trim. Throttle Only Button - Allows engine throttle advancement without shifting the engine.

The throttle only button can be depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up the engine.

Start/Stop Button - Allows the boat operator to start or stop the engine without using the ignition key.

Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension.

Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.

Page 18 90-864839060 MAY 2006

Page 27

Console Mount Features - Single Engine

Section 2 - Getting to Know Your Power Package

3410

a - Control handle b - Trim/tilt switch c - Active light d - Neutral light e - Select key f - Arrow trackpad g - Throttle only/station select key h - Detent tension adjustment i - Control handle friction adjustment screw

Control Handle - Operation of the shift and throttle are controlled by the movement of the

control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.

Trim/Tilt Switch (if equipped) - Refer to Power Trim. Active Light - The active light is illuminated to show the remote control is active and ready

for use. Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.

NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch.

Select Key - Selects System View on-screen options and confirms data entries. Arrow Trackpad - Navigates through System View on-screen function messages. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting

the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms. Refer to Dual Helm Station Transfer.

90-864839060 MAY 2006 Page 19

Page 28

Section 2 - Getting to Know Your Power Package

START

STOP

14637

Slim Binnacle Console Mount Features - Single Engine

a - Control handle b - Trim/tilt switch c - Active light d - Neutral light e - Start/stop button f - Throttle only/station select key g - Detent tension adjustment h - Control handle friction adjustment screw

Control Handle - Operation of the shift and throttle are controlled by the movement of the

Trim/Tilt Switch (if equipped) - Refer to Power Trim. Active Light - The active light is illuminated to show the remote control is active and ready

for use. Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.

NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch.

Stop/Start Button - Allows the boat operator to start or stop the engine without using the ignition key.

Throttle Only/Station Select Key - Allows engine throttle advancement without shifting the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms. Refer to Dual Helm Station Transfer.

Page 20 90-864839060 MAY 2006

Page 29

Console Mount Features- Dual Engine

Section 2 - Getting to Know Your Power Package

THROTTLE

ONLY

STATION SELECT

SYNC

ACTIVE

3411

a - Trim/tilt switch b - Control handles c - Active light d - Neutral light e - Select key

f - Arrow trackpad g - Sync light h - Throttle only/station select key i - Detent tension adjustment j - Control handle friction adjustment

screw

Trim/Tilt Switch (if equipped) - Refer to Power Trim. Control Handle - Operation of the shift and throttle are controlled by the movement of the

Active Light - The active light is illuminated to show the remote control is active and ready for use.

Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.

NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch.

Select Key - Selects System View on-screen options and confirms data entries. Arrow Trackpad - Navigates through System View on-screen function messages. Sync Light - The sync light is illuminated when the RPM of the two engines are being

synchronized by the DTS system. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting

90-864839060 MAY 2006 Page 21

Page 30

Section 2 - Getting to Know Your Power Package

Synchronizing Dual Engines

The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine.

Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5° of each other.

Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the engines are synchronized.

To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.

Dual Helm Station Transfer

The throttle only/station select button allows the boat operator to select which remote control is in control of the engine operation.

The active light is illuminated at the remote control station that is in control of the engine.

Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One person helm transfer should only be performed while engine is in neutral.

NOTE: Idle position is preferred when doing a station transfer. If conditions do not allow the remote control to be placed at idle position, a station transfer can be done while in gear.

NOTE: Pressing and releasing station select button at new station allows the engine control to be transferred to the new station. The control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new station. Adjust control handles to the desired throttle and gear position.

1. Place active remote control lever to idle position.

2. Proceed to the inactive helm station and position remote control lever to the idle position.

ACTIVE

SYNC

THROTTLE

ONLY

STATION SELECT

WARNING

3434

Page 22 90-864839060 MAY 2006

Page 31

Section 2 - Getting to Know Your Power Package

3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to

indicate the remote control station is in control of the engine.

ACTIVE

THROTTLE

ONLY

STATION SELECT

a - Active light b - Throttle only/station select button

4. The active light will switch off at the original remote control station.

SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER

Pressing the station select button and holding it in allows the boat operator 10 seconds to match up the control handle settings at the new station with the handle settings that are at the old (to be inactive) station. If the handles are not matched, the neutral light will flash. The light blinks faster as the handles are nearing match position. Once the light stays on continuously, the handles are matched and the button can be released. Transfer process is complete and the new station is now in control. If the button is held for over 10 seconds, the station transfer is cancelled.

Zero Effort Features

ACTIVE

THROTTLE

ONLY

STATION SELECT

SYNC

3433

a - Shift ever b - Throttle lever

Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into

reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position.

Trim/Tilt Switch - Refer to Power Trim.

90-864839060 MAY 2006 Page 23

5656

c - Trim/tilt switch

Page 32

Section 2 - Getting to Know Your Power Package

Power Trim

Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.

Never trim the sterndrive unit up\out using the trailer switch while boat is underway at engine speeds above 1200 rpm. Use extreme caution when operating with sterndrive unit raised. Severe damage to the sterndrive unit may result if unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 rpm.

For best performance trim the sterndrive unit so that the boat bottom is at a 3-5° angle to the water.

CAUTION

3 - 5

mc79528

Trimming sterndrive unit up/out can:

• Generally increase top speed

• Increase clearance over submerged objects or a shallow bottom

• Cause boat to accelerate and plane off slower

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

• Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line

mc78529

Trimming sterndrive unit down/in can:

• Help the boat accelerate and plane off quicker

• Generally improve the ride in choppy water

• In most cases, reduce boat speed

Page 24 90-864839060 MAY 2006

Page 33

• If in excess, lower the bow of some boats to a point at which they begin to plow with

their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.

SINGLE ENGINE TRIM/TRAILER

Single engine applications will have a button that can be pressed to trim the sterndrive unit up or down.

To raise the sterndrive unit for trailering, beaching, launching, low speed (below 1200 rpm), and shallow water operation push the trim button to raise the sterndrive unit to the full up/ out position.

Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.

NOTE: The DTS control system limits the extent to which the sterndrive unit can be trimmed up/out when engine speed is above 3500 RPM.

DUAL ENGINE TRIM/TRAILER

Section 2 - Getting to Know Your Power Package

mc79530

Avoid twisting or binding dual engine tie bars. Damage to the tie bar and sterndrives could occur. Always raise or lower the sterndrive units evenly.

Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit.

Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.

Trim without Key

Trim without key is a method of allowing trim operation after the ignition key switch is turned off. The command module and PCM remain powered and are able to process trim requests for up to 15 minutes after the key switch is turned off. The command module does not process any requests other than trim during this period. Once the 15 minute period expires, the command module sends a command through the CAN lines to shut down the PCM. On multi-engine applications, the timeout is managed seperately for each engine.

The trim without key period may be ended at any time by moving the control handle to Wide Open Throttle Reverse (WOTR) with the key off. To end the 15 minute period for the center engine in a shadow mode application, ensure all ignition key switches are in the "OFF" position and both remote control handles are in the Wide Open Throttle Reverse (WOTR) position.

CAUTION

90-864839060 MAY 2006 Page 25

Page 34

Section 2 - Getting to Know Your Power Package

Trim Delta

Trim delta controls the distance between the individual adjacent drive angles when trimming. The trim delta limit is preset, and will not allow extreme drive angle differences that could damage tie bars. If the maximum trim delta limit is met, the drive furthest in the trim process "up or down", will stop trimming until the adjacent drive is back within the delta limit. Once the drive or drives are back within this delta window, the trim process will continue.

Electrical System Overload Protection

If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing the fuse or resetting the circuit breaker.

NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn off or disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your authorized dealer.

1. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset after testing, or if tripped, by pushing the yellow lever back into the housing.

Yellow lever style circuit breaker-typical

a - Yellow lever-shown tripped b - Red test button

Page 26 90-864839060 MAY 2006

22529

Page 35

Section 2 - Getting to Know Your Power Package

2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed

to protect the engine wiring harness if an electrical overload occurs.

mc74907-1

3. Four fuses are located on the port side of the engine. These fuses protect various

Electronic Fuel Injection (EFI) circuits.

mc77602-1

4. The main power and fuel pump relays are located next to the fuses and control voltage

to the engine with the ignition key in the "ON" position.

mc77602-2

5. A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the

electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped).

90-864839060 MAY 2006 Page 27

mc70525-1

Page 36

Section 2 - Getting to Know Your Power Package

6. The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump. The trim pump may also have an in-line circuit protection device in the power trim positive lead near the battery switch or battery connection.

9208

a - 20 amp spade fuse b - 110 amp fuse

7. The Quicksilver Three-Button Power Trim Control Panel is further protected by a 20 amp in-line fuse.

mc70527-1

8. The Quicksilver MerCathode System has a 20 amp in-line fuse in the wire which connects to the positive (+) terminal on controller. If the fuse is blown, the system will not operate resulting in a loss of corrosion protection.

Audio Warning System

Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.

The audio warning system will sound with a continuous horn if one of the following occurs:

Page 28 90-864839060 MAY 2006

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Page 37

• Engine oil pressure too low

• Engine temperature too hot

• Seawater pressure too low The audio warning system will sound with an intermittent beeping if the following occurs:

• Sterndrive oil level too low

Operation of the engine after the audio warning system alarm has sounded could result in damage to the power package. When the alarm has sounded, do not operate engine except to avoid a hazardous situation.

If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser dealer.

Testing The Audio Warning System

1. Turn the ignition switch to the "ON" position without cranking the engine.

2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.

Engine Guardian Strategy

Section 2 - Getting to Know Your Power Package

CAUTION

IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle.

Engine Guardian Strategy is designed to help reduce the potential for engine damage by reducing engine power when a potential problem is sensed by the ECM. Engine Guardian monitors:

• Oil pressure

• Coolant temperature

• Seawater pressure

• Engine overspeed

• Exhaust Manifold Temperature [8.1 liter (496 cid) engines only] Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if

any sensor on the power package fails. For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will

reduce the available power level of the engine to help prevent damage from decreased water flow to the engine. If the debris passes through and full water flow is restored, engine power levels are restored to normal.

To avoid a possible recurrence of the problem you should contact an authorized dealer. The ECM stores the fault and with this information the technician will be able to more rapidly diagnose problems.

Warning Horn Signals

Most faults will cause the warning horn circuit to activate. How the warning horn activates depends on how serious the problem is. There are four warning horn states:

• Caution - horn signal varies with product line and calibration. Minimal guardian.

• Warning - horn signal varies with product line and calibration.

• Severe - horn is beeping constantly.

• Critical - horn is beeping constantly and guardian will be at forced idle. In addition, depending on the gauge package, there will be warning icons and fault

messages on the dash mounted gauges.

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Page 38

Section 2 - Getting to Know Your Power Package

Emissions Information

Emission Control Information Label

A tamper-resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, FEL (emission level), date of manufacture (month, year), and the engine displacement. Please note that the low emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# OMXXXXXXXX FAMILY XXXXX_XXXXXX FEL. XX.X g/kW-hr

Emission Control Label - Non CE Marked

EMISSION CONTROL INFORMATION

D.O.M. JAN. 2003 DISP X.XL

11018

"SERIAL#" - Engine Serial Number "FAMILY" - Engine Family "FEL." - Family Emission Limit "D.O.M." - Date of Manufacture "DISP" - Piston Displacement

EMISSION CONTROL INFORMATION

THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS

SERIAL#

FAMILY

FEL.

OMXXXXXX

XXXXX XXXXXX

XX.X g/kW-hr

D.O.M.

DISP.

Dec 2004

X.XL

Emission Control Label - CE Marked

"SERIAL#" - Engine Serial Number "FAMILY" - Engine Family "FEL." - Family Emission Limit "D.O.M." - Date of Manufacture "DISP" - Piston Displacement

0575

10652

Page 30 90-864839060 MAY 2006

Page 39

CE - When this mark is present in the lower right corner of the Emission Control Information Label, on the engine, the Declaration of Conformance applies. Refer to the front page of this Manual for further information.

OWNER RESPONSIBILITY

The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards.

The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.

Star Label

Beginning January 1, 2003, one Three-Star label will be included with each factory-certified Mercury MerCruiser engine.

All Mercury MerCruiser engines (500 hp and below) will have a Three-Star Ultra Low Emission rating. The Three-Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One-Star Low Emissions engines.

The Three-Star label will be affixed on the left side of the hull as shown.

Section 2 - Getting to Know Your Power Package

XX 1234 XX

a - Recommended location b - Secondary location

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Section 2 - Getting to Know Your Power Package

One Star - Low emission

Two Stars - Very Low emission

mc79569-1

The one-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission 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.

IDA

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Three Stars - Ultra Low emission

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Four Stars - Super Ultra Low emission

mc79572-1

The two-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star Low-Emission engines.

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

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.

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Table of Contents

Section 3 - On The Water

Safe Boating Suggestions.................................. 34

Be Alert To Carbon Monoxide Poisoning........... 35

Good Ventilation ........................................... 36

Poor Ventilation ........................................... 36

Basic Boat Operation (Non-DTS Models)........... 36

Launching and Boat Operation.....................36

Operation Chart ...................................... 37

Starting and Stopping the Engine.................37

Starting the Engine ................................. 37

Stopping the Engine ............................... 38

Starting Engine After Stopped While In Gear

......................................................................38

Throttle Only Operation.................................38

Trailering the Boat.........................................38

Freezing Temperature Operation..................39

Drain Plug and Bilge Pump...........................39

Basic Boat Operation (DTS Models)................... 39

Launching and Boat Operation.....................39

Operation Chart ...................................... 39

Starting and Stopping the Engine.................40

Starting the Engine ................................. 40

Stopping the Engine ............................... 41

Throttle Only Operation.................................41

Trailering the Boat.........................................42

Freezing Temperature Operation..................42

Drain Plug and Bilge Pump...........................42

Protecting People In The Water.......................... 42

While You Are Cruising ................................ 42

While Boat Is Stationary ............................... 42

High-Speed And High-Performance Boat Operation

............................................................................ 43

Passenger Safety In Pontoon Boats And Deck

Boats................................................................... 43

Boats Having An Open Front Deck .............. 43

Boats With Front-Mounted, Raised Pedestal

Fishing Seats ............................................... 43

Wave And Wake Jumping.................................. 44

Impact With Underwater Hazards....................... 44

Drive Unit Impact Protection ........................ 45

Operating With Low Water Inlets In Shallow Water

............................................................................ 45

Conditions Affecting Operation........................... 46

Weight Distribution (Passengers and Gear)

Inside the Boat..............................................46

Bottom Of Boat..............................................46

Cavitation......................................................46

Ventilation.....................................................46

Elevation And Climate...................................47

Propeller Selection........................................47

Getting Started.................................................... 47

20-Hour Break-In Period...............................47

After Break-In Period.....................................48

End of First Season Checkup.......................48

90-864839060 MAY 2006 Page 33

Page 42

Section 3 - On The Water

Safe Boating Suggestions

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

Know and obey all nautical rules and laws of the waterways.

• Mercury MerCruiser strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency. Inquiries may be made to the Boating Hotline at 1-800-368-5647 or the Boat U.S. Foundation at 1-800-336-BOAT.

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 some suggestions of the types of safety equipment to carry when boating:

• Approved fire extinguishers

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

• Tools necessary for minor repairs

• Anchor and extra anchor line

• Manual bilge pump and extra drain plugs

• Drinking water

• Transistor radio

• Paddle or oar

• Spare propeller, thrust hubs, and an appropriate wrench

• First aid kit and instructions

• Water-proof storage containers

• Spare operating equipment, batteries, bulbs and fuses

• Compass and map or chart of the area

• Personal flotation device (1 per person on board)

Watch for signs of weather change and avoid foul weather and rough-sea boating.

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

Passenger boarding.

• Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

Use personal flotation devices.

• Federal Law requires that there be a U. S. Coast Guard approved life jacket (personal flotation device), correctly sized and readily accessible for every person on board, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

• Instruct at least 1 person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard.

Do not overload your boat.

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Section 3 - On The Water

• Most boats are rated and certified for maximum load (weight) capacities (refer to your

boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

• Do not allow anyone to sit or ride on any part of the boat that was not intended for such

use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

Never be under the influence of alcohol or drugs while boating (it is the law).

• They impair your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

Be alert.

• The operator of the boat is responsible by law to maintain a proper lookout by sight and

hearing. The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when the boat is above idle or planing transition speed. Watch out for others, the water and your wake.

Never drive your boat directly behind a water skier in case the skier falls.

• As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier who

was 61 m (200 ft.) in front of you in 5 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 attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

Report accidents.

• Boat operators are required by law to file a Boating Accident Report with their state

boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.

Be Alert To Carbon Monoxide Poisoning

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

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

Avoid prolonged exposure to carbon monoxide. Carbon monoxide poisoning can lead to unconsciousness, brain damage or death. Ensure that the boat, while at rest or underway, is well ventilated.

90-864839060 MAY 2006 Page 35

WARNING

Page 44

Section 3 - On The Water

Good Ventilation

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

1. Example of desired air flow through the boat.

Poor Ventilation

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

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

1. Examples of poor ventilation while a boat is stationary:

mc79553-1

a - Operating the engine when the

boat is moored in a confined space

2. Examples of poor ventilation while a boat is moving:

a - Operating the boat with the trim

angle of the bow too high

Basic Boat Operation (Non-DTS Models)

Launching and Boat Operation

IMPORTANT: Install bilge drain plug prior to launching boat.

CAUTION

To avoid possible ingestion of water that can damage engine components, do not turn the ignition key off when the engine is above idle speed. When launching your boat from a steep ramp, enter the water slowly. Do not use the lanyard stop switch to shut off the engine above idle speed. When coming off plane, if a large following wave may roll over the boat's transom, apply a short, light burst of throttle to minimize the wave action against the stern of the boat. Do not come off plane quickly and then shut off the engine. Also avoid shifting into reverse while on plane.

b - Mooring close to another boat with

its engine operating

b - Operating the boat with no forward

hatches open (station wagon effect)

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Page 45

OPERATION CHART

BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING

Install bilge drain plug.

Open engine hatch.

Turn battery switch on.

Operate bilge blowers. Check steering operation.

Open fuel shut off valve.

Open seacock, if equipped.

Close the drain system.

Place sterndrive unit in full down/in position.

Check the engine oil.

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

Listen for Audio Warning Alarm to sound when the ignition switch is in the "ON" position.

Operation Chart

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

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

Check shift and throttle control operation.

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

Listen for the audio alarm.

Section 3 - On The Water

Turn ignition key to the "OFF" position.

Turn battery switch to the "OFF" position.

Close fuel shut off valve.

Close seacock, if equipped.

Flush cooling system if in saltwater.

Drain bilge.

Starting and Stopping the Engine

NOTE: Only perform those functions applicable to your power package.

STARTING THE ENGINE

1. Check all items listed in the Operation Chart.

2. Place the remote control handle in neutral.

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

Explosive gasoline fumes collect in the engine compartment. Avoid injury or property damage, operate the bilge blower for at least 5 minutes prior to starting the engine. If the boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine.

3. Turn ignition key to "START". Release key when engine starts and allow switch to return

to "ON" position. Allow engine to warm up (6-10 minutes on first start of the day).

4. If engine does not start after 3 attempts:

a. Push the throttle only button and position the remote control handle/throttle lever

to the 1/4 throttle position.

CAUTION

WARNING

90-864839060 MAY 2006 Page 37

Page 46

Section 3 - On The Water

b. Turn ignition key to "START". Release key when engine starts and allow switch

5. If engine does not start after step 4: a. Move the remote control handle/throttle lever to full throttle position, then return

b. Turn ignition key to "START". Release key when engine starts and allow switch

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

7. Move control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting, advance throttle to desired setting.

Avoid damage to the drive system. Shifting the drive system at RPMs greater than engine idle speed may cause internal damage to the drive system. Shift the drive system only when the engine is at idle RPM.

STOPPING THE ENGINE

1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes.

2. Turn ignition key to the "OFF" position.

to return to "ON" position.

to 1/4 throttle.

to return to "ON" position.

CAUTION

Starting Engine After Stopped While In Gear

IMPORTANT: Avoid stopping the engine if the sterndrive unit is in gear. If the engine does stop, refer to the following procedure:

1. Push and pull repeatedly on the remote control handle until handle returns to the neutral/idle position. This may take several tries if the power package was operating above idle RPM when the engine stopped.

2. After the handle returns to the neutral/idle position, resume normal starting procedures.

Throttle Only Operation

1. Refer to Remote Controls section for remote control features.

2. Move the control lever to the idle/neutral position.

3. Depress and hold the throttle only button, and move the control lever to the idle/forward or idle/reverse position.

4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase.

IMPORTANT: Moving the control lever back to the idle/neutral position will disengage the throttle only button and allow the engine to shift into gear.

5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position. Moving the control lever from the idle/neutral position to the idle/forward or idle/reverse position without pressing the throttle only button will shift the unit into the chosen gear.

Trailering the Boat

Your boat can be trailered with the sterndrive unit in the up or down position. Adequate clearance is required between the road and sterndrive when transporting.

If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer.

Page 38 90-864839060 MAY 2006

Page 47

Freezing Temperature Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser 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 come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

Basic Boat Operation (DTS Models)

Launching and Boat Operation

IMPORTANT: Install bilge drain plug prior to launching boat.

CAUTION

Section 3 - On The Water

OPERATION CHART

BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING

Install bilge drain plug.

Open engine hatch.

Turn battery switch on.

Operate bilge blowers. Check steering operation.

Open fuel shut off valve.

Open seacock, if equipped.

Close the drain system.

Place sterndrive unit in full down/in position.

Check the engine oil.

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

Operation Chart

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

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

Check shift and throttle control operation.

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

Listen for the audio alarm.

Turn ignition key to the "OFF" position.

Turn battery switch to the "OFF" position.

Close fuel shut off valve.

Close seacock, if equipped.

Flush cooling system if in saltwater.

Drain bilge.

90-864839060 MAY 2006 Page 39

Page 48

Section 3 - On The Water

BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING

Listen for Audio Warning Alarm to sound when the ignition switch is in the "ON" position.

Starting and Stopping the Engine

NOTE: Perform only those functions applicable to your power package.

STARTING THE ENGINE

1. Check all items listed in the Operation Chart.

2. Place the remote control handle in neutral.

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

Operation Chart

CAUTION

WARNING

NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process. When the start button is pushed, the DTS system signals the engine PCM to start the engine. If the engine does not start, the starting process times out after eight seconds or when the engine reaches 400 RPM. Attempting to start the engine with the engine already running will turn the engine off.

3. Turn ignition key to "RUN" position.

4. Turn the ignition key switch to the "START" position then release, or depress the start/ stop button and release. If the engine is cold, allow the engine to operate at idle for 6-10 minutes or until the engine temperature reaches 60 °C (140 °F).

5. If the engine does not start after three attempts: a. Push the throttle-only button and position the remote control handle or throttle

lever to the 1/4 throttle position.

b. Turn the ignition key to "start." Release key when the engine starts and allow the

switch to return to the "on" position.

6. If the engine does not start after step 5: a. Move the remote control handle.throttle lever to the full throttle position, then return

to 1/4 throttle.

b. Turn the ignition key to "start." Release key when the engine starts and allow the

switch to return to the "on" position.

7. Inspect the power package for fuel, oil, water, and exhaust leaks.

8. Move the control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting, advance throttle to desired setting.

Page 40 90-864839060 MAY 2006

Page 49

STOPPING THE ENGINE

1. Move the remote control handle to neutral/idle and allow the engine to slow to idle

speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes.

2. The engine can be stopped by any one of the following 4 methods:

a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine

b. Depress the start/stop button, if equipped. The engine will stop and the control

c. Momentarily move the ignition key switch to the "START" position, then release

d. Activate the lanyard stop switch, if equipped. The engine will stop, but the control

Section 3 - On The Water

CAUTION

will stop and the control system will be deactivated.

system will remain active.

immediately. The control system will recognize that the engine is running and will stop the engine. The control system will remain active. Moving the ignition key switch to the "START" position again will issue a start request to the control system and the control system will start the engine, if appropriate.

system will remain active. The control system will not allow the engine to start if the lanyard stop switch is activated.

Throttle Only Operation

NOTE: When operating in throttle only (neutral) mode, the DTS Control System will not allow the engine speed to increase above 3500 RPM.

Zero effort remote controls: Zero effort remote controls have seperate throttle control and shift control levers. Advancing the throttle control lever beyond the idle position while the shift control lever is in the neutral position will cause engine speed to increase, but only up to the maximum neutral engine speed of 3500 RPM.

When using a Digital Throttle and Shift (DTS) Zero Effort shift control lever, the DTS Control System can shift the sterndrive unit or transmission at engine speeds greater than idle. The resulting forward or reverse motion of the boat at engine speeds greater than idle could be sudden and unexpected or create a hazardous situation, resulting in injury or death and property damage, caused by a loss of boat control. Always place the throttle control lever in the idle position before moving the DTS shift control lever into forward or reverse gear position.

Panel Mount and Console Mount Remote Controls: Panel mount and console mount

remote controls are equipped with a throttle only button. To activate throttle only mode:

1. Refer to Remote Controls section for remote control features.

2. Move the control lever to the idle/neutral position.

3. Depress the throttle only button, and move the control lever to the idle/forward or idle/

reverse position. The DTS control system will sound two beeps on the audio warning horn to indicate throttle only mode is active. On console mount remote controls, the neutral light will begin to blink.

4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause

engine speed to increase.

WARNING

90-864839060 MAY 2006 Page 41

Page 50

Section 3 - On The Water

21604

IMPORTANT: Moving the control lever back to the idle/neutral position will deactivate the throttle only mode and allow the engine to shift into gear.

Trailering the Boat

Your boat can be trailered with the sterndrive unit in the up or down position. Adequate clearance is required between the road and sterndrive when transporting.

Freezing Temperature Operation

Drain Plug and Bilge Pump

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.

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

Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or any solid device rigidly attached to a moving boat or gearcase.

WARNING

Page 42 90-864839060 MAY 2006

Page 51

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

High-Speed And High-Performance Boat Operation

If your boat is considered a high-speed or high-performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to Hi-Performance Boat

Operation booklet (90-849250-R2) from your dealer, distributor or Mercury Marine.

Passenger Safety In Pontoon Boats And Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat. Falling over the front of the boat between the two pontoons will position them to be run over.

Boats Having An Open Front Deck

No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure.

Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.

Section 3 - On The Water

WARNING

Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over. Stay back from the front end of the deck and remain seated while the boat is in motion.

Boats With Front-Mounted, Raised Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

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Section 3 - On The Water

Wave And Wake Jumping

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

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

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

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

WARNING

mc79680-1

Impact With Underwater Hazards

Reduce speed and proceed with caution whenever you're driving a boat in shallow water or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom.

IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of 24 to 40 km/h (15 to 25 MPH).

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

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

mc79679-1

Page 44 90-864839060 MAY 2006

Page 53

• Impact damage to the underwater drive components, rudder and/or boat. Keep in mind, one of the most important things you can do to help reduce injury or impact

damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles.

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

The boat should be checked for hull fractures, transom fractures and water leaks. Operating with damaged underwater drive components, rudder or boat bottom could cause

additional damage to other parts of the power package, or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.

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

Drive Unit Impact Protection

The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit. After the sterndrive unit has cleared the object, the hydraulic system allows the sterndrive unit to return to its original operating position, preventing loss of steering control and engine overspeed.

Use extreme caution when operating in shallow water or where underwater objects are known to be present. No impact protection is provided in reverse; use extreme care to prevent striking submerged objects while operating in reverse.

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

WARNING

Section 3 - On The Water

Operating With Low Water Inlets In Shallow Water

a - Low Water Inlets

90-864839060 MAY 2006 Page 45

mc75827-1

Page 54

Section 3 - On The Water

CAUTION

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

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

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to rear (stern):

• Generally increases speed and engine RPM

• Causes bow to bounce in choppy water

• Increases danger of following wave splashing into the boat when coming off plane

• At extremes, can cause the boat to porpoise

Shifting weight to front (bow):

• Improves ease of planing

• Improves rough water ride

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

Bottom Of Boat

Cavitation

Ventilation

To maintain maximum speed, the boat bottom should be:

• Clean, free of barnacles and marine growth

• Free of distortion; nearly flat where it contacts the water

• Straight and smooth, fore and aft

Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the water inlets and cause the engine to overheat.

Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or a 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 the propeller. Common causes of cavitation are:

• Weeds or other debris snagged on the propeller

• Bent propeller blade

• Raised burrs or sharp edges on the propeller

Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed-up and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:

• Drive unit trimmed out too far.

• A missing propeller diffuser ring.

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

• Drive unit installed too high on transom.

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Elevation And Climate

Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by:

• Higher elevations

• Higher temperatures

• Low barometric pressures

• High humidity For you to have optimum engine performance under changing weather conditions, it is

essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating weather conditions.

In most cases, recommended RPM can be achieved by changing to a lower pitch propeller.

Propeller Selection

IMPORTANT: The engines covered in this manual are equipped with an RPM rev-limiter that is set to an upper (or limited) RPM amount. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM. Once the RPM returns to the recommended operating RPM range, normal engine operation resumes.

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. Refer to Mercury Marine's web page http:// www.mercurymarine.com/everything_you_need_to_know_about_propellers6.

Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load.

If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause higher than normal wear and/or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch.

• Warmer weather and greater humidity cause a loss of RPM.

• Operating in a higher elevation causes a loss of RPM.

• Operating with a dirty boat bottom causes a loss of RPM.

• Operating with increased load (additional passengers, pulling skiers) causes a loss of

RPM.

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. When not pulling skiers, do not operate at full throttle when using the lower pitch propeller.

Section 3 - On The Water

Getting Started

20-Hour Break-In Period

IMPORTANT: The first 20 hours of operation is the engine break-in period. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. During this break-in period, the following rules must be observed:

• Do not operate below 1500 RPM for extended periods of time for the first 10 hours.

Shift into gear as soon as possible after starting and advance the throttle above 1500 rpm if conditions permit safe operation.

90-864839060 MAY 2006 Page 47

Page 56

Section 3 - On The Water

• Do not operate at one speed consistently for extended periods.

• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is permissible (5 minutes at a time maximum).

• Avoid full throttle acceleration from idle speed.

• Do not operate at full throttle until the engine reaches normal operating temperature.

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

After Break-In Period

To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered;

• Ensure that propeller allows the engine to operate at or near the top of the specified WOT RPM range (Refer to Specifications and Maintenance) when at full throttle with a normal boat load.

• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at WOT RPM.

• Change the engine oil and oil filter. Refer to Maintenance.

• Change the transmission oil and filter. Refer to Maintenance (ZF Transmission models).

End of First Season Checkup

At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year-round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

1. Require fluid and filter change after the first 25 hours and then every 100 hours.

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Table of Contents

Section 4 - Specifications

Fuel Requirements............................................. 50

Fuel Ratings ................................................. 50

Using Reformulated (Oxygenated) Gasolines

(USA Only) ................................................... 50

Gasolines Containing Alcohol ...................... 50

Engine Oil........................................................... 51

Engine Specifications......................................... 52

Fluid Specifications............................................. 52

Sterndrives ................................................... 52

Engine .......................................................... 52

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Page 58

Section 4 - Specifications

Fuel Requirements

IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.

Fuel Ratings

Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications:

USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline [92 (R+M)/2 Octane] is also acceptable. Do not use leaded gasoline.

Outside USA and Canada - having a posted pump Octane Rating of 90 RON minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.

Using Reformulated (Oxygenated) Gasolines (USA Only)

This type of gasoline is required in certain areas of the USA. The 2 types of oxygenates used in these fuels is Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol.

These Reformulated Gasolines are acceptable for use in your Mercury MerCruiser engine.

Gasolines Containing Alcohol

If the gasoline 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 gasoline 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 MerCruiser 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 boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel components should be inspected for leakage, softening, hardening, swelling or corrosion. Any sign of leakage or deterioration requires replacement before further engine operation.

WARNING

Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol-free gasoline 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.

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Engine Oil

Section 4 - Specifications

IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars alcohol-blend fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components.

To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of the following oils listed in the order of recommendation:

1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC-W rated, 4 cycle oil.

2. MerCruiser / Quicksilver 25W40 NMMA FC-W rated oil.

3. A NMMA FC-W rated oil.

4. MerCruiser / Quicksilver 4-cycle 25W40, non FC-W rated oil.

5. A good grade straight weight detergent automotive oil per the operating chart below.

NOTE: The use of non-detergent oils, multi-viscosity oils (other than as specified), non FC-W rated synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended.

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Section 4 - Specifications

Engine Specifications

Horsepower

Kilowatts

Displacement 8.1 L (496 cid)

Specified WOT RPM Range

Idle rpm in Neutral

Minimum Oil Pressure @ Idle

Minimum Oil Pressure @ 2000 rpm

Thermostat 71° C (160° F)

Timing @ Idle

Firing Order 1-8-7-2-6-5-4-3

Electrical System 12-Volt Negative (-) Ground

Alternator Rating - Hot Operating Amps 65 amp

Alternator Rating - Cold Operating Amps 72 amp

Recommended Battery Rating (Non-DTS Models) (Minimum) 750 CCA, 950 MCA, or 180 Ah

Recommended Battery Rating (DTS Models) (Minimum) 800 CCA, 1000 MCA, or 190 Ah

Spark Plug Type AC Platinum (AC 41-983)

Spark Plug Gap 1.5 mm (0.060 in.)

Models 496 MAG 496 MAG HO

375 425

280 317

4400-4800 4600-5000

650

103 kPa (15 psi)

207 kPa (30 psi)

Not Adjustable

Fluid Specifications

Sterndrives

NOTE: Oil capacity includes gear lube monitor.

Model Capacity Fluid Type

Bravo One 2736 ml (92-1/2 oz.)

Bravo Three 2972 ml (100-1/2 oz.)

Engine

IMPORTANT: All capacities are approximate fluid measures.

IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines).

High Performance Gear LubricantBravo Two 3209 ml (108-1/2 oz.)

1. Performance obtained and corrected in accordance with SAE J1228 Crankshaft Power.

2. Measured using an accurate service tachometer with the engine at normal operating temperatures

3. Idle speed and timing on EFI models are not adjustable

4. Oil pressure must be checked with the engine at normal opeating temperature.

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Section 4 - Specifications

All Models Capacity Fluid Type

Engine Oil (With Filter)

Seawater Cooling System

Closed Cooling System 18 liters (19 U.S. qt.)

8.5 liters (9 U.S. qt.)

20 liters (21 U.S. qt.) Propylene Glycol and Purified Water

Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W-40

Mercury Extended Life Coolant/Antifreeze or Extended Life Ethylene Glycol 5/100 Coolant/Antifreeze mixed 50/50 with Purified Water

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

2. Seawater cooling system capacity information is for winterization use only.

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Section 4 - Specifications

Notes:

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Table of Contents

Section 5 - Maintenance

Owner/Operator Responsibilities........................ 56

Dealer Responsibilities....................................... 56

Maintenance....................................................... 56

Do It Yourself Maintenance Suggestions........... 57

Inspection........................................................... 57

Maintenance Schedule - Sterndrive Models....... 58

Routine Maintenance ................................... 58

Each Day Start ....................................... 58

Each Day End ........................................ 58

Weekly ................................................... 58

Every Two Months or 50 Hours .............. 58

Scheduled Maintenance ............................... 58

After the initial 20 Hour Break-in Period

............................................................... 58

Every 100 Hours or Annually (Whichever

Occurs First) ........................................... 58

Every 200 Hours or 3 Years ................... 59

Every 300 Hours or 3 Years ................... 59

Every 5 Years ......................................... 59

Maintenance Log................................................ 59

Engine Oil........................................................... 60

Checking ...................................................... 60

Filling ............................................................ 60

Changing Oil and Filter ................................ 61

Easy Engine Oil Drain System ............... 61

Engine Oil Drain Pump ........................... 62

Changing Filter ....................................... 62

Power Steering Fluid.......................................... 63

Checking ...................................................... 63

Filling ............................................................ 64

Changing ...................................................... 64

Engine Coolant................................................... 64

Checking ...................................................... 64

Filling ............................................................ 65

Changing ..................................................... 65

Drive Unit Oil....................................................... 65

Checking ...................................................... 65

Filling ............................................................ 66

Changing ...................................................... 67

Power Trim Fluid................................................. 69

Checking ...................................................... 69

Filling ............................................................ 69

Changing ...................................................... 69

Cleaning The Flame Arrestor.............................. 70

Cleaning The IAC Muffler................................... 70

Changing Water Separating Fuel Filter.............. 71

Lubrication.......................................................... 73

Steering System............................................73

Throttle Cable................................................75

Shift Cable - Typical......................................75

Sterndrive Unit and Transom Assembly........76

Sterndrive U-joint Shaft Splines And O-rings

(Sterndrive Unit Removed)............................76

Engine Coupler.............................................76

Engine Coupler.............................................77

Driveshaft Extension Models.........................78

Propellers............................................................ 78

Propeller Repair............................................78

Bravo One Propeller Removal......................78

Bravo One Propeller Installation...................79

Bravo Two Propeller Removal......................80

Bravo Two Propeller Installation...................80

Bravo Three Propeller Removal....................81

Bravo Three Propeller Installation.................82

Serpentine Drive Belt.......................................... 84

Checking ...................................................... 84

Replacing ..................................................... 85

Flushing the Power Package.............................. 86

Flushing Attachments ................................... 87

Sterndrive Water Pickups ............................. 87

Alternative Water Pickups ............................ 89

Battery................................................................ 90

Multiple EFI Engine Battery Precautions.......91

Corrosion Protection........................................... 92

Painting Your Power Package ..................... 96

90-864839060 MAY 2006 Page 55

Page 64

Section 5 - Maintenance

Owner/Operator Responsibilities

It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup.

Normal maintenance service and replacement parts are the responsibility of the owner/ operator and as such, are not considered defects in workmanship or material within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

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

Dealer Responsibilities

In general, a dealer's responsibilities to the customer include predelivery inspection and preparation such as:

• Ensure that the boat is properly equipped.

• Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition.

• Make all necessary adjustments for maximum efficiency.

• Familiarize the customer with the on-board equipment.

• Explain and demonstrate the operation of the power package and boat.

• Provide you with a copy of a Predelivery Inspection Checklist.

• Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product.

Maintenance

WARNING

Avoid injury or death and product damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package.

WARNING

Fuel vapors can be present in the engine compartment. Avoid injury or power package damage caused by fuel vapors or explosion. Always ventilate the engine compartment prior to servicing the power package.

IMPORTANT: Refer to the maintenance schedule for complete listing of all scheduled maintenance to be performed. Some listings can be done by owner/operator, while others should be performed by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly.

NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.

Maintenance Point Color Codes

Blue Coolant

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Page 65

Maintenance Point Color Codes

Yellow Engine Oil

Orange Fuel

Black Gear Lube Oil (Sterndrive models only)

Brown Transmission (Inboard models only)

Do It Yourself Maintenance Suggestions

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

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

• Do not attempt any repairs unless you are aware of the Cautions, Warnings and

procedures required. Your safety is our concern.

• If you attempt to service the product yourself, we suggest you order the service manual

for that model. The service manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't understand. Do not attempt repairs if you do not understand the procedures.

• There are special tools and equipment that are required to perform some repairs. Do

not attempt these repairs unless you have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would charge you.

• Also, if you partially disassemble an engine or drive assembly and are unable to repair

it, the dealer's mechanic must reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem.

• Do not telephone the dealer, service office or the factory to attempt for them to diagnose

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

Your authorized dealer is there to service your power package. They have qualified factory trained mechanics.

It is recommended you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble free boating pleasure.

Section 5 - Maintenance

Inspection

Inspect your power package often, and at regular intervals, to help maintain its top operating performance and correct potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.

• Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as

necessary.

• Check plug leads and electrical leads for damage.

• Remove and inspect the propeller. If badly nicked, bent or cracked, contact your

authorized Mercury MerCruiser dealer.

• Repair nicks and corrosion damage on power package exterior finish. Contact your

authorized Mercury MerCruiser dealer.

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Page 66

Section 5 - Maintenance

Maintenance Schedule - Sterndrive Models

Routine Maintenance

NOTE: Only perform maintenance which applies to your particular power package.

EACH DAY START

• Check the crankcase oil (interval can be extended based on experience).

• Check the drive unit oil level, the trim pump oil level, and the power steering pump or compact hydraulic steering fluid level.

EACH DAY END

• If operating in salt, brackish or polluted waters, flush the cooling system after each use.

WEEKLY

• Check the water inlets for debris or marine growth. Check the seawater strainer and clean. Check the coolant level.

• Inspect the drive unit anodes and replace if 50 percent eroded.

EVERY TWO MONTHS OR 50 HOURS

• Lubricate the propeller shaft and retorque the nut (if operating in only freshwater, this maintenance may be extended to every four months).

• Operating in saltwater or brackish or polluted water only: treat the power package with Corrosion Guard.

• Check the battery connections and the fluid level.

•

Ensure that the gauges and the wiring connections are secure. Clean the gauges.

Scheduled Maintenance

NOTE: Only perform maintenance which applies to your particular power package.

AFTER THE INITIAL 20 HOUR BREAK-IN PERIOD

To help extend the life of your Mercury MerCruiser power package, the following is reccommended:

• Change the engine oil and filter.

• Change the sterndrive lube.

EVERY 100 HOURS OR ANNUALLY (WHICHEVER OCCURS FIRST)

• Touch-up the paint on the power package.

• Change the crankcase oil and filter.

• Change the drive unit oil

• Retorque the connection of the gimbal ring to the steering shaft.

• Replace the water separating fuel filter element.

• Check the steering system and the remote control for loose, missing or damaged parts. Lubricate the cables and the linkages.

• Check the continuity circuit for loose or damaged connections. Test the MerCathode unit output on Bravo Models.

NOTE: On V6 models the PCV valve is non serviceable and is an internal component of the valve cover assembly.

• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped.

• Inspect the condition and the tension of the belts.

1. If operating in saltwater, interval is reduced to every 25 hours or 30 days whichever occurs first.

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Page 67

• Driveshaft extension models: Lubricate the driveshaft U-joints, and tailstock input and

output bearings.

EVERY 200 HOURS OR 3 YEARS

• Inspect the U-joints, the splines and the bellows. Check the clamps. Check the engine

alignment. Lubricate the U-joint splines and cross bearing, if equipped with a grease fitting.

•

Lubricate the gimbal bearing and the engine coupler.

EVERY 300 HOURS OR 3 YEARS

• Check the engine mount for tightness and retorque if necessary.

• Check the distributor cap, if equipped.

• Check the electrical system for loose, damaged, or corroded fasteners.

• Check the cooling system and the exhaust system hose clamps for tightness. Inspect

both systems for damage or leaks.

• Disassemble and inspect the seawater pump and replace worn components.

• Clean the seawater section of the closed cooling system. Clean, inspect, and test the

pressure cap.

• Inspect the exhaust system components and verify that the flapper valves are not

missing or worn, if equipped.

EVERY 5 YEARS

• Replace the coolant (every two years if extended life antifreeze coolant is not being

used).

Section 5 - Maintenance

Maintenance Log

Record all maintenance performed on your power package here. Be sure to save all work orders and receipts.

Date Maintenance Performed Engine Hours

2. Lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time.

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Page 68

Section 5 - Maintenance

Date Maintenance Performed Engine Hours

Engine Oil

ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as directed by local authorities.

Checking

1. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The

2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60

NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end).

boat must be at rest in the water.

seconds to allow trapped air to vent.

CAUTION

Filling

8481

a - Dipstick tube

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and add. Reinstall dipstick into dipstick tube.

IMPORTANT: Do not overfill the engine with oil.

IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required.

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Section 5 - Maintenance

7284

1. Remove oil fill cap.

5581

a - Oil fill cap

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

2. Add the specified engine oil to bring the level up to, but not over, the full or OK range

mark on the dipstick. Recheck oil level.

3. Replace the fill cap.

All Models Capacity Fluid Type

Engine Oil (With Filter)

Changing Oil and Filter

Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.

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

EASY ENGINE OIL DRAIN SYSTEM

NOTE: Boat must be out of water to perform this procedure.

1. Loosen the oil filter to vent the system.

2. Remove the bilge drain plug.

3. Pull tether through the bilge drain.

8.5 liters

(9 U.S. Quart)

Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil

25W-40

b - Tether c - Clip

90-864839060 MAY 2006 Page 61

a - Bilge drain plug

d - Oil drain hose plug e - Oil drain hose f - Bilge drain flange

Page 70

Section 5 - Maintenance

4. Place the oil drain hose in a suitable container.

5. Remove the drain plug from the oil drain hose.

6. After oil has drained completely, install the drain plug in the oil drain hose.

7. Push the hose through bilge drain and install the plug.

ENGINE OIL DRAIN PUMP

1. Loosen the oil filter to vent the system.

2. Remove the dipstick.

3. Install the oil pump onto the dipstick tube.

mc70571-1

4. Insert the hose end of the crankcase oil pump onto an appropriate container and, using

5. Remove the pump.

6. Install the dipstick.

CHANGING FILTER

1. Remove and discard oil filter.

a - Typical oil pump b - Dipstick tube

the handle, pump until the crankcase is empty.

c - Oil drain hose

a - Oil filter

Page 62 90-864839060 MAY 2006

8483

Page 71

2. Coat sealing ring on new filter with engine oil and install.

3. Tighten oil filter securely (following filter manufacturer's instructions). Do not

overtighten.

4. Remove oil fill cap.

IMPORTANT: Always use dipstick to determine exactly how much oil is required.

5. Add recommended engine oil to bring level up to the bottom of the OK range on the

dipstick.

6. With the boat at rest in the water, check the oil level and add specified fluid to bring the

oil level up to, but not over, the full or OK range.

NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the add mark to the top of the OK range.

All Models Capacity Fluid Type

Engine Oil (With Filter)

7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.

Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water.

Power Steering Fluid

8.5 liters

(9 U.S. Quart)

Section 5 - Maintenance

Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil

25W-40

Checking

1. Stop the engine and center the sterndrive unit.

2. Remove the fill cap/dipstick from the power steering pump reservoir and observe the

level. a. Proper fluid level with engine at normal operating temperature should be within

the warm range.

b. Proper fluid level with engine cold should be within the cold range.

a - Power steering pump reservoir b - Cold range

90-864839060 MAY 2006 Page 63

8484

c - Warm range

Page 72

Section 5 - Maintenance

3. Fill to full line with specified fluid.

IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer.

Filling

1. Remove the fill cap/dipstick and observe the level.

2. Add the specified fluid to bring the fluid level up to the proper range.

Tube Ref No. Description Where Used Part No.

Dexron III Automatic Transmission Fluid

Power steering system Obtain Locally

3. Reinstall the fill cap/dipstick.

Changing

Power steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer.

Engine Coolant

Checking

Allow the engine to cool down before removing the coolant pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.

1. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.

114

Power Trim and Steering Fluid Power steering system 92-802880A1

WARNING

a - Coolant recovery bottle

2. Add the specified fluid as necessary.

Tube Ref No. Description Where Used Part No.

122

Page 64 90-864839060 MAY 2006

Extended Life Antifreeze/ Coolant

5649

Closed Cooling System 92-877770K1

Page 73

Filling

Section 5 - Maintenance

CAUTION

Alcohol or Methanol based antifreeze or plain water, are not recommended for use in the coolant section of the Closed Cooling System at any time.

CAUTION

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

CAUTION

Air trapped in the closed cooling section of an engine cooling system can cause the engine to overheat resulting in engine damage. To minimize the possibility of trapping air when initially filling the closed cooling system, position the boat so that the front of the engine is higher than the rear of the engine.

NOTE: Add coolant only when engine is at normal operating temperature.

1. Remove the fill cap from the coolant recovery bottle and inspect the gasket. Replace

the gasket if necessary.

IMPORTANT: This closed cooling system flows coolant at a high rate. Higher idle speeds increase dispersion of trapped air into the system making it more difficult to purge trapped air. Operate at idle during filling and air purging when specified.

2. Fill to the full mark with the specified coolant.

3. Install the fill cap onto the coolant recovery bottle.

Changing

Contact your authorized Mercury MerCruiser dealer.

Drive Unit Oil

Checking

NOTE: Oil level will fluctuate during operation. Oil level should be checked with the engine cold, before starting.

Tube Ref No. Description Where Used Part No.

122

Extended Life Antifreeze/ Coolant

CAUTION

Closed Cooling System 92-877770K1

90-864839060 MAY 2006 Page 65

Page 74

Section 5 - Maintenance

1. Check the gear lube oil level. Keep the oil level within the recommended operating range. If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.

Filling

8530

a - Gear lube monitor

IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lubricant is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer.

1. Remove the gear lube monitor cap.

2. Fill the monitor with the specified fluid so that the oil level is in the operating range. Do not overfill.

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Gear lube monitor 92-802854A1

3. Replace the cap.

NOTE: When filling the entire sterndrive unit refer to Changing instructions, following.

Page 66 90-864839060 MAY 2006

Page 75

Changing

Section 5 - Maintenance

1. Remove the gear lube monitor from the bracket.

8530

a - Gear lube monitor

2. Empty the contents into a suitable container.

3. Install the gear lube monitor in the bracket.

4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/

in position, remove the oil fill/drain screw and sealing washer and drain the oil.

mc79506-1

a - Oil fill/drain screw b - Sealing washer

90-864839060 MAY 2006 Page 67

Page 76

Section 5 - Maintenance

5. All Other Models: Place the sterndrive unit in full trim limit out position, remove the oil

6. Remove the oil vent screw and sealing washer. Allow the oil to drain completely.

fill/drain screw and sealing washer and drain the oil.

mc79507-1

a - Oil fill/drain screw b - Sealing washer

mc77106-1

a - Oil vent screw b - Sealing washer

IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer.

7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air-free stream of lubricant flows from oil vent hole.

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Sterndrive unit 92-802854A1

IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in sterndrive unit.

8. Install the oil vent screw and sealing washer.

9. Continue to pump gear lubricant into the drive through the oil fill/drain hole until the gear lubricant appears in the gear lube monitor.

10. Fill the monitor so that the oil level is in the operating range. Do not overfill. Ensure that the rubber gasket is inside the cap and install. Do not overtighten.

NOTE: Oil capacity includes gear lube monitor.

Page 68 90-864839060 MAY 2006

Page 77

Model Capacity Fluid Type

Bravo One 2736 ml (92-1/2 oz.)

Bravo Three 2972 ml (100-1/2 oz.)

11. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and oil

fill/drain screw. Tighten securely.

12. Reinstall the propeller. Refer to Propellers.

13. Recheck the oil level after the first use.

IMPORTANT: Oil level in the gear lube monitor will rise and fall during sterndrive operation; always check the oil level when the sterndrive is cool and the engine is shut down.

Power Trim Fluid

Checking

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

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

2. Observe the oil level. Level must be between the "MIN" and "MAX" lines on the

reservoir.

Section 5 - Maintenance

High Performance Gear LubricantBravo Two 3209 ml (108-1/2 oz.)

Filling

Changing

7876

a - Reservoir b - "MIN" and "MAX" lines

3. Fill as necessary with the specified fluid.

Tube Ref No. Description Where Used Part No.

114

Power Trim and Steering Fluid Power trim pump 92-802880A1

1. Remove the fill cap from the reservoir.

NOTE: Fill cap is vented.

2. Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir.

Tube Ref No. Description Where Used Part No.

114

Power Trim and Steering Fluid Power trim pump 92-802880A1

3. Install the cap.

Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer.

90-864839060 MAY 2006 Page 69

Page 78

Section 5 - Maintenance

Cleaning The Flame Arrestor

Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Be careful when cleaning flame arrestor; ensure that ignition is off. Do not smoke or allow sources of spark or open flame in area when cleaning flame arrestor.

1. Remove the engine cover.

2. Loosen the flame arrestor clamp and remove the flame arrestor.

Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Never use gasoline as a cleaning solvent.

3. Clean the flame arrestor with solvent. Dry with compressed air or allow to air dry completely.

WARNING

a - Flame arrestor

4. Install flame arrestor. Tighten the flame arrestor clamp.

5. Install the engine cover.

Cleaning The IAC Muffler

WARNING

8482

Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Be careful when cleaning IAC muffler; ensure that ignition is off. Do not smoke or allow sources of spark or open flame in area when cleaning IAC muffler.

Page 70 90-864839060 MAY 2006

Page 79

Section 5 - Maintenance

18495

WARNING

Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Never use gasoline as a cleaning solvent.

1. Remove the engine cover.

2. Remove the IAC muffler.

IAC muffler installed in the throttle body

a - IAC muffler

3. Inspect the IAC muffler for damage such as, holes, cracks or deterioration. Replace

the IAC muffler if damaged.

IMPORTANT: Do not use cleaner containing methyl ethyl ketone.

IMPORTANT: Do not get cleaner on electrical connections.

4. Clean or replace the IAC muffler if grey or black, as the muffler should be white.

5. Clean the IAC muffler with warm water and a mild detergent.

6. Allow the IAC muffler to completely air dry before use.

7. Reinstall the IAC muffler.

Changing Water Separating Fuel Filter

WARNING

Avoid serious injury or death from a gasoline fire or explosion; gasoline is extremely flammable and highly explosive under certain conditions. When servicing the fuel system components ensure that the engine is cool, the ignition switch is in the off position, and that the lanyard stop switch, if equipped, is in the off position. Do not smoke or allow spark or open flame in the area. Wipe up any spilled fuel immediately. Ensure that no fuel leaks exist before closing the engine hatch.

1. Allow the engine to cool down.

NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal.

2. Close fuel supply valve, if equipped.

3. Disconnect the Cool Fuel Module harness from the engine wiring harness.

4. Turn the key switch to the start position and allow the starter to operate for 5 seconds.

5. Turn key switch to off position.

90-864839060 MAY 2006 Page 71

Page 80

Section 5 - Maintenance

6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap.

8837

a - Cool Fuel Module b - Cool Fuel Module harness c - Filter cap d - Filter assembly retaining screw

7. Unseat the filter assembly by grasping the filter assembly handle and pulling upward. Do not remove the filter assembly from the Cool Fuel Module at this time.

8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool Fuel Module filter reservoir.

9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a clockwise direction while holding the filter cup stationary.

10. Remove the used water separating fuel filter element from the filter cup, place it in a clean, approved container.

11. Dispose of any water or debris that may be in the filter cup.

12. Install a new water separating fuel filter element into the filter cup. Push the element into the cup until completely seated.

13. Install new O-ring on the filter cup.

14. Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter clockwise direction while holding the filter cup stationary, until the filter cap locks securely into place.

15. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel, and align the screws retained in the filter cap with the screw holes in the Cool Fuel Module. Tighten the filter assembly retaining screws until hand tight.

16. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each filter assembly retaining screw.

e - Fuel filter element f - Filter cup g - Cool Fuel Module filter reservoir h - O-ring

Page 72 90-864839060 MAY 2006

Page 81

Description Nm lb. in. lb. ft.

Filter assembly retaining screw 6 53

17. Open fuel supply valve, if equipped.

18. Reconnect the Cool Fuel Module harness to the engine wiring harness.

19. Supply cooling water to the engine.

20. Properly ventilate the engine compartment.

21. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist,

Lubrication

Steering System

Do not grease the steering cable while its extended. Hydraulic lock could occur and cause loss of steering control.

Section 5 - Maintenance

stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer.

CAUTION

NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased.

1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully

retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand-operated grease gun.

6221

a - Steering cable grease fitting

Tube Ref No. Description Where Used Part No.

Special Lubricant 101 Steering cable grease fitting 92-802865A1

90-864839060 MAY 2006 Page 73

Page 82

Section 5 - Maintenance

2. Turn steering wheel until steering cable fully extended. Lightly lubricate the exposed part of cable.

6222

a - Extended steering cable

Tube Ref No. Description Where Used Part No.

Special Lubricant 101 Steering cable 92-802865A1

3. Lubricate the steering pin.

mc71904-1

a - Steering pin

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil SAE25W-40

4. On dual engine boats: Lubricate the tie bar pivot points.

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil SAE25W-40

Steering pin 92-883725K01

Tie bar pivot points 92-883725K01

5. Upon first starting engine, turn steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway.

Page 74 90-864839060 MAY 2006

Page 83

Throttle Cable

Section 5 - Maintenance

1. Lubricate the pivot points and the guide contact surfaces.

5577

a - Pivot points b - Guide contact surfaces

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil SAE25W-40

Throttle cable pivot points &

guide contact surfaces

92-883725K01

Shift Cable - Typical

1. Lubricate the pivot points and the guide contact surfaces.

Tube Ref. No. Description Where Used Part No.

mc79736

a - Pivot points b - Guide contact surfaces

Synthetic Blend MerCruiser Engine Oil SAE25W-40

Shift cable pivot points & guide

contact surfaces

92-883725K01

90-864839060 MAY 2006 Page 75

Page 84

Section 5 - Maintenance

Sterndrive Unit and Transom Assembly

1. Lubricate gimbal bearing by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun.

a - Gimbal bearing grease fitting

Tube Ref No. Description Where Used Part No.

U-joint and Gimbal Bearing Grease

mc77068-1

Gimbal bearing 92-802870A1

2. For propeller shaft lubrication, refer to Propellers.

Sterndrive U-joint Shaft Splines And O-rings (Sterndrive Unit Removed)

1. Coat sterndrive U-joint O-rings and driveshaft splines with grease.

8591

a - Driveshaft splines b - U-joint O-rings (3)

Tube Ref No. Description Where Used Part No.

Engine Coupler Spline Grease

Driveshaft splines and U-joint

O-rings

92-802869A1

2. For propeller shaft lubrication, refer to Propellers.

Engine Coupler

1. Lubricate engine coupler splines through grease fittings on coupler by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun.

Page 76 90-864839060 MAY 2006

Page 85

Section 5 - Maintenance

NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated Bravo Models - every 50 hours; Alpha Models - every 150 hours.

Alpha drive coupler Bravo drive coupler

Engine Coupler

6213

6212

a - Grease fitting

Tube Ref No. Description Where Used Part No.

Engine Coupler Spline Grease Coupler 92-802869A1

NOTE: Alpha Models - Your power package is equipped with a sealed engine coupler and Perm-a-Lube U-joints. The sealed coupler and shaft splines can be lubricated without removing the sterndrive unit.

NOTE: Bravo Models - The coupler and shaft splines can be lubricated without removing the sterndrive unit. Apply lubricant from a typical hand-operated grease gun until a small amount of grease begins to push out.

1. Lubricate engine coupler splines through grease fittings on coupler by applying

approximately 8-10 pumps of grease from a typical hand-operated grease gun.

NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated Bravo Models - every 50 hours; Alpha Models - every 150 hours.

a - Grease fitting

Tube Ref No. Description Where Used Part No.

90-864839060 MAY 2006 Page 77

6212

Bravo drive coupler

Engine Coupler Spline Grease Coupler 92-802869A1

Page 86

Section 5 - Maintenance

17014

Driveshaft Extension Models

1. Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10 - 12 pumps of grease from a typical hand-operated grease gun.

2. Lubricate the driveshaft grease fittings by applying approximately 3 - 4 pumps of grease from a typical hand-operated grease gun.

a - Driveshaft grease fittings b - Transom end grease fitting

Tube Ref No. Description Where Used Part No.

U-joint and Gimbal Bearing Grease

Propellers

Propeller Repair

Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.

Bravo One Propeller Removal

Avoid Injury: Remote Control must be in neutral and ignition key removed from switch before removing and/or installing propeller.

Transom end grease fitting,

engine end grease fitting,

driveshaft grease fittings

WARNING

c - Engine end grease fitting

92-802870A1

Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.

1. Place wood block between propeller blade and anti-ventilation plate to prevent rotation. Straighten bent tabs on tab washer.

2. Turn propeller shaft nut counterclockwise to remove nut.

3. Slide tab washer, drive sleeve, propeller and thrust hub off propeller shaft.

Page 78 90-864839060 MAY 2006

Page 87

Bravo One Propeller Installation

Avoid injury and propeller damage or sterndrive damage, or both, caused by a loose propeller or propellers. The propeller may become loose during normal operation. Periodically throughout the boating season and at the maintenance intervals specified, the propeller nut or nuts must be checked for tightness. Torque the propeller nut or nuts to specification.

IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.

Section 5 - Maintenance

CAUTION

6215

a - Propeller shaft b - Thrust hub c - Flo-Torq II drive hub d - Propeller

1. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub.

2. Apply a liberal coat of one of the following lubricants to the propeller shaft.

Tube Ref No. Description Where Used Part No.

Special Lubricant 101 Propeller shaft 92-802865A1

Anti-Corrosion Grease Propeller shaft 92-802867A1

2-4-C Marine Lubricant with Teflon

3. Install Flo-Torq II Drive Hub into propeller.

NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued.

4. Align splines and place propeller on propeller shaft.

5. Install drive sleeve and locking tab washer.

6. Install and torque the propeller nut.

e - Drive sleeve f - Locking tab washer g - Propeller nut

Propeller shaft 92-802859A1

Description Nm lb. in. lb. ft.

Propeller nut

1. The propeller torque stated is a minimum torque value.

90-864839060 MAY 2006 Page 79

75 55

Page 88

Section 5 - Maintenance

14946

7. Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.

Bravo Two Propeller Removal

Avoid Injury: Remote Control must be in neutral and ignition key removed from switch before removing and/or installing propeller.

Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.

1. Place wood block between propeller blade and anti-ventilation plate to prevent rotation. Straighten bent tabs on tab washer.

2. Turn propeller shaft nut counterclockwise to remove nut.

3. Slide tab washer, spline washer, propeller and thrust hub off propeller shaft.

WARNING

Bravo Two Propeller Installation

IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.

a - Propeller shaft b - Thrust hub c - Propeller

CAUTION

d - Propeller nut e - Spline washer f - Tab washer

1. Slide thrust hub into propeller hub with stepped side toward propeller hub.

2. Apply a liberal coat of one of the following lubricants to the propeller shaft.

Tube Ref No. Description Where Used Part No.

Page 80 90-864839060 MAY 2006

Special Lubricant 101 Propeller shaft 92-802865A1

Page 89

Section 5 - Maintenance

Tube Ref No. Description Where Used Part No.

Anti-Corrosion Grease Propeller shaft 92-802867A1

2-4-C Marine Lubricant with Teflon

3. Align splines and place propeller on propeller shaft.

4. Install spline washer and tab washer.

5. Install and torque the propeller nut.

Description Nm lb. in. lb. ft.

Propeller nut

6. Bend 3 tabs on the tab washer down into the grooves in spline washer. After the first

use, bend the 3 tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.

Bravo Three Propeller Removal

Avoid Injury: Remote Control must be in neutral and ignition key removed from switch before removing and/or installing propeller.

WARNING

Propeller shaft 92-802859A1

81 60

Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.

1. Place wood block between propeller blades and anti-ventilation plate to prevent

rotation.

2. Remove the bolt and washers securing the propeller shaft anode.

3. Remove the propeller shaft anode.

a - Propeller b - Propeller shaft nut c - Propeller shaft anode

5303

d - Propeller shaft anode screw e - Flat washer f - Star washer

4. Turn aft propeller shaft nut 37 mm (1-7/16 in.) counterclockwise to remove nut.

5. Slide propeller and thrust hub off propeller shaft.

1. Propeller torque stated is a minimum torque value.

90-864839060 MAY 2006 Page 81

Page 90

Section 5 - Maintenance

6. Turn front propeller shaft nut 70 mm (2-3/4 in.) counterclockwise to remove nut.

7. Slide propeller and thrust hub off propeller shaft.

NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.

a - Rear propeller nut b - Rear propeller c - Rear propeller thrust hub d - Front propeller nut e - Front propeller

Bravo Three Propeller Installation

5304

f - Front propeller thrust hub g - Propeller shaft anode screw h - Flat washer i - Star washer j - Propeller shaft anode

CAUTION

a - Rear propeller nut b - Rear propeller c - Rear propeller thrust hub d - Front propeller nut e - Front propeller

Page 82 90-864839060 MAY 2006

5304

f - Front propeller thrust hub g - Propeller shaft anode screw h - Flat washer i - Star washer j - Propeller shaft anode

Page 91

Section 5 - Maintenance

1. Slide forward thrust hub onto propeller shaft with tapered side toward propeller hub

(toward end of shaft).

2. Apply a liberal coat of one of the following lubricants to the propeller shaft.

Tube Ref No. Description Where Used Part No.

Special Lubricant 101 Propeller shaft 92-802865A1

Anti-Corrosion Grease Propeller shaft 92-802867A1

2-4-C Marine Lubricant with Teflon

Propeller shaft 92-802859A1

3. Align splines and place propeller on propeller shaft.

4. Install and torque the propeller nut. Check propeller at least every 20 hours of operation

and retorque as needed.

Description Nm lb. in. lb. ft.

Forward propeller nut 136 100

5. Slide aft thrust hub onto propeller shaft, with tapered side toward propeller hub (toward

end of shaft).

6. Align splines and place propeller on propeller shaft.

7. Install and torque the propeller nut. Check propeller at least every 20 hours of operation

and retorque as needed.

Description Nm lb. in. lb. ft.

Aft propeller nut 81 60

8. Install the propeller shaft anode over the propeller shaft nut.

9. Place the flat washer onto the propeller shaft anode screw.

10. Place the star washer onto the propeller shaft anode screw.

11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads

of the propeller shaft anode screw.

a - Propeller b - Propeller shaft nut c - Propeller shaft anode

Tube Ref No. Description Where Used Part No.

12. Secure the propeller shaft anode to the propeller shaft using the propeller shaft anode

screw and washers. Torque the screw.

90-864839060 MAY 2006 Page 83

Loctite 271 Threadlocker Propeller shaft threads 92-809819

5303

d - Propeller shaft anode screw e - Flat washer f - Star washer

Page 92

Section 5 - Maintenance

Description Nm lb. in. lb. ft.

Propeller shaft anode screw 38 mm (0.3125-18 x 1.5 in.) long 27 20

Serpentine Drive Belt

Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt.

WARNING

Checking

Belt Routing Diagram

a - Idler pulley b - Water circulating pump pulley c - Crankshaft pulley d - Alternator pulley

1. Inspect the drive belt for proper tension and for the following:

• Excessive wear

• Cracks

NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are NOT acceptable.

• Fraying

• Glazed surfaces

• Proper tension - 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the

belt at the location that has the longest distance between two pulleys.

e - Seawater pump pulley f - Power steering pump pulley g - Tensioner pulley

8118

Page 84 90-864839060 MAY 2006

mc75130-1

Page 93

Replacing

Section 5 - Maintenance

IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before.

The belt tensioner is designed to operate within the limits of arm movement provided by the cast stops when the belt length and geometry are correct.

If the tensioner is contacting either of the limits during operation, check the mounting brackets and the belt length. Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the limits.

See your authorized MerCruiser dealer for service if these conditions exist.

CAUTION

The belt tensioner assembly contains a high tension spring. Rapid release of the tensioner, or allowing the tensioner to snap back quickly, could injure the operator or cause product damage. Relieve the spring tension slowly to avoid injury or product damage.

1. Use a breaker bar and appropriate socket to hold back the tensioner and relieve the

belt tension. Rotate the tensioner away from belt until it stops. Remove the belt from the idler pulley and slowly relieve the tension on the breaker bar.

Breaker bar with arrow in direction of movement to relieve tension.

a - Breaker bar

2. Remove the belt and reroute the replacement belt according to the belt routing diagram.

90-864839060 MAY 2006 Page 85

8115

Page 94

Section 5 - Maintenance

3. Use a breaker bar and appropriate socket to position the tensioner back to the engine running location and slide the belt over the tensioner pulley. Slowly relieve the tensioner to the belt.

Breaker bar with arrow in direction of movement to reposition in tension.

a - Breaker bar

Flushing the Power Package

Your boat could come equipped with a combination of any of three different types of water pickups: through the hull, through the transom, and through the sterndrive. The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation.

IMPORTANT: Bravo models equipped with closed cooling require dual water pickups and must be equipped with a through the hull or through the transom pickup in addition to the sterndrive water inlets.

IMPORTANT: Alpha engines with the sterndrive water inlet blocked off at the gimbal housing, and using a through the hull water inlet, need a supply of cooling water available to both the sterndrive unit and to the engine during operation

8115

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Flushing Attachments

9192

9194

Flushing Device 91-44357Q 2

Dual Water Pick-up Flush Gearcase Seal Kit 91-881150K 1

Sterndrive Water Pickups

There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).

Section 5 - Maintenance

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

Blocks off the front water inlet holes on the dual water inlet gearcases.

Dual Water Pickup Side Pickup

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results.

If flushing with the boat in the water, seawater can flow into the engine causing engine damage. Water inlet must be closed when flushing the engine.

1. On seawater cooled models: Proceed to Step 5. or Step 6.

NOTE: Closed cooled models are equipped with a heat exchanger on the front of the engine.

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5752

CAUTION

5773

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Section 5 - Maintenance

2. On Alpha closed cooled models with the sterndrive seawater inlet blocked:

3. On Bravo closed cooled models using the sterndrive seawater inlet and a

4. If flushing the cooling system with the boat in the water:

5. If flushing the cooling system with the boat out of the water:

Flushing water will need to be supplied to the sterndrive unit and to the engine. Refer to Alternative Water Pickups.

through the hull or through the transom alternative water pickup: Flushing water will need to be supplied to only the sterndrive unit by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet Y-fitting.

a. If equipped with a seacock, close the seacock in the hose from the alternative

water pickup.

b. If not equipped with a seacock, disconnect the hose from the alternative water

pickup and plug both ends.

c. If there is not a hose running to the transom, refer to Alternative Water

Pickups.

a. Raise sterndrive unit to trailer position. b. Install the appropriate flushing attachment over the water inlet holes in the gear

housing.

c. Lower sterndrive unit to full down/in position.

a. Lower sterndrive unit to full down/in position.

WARNING

Contact with moving drive components and the propeller can cause personal injury or death. To avoid possible injury, remove the propeller and ensure that no people or animals are in the area of the drive unit while flushing.

b. Remove propeller. c. Install the appropriate flushing attachment over the water inlet holes in the gear

housing.

6. Connect hose between flushing attachment and water source.

7. With sterndrive unit in normal operating position, open the water source fully.

8. Place the remote control in the neutral idle speed position and start engine.

CAUTION

Avoid engine damage from overheating. If the engine is operated above 1500 RPM during flushing, suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat.

9. Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).

CAUTION

Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range.

10. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

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11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water

is clear.

12. Slowly return throttle to idle speed position.

13. Stop engine.

14. Shut off water and remove flushing attachment.

15. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent

water from siphoning into the engine.

16. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be

reconnected prior to operating engine.

Alternative Water Pickups

IMPORTANT: Two water sources are needed for this procedure.

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results.

IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive unit and to the engine during operation.

1. If flushing the cooling system with the boat in the water:

a. Raise sterndrive unit to trailer position. b. Install the appropriate flushing attachment over the water inlet holes in the gear

housing.

c. Lower sterndrive unit to full down/in position.

2. If flushing the cooling system with the boat out of the water:

a. Lower sterndrive unit to full down/in position.

Section 5 - Maintenance

WARNING

b. Remove propeller. c. Install the appropriate flushing attachment over the water inlet holes in the gear

housing.

3. Connect hose between flushing attachment and water source.

4. Close the seacock, if equipped, to prevent water from siphoning into the engine or boat.

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Section 5 - Maintenance

5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent

6. Using a suitable adapter, connect the flushing hose from the water source to the water

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

water from siphoning into the engine or boat.

inlet of the seawater pump.

CAUTION

6147

7. With sterndrive unit in normal operating position, open the water source fully.

8. Place the remote control in neutral idle speed position and start engine.

CAUTION

9. Slowly advance throttle until engine reaches 1300 RPM (+/-100 RPM).

CAUTION

Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range.

10. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear.

12. Slowly return throttle to idle speed position.

13. Stop engine.

14. Shut off the water and remove flushing attachments.

15. If the boat is out of the water: Install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp securely.

16. If the boat is in the water: Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.

Battery

Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

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Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine. Do not recharge a weak battery in the boat. Remove battery and recharge in a ventilated area away from fuel vapors, sparks or flames.

Batteries contain acid which can cause severe burns. Avoid contact with skin, eyes and clothing. If electrolyte is spilled or splashed on any part of the body, immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible. Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte.

Multiple EFI Engine Battery Precautions

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

to the engine that the alternator is mounted on. When batteries for 2 different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine's alternator will not be required to supply any charging current.

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

In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself, and the engine will operate normally. The ECM shuts off and resets itself so quickly that the engine may only seem to have an ignition miss.

Batteries: Boats with multi-engine EFI power packages require each engine be connected to its own battery. This ensures that the engine's ECM has a stable voltage source.

Battery Switches: Battery switches should always be positioned so each engine is operating off of its own battery. Do not operate engines with switches in both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.

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

Generators: The generators battery should be considered another engine's battery.

WARNING

Section 5 - Maintenance

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Section 5 - Maintenance

6211

Corrosion Protection

Improper boat-cleaning procedures can cause product damage. Washing the MerCathode assembly, especially with a brush or high-pressure washer, will damage the MerCathode assembly making it unable to inhibit galvanic corrosion. When cleaning the boat, do not use a brush or a high-pressure washer to wash the MerCathode assembly found on the bottom of the transom assembly.

CAUTION

a - MerCathode reference electrode b - Do not paint

Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion and, if not controlled, it will in time cause the need for replacement of power package components exposed to water. Refer to the Marine

Corrosion Protection Guide (90-88181301).

c - Do not pressure wash

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Mercury mercruiser User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual