Mercury MerCruiser 4.3 TKS, MerCruiser 5.0 TKS, MerCruiser 5.7 TKS 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

90-899883179 1007

*899883179*

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, dangers, warnings, cautions, and

notices, accompanied by the International Hazard Symbol installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials. 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.

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

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

DANGER

WARNING

, may be used to alert the

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

CAUTION

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NOTICE

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

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

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

WARNING

The 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

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

Warranty Registration: United States and

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

Warranty Registration: Outside the United States and

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

Transfer of Warranty................................................3

Mercury Product Protection Plan: United States and

Canada....................................................................3

Mercury MerCruiser Limited Warranty

(Gasoline‑Fueled Products Only) ...........................4

Section 2 - Getting to Know Your Power Package

Identification..........................................................14

Engine Serial Number Decal .........................14

Bravo Sterndrive Serial Number and

Identification...................................................14

Bravo Transom Serial Number.......................15

Lanyard Stop Switch..............................................16

Instrumentation......................................................17

Remote Controls....................................................18

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

3‑Year Limited Warranty Against Corrosion............6

Global Warranty Charts...........................................7

Consumer Application Warranty Chart...............7

Commercial Application Warranty Chart.............8

Government Application Warranty Chart............9

Mercury Installation Quality Certification Program..9

Emission Control Information Label.......................10

Owner Responsibility........................................11

Console Mount Features..................................19

Power Trim............................................................19

Single Engine Trim/Trailer................................20

Dual Engine Trim/Trailer...................................21

Electrical System Overload Protection‑Carbureted

Engines..................................................................21

Audio Warning System..........................................23

Testing The Audio Warning System.................24

Section 3 - On The Water

Safe Boating Suggestions.....................................26

Be Alert to Carbon Monoxide Poisoning................27

Good Ventilation...............................................27

Poor Ventilation ...............................................28

Basic Boat Operation.............................................28

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

Operation Chart............................................28

Starting and Stopping the Engine...................29

Starting the Engine.......................................29

Stopping the Engine.....................................30

Starting the Engine After It Has Been Stopped

While In Gear.................................................30

Throttle‑Only Operation..................................30

Trailering the Boat..........................................30

Freezing Temperature Operation...................30

Drain Plug and Bilge Pump............................31

Protecting People in the Water..............................31

While You Are Cruising.....................................31

While Boat Is Stationary...................................31

High‑Speed and High‑Performance Operation......31

Passenger Safety in Pontoon Boats and Deck

Boats.....................................................................31

Boats Having An Open Front Deck...................32

Boats With Front‑Mounted, Raised Pedestal

Fishing Seats....................................................32

Wave and Wake Jumping......................................32

Impact with Underwater Hazards..........................33

Drive Unit Impact Protection.............................34

Operating with Low Water Inlets in Shallow

Water.....................................................................34

Conditions Affecting Operation..............................34

Weight Distribution (Passengers and Gear)

Inside the Boat...............................................34

The Bottom of the Boat..................................34

Cavitation.......................................................35

Ventilation.......................................................35

Elevation and Climate....................................35

Propeller Selection.........................................35

Getting Started......................................................36

20‑Hour Break‑In Period................................36

After Break‑In Period......................................36

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End of First Season Checkup....................... 37

Section 4 - Specifications

Fuel Requirements...............................................40

Fuel Ratings.....................................................40

Using Reformulated (Oxygenated) Gasolines

(USA Only).......................................................40

Gasolines Containing Alcohol..........................40

Section 5 - Maintenance

Owner/Operator Responsibilities..........................44

Dealer Responsibilities.........................................44

Maintenance.........................................................44

Do‑It‑Yourself Maintenance Suggestions.............45

Inspection.............................................................45

Maintenance Schedule–Sterndrive Models..........46

Routine Maintenance.................................... 46

Scheduled Maintenance................................46

Maintenance Log..................................................47

Sealed Carburetor Mixture Screw........................ 48

Engine Oil.............................................................48

Checking..........................................................48

Filling............................................................... 48

Changing Oil and Filter....................................49

Easy Engine Oil Drain System....................49

Engine Oil Drain Pump............................... 50

Changing Filter............................................50

Power Steering Fluid............................................51

Checking..........................................................51

Filling............................................................... 51

Changing......................................................... 51

Engine Coolant.....................................................51

Checking..........................................................51

Filling............................................................... 52

Changing ........................................................ 53

Drive Unit Oil........................................................ 53

Checking..........................................................53

Filling............................................................... 54

Changing......................................................... 55

Power Trim Fluid.................................................. 57

Checking..........................................................57

Filling............................................................... 57

Changing......................................................... 58

Engine Oil.............................................................41

Engine Specifications...........................................42

Fluid Specifications.............................................. 42

Sterndrives.......................................................42

Engine..............................................................42

Cleaning The Flame Arrestor............................... 58

Positive Crankcase Ventilation Valve (PCV)... 59

Changing.....................................................59

Changing the Water‑Separating Fuel Filter..........59

Lubrication............................................................60

Steering System............................................60

Throttle Cable................................................62

Shift Cable ‑ Typical......................................62

Sterndrive Unit and Transom Assembly........63

Sterndrive U‑joint Shaft Splines And O‑rings

(Sterndrive Unit Removed)............................63

Engine Coupler............................................. 63

Driveshaft Extension Models.........................64

Propellers............................................................. 65

Propeller Repair............................................ 65

Alpha Propeller Removal.............................. 65

Alpha Propeller Installation........................... 65

Bravo One Propeller Removal...................... 66

Bravo One Propeller Installation................... 66

Bravo Two Propeller Removal...................... 68

Bravo Two Propeller Installation................... 68

Bravo Three Propeller Removal....................69

Bravo Three Propeller Installation.................70

Serpentine Drive Belt........................................... 72

Checking..........................................................72

Replacing Belt and/or Adjusting Tension.........72

Flushing the Power Package................................73

Flushing Attachments...................................... 74

Sterndrive Water Pickups................................ 74

Alternative Water Pickups................................76

Battery..................................................................77

Corrosion Protection.............................................78

Painting Your Power Package.........................82

Cold Weather or Extended Storage..................... 86

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Section 6 - Storage

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Preparing Power Package for Storage...........86

Engine and Fuel System Preparation..........87

Draining the Seawater System..............................88

Drain System Identification.............................89

Air Actuated Single Point Drain System.......89

Manual Single Point Drain System...............89

Three Point Manual Drain System...............90

Multi‑Point Drain (MPD) System..................90

Air‑Actuated Single‑Point Drain System.........91

Boat in the Water.........................................91

Boat out of the Water...................................93

Manual Single Point Drain System.................96

Section 7 - Troubleshooting

Boat in the Water.........................................96

Boat out of the Water...................................97

Three Point Manual Drain System.................98

Boat in the Water.........................................98

Boat out of the Water...................................99

Multi‑Point Drain (MPD) System..................100

Boat out of the Water.................................100

Boat in the Water.......................................102

Draining the Sterndrive........................................104

Battery Storage....................................................105

Power Package Recommissioning......................105

Starter Motor Will Not Crank Engine, Or Cranks

Slow.....................................................................108

Engine Will Not Start Or Is Hard To Start............108

Engine Runs Rough, Misses or Backfires...........108

Poor Performance...............................................108

Excessive Engine Temperature...........................109

Insufficient Engine Temperature..........................109

Low Engine Oil Pressure.....................................109

Section 8 - Customer Assistance Information

Owner Service Assistance...................................112

Local Repair Service.......................................112

Service Away From Home..............................112

Stolen Power Package...................................112

Attention Required after Submersion..............112

Replacement Service Parts............................112

Battery Will Not Recharge...................................109

Remote Control Is Difficult to Move, Has Excessive

Play, or Makes Unusual Sounds.........................110

Steering Wheel Jerks or Is Difficult to Turn.........110

Power Trim Does Not Operate (Motor Does Not

Operate)..............................................................110

Power Trim Does Not Operate (Motor Operates but

Sterndrive Unit Does Not Move)..........................110

Parts and Accessories Inquiries.................113

Resolving a Problem.......................................113

Mercury Marine Service Offices......................113

Ordering Literature..............................................114

United States and Canada..............................114

Outside The United States and Canada.........114

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Section 1 - Warranty

Table of Contents

Warranty Registration: United States and Canada

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

Warranty Registration: Outside the United States

and Canada.......................................................... 2

Transfer of Warranty............................................. 3

Mercury Product Protection Plan: United States and

Canada................................................................. 3

Mercury MerCruiser Limited Warranty (Gasoline-

Fueled Products Only) ......................................... 4

3-Year Limited Warranty Against Corrosion......... 6

Global Warranty Charts........................................ 7

Consumer Application Warranty Chart ........... 7

Commercial Application Warranty Chart ........ 8

Government Application Warranty Chart ....... 9

Mercury Installation Quality Certification Program

.............................................................................. 9

Emission Control Information Label.................... 10

Owner Responsibility ................................... 11

90-899883179 OCTOBER 2007 Page 1

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Section 1 - Warranty

Warranty Registration: United States and Canada

To ensure that your warranty coverage begins promptly, your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product.

The Warranty Registration Card identifies the name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name, and address. The dealer also certifies that you are the original purchaser and user of the product. A temporary Owner Warranty Registration Card will be presented to you when you purchase the product.

Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.

Because of your selling dealer’s ongoing interest in your satisfaction, the product should be returned to him for warranty service.

The product warranty is not effective until the product is registered at the factory.

NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required.

You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number. Your dealer can also process this change of information.

United States customers or dealers may contact: 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

Canadian customers or dealers may contact: Mercury Marine Canada Limited 2395 Meadowpine Blvd. Mississauga, ON Canada, L5N 7W6 Fax 1-800-663-8334

Warranty Registration: Outside the United States and Canada

To ensure that your warranty coverage begins promptly, your selling dealer should fill out the warranty registration card completely and mail it to the distributor responsible for administering the warranty registration and claim program for your area.

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Section 1 - Warranty

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 and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product. A copy of the warranty registration card, designated as the purchaser’s copy, MUST be given to you immediately after the card has been completely filled out by the selling distributor or dealer. This card represents your factory registration identification. Keep the card; if you ever need 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.

In some countries, the distributor will issue a permanent (plastic) warranty registration card to you within 30 days after receiving the factory copy of the warranty registration card from your distributor or dealer. If you receive a plastic warranty registration card, you may discard the purchaser’s copy that you received from the distributor or dealer when you purchased the product. Ask your distributor or dealer if this plastic card program applies to you. For further information concerning the warranty registration card and its relationship to warranty claim processing, refer to the International Warranty. See Table of Contents.

NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event of a safety recall notification under the Federal Boat Safety Act.

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 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

In Canada mail to: Mercury Marine Canada Limited 2395 Meadowpine Blvd. Mississauga, ON Canada, L5N 7W6 Fax 1-800-663-8334

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 distributor closest to you.

Mercury Product Protection Plan: United States and Canada

(Certain performance products, triple engine installations, and commercial applications are excluded.)

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Section 1 - Warranty

The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty.

The optional Mercury Product Protection Plan is the only Factory Plan available for your engine.

One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date.

See your participating Mercury MerCruiser dealer for complete program details.

Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)

Mercury MerCruiser Limited Warranty (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 following.

Duration of Coverage

Warranty Period for Recreational Use

The warranty period begins on 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. Products installed by an Installation Quality Certified Installer receive one (1) year of additional warranty coverage. 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. The warranty period is specific to the model covered; see your model for the base coverage period:

Coverage for Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, and Vazer 100 Models The Limited Warranty for Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, and

Vazer 100 Models is four (4) years when installed by an Installation Quality Certified Installer or three (3) years for noncertified installations.

Coverage for SeaCore Sterndrive Models

The Limited Warranty for SeaCore Sterndrive Models is four (4) years when installed by an Installation Quality Certified Installer or three (3) years for noncertified installations.

Coverage for Standard Models

The Limited Warranty for Standard Models, which do not include Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, Vazer 100 Models, or SeaCore Sterndrive Models, is two (2) years when installed by an Installation Quality Certified Installer or one (1) year for noncertified installations.

Warranty Period for Commercial Use

The warranty period begins on the date the product is first sold to a commercial‑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‑related or employment‑related use of the product, or any use of the product that 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.

Transfer of Coverage

Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use customer.

Termination of Coverage

Warranty coverage is terminated for used product obtained in any of the following ways:

• Repossession from a retail customer

• Purchase at auction

• Purchase from a salvage yard

• Purchase from an insurance company that obtained the product as a result of an insurance claim

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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 pre‑delivery inspection process specified by Mercury Marine is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial (unless properly reregistered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance must be performed according to the maintenance schedule in the Operation, Maintenance & Warranty manual in order to obtain warranty coverage. Mercury Marine reserves the right to make any warranty coverage contingent upon proof of proper maintenance.

What Mercury Marine Will Do

Mercury Marine'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 Marine product. Mercury Marine 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 Marine 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 Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair. The purchaser in that case shall pay for all related transportation charges and travel time. If the service provided is not covered by this warranty, the purchaser shall pay for all related labor and material and any other expenses associated with that service. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. 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 the following:

• Routine maintenance items

• Adjustments

• Normal wear and tear

• Damage caused by abuse

• Abnormal use

• Use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation, Maintenance & Warranty manual)

• Operation of the product in a manner inconsistent with the recommended operation and duty cycle section of the Operation, Maintenance & Warranty 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 that was not manufactured or sold by Mercury Marine and that damages the Mercury product

• Jet pump impellers and liners

• Operation with fuels, oils, or lubricants that are not suitable for use with the product (see the Operation, Maintenance & Warranty manual)

• Alteration or removal of parts

• Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body

• Running the engine out of water

• Mounting the engine too high on the transom

• Operating the boat with the engine over trimmed

90-899883179 OCTOBER 2007 Page 5

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Section 1 - Warranty

Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any point, even by a previous 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 or replacement of boat partitions or other material in order to gain 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. If such affirmation, representation, or warranty is made, it shall not be enforceable against Mercury Marine.

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.

3‑Year Limited Warranty Against Corrosion

3-YEAR LIMITED WARRANTY AGAINST CORROSION

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.

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 and 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 (noncommercial use) purchaser upon proper re‑registration of the product. Warranty coverage is terminated for used product repossessed from a retail customer, purchased at auction, from a salvage yard, or from an insurance company that obtained the product as a result of an insurance claim.

Condition 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, Maintenance & Warranty manual must be in use on the boat, and routine maintenance outlined in the Operation, Maintenance & Warranty 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.

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

Page 6 90-899883179 OCTOBER 2007

Page 15

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 the 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 warranty period, even if the product is only occasionally used for such purposes.

Global Warranty Charts

IMPORTANT: Please refer to www.mercurymarine.com/global_warranty for the most currant Global Warranty Charts.

Consumer Application Warranty Chart

Section 1 - Warranty

Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand

Non-Certified Boat Brand Certified Boat Brand All Boat Brands

Region Standard SeaCore

USA and Canada

Latin America

Mexico

Europe

Japan

Australia and New Zealand

South Pacific

Asia (excluding Japan, South Pacific, Australia, New Zealand)

1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years

1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years

1 year 3 years 1 year 1 year 1 year 4 years 1 year 1 year 1 year 4 years

2 years 3 years 2 years 2 years 3 years 4 years 3 years 3 years 3 years 4 years

1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year

2 years 3 years 3 years

1 year 3 years 1 year 1 year 1 year 3 years 1 year 1 year 3 years 4 years

2 years 2 years 2 years

Vazer and

Models

with

Closed

Cooling

Scorpion

377

3 years all

Tow

Sports

3 years all

Tow

Sports

Vazer and

Models

Standard SeaCore

2 years 3 years 3 years

2 years 2 years 2 years

with

Closed

Cooling

Scorpion

377

3 years all

Tow

Sports

3 years all

Tow

Sports

Limited Corrosion

Warranty

Vazer,

Standard

Models, and and

Models

with

Closed

Cooling

3 years 4 years

2 years 2 years

SeaCore

NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies. NOTE: In regions where TBD (To Be Determined) is listed, check with your local dealer for warranty length and conditions.

90-899883179 OCTOBER 2007 Page 7

Page 16

Section 1 - Warranty

Commercial Application Warranty Chart

Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand

Non-Certified Boat Brand Certified Boat Brand All Boat Brands

Region Standard SeaCore

USA and Canada

Latin America

Mexico

Europe

Japan

Australia and New Zealand

South Pacific

Asia (excluding Japan, South Pacific, Australia, New Zealand)

1 year or

500 hours

1 year or

500 hours

1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Vazer and

Models

with

Closed

Cooling

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Scorpion

377

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Standard SeaCore

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Vazer and

Models

with

Closed

Cooling

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Scorpion

377

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Limited Corrosion

Warranty

Vazer,

Standard

Models, and and

Models

with

Closed

Cooling

none none

NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies

SeaCore

Page 8 90-899883179 OCTOBER 2007

Page 17

Government Application Warranty Chart

Section 1 - Warranty

Government Application: Standard Factory Limited Warranty by Region & Boat Brand

Non-Certified Boat Brand Certified Boat Brand All Boat Brands

Region Standard SeaCore

USA and Canada

Latin America

Mexico

Europe

Japan

Australia and New Zealand

South Pacific

Asia (excluding Japan, South Pacific, Australia, New Zealand)

1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years

1 year or

500 hours

1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1year

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Vazer and

Models

with

Closed

Cooling

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Scorpion

377

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Standard SeaCore

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Vazer and

Models

with

Closed

Cooling

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Scorpion

377

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

1 year or

500 hours

Limited Corrosion

Warranty

Vazer,

Standard

Models, and and

Models

with

Closed

Cooling

none none

NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies

SeaCore

Mercury Installation Quality Certification Program

90-899883179 OCTOBER 2007 Page 9

15502

Page 18

Section 1 - Warranty

Mercury MerCruiser products installed by a Mercury Installation Quality Certified Manufacturer are Installation Quality certified products and may receive an additional one (1) year of limited warranty coverage.

The Installation Quality Certification program was developed to recognize MerCruiser boatbuilder customers who have achieved higher manufacturing standards. It is the first and only comprehensive manufacturer‑installation certification program in the industry.

The program has three goals:

1. To enhance overall product quality.

2. To improve the boat ownership experience.

3. To enhance overall customer satisfaction. The certification process is designed to review all facets of manufacturing and engine

installation. The program is composed of design, manufacturing and installation review stages with which builders must comply. Certification applies leading‑edge methodologies to create:

• Efficiencies and best practices specific to engine installation.

• World‑class assembly and component specifications.

• Efficient installation processes.

• Industry standard end‑of‑line test procedures Boat builders that successfully complete the program and meet all certification

requirements earn Installation Quality System Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiser‑powered boats that are registered on and after the boat builder's certification date for all worldwide registrations.

Mercury has designated a section of our Website to promote the Installation Quality Certification Program and communicate its benefits to consumers. For a current list of MerCruiser‑powered boat brands that have earned Installation Quality Certification, visit

www.mercurymarine.com/mercruiser_warranty.

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, STD (emission standard/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.

Page 10 90-899883179 OCTOBER 2007

Page 19

Section 1 - Warranty

EMISSION CONTROL

INFORMATION

THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS

SERIAL #

FAMILY

STD.

D.O.M.

DISP

31656

XXXXXXXXXXXX XX.X g/kW-hr

XXXXXXXX

X.XL

MMM YYYY

0575

EMISSION CONTROL

INFORMATION

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS

SERIAL #

FAMILY

STD.

D.O.M.

DISP

31657

XXXXXXXXXXXX XX.X g/kW-hr

XXXXXXXX

X.XL

MMM YYYY

NOT FOR SALE IN CALIFORNIA

NOTE: When the CE 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.

Emission Control Label—California Emissions–Compliant

"SERIAL#"—Engine Serial Number "FAMILY"—Engine Family "STD."—Emissions Standard "D.O.M."—Date of Manufacture "DISP"—Piston Displacement

Emission Control Label—Not for Sale in California

"SERIAL#"—Engine Serial Number "FAMILY"—Engine Family "STD."—Emissions Standard "D.O.M."—Date of Manufacture "DISP"—Piston Displacement

Owner Responsibility

The operator must have routine engine maintenance performed to maintain emission levels within prescribed certification standards.

The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed their factory specifications.

90-899883179 OCTOBER 2007 Page 11

Page 20

Section 1 - Warranty

Notes:

Page 12 90-899883179 OCTOBER 2007

Page 21

Section 2 - Getting to Know Your Power Package

Table of Contents

Section 2 - Getting to Know Your Power Package

Identification........................................................ 14

Engine Serial Number Decal ........................14

Bravo Sterndrive Serial Number and

Identification..................................................14

Bravo Transom Serial Number......................15

Lanyard Stop Switch........................................... 16

Instrumentation................................................... 17

Remote Controls................................................. 18

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

Console Mount Features .............................. 19

Power Trim......................................................... 19

Single Engine Trim/Trailer ............................ 20

Dual Engine Trim/Trailer .............................. 21

Electrical System Overload Protection-Carbureted

Engines............................................................... 21

Audio Warning System....................................... 23

Testing The Audio Warning System ............. 24

90-899883179 OCTOBER 2007 Page 13

Page 22

Section 2 - Getting to Know Your Power Package

26301

25906

25907

Identification

The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers.

Engine Serial Number Decal

The serial number decal is located on the engine cover.

Serial numbers and maintenance color codes decal

The engine serial number is also stamped in the engine block.

Bravo Sterndrive Serial Number and Identification

The sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive.

a - Bar code b - Serial Number

The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers.

Bravo sterndrive serial number stamping

a - Serial number stamping

Page 14 90-899883179 OCTOBER 2007

c - Gear ratio d - Model number

Page 23

Bravo Transom Serial Number

25904

25905

The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.

Bravo transom assembly U‑bolt plate

a - Transom assembly serial Number

Section 2 - Getting to Know Your Power Package

The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers.

Gimbal housing with serial number stamping

a - Transom assembly serial Number

90-899883179 OCTOBER 2007 Page 15

Page 24

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 ft) 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

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

Page 16 90-899883179 OCTOBER 2007

WARNING

Page 25

Accidental or unintended activation of the switch during normal operation is also a

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

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 serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.

Instrumentation

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.

Section 2 - Getting to Know Your Power Package

WARNING

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. Ignition Switch: Allows operator to start and stop engine. Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in).

90-899883179 OCTOBER 2007 Page 17

Page 26

Section 2 - Getting to Know Your Power Package

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

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

Page 18 90-899883179 OCTOBER 2007

Page 27

Console Mount Features

Section 2 - Getting to Know Your Power Package

a - Throttle Only Button b - Control Handle

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

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.

Excessive trim can cause serious injury or death at high speeds. Use caution when trimming the sterndrive, and never trim out beyond the gimbal ring support flanges while the boat is underway or at engine speeds above 1200 RPM.

90-899883179 OCTOBER 2007 Page 19

WARNING

Page 28

Section 2 - Getting to Know Your Power Package

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

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

3 - 5

mc79528

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

• 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.

mc78529

mc79530

Page 20 90-899883179 OCTOBER 2007

Page 29

Section 2 - Getting to Know Your Power Package

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

Dual Engine Trim/Trailer

NOTICE

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

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.

Electrical System Overload Protection‑Carbureted Engines

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 the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.

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

90-899883179 OCTOBER 2007 Page 21

22529

Yellow lever style circuit breaker‑typical

Page 30

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.

3. A 15 amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits.

mc74907-1

7524

4. 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).

mc70525-1

Page 22 90-899883179 OCTOBER 2007

Page 31

Section 2 - Getting to Know Your Power Package

5. 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

6. The Quicksilver Three‑Button Power Trim Control Panel is further protected by a 20

amp in‑line fuse.

mc70527-1

7. 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:

90-899883179 OCTOBER 2007 Page 23

mc79977

Page 32

Section 2 - Getting to Know Your Power Package

• Engine oil pressure too low

• Engine temperature too hot

• Sterndrive oil level too low

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

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.

NOTICE

Page 24 90-899883179 OCTOBER 2007

Page 33

Table of Contents

Section 3 - On The Water

Safe Boating Suggestions.................................. 26

Be Alert to Carbon Monoxide Poisoning............. 27

Good Ventilation ........................................... 27

Poor Ventilation ........................................... 28

Basic Boat Operation.......................................... 28

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

Operation Chart ...................................... 28

Starting and Stopping the Engine.................29

Starting the Engine ................................. 29

Stopping the Engine ............................... 30

Starting the Engine After It Has Been Stopped

While In Gear................................................30

Throttle-Only Operation.................................30

Trailering the Boat.........................................30

Freezing Temperature Operation..................30

Drain Plug and Bilge Pump...........................31

Protecting People in the Water........................... 31

While You Are Cruising ................................ 31

While Boat Is Stationary ............................... 31

High-Speed and High-Performance Operation

............................................................................ 31

Passenger Safety in Pontoon Boats and Deck Boats

............................................................................ 31

Boats Having An Open Front Deck .............. 32

Boats With Front-Mounted, Raised Pedestal

Fishing Seats ............................................... 32

Wave and Wake Jumping................................... 32

Impact with Underwater Hazards........................ 33

Drive Unit Impact Protection ........................ 34

Operating with Low Water Inlets in Shallow Water

............................................................................ 34

Conditions Affecting Operation........................... 34

Weight Distribution (Passengers and Gear)

Inside the Boat..............................................34

The Bottom of the Boat.................................34

Cavitation......................................................35

Ventilation.....................................................35

Elevation and Climate...................................35

Propeller Selection........................................35

Getting Started.................................................... 36

20-Hour Break-In Period...............................36

After Break-In Period.....................................36

End of First Season Checkup.......................37

90-899883179 OCTOBER 2007 Page 25

Page 34

Section 3 - On The Water

Safe Boating Suggestions

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.

• We recommend that all powerboat operators complete a boating safety course. In the US, the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the US, call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).

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.

• 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.

Page 26 90-899883179 OCTOBER 2007

Page 35

Section 3 - On The Water

• 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.

WARNING

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

Good Ventilation

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

90-899883179 OCTOBER 2007 Page 27

Page 36

Section 3 - On The Water

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

Launching and Boat Operation

IMPORTANT: Install bilge drain plug prior to launching boat.

OPERATION CHART

BEFORE STARTING AFTER STARTING

Install bilge drain plug.

Open engine hatch.

Operation Chart

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

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

mc79554-1

b - Mooring close to another boat with

its engine operating

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b - Operating the boat with no forward

hatches open (station wagon effect)

WHILE

UNDERWAY

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

Listen for the audio alarm.

AFTER STOPPING

Turn ignition key to the "OFF" position.

Turn battery switch to the "OFF" position.

Page 28 90-899883179 OCTOBER 2007

Page 37

Section 3 - On The Water

Operation Chart

BEFORE STARTING AFTER STARTING

Check shift and

Turn battery switch on.

Operate bilge blowers.

Open fuel shut off valve.

Open seacock, if equipped. Drain bilge.

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.

throttle control operation.

Check steering operation.

WHILE

UNDERWAY

AFTER STOPPING

Close fuel shut off valve.

Close seacock, if equipped.

Flush cooling system if in saltwater.

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.

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

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

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).

NOTE: If the engine has not run for a long period of time it may require a couple of attempts while the fuel bowl refills.

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.

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

to return to "ON" position.

5. If engine does not start after step 4:

a. Move the remote control handle/throttle lever to full throttle position, then return

to 1/4 throttle.

NOTICE

WARNING

90-899883179 OCTOBER 2007 Page 29

Page 38

Section 3 - On The Water

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

to return to "ON" position.

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.

NOTICE

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

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.

Starting the Engine After It Has Been 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.

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.

Page 30 90-899883179 OCTOBER 2007

Page 39

Drain Plug and Bilge Pump

21604

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.

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.

Section 3 - On The Water

Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.

While Boat Is Stationary

WARNING

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

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

High‑Speed and High‑Performance 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.

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Page 40

Section 3 - On The Water

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.

WARNING

Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms 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.

mc79555-1

Wave and Wake Jumping

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

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.

WARNING

mc79680-1

mc79557-1

Page 32 90-899883179 OCTOBER 2007

Page 41

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.

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.

• 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.

Section 3 - On The Water

mc79679-1

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

90-899883179 OCTOBER 2007 Page 33

WARNING

Page 42

Section 3 - On The Water

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.

Operating with Low Water Inlets in Shallow Water

a - Low Water Inlets

mc75827-1

NOTICE

Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling 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)

The Bottom of the Boat

To maintain maximum speed, the boat bottom should be:

Page 34 90-899883179 OCTOBER 2007

Page 43

Cavitation

Ventilation

Section 3 - On The Water

• 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 increases propeller speed while reducing boat speed. 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.

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 RPM limit. This limit, which is slightly above the normal operating range of the engine, helps prevent damage from excessive engine RPM. Once the RPM returns to the recommended operating RPM range, normal engine operation resumes.

The boat manufacturer and the selling dealer are responsible for equipping 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.

90-899883179 OCTOBER 2007 Page 35

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Section 3 - On The Water

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 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.

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.

• 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).

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

Page 36 90-899883179 OCTOBER 2007

Page 45

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.

Section 3 - On The Water

90-899883179 OCTOBER 2007 Page 37

Page 46

Section 3 - On The Water

Notes:

Page 38 90-899883179 OCTOBER 2007

Page 47

Table of Contents

Section 4 - Specifications

Fuel Requirements............................................. 40

Fuel Ratings ................................................. 40

Using Reformulated (Oxygenated) Gasolines

(USA Only) ................................................... 40

Gasolines Containing Alcohol ...................... 40

Engine Oil........................................................... 41

Engine Specifications......................................... 42

Fluid Specifications............................................. 42

Sterndrives ................................................... 42

Engine .......................................................... 42

90-899883179 OCTOBER 2007 Page 39

Page 48

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 increase:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Difficulty starting and operating the engine

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

WARNING

Because of possible adverse effects of alcohol in gasoline, we recommend only alcohol‑free gasoline when possible. If the only fuel available contains alcohol or if you do not know whether the fuel contains alcohol, inspect for leaks and abnormalities more frequently.

Page 40 90-899883179 OCTOBER 2007

Page 49

Engine Oil

Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rated

MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle MerCruiser oil

Other recognized brands of NMMA FC-W rated oils

SAE 20W

SAE30W

SAE40W

AIR TEMPERATURE

ORDER OF PREFERENCE

(32° F)

0° C

(50° F)

10° C

32878

Mercury/Quicksilver 25W-40, NMMA FC-W rated 4-cycle MerCruiser oil

Section 4 - Specifications

IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, do not store the gasoline in the fuel tank for long periods. Whereas cars normally consume alcohol‑blend fuels before they can absorb enough moisture to cause trouble, 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 recommend using the following oil:

Application Recommended Oil

All MerCruiser engines Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated

If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation:

1. Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W–rated 4‑cycle MerCruiser

oil

2. Mercury/Quicksilver 25W‑40, NMMA FC‑W–rated 4‑cycle MerCruiser oil

3. Other recognized brands of NMMA FC‑W–rated 4‑cycle oils

4. A good‑grade, straight‑weight detergent automotive oil per the operating chart below.

NOTE: We do not recommend 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.

90-899883179 OCTOBER 2007 Page 41

Page 50

Section 4 - Specifications

Engine Specifications

Models 4.3 TKS 5.0 TKS 5.7 TKS

Power 142 kW (190 hp) 164 kW (220 hp) 186 kW (250 hp)

Displacement 4.3 L (262 cid) 5.0 L (305 cid) 5.7 L (350 cid)

Specified WOT RPM range

Idle RPM in neutral 650

Minimum oil pressure at idle

Thermostat 71° C (160° F)

Timing at idle 10° BTDC

Firing order 1‑6‑5‑4‑3‑2 1‑8‑4‑3‑6‑5‑7‑2

Electrical system 12 V negative (–) ground

Alternator rating 65 A

Recommended minimum battery rating

Spark plug type AC MR43LTS or AC 41‑993 (platinum)

Spark plug gap 1.50 mm (0.060 in.) 1.14 mm (0.045 in.)

4400–4800

28 kPa (4 psi)

375 CCA, 475 MCA, or 90 Ah

Fluid Specifications

Sterndrives

NOTE: Oil capacity includes gear lube monitor.

Model Capacity Fluid Type

Alpha One 1892 mL (64 oz)

Bravo One 2736 mL (92‑1/2 oz)

Bravo Two 3209 mL (108‑1/2 oz)

Bravo Three (single seawater pickup) 2972 mL (100‑1/2 oz)

Bravo Three (dual seawater pickup) 2736 mL ( 92‑1/2 oz)

Engine

IMPORTANT: Your application may require more or less than the listed capacity. Use the dipstick to determine the exact quantity of oil or fluid required. Listed capacities are approximate.

4.3 TKS Models Capacity Fluid Type

Engine oil (with filter) 3.8 L (4 US qt)

Seawater cooling system 14.1 L (15 US qt) Propylene glycol and purified water

Closed cooling system 19 L (20 US qt)

High Performance Gear Lubricant

Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated

Mercury Extended Life Coolant/Antifreeze or Extended Life Ethylene Glycol 5/100 Coolant/ Antifreeze mixed 50/50 with purified water

5.0 TKS and 5.7 TKS Models Capacity Fluid Type

Engine oil (with filter) 4.25 L (4.5 US qt)

Seawater cooling system 20 L (21 US qt) Propylene glycol and purified water

Page 42 90-899883179 OCTOBER 2007

Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated

Page 51

Table of Contents

Section 5 - Maintenance

Owner/Operator Responsibilities........................ 44

Dealer Responsibilities....................................... 44

Maintenance....................................................... 44

Do-It-Yourself Maintenance Suggestions........... 45

Inspection........................................................... 45

Maintenance Schedule–Sterndrive Models........ 46

Routine Maintenance....................................46

Scheduled Maintenance................................46

Maintenance Log................................................ 47

Sealed Carburetor Mixture Screw....................... 48

Engine Oil........................................................... 48

Checking ...................................................... 48

Filling ............................................................ 48

Changing Oil and Filter ................................ 49

Easy Engine Oil Drain System ............... 49

Engine Oil Drain Pump ........................... 50

Changing Filter ....................................... 50

Power Steering Fluid.......................................... 51

Checking ...................................................... 51

Filling ............................................................ 51

Changing ...................................................... 51

Engine Coolant................................................... 51

Checking ...................................................... 51

Filling ............................................................ 52

Changing ..................................................... 53

Drive Unit Oil....................................................... 53

Checking ...................................................... 53

Filling ............................................................ 54

Changing ...................................................... 55

Power Trim Fluid................................................. 57

Checking ...................................................... 57

Filling ............................................................ 57

Changing ...................................................... 58

Cleaning The Flame Arrestor.............................. 58

Positive Crankcase Ventilation Valve

(PCV) ........................................................... 59

Changing ................................................ 59

Changing the Water-Separating Fuel Filter........ 59

Lubrication.......................................................... 60

Steering System............................................60

Throttle Cable................................................62

Shift Cable - Typical......................................62

Sterndrive Unit and Transom Assembly........63

Sterndrive U-joint Shaft Splines And O-rings

(Sterndrive Unit Removed)............................63

Engine Coupler.............................................63

Driveshaft Extension Models.........................64

Propellers............................................................ 65

Propeller Repair............................................65

Alpha Propeller Removal..............................65

Alpha Propeller Installation...........................65

Bravo One Propeller Removal......................66

Bravo One Propeller Installation...................66

Bravo Two Propeller Removal......................68

Bravo Two Propeller Installation...................68

Bravo Three Propeller Removal....................69

Bravo Three Propeller Installation.................70

Serpentine Drive Belt.......................................... 72

Checking ...................................................... 72

Replacing Belt and/or Adjusting Tension ..... 72

Flushing the Power Package.............................. 73

Flushing Attachments ................................... 74

Sterndrive Water Pickups ............................. 74

Alternative Water Pickups ............................ 76

Battery................................................................ 77

Corrosion Protection........................................... 78

Painting Your Power Package ..................... 82

90-899883179 OCTOBER 2007 Page 43

Page 52

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

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components.

WARNING

Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package.

IMPORTANT: Refer to the maintenance schedule for complete listing of all scheduled maintenance to be performed. Whereas you can perform some items, others should be performed only by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, we recommend that you purchase a Mercury MerCruiser service manual and read it thoroughly.

NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.

Page 44 90-899883179 OCTOBER 2007

Page 53

Maintenance Point Color Codes

Blue Coolant

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.

90-899883179 OCTOBER 2007 Page 45

Page 54

Section 5 - Maintenance

Maintenance Schedule–Sterndrive Models

Routine Maintenance

NOTE: Only perform maintenance that applies to your particular power package.

Task Interval Maintenance to Be Performed

• Check the engine oil level. (You can extend this interval based on experience with the product.)

Each day start

Each day end

Weekly

Every two months or 50

hours

• Check the sterndrive gear lube level.

• Check the trim pump oil level.

• Check the power‑assisted steering pump or the compact hydraulic steering fluid level, depending on the steering system of your model.

• If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system after each use.

• Check the water inlets for debris or marine growth.

• Check and clean the seawater strainer, if equipped.

• Check the coolant level.

• Inspect the sterndrive anodes and replace if 50% eroded.

• Lubricate the propeller shaft and retorque the nut. (If operating only in freshwater, you can extend the interval to every four months.)

• If operating in saltwater, brackish water, or polluted water, apply Corrosion Guard to the power package.

• Check the battery connections and the fluid level.

• Ensure that the gauges and the wiring connections are secure. Clean the gauges. (If operating in saltwater, reduce this interval to every 25 hours or 30 days, whichever occurs first.)

Scheduled Maintenance

NOTE: Only perform maintenance that applies to your particular power package.

Task Interval Maintenance to Be Performed

After the initial 20‑hour

break‑in period

Every 100 hours or

annually

(whichever occurs first)

Change the engine oil and filter.

• Touch up the paint on the power package.

• Change the engine oil and filter.

• Change the sterndrive gear lube.

• Tighten the connection of the gimbal ring to the steering shaft to specifications.

• 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. If the package is equipped with a MerCathode, test the MerCathode unit output.

• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped.

NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly.

• Inspect the condition and the tension of the belts.

• Check the coolant level and antifreeze concentration for adequate freeze protection. Correct if necessary. Refer to the Specifications section.

• On driveshaft extension models, lubricate the driveshaft U‑joints and tailstock input and output bearings.

Page 46 90-899883179 OCTOBER 2007

Page 55

Task Interval Maintenance to Be Performed

• Inspect the U‑joints, the splines, and the bellows. Check the clamps.

• Check the engine alignment.

Every 200 hours or 3

years

• Lubricate the U‑joint splines and cross bearing, if equipped with grease

fittings.

• Lubricate the gimbal bearing and the engine coupler.

NOTE: Lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time.

• Check the engine mounts for tightness and tighten to specifications if

necessary.

• Check the electrical system for loose, damaged, or corroded fasteners.

• Check the cooling system and the exhaust system hose clamps for tightness.

Every 300 hours or 3

years

Every 5 years

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. If the package was equipped with

water shutters (flapper valves), verify that they are not missing or worn.

• Replace the coolant/anitifreeze. Replace every two years if not using

extended‑life coolant/antifreeze.

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

90-899883179 OCTOBER 2007 Page 47

Page 56

Section 5 - Maintenance

Sealed Carburetor Mixture Screw

IMPORTANT: Changing the mixture setting on this engine can affect the exhaust emissions level and void the emissions certification. Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury dealer or emissions testing agency.

Engine Oil

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

Checking

1. 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.

2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.

NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end).

NOTICE

Filling

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.

Page 48 90-899883179 OCTOBER 2007

Page 57

Section 5 - Maintenance

7284

1. Remove oil fill cap.

6501

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.

Engine Model Engine Oil Capacity Fluid type

4.3 TKS 3.8 liters (4 U.S. qt.)

5.7 TKS

4.25 liters (4.5 U.S. qt.)

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.

Mercury Full‑Synthetic MerCruiser Oil 20W‑405.0 TKS

a - Bilge drain plug b - Tether c - Clip

90-899883179 OCTOBER 2007 Page 49

d - Oil drain hose plug e - Oil drain hose f - Bilge drain flange

Page 58

Section 5 - Maintenance

2. Remove the bilge drain plug.

3. Pull tether through the bilge drain.

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.

2. Coat sealing ring on new filter with engine oil and install.

3. Tighten oil filter securely (following filter manufacturer's instructions). Do not

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

6. With the boat at rest in the water, check the oil level and add specified fluid to bring the

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.

a - Typical oil pump

c - Oil drain hose

b - Dipstick tube

the handle, pump until the crankcase is empty.

overtighten.

dipstick.

oil level up to, but not over, the full or OK range.

Engine Model

4.3 TKS 3.8 liters (4 U.S. qt.)

5.7 TKS

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.

Page 50 90-899883179 OCTOBER 2007

Engine Oil Capacity Fluid type

4.25 liters (4.5 U.S. qt.)

Mercury Full‑Synthetic MerCruiser Oil 20W‑405.0 TKS

Page 59

Power Steering Fluid

Checking

1. Stop the engine and center the sterndrive unit.

2. Remove the fill cap/dipstick 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.

Section 5 - Maintenance

6631

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 Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission

Fluid (ATF) to bring the fluid level up to the proper level.

Tube Ref No. Description Where Used Part No.

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

a - Power steering pump b - Cold range

114

Power Trim and Steering Fluid Power steering system 92-858074K01

c - Warm range

Checking

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

90-899883179 OCTOBER 2007 Page 51

CAUTION

Page 60

Section 5 - Maintenance

1. Remove the cap from the heat exchanger and observe the fluid level.

2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the

3. Install the cap onto the heat exchanger.

IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck.

4. With the engine at normal operating temperature, check the coolant level in the coolant

5. The coolant level should be between the "ADD" and "FULL" marks.

6101

a - Heat exchanger cap

coolant level is low, contact your authorized Mercury MerCruiser dealer.

recovery bottle.

6. Add the specified fluid as necessary.

Tube Ref No. Description Where Used Part No.

122

Filling

Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.

Page 52 90-899883179 OCTOBER 2007

Extended Life Antifreeze/ Coolant

6102

Closed Cooling System 92-877770K1

NOTICE

Page 61

Section 5 - Maintenance

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

NOTICE

Air trapped in the closed cooling system can cause the engine to overheat, resulting in engine damage. Minimize the possibility of trapping air when initially filling the closed cooling system by positioning 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.

2. Fill to the "FULL" line with the specified coolant.

Tube Ref No. Description Where Used Part No.

122

3. Install the fill cap onto the coolant recovery bottle.

Extended Life Antifreeze/ Coolant

Closed Cooling System 92-877770K1

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.

NOTICE

90-899883179 OCTOBER 2007 Page 53

Page 62

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

6107

6105

Seawater cooled models Closed cooled models

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 92-858064K01

3. Replace the cap.

NOTE: When filling the entire sterndrive unit refer to Changing.

Page 54 90-899883179 OCTOBER 2007

Page 63

Changing

Section 5 - Maintenance

1. Remove the gear lube monitor from the bracket.

6109

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.

a - Oil fill/drain screw

mc79506-1

b - Sealing washer

90-899883179 OCTOBER 2007 Page 55

Page 64

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 92-858064K01

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 gear lube monitor circuit 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 56 90-899883179 OCTOBER 2007

Page 65

Model Capacity Fluid Type

Alpha One 1892 mL (64 oz)

Bravo One 2736 mL (92‑1/2 oz)

Bravo Two 3209 mL (108‑1/2 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.

Check the oil level only 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. Remove the fill cap from the reservoir.

Section 5 - Maintenance

High Performance Gear Lubricant

Filling

5573

a - Fill cap b - Reservoir fill neck

3. Observe the oil level. Level must be between the "MIN" and "MAX" lines on the

reservoir.

c - "MIN" and "MAX" lines

NOTE: Fill cap is vented.

4. Fill as necessary with the specified fluid.

Tube Ref No.

114

Power Trim and Steering Fluid Power trim pump 92-858074K01

Description Where Used Part No.

1. Remove the fill cap from the reservoir.

2. Add lubricant to bring level to the bottom of the filler neck.

Tube Ref No.

114

90-899883179 OCTOBER 2007 Page 57

Description Where Used Part No.

Power Trim and Steering Fluid Power trim pump 92-858074K01

Page 66

Section 5 - Maintenance

16330

3. Install the cap.

Changing

Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer.

Cleaning The Flame Arrestor

Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately.

1. Disconnect and remove the crankcase ventilation hose from the fitting on the flame arrestor and valve cover.

2. Remove the flame arrestor.

WARNING

a - Locknut b - Sealing washer c - Typical carburetor

3. Clean the flame arrestor with warm water and a mild detergent.

4. Inspect the flame arrestor for holes, cracks or deterioration. Replace if necessary.

5. Allow the flame arrestor to air dry completely before use.

6. Clean the crankcase ventilation hose with warm water and a mild detergent. Dry with compressed air or allow to air dry completely.

7. Inspect the crankcase ventilation hose for cracks or deterioration. Replace if necessary.

8. Install the flame arrestor, sealing washer, and locknut. Torque the flame arrestor locknut.

Description

Flame arrestor nut 12 106

9. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover.

d - Crankcase ventilation hose e - Flame arrestor

Nm lb. in. lb. ft.

Page 58 90-899883179 OCTOBER 2007

Page 67

Positive Crankcase Ventilation Valve (PCV)

CHANGING

IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations.

NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover.

1. Remove the PCV valve from the port valve cover.

Section 5 - Maintenance

a - PCV valve b - Hose

2. Disconnect the PCV valve from the hose and discard the valve.

3. Install a new PCV valve in the valve cover and reconnect the hose.

4. Ensure the PCV valve is tightly seated in the valve cover.

Changing the Water‑Separating Fuel Filter

WARNING

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. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray.

4. Remove and discard the water separating fuel filter and sealing ring from the mounting

bracket.

5. Coat the sealing ring on the new filter with engine oil.

mc71925-1

Tube Ref. No.

90-899883179 OCTOBER 2007 Page 59

Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Filter sealing ring 92‑883725K01

Page 68

Section 5 - Maintenance

6. Thread filter onto bracket and tighten securely by hand. Do NOT use a filter wrench.

6527

7. Open fuel supply valve, if equipped.

8. Ensure that engine compartment is properly ventilated.

9. Supply cooling water to the engine.

10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist,

Lubrication

Steering System

Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant.

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

a - Fuel filter base

c - Fuel filter

b - Sealing ring

stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop the engine immediately and contact your authorized Mercury MerCruiser dealer.

WARNING

retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand‑operated grease gun.

a - Steering cable grease fitting

Tube Ref No. Description Where Used Part No.

Page 60 90-899883179 OCTOBER 2007

6221

Special Lubricant 101 Steering cable grease fitting 92-802865Q02

Page 69

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 92-802865Q02

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.

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Description Where Used Part No.

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.

90-899883179 OCTOBER 2007 Page 61

Page 70

Section 5 - Maintenance

Throttle Cable

1. Lubricate the pivot points and the guide contact surfaces.

Tube Ref. No. Description Where Used Part No.

Shift Cable ‑ Typical

1. Lubricate the pivot points and the guide contact surfaces.

6208

a - Pivot points b - Guide contact surfaces

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Throttle cable pivot points &

guide contact surfaces

92‑883725K01

mc79736

a - Pivot points

b - Guide contact surfaces

Tube Ref. No. Description Where Used Part No.

Page 62 90-899883179 OCTOBER 2007

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Shift cable pivot points & guide

contact surfaces

92‑883725K01

Page 71

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

Section 5 - Maintenance

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

Tube Ref No. Description Where Used Part No.

Engine Coupler Spline Grease

b - U‑joint O‑rings (3)

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.

90-899883179 OCTOBER 2007 Page 63

Page 72

Section 5 - Maintenance

17014

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

a - Grease fitting

Tube Ref No. Description Where Used Part No.

NOTE:

Alpha Models

and Perm‑a‑Lube U‑joints. The sealed coupler and shaft splines can be lubricated without removing the sterndrive unit. The Perm‑a‑Lube U‑joints do not require lubrication.

NOTE:

Bravo Models

the sterndrive unit. Apply lubricant from a typical hand‑operated grease gun until a small amount of grease begins to push out. The Perm‑a‑Lube U‑joints do not require lubrication.

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.

Engine Coupler Spline Grease Coupler 92-802869A1

6213

6212

‑ Your power package is equipped with a sealed engine coupler

‑ The coupler and shaft splines can be lubricated without removing

a - Driveshaft grease fittings b - Transom end grease fitting

Tube Ref No. Description Where Used Part No.

Page 64 90-899883179 OCTOBER 2007

U-joint and Gimbal Bearing Grease

c - Engine end grease fitting

Transom end grease fitting,

engine end grease fitting,

driveshaft grease fittings

92-802870A1

Page 73

Propellers

Propeller Repair

Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.

Alpha Propeller Removal

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

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.

Alpha Propeller Installation

WARNING

Section 5 - Maintenance

NOTICE

Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval.

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 - Flo‑Torq II drive hub d - Propeller

e - Drive sleeve f - Locking tab washer g - Propeller nut

6215

1. Apply a liberal coat of one of the following lubricants to the propeller shaft.

Tube Ref No.

90-899883179 OCTOBER 2007 Page 65

Description Where Used Part No.

Special Lubricant 101 Propeller shaft 92-802865Q02

Page 74

Section 5 - Maintenance

Tube Ref No. Description Where Used Part No.

Anti-Corrosion Grease Propeller shaft 92-802867Q 1

2-4-C Marine Lubricant with Teflon

2. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub.

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.

Description Nm lb‑in. lb‑ft

Propeller nut (minimum) 75 – 55

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 One Propeller Removal

WARNING

Propeller shaft 92-802859A1

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.

Bravo One Propeller Installation

NOTICE

Page 66 90-899883179 OCTOBER 2007

Page 75

Section 5 - Maintenance

IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.

6215

a - Propeller shaft b - Thrust hub c - Flo‑Torq II drive hub

e - Drive sleeve f - Locking tab washer g - Propeller nut

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 92-802865Q02

Anti-Corrosion Grease Propeller shaft 92-802867Q 1

2-4-C Marine Lubricant with Teflon

Propeller shaft 92-802859A1

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.

Description Nm lb. in. lb. ft.

Propeller nut

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.

1. The propeller torque stated is a minimum torque value.

90-899883179 OCTOBER 2007 Page 67

75 55

Page 76

Section 5 - Maintenance

14946

Bravo Two Propeller Removal

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.

Bravo Two Propeller Installation

WARNING

NOTICE

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

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.

d - Propeller nut e - Spline washer f - Tab washer

Tube Ref No.

Page 68 90-899883179 OCTOBER 2007

Description Where Used Part No.

Special Lubricant 101 Propeller shaft 92-802865Q02

Anti-Corrosion Grease Propeller shaft 92-802867Q 1

2-4-C Marine Lubricant with Teflon

Propeller shaft 92-802859A1

Page 77

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 (minimum) 81 – 60

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

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.

WARNING

Section 5 - Maintenance

a - Propeller b - Propeller shaft nut c - Propeller shaft anode

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.

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.

5303

d - Propeller shaft anode screw e - Flat washer f - Star washer

90-899883179 OCTOBER 2007 Page 69

Page 78

Section 5 - Maintenance

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

NOTICE

5304

a - Rear propeller nut b - Rear propeller c - Rear propeller thrust hub d - Front propeller nut e - Front propeller

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.

f - Front propeller thrust hub g - Propeller shaft anode screw h - Flat washer i - Star washer j - Propeller shaft anode

Page 70 90-899883179 OCTOBER 2007

Page 79

Section 5 - Maintenance

Tube Ref No. Description Where Used Part No.

Special Lubricant 101 Propeller shaft 92-802865Q02

Anti-Corrosion Grease Propeller shaft 92-802867Q 1

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.

Description

Propeller shaft anode screw 38 mm (0.3125‑18 x 1.5 in.) long 27 – 20

90-899883179 OCTOBER 2007 Page 71

Loctite 271 Threadlocker Propeller shaft threads 92-809819

5303

d - Propeller shaft anode screw e - Flat washer f - Star washer

Nm llb‑in. lb‑ft

Page 80

Section 5 - Maintenance

Serpentine Drive Belt

Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts.

WARNING

Checking

With a seawater pump Without a seawater pump

a - Idler pulley b - Water circulating pump pulley c - Crankshaft pulley

1. Inspect the drive belt for proper tension and for the following:

• Excessive wear

• Cracks

6116

d - Alternator pulley e - Seawater pump pulley f - Power steering pump pulley

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.

6117

Replacing Belt and/or Adjusting Tension

IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before.

NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys.

1. Loosen the 16 mm (5/8 in.) locking nut on the adjustment stud.

Page 72 90-899883179 OCTOBER 2007

mc75130-1

Page 81

Section 5 - Maintenance

COLOR GUIDE

for

PATENT

2.83918

NEWTONE

14980

2. Turn the adjustment stud and loosen the belt.

3. If a new serpentine drive belt is required, remove the old belt and install a new belt onto

the pulleys.

4. Put a wrench on the adjustment stud 16 mm (5/8 in.) locking nut.

5. Use a 8 mm (5/16 in.) socket and tighten adjusting the stud to adjust the belt deflection.

6. Using one of the 2 methods following, check for correct deflection.

a. Push down with moderate thumb pressure on the longest stretch of belt. Proper

deflection is 13 mm (1/2 in.).

b. Attach the Kent Moore Belt Tension Gauge to the belt. The gauge has different

ranges for new and used belts.

a - Kent Moore Tension Gauge

7. While holding the adjustment stud at the correct belt tension, tighten the 16 mm

(5/8 in.) locking nut.

a - 16 mm (5/8 in.) locking nut

8. Operate the engine for a short period of time and recheck the belt adjustment.

Flushing the Power Package

b - Serpentine belt

6119

b - 8 mm (5/8 in.) adjusting stud

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.

90-899883179 OCTOBER 2007 Page 73

Page 82

Section 5 - Maintenance

9192

9194

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

Flushing Attachments

Flushing Device 91‑44357Q 2

Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1

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.

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).

Dual Water Pickup

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results.

5752

5773

Side Pickup

Page 74 90-899883179 OCTOBER 2007

Page 83

Section 5 - Maintenance

NOTICE

Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine. Keep the seacock closed until starting 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.

On Alpha closed cooled models with the sterndrive seawater inlet blocked:

Flushing water will need to be supplied to the sterndrive unit and to the engine. Refer to Alternative Water Pickups.

On Bravo closed cooled models using the sterndrive seawater inlet and a

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.

4. 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.

5. If flushing the cooling system with the boat out of the water:

a. Lower sterndrive unit to full down/in position.

WARNING

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.

NOTICE

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

90-899883179 OCTOBER 2007 Page 75

Page 84

Section 5 - Maintenance

9. Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).

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 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.

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.

Page 76 90-899883179 OCTOBER 2007

Page 85

Section 5 - Maintenance

5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent

water from siphoning into the engine or boat.

6147

6. Using a suitable adapter, connect the flushing hose from the water source to the water

inlet of the seawater pump.

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

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.

NOTICE

9. Slowly advance throttle until engine reaches 1300 RPM (+/‑100 RPM).

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.

90-899883179 OCTOBER 2007 Page 77

Page 86

Section 5 - Maintenance

6211

Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.

An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.

Corrosion Protection

Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.

WARNING

NOTICE

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).

Page 78 90-899883179 OCTOBER 2007

c - Do not pressure wash

Page 87

Section 5 - Maintenance

Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed (some models have a MerCathode System as standard equipment).

8716

IMPORTANT: Replace sacrificial anodes if eroded 50 percent or more. The following sacrificial anodes are installed at different locations on your power package.

These anodes help protect against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package.

1 - Gearcase anodic plate 2 - Ventilation plate anode 3 - Gimbal mounted anodic block 4 - MerCathode System

2 2

5 - Anode kit 6 - Trim cylinder anodes 7 - Bearing carrier anodes (Alpha

only)

8 - Propshaft Anode (Bravo III

standard)

90-899883179 OCTOBER 2007 Page 79

Page 88

Section 5 - Maintenance

Gearcase Anodic Plate ‑ Mounted on the underside of the lower gearcase.

Alpha, Bravo One, Bravo Two Models All Bravo Three Models

6205

a - Anode

Ventilation Plate Anode ‑ Mounted on the front of the gearcase.

6122

a - Anode

Drive Mounted Anodic Block (if equipped) ‑ Mounted to underside of gimbal housing.

5640

5639

MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer.

Page 80 90-899883179 OCTOBER 2007

Page 89

Section 5 - Maintenance

IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash.

6206

a - MerCathode controller b - MerCathode assembly

Anode Kit (if equipped) ‑ Mounted to the boat transom.

5642

Trim Cylinder Anodes ‑ Mounted on each trim cylinder.

5643

a - Trim cylinder anodes

90-899883179 OCTOBER 2007 Page 81

Page 90

Section 5 - Maintenance

Bearing Carrier Anode (Alpha and Bravo One) ‑ Located in front of the propeller, between the front side of the propeller and the gear housing.

Propshaft Anode (Bravo Three) ‑ Located behind the aft propeller.

5644

a - Bearing carrier anode

a - Propshaft anode

In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion:

1. Paint your power package, refer to Painting Your Power Package.

2. Spray power package components on inside of boat annually with Corrosion Guard to protect finish from dulling and corrosion. External power package components may also be sprayed.

3. All lubrication points, especially steering system, shift and throttle linkages, should be kept well lubricated.

4. Flush cooling system periodically, preferably after each use.

Painting Your Power Package

IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the limited warranty.

1. Painting Boat Hull or Boat Transom: Anti‑fouling paint may be applied to boat hull and boat transom but you must observe the following:

IMPORTANT: Do NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper or tin base paints, if not prohibited by law, can be used. If using copper or tin based anti‑fouling paints, observe the following:

5821

Page 82 90-899883179 OCTOBER 2007

Page 91

Section 5 - Maintenance

• Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.

5578

a - Painted boat transom b - Unpainted Area on Transom

2. Painting Sterndrive Unit or Transom Assembly: Sterndrive unit and transom assembly should be painted with a good quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct electrical current. Do not paint drain holes, anodes, MerCathode system, and items specified by boat manufacturer.

90-899883179 OCTOBER 2007 Page 83

Page 92

Section 5 - Maintenance

Notes:

Page 84 90-899883179 OCTOBER 2007

Page 93

Table of Contents

Section 6 - Storage

Cold Weather or Extended Storage.................... 86

Preparing Power Package for Storage..........86

Engine and Fuel System Preparation ....87

Draining the Seawater System........................... 88

Drain System Identification...........................89

Air Actuated Single Point Drain System

............................................................... 89

Manual Single Point Drain System ......... 89

Three Point Manual Drain System ......... 90

Multi-Point Drain (MPD) System ............ 90

Air-Actuated Single-Point Drain System.......91

Boat in the Water ................................... 91

Boat out of the Water ............................. 93

Manual Single Point Drain System................96

Boat in the Water ................................... 96

Boat out of the Water ............................. 97

Three Point Manual Drain System................98

Boat in the Water ................................... 98

Boat out of the Water ............................. 99

Multi-Point Drain (MPD) System.................100

Boat out of the Water ........................... 100

Boat in the Water ................................. 102

Draining the Sterndrive..................................... 104

Battery Storage................................................. 105

Power Package Recommissioning................... 105

90-899883179 OCTOBER 2007 Page 85

Page 94

Section 6 - Storage

Cold Weather or Extended Storage

IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty.

Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.

IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

NOTICE

Preparing Power Package for Storage

1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline. Follow instructions on the container.

2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Mercury/Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank. Refer to Fuel Requirements for additional information.

3. Flush the cooling system. Refer to the Maintenance section.

IMPORTANT: In order to run the engine as required in the remainder of the storage preparation procedure, water must be supplied to the engine as described in the flushing procedure.

4. Provide cooling water to the engine as done in the previous step.

5. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel with Mercury/Quicksilver Gasoline Stabilizer to circulate through the fuel system. Shut off the engine.

6. Change the oil and oil filter.

7. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System Preparation.

8. Drain the engine seawater cooling system. Refer to Draining the Seawater System.

Page 86 90-899883179 OCTOBER 2007

Page 95

9. Ensure that the sterndrive vent holes and water drain holes and passages are

unobstructed and open (refer to Draining Instructions).

10. For additional assurance against freezing and rust, after draining, fill the cooling system

with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.

The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.

11. Store boat with drive unit in full down/in position.

12. Store the battery according to the manufacturer's instructions.

ENGINE AND FUEL SYSTEM PREPARATION

Section 6 - Storage

NOTICE

WARNING

1. Prepare carbureted fuel system for extended storage as follows:

a. Start engine. b. Provide cooling water to the engine as done in the previous step. c. Remove flame arrestor assembly. d. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting

if not equipped with a fuel shut off valve.

e. While operating engine at fast idle (1300 RPM), fog internal surfaces of induction

system and combustion changers by spraying approximately 227 g (8 oz.) of Mercury/Quicksilver Storage Seal or SAE 20W engine oil into carburetor bores.

f. Spray the remaining 57 g (2 oz.) of Storage Seal (or oil) rapidly into carburetor,

just as the engine begins to stall, due to lack of fuel. Allow engine to stop.

90-899883179 OCTOBER 2007 Page 87

Page 96

Section 6 - Storage

Tube Ref No. Description Where Used Part No.

119

Storage Seal Rust Inhibitor Carburetor 92-858081K01

g. Turn ignition key to "OFF" position.

2. Refer to Flushing the Power Package and appropriately remove the water supply the the seawater pickup pump.

3. Clean the flame arrestor and crankcase ventilation hoses and reinstall.

4. Lubricate all items listed in the Lubrication section.

5. On models with closed cooling systems: Test coolant to ensure that it will withstand the lowest temperature expected during storage.

6. Service batteries according to the manufacturer's instructions.

7. Clean the outside of the engine and repaint any areas required with Mercury/ Quicksilver Light Gray Primer and Phantom Black Paint. After paint has dried, wipe down the outside of the engine with Corrosion Guard.

Tube Ref No. Description Where Used Part No.

120

Corrosion Guard Outside of engine 92-802878 55

8. For sterndrive unit lay‑up, refer to appropriate Mercury MerCruiser sterndrive service manual.

9. Replace the fuel filter. Refer to the Maintenance section for proper procedure.

10. Change the oil and oil filter.

Draining the Seawater System

Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining. Do not operate the engine with the drain system open.

IMPORTANT: Only drain the seawater section of the closed‑cooling system. IMPORTANT: The boat must be as level as possible to ensure complete draining of the

cooling system. Your power package is equipped with a drain system. Refer to Drain System

Identification to determine which instructions apply to your power package. IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the

manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

CAUTION

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Drain System Identification

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

Section 6 - Storage

6124

Closed Cooled Models Seawater Cooled Models

a - Blue drain plug location b - Blue air pump

c - Air manifold d - Green indicators

6125

a - Blue air pump b - Air manifold

MANUAL SINGLE POINT DRAIN SYSTEM

a - Blue handle

21125

Scorpion Models

c - Green indicators d - Blue drain plug locations

6128

b - Blue drain plug location

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Section 6 - Storage

THREE POINT MANUAL DRAIN SYSTEM

a - Blue drain plug

MULTI-POINT DRAIN (MPD) SYSTEM

93235672

10226

M110050

a - Side of cylinder block

6126

6129

b - Bottom of exhaust manifolds

a - Water circulating pump hose b - Fuel cooler to thermostat housing

Page 90 90-899883179 OCTOBER 2007

6130

Page 99

a - Check valve (if equipped)

Air‑Actuated Single‑Point Drain System

BOAT IN THE WATER

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.

1. Close the seacock (if equipped) or remove and plug the water inlet hose.

2. Remove the air pump from the engine.

3. Ensure that the lever on top of the pump is flush with the handle (horizontal).

4. Install the air pump on the actuator fitting.

5. Pull lever on air pump (vertical) to lock pump on the fitting.

Section 6 - Storage

6131

a - Actuator fitting b - Green indicators

8293

d - Air pump e - Lever (locking)

c - Manual release valve

6. Pump air into the system until both green indicators extend and water drains from both

sides of the engine. The port side will begin draining before the starboard side.

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Section 6 - Storage

7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system.

6124

Closed Cooled Models Seawater Cooled Models

a - Blue drain plug location b - Blue air pump

c - Air manifold d - Green indicators

6125

a - Blue air pump b - Air manifold

21125

Scorpion Models

c - Green indicators d - Blue drain plug locations

Page 92 90-899883179 OCTOBER 2007

Mercury MerCruiser 4.3 TKS, MerCruiser 5.0 TKS, MerCruiser 5.7 TKS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual