Mercury MerCruiser 5.7 MPI, MerCruiser 5.7 Horizon 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

90-899883173 1207

*899883173*

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

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

Section 2 - Getting to Know Your Power Package

Identification..........................................................20

Engine Serial Number Decal..........................20

Transmissions................................................20

Velvet Drive Transmissions .........................20

ZF Marine Transmissions.............................21

Walter V‑Drive Transmissions......................22

Lanyard Stop Switch..............................................22

Instrumentation......................................................23

VesselView.....................................................23

Digital Gauges................................................24

Analog Gauges...............................................25

Remote Controls (Non‑DTS Models).....................25

Remote Controls............................................25

Panel Mount Features..................................26

Console Mount Features..............................27

Zero Effort Features.......................................27

Remote Controls (DTS Models)............................28

Remote Controls............................................28

California Emissions Limited Warranty..................10

What Is Covered...............................................10

Duration Of Coverage.......................................11

How To Obtain Warranty Coverage..................12

What Mercury Will Do.......................................12

What Is Not Covered........................................12

Components Of The Emission Control System 12

Disclaimers And Limitations..............................14

California Emission Control Warranty Statement..14

Your Warranty Rights and Obligations.............14

Manufacturer's Warranty Coverage..................14

Owner's Warranty Responsibilities...................14

Emission Control Information Label.......................15

Owner Responsibility........................................16

Emission Certification Star Label...........................16

Panel Mount Features....................................28

Console Mount Features ‑ Single Engine.......29

Slim Binnacle Console Mount Features ‑ Single

Engine............................................................30

Console Mount Features‑ Dual Engine..........31

Synchronizing Dual Engines..........................31

Dual Helm Station Transfer............................32

Synchronizing Dual Helms Prior To Station

Transfer........................................................33

Zero Effort Features.......................................33

Electrical System Overload Protection..................33

Audio Warning System..........................................36

Caution.............................................................36

Severe..............................................................36

OBDM...............................................................37

Testing The Audio Warning System.................37

Guardian Strategy.................................................37

Safe Boating Suggestions.....................................40

Be Alert to Carbon Monoxide Poisoning................41

Good Ventilation...............................................41

Poor Ventilation ...............................................42

Basic Boat Operation (Non‑DTS Models)..............42

Launching and Boat Operation.......................42

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Section 3 - On the Water

Operation Chart............................................42

Starting and Stopping the Engine...................43

Starting the Engine.......................................43

Stopping the Engine.....................................44

Throttle‑Only Operation..................................44

Freezing Temperature Operation...................44

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Drain Plug and Bilge Pump...........................44

Basic Boat Operation (DTS Models).................... 44

Launching and Boat Operation..................... 44

Operation Chart.......................................... 44

Starting and Stopping the Engine................. 45

Starting the Engine..................................... 45

Stopping the Engine....................................46

Throttle‑Only Operation.................................46

Freezing Temperature Operation..................47

Drain Plug and Bilge Pump...........................47

Protecting People in the Water.............................47

While You Are Cruising....................................47

While Boat Is Stationary.................................. 47

High‑Speed and High‑Performance Operation.... 48

Passenger Safety in Pontoon Boats and Deck

Boats.................................................................... 48

Section 4 - Specifications

Boats Having An Open Front Deck..................48

Boats With Front‑Mounted, Raised Pedestal

Fishing Seats...................................................48

Wave and Wake Jumping.................................... 49

Impact with Underwater Hazards......................... 49

Conditions Affecting Operation.............................50

Weight Distribution (Passengers and Gear)

Inside the Boat.............................................. 50

The Bottom of the Boat................................. 50

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

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

Elevation and Climate................................... 51

Getting Started..................................................... 51

20‑Hour Break‑In Period............................... 51

After Break‑In Period.....................................51

End of First Season Checkup....................... 52

Cruising RPM....................................................... 54

Fuel Requirements...............................................54

Fuel Ratings.....................................................54

Using Reformulated (Oxygenated) Gasoline

(USA Only).......................................................54

Gasoline Containing Alcohol........................... 54

Section 5 - Maintenance

Owner/Operator Responsibilities..........................60

Dealer Responsibilities.........................................60

Maintenance.........................................................60

Do‑It‑Yourself Maintenance Suggestions.............61

Inspection.............................................................61

Maintenance Schedule—Inboard Models............ 62

Routine Maintenance.................................... 62

Scheduled Maintenance................................62

Maintenance Log..................................................63

Engine Oil.............................................................64

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

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

Changing Oil and Filter................................. 65

Easy Engine Oil Drain System......................65

Engine Oil Drain Pump..................................66

Changing the Oil Filter.................................. 67

Transmission Fluid............................................... 67

Checking While the Engine is Warm............... 67

Checking While Engine is Cold........................68

Changing......................................................... 68

Engine Coolant.....................................................68

Checking....................................................... 68

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

Engine Oil.............................................................55

Engine Specifications...........................................56

Fluid Specifications.............................................. 57

Engine...........................................................57

Transmission.................................................57

Changing ......................................................70

Battery..................................................................70

Multiple EFI Engine Battery Precautions.......70

Cleaning the Flame Arrestor................................ 71

Positive Crankcase Ventilation Valve (PCV)... 72

Changing.....................................................72

Cleaning The IAC Muffler.....................................72

Water‑Separating Fuel Filter................................ 73

GEN III Models..............................................74

Removal......................................................74

Installation...................................................75

Lubrication............................................................75

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

Transmission Linkage................................... 76

Serpentine Drive Belt........................................... 77

Checking..........................................................77

Replacing Belt and/or Adjusting Tension.........77

Flushing The Power Package.............................. 78

Horizon Models................................................78

The Boat Out of the Water...............................80

The Boat In the Water......................................81

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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.............................88

Air Actuated Single Point Drain System.......88

Three Point Manual Drain System...............89

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

Section 7 - Troubleshooting

Diagnosing EFI Problems......................................98

Diagnosing DTS Problems....................................98

Engine Guardian System.......................................98

Troubleshooting Charts.........................................98

Starter Motor Will Not Crank Engine, or Cranks

Slowly.............................................................98

Engine Will Not Start or Is Hard to Start.........99

Engine Runs Rough, Misses, or Backfires.....99

Boat in the Water.........................................89

Boat out of the Water...................................91

Three‑Point Manual Drain System.................93

Boat in the Water.........................................93

Boat out of the Water...................................94

Battery Storage......................................................95

Power Package Recommissioning........................95

Poor Performance..........................................99

Excessive Engine Temperature.....................99

Insufficient Engine Temperature..................100

Low Engine Oil Pressure..............................100

Battery Will Not Recharge............................100

Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds. 100 Steering Wheel Jerks or Is Difficult to Turn..101

Section 8 - Customer Assistance Information

Owner Service Assistance...................................104

Local Repair Service.......................................104

Service Away From Home..............................104

Stolen Power Package...................................104

Attention Required after Submersion..............104

Replacement Service Parts............................104

Parts and Accessories Inquiries.................105

Resolving a Problem.......................................105

Mercury Marine Service Offices......................105

Ordering Literature..............................................106

United States and Canada..............................106

Outside The United States and Canada.........106

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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

California Emissions Limited Warranty............... 10

What Is Covered .......................................... 10

Duration Of Coverage .................................. 11

How To Obtain Warranty Coverage ............. 12

What Mercury Will Do .................................. 12

What Is Not Covered .................................... 12

Components Of The Emission Control

System ......................................................... 12

Disclaimers And Limitations ......................... 14

California Emission Control Warranty Statement

............................................................................ 14

Your Warranty Rights and Obligations ......... 14

Manufacturer's Warranty Coverage ............. 14

Owner's Warranty Responsibilities .............. 14

Emission Control Information Label.................... 15

Owner Responsibility ................................... 16

Emission Certification Star Label........................ 16

90-899883173 DECEMBER 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

90-899883173 DECEMBER 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 90-899883173 DECEMBER 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.

90-899883173 DECEMBER 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 90-899883173 DECEMBER 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

90-899883173 DECEMBER 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.

California Emissions Limited Warranty

NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

The California Air Resources Board has promulgated air emissions regulations for inboard and sterndrive engines. The regulations apply to all inboard and sterndrive engines that were manufactured for the 2003 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components of the emission control system listed following), and further warrants that the inboard or sterndrive engine was designed, built, and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. For information regarding the limited warranty for the non‑emissions related components of the inboard or sterndrive engine, please see the limited warranty statement for your engine.

What Is Covered

Page 10 90-899883173 DECEMBER 2007

Page 19

NOTE: Your dealer will register your engine for warranty coverage for you. The warranty registration process is not related in any way to the process of obtaining a license, title or registration from state boating authorities. You should ask your dealer to update your warranty registration information to reflect a change of address or a transfer of ownership. (This change may be made at any time.) See the Warranty Registration section of your manual or your dealer for more information.

Mercury Marine warrants the components of the emissions control systems (see the components of the emission control system listed following) of its new, 2003 model year and later California certified inboard and sterndrive engines, registered to a California resident, to be free from defects in material or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved). Damage to other engine components caused by the failure of a warranted part will also be repaired under warranty.

Duration Of Coverage

This limited warranty provides coverage for the components of the emissions control systems. Select emission control parts from model year 2003‑2005 (inboard or sterndrive) engines are warranted for 2 years from either the date the product is first sold, or first put into service, whichever occurs first. Select emission control parts from 2006‑2007 (inboard or sterndrive) engines are warranted for 2 years from either the date the product is first sold, or first put into service, whichever occurs first. Select emission control parts from 2008 (inboard or sterndrive) engines are warranted for 3 years or 480 hours, whichever first occurs, from either the date the product is first sold, or first put into service, whichever occurs first. Select emission control parts from 2009 and later (inboard or sterndrive) engines are warranted for 3 years or 480 hours, whichever first occurs, from either the date the product is first sold, or first put into service, whichever occurs first. Emission related normal maintenance items such as spark plugs and filters, that are on the warranted parts list (see following) are warranted up to their first required replacement interval only. (See Maintenance Schedule). The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent purchaser. (See instructions on transfer of warranty). 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.

Section 1 - Warranty

90-899883173 DECEMBER 2007 Page 11

Page 20

Section 1 - Warranty

How To Obtain Warranty Coverage

The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury 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 Mercury Will Do

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

What Is Not Covered

This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range (see Specifications), operation of the product in a manner inconsistent with the recommended operation procedures, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for use with the product (see Specifications), alteration or removal of parts, or water entering the engine through the fuel intake, air intake or exhaust system. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

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

Non‑warranty maintenance, replacement, or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual. The use of non‑Mercury parts for non‑warranty maintenance or repairs will not be grounds for disallowing other warranty work. The use of add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a non‑exempted add‑on or modified part will not be covered.

Components Of The Emission Control System

1. Fuel Metering System a. Carburetor and internal parts (and/or pressure regulator or fuel injection system) b. Air/fuel ratio feedback and control system

Page 12 90-899883173 DECEMBER 2007

Page 21

Section 1 - Warranty

c. Cold start enrichment system d. Intake valve(s)

2. Air Induction System

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

3. Ignition System

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

4. Lubrication System

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

5. Positive Crankcase Ventilation (PCV) System

a. PCV Valve b. Oil filler cap

6. Exhaust System.

a. Exhaust manifold b. Exhaust elbow c. Intermediate exhaust elbow d. Lower exhaust pipe e. Tailpipe

7. Catalysts or Thermal Reactor System

a. Catalytic converter b. Thermal reactor c. Exhaust manifold d. Exhaust valve(s)

8. Miscellaneous Items Used in Above Systems

a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting

hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensitive valves and switches d. Electronic controls

90-899883173 DECEMBER 2007 Page 13

Page 22

Section 1 - Warranty

Disclaimers And Limitations

If you have any questions regarding your warranty rights and responsibilities, refer to Owner Service Assistance for contact information.

California Emission Control Warranty Statement

Your Warranty Rights and Obligations

The California Air Resources Board is pleased to explain the emission control system warranty on your 2003 model year1. and later inboard or sterndrive engine. In California,

new inboard and sterndrive engines must be designed, built and equipped to meet the State's stringent anti‑smog standards. Mercury Marine must warrant the emission control system on your inboard or sterndrive engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your inboard or sterndrive engine.

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

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

Manufacturer's Warranty Coverage

For 2003‑2008 spark‑ignition inboard and sterndrive marine engines: Select emission control parts from model year

2003‑2008 inboard and sterndrive engines are warranted for 2 years. If any emission‑related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Marine.

Owner's Warranty Responsibilities

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

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

1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

Page 14 90-899883173 DECEMBER 2007

Page 23

You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine

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

dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, refer to Owner Service Assistance for contact information.

Emission Control Information Label

A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, 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.

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.

Section 1 - Warranty

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

90-899883173 DECEMBER 2007 Page 15

"SERIAL#"—Engine Serial Number "FAMILY"—Engine Family

Emission Control Label—Not for Sale in California

Page 24

Section 1 - Warranty

XX 1234 XX

32770

"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.

Emission Certification Star Label

Your boat is labeled on the hull with one of the following star labels. The Symbol for Cleaner Marine Engines Means:

1. Cleaner Air and Water ‑ for a healthier lifestyle and environment.

2. Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil than conventional carbureted two‑stroke engines, saving money and resources.

3. Longer Emission Warranty ‑ Protects consumer for worry free operation.

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

All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards. Engines meeting these standards have 65‑90% lower emissions than One‑Star – Low Emissions engines.

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

a - Recommended location

Page 16 90-899883173 DECEMBER 2007

b - Secondary location

Page 25

One Star - Low emission

Two Stars - Very Low emission

mc79569-1

Section 1 - Warranty

The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

IDA

mc79570-1

Three Stars - Ultra Low emission

mc79571-1

Four Stars - Super Ultra Low emission

mc79572-1

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

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

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

90-899883173 DECEMBER 2007 Page 17

Page 26

Section 1 - Warranty

Notes:

Page 18 90-899883173 DECEMBER 2007

Page 27

Section 2 - Getting to Know Your Power Package

Table of Contents

Section 2 - Getting to Know Your Power Package

Identification........................................................ 20

Engine Serial Number Decal.........................20

Transmissions...............................................20

Velvet Drive Transmissions ................... 20

ZF Marine Transmissions ....................... 21

Walter V-Drive Transmissions ................ 22

Lanyard Stop Switch........................................... 22

Instrumentation................................................... 23

VesselView....................................................23

Digital Gauges...............................................24

Analog Gauges.............................................25

Remote Controls (Non-DTS Models).................. 25

Remote Controls...........................................25

Panel Mount Features ............................ 26

Console Mount Features ........................ 27

Zero Effort Features......................................27

Remote Controls (DTS Models).......................... 28

Remote Controls...........................................28

Panel Mount Features...................................28

Console Mount Features - Single Engine.....29

Slim Binnacle Console Mount Features - Single

Engine...........................................................30

Console Mount Features- Dual Engine.........31

Synchronizing Dual Engines.........................31

Dual Helm Station Transfer...........................32

Synchronizing Dual Helms Prior To Station

Transfer .................................................. 33

Zero Effort Features......................................33

Electrical System Overload Protection............... 33

Audio Warning System....................................... 36

Caution ......................................................... 36

Severe .......................................................... 36

OBDM .......................................................... 37

Testing The Audio Warning System ............. 37

Guardian Strategy............................................... 37

90-899883173 DECEMBER 2007 Page 19

Page 28

Section 2 - Getting to Know Your Power Package

25902

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 top of the engine.

Serial numbers and maintenance color codes decal

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

Transmissions

VELVET DRIVE TRANSMISSIONS

On Velvet Drive In‑Line and V‑Drive Transmissions (71C, 72C, 72C V‑Drive, with or without Walter transmissions) the gear ratio (in forward gear) is marked on transmission identification plate. Transmission output shaft rotation and propeller rotation required (in forward gear) is indicated on a decal on transmission case. Transmission rotation is described when viewed from the rear of transmission.

7424

In‑Line transmission shown (others similarly located)

a - Transmission identification plate b - Gear ratio (in Forward gear)

c - Output flange rotation decal (in

Forward gear)

Page 20 90-899883173 DECEMBER 2007

Page 29

On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate indicates gear ratio, serial number and model.

Velvet Drive 5000A ‑ 8 degree down‑angle transmission shown (5000V ‑ V‑drive similar)

a - Transmission identification plate

ZF MARINE TRANSMISSIONS

On the ZF Marine 8 Degree Down‑Angle and V‑Drive Transmissions, the transmission identification plate indicates gear ratio, serial number, and model.

Section 2 - Getting to Know Your Power Package

7370

7449

Typical ZF Marine down‑angle transmission shown (V‑drive similar)

a - Transmission identification plate

90-899883173 DECEMBER 2007 Page 21

Page 30

Section 2 - Getting to Know Your Power Package

WALTER V-DRIVE TRANSMISSIONS

On the Walter V‑Drive Transmissions, the transmission identification plate indicates gear ratio, serial number, and model.

7452

a - Transmission identification plate

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).

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

Walter RV‑36 V‑drive

RUN

74608

c - Clips to the operator

Page 22 90-899883173 DECEMBER 2007

Page 31

Section 2 - Getting to Know Your Power Package

• 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).

WARNING

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

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

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

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

• Loss of control when docking.

Avoid 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

VesselView

Your power package may come equipped with the following system viewer.

WARNING

90-899883173 DECEMBER 2007 Page 23

Page 32

Section 2 - Getting to Know Your Power Package

24797

26238

Your power package may be connected to a SmartCraft VesselView display. This display provides a single, easy‑to‑use source for real‑time information about a variety of vessel systems. The interactive VesselView display continuously monitors and reports information about speed and performance, trim angle, water temperature and depth, and other operating data. When VesselView detects a problem with any connected system, it displays an alarm message to signal the problem to the boat operator.

Digital Gauges

Typical VesselView application

VesselView may also be connected to other vessel systems, such as GPS, generators, and cabin environmental controls. This comprehensive vessel integration allows the operator to monitor and control a wide range of vessel systems from a single, convenient display.

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

SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between 500 and 1200 RPM.

a - Tachometer b - Speedometer

Page 24 90-899883173 DECEMBER 2007

SmartCraft gauges

c - LCD system view display

Page 33

Analog Gauges

OIL

C H

TEMP

R P M

X 1000

MPH

KPH

100

120

110

10 16

BATT

FUEL

CRUISELOG

0 0 0 0

17352

Section 2 - Getting to Know Your Power Package

The SmartCraft instrument package also aids in Engine Guardian diagnostics. The SmartCraft Instrument package displays critical engine alarm data and potential problems.

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

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.

Reference Gauge Function

a Speedometer Indicates boat speed.

b Tachometer Indicates engine RPM.

c Oil pressure gauge Indicates engine oil pressure.

d Voltmeter Indicates battery voltage.

e Coolant temperature gauge Indicates engine operating temperature.

f Fuel gauge Indicates quantity of fuel in tank.

g Hour meter Records engine operating time.

h Bilge blower switch Operates the bilge blower.

i Ignition switch Allows the operator to start and stop engine.

Remote Controls (Non‑DTS Models)

Remote Controls

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

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Section 2 - Getting to Know Your Power Package

17355

PANEL MOUNT FEATURES

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

d - Control handle tension adjustment

screw

e - Control handle

Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed in to 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.

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Page 35

CONSOLE MOUNT FEATURES

17356

17357

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.

Section 2 - Getting to Know Your Power Package

Zero Effort Features

Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift

a - Shift ever

b - Throttle lever

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

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Section 2 - Getting to Know Your Power Package

17358

Throttle Lever - Throttle functions are controlled by the movement of the throttle lever.

Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.

Remote Controls (DTS Models)

Remote Controls

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

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

Panel Mount Features

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

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

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

Page 28 90-899883173 DECEMBER 2007

Page 37

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

17359

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

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

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

Console Mount Features ‑ Single Engine

Section 2 - Getting to Know Your Power Package

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

Control Handle -

Operation of the shift and throttle are controlled by the movement of the 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.

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

Neutral Light - The neutral light is illuminated when the engine is in neutral gear position. Select Key - Selects System View on‑screen options and confirms data entries. Arrow Trackpad - Navigates through System View on‑screen function messages. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting

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

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Section 2 - Getting to Know Your Power Package

START

STOP

17360

Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease

the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension.

Slim Binnacle Console Mount Features ‑ Single Engine

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

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

Neutral Light - The neutral light is illuminated when the engine is in neutral gear position. Start/Stop Button - Allows the boat operator to start or stop the engine without using the

ignition key. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting

Page 30 90-899883173 DECEMBER 2007

Page 39

Console Mount Features‑ Dual Engine

ACTIVE

SYNC

THROTTLE

ONLY

STATION SELECT

17365

Section 2 - Getting to Know Your Power Package

a - Control handles b - Active light c - Neutral light d - Select key e - Arrow trackpad

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

screw

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

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

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

90-899883173 DECEMBER 2007 Page 31

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

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

Synchronizing Dual Engines

Page 40

Section 2 - Getting to Know Your Power Package

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

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

Dual Helm Station Transfer

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

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

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

NOTE: the remote control to be placed at idle position, a station transfer can be done while in gear.

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

1. Place active remote control lever to idle position.

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

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

Idle position is preferred when doing a station transfer. If conditions do not allow

position.

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

ACTIVE

SYNC

THROTTLE

ONLY

STAT ION SELECT

WARNING

3434

a - Active light

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

Page 32 90-899883173 DECEMBER 2007

ACTIVE

STATION SELECT

THROTTLE

ONLY

ACTIVE

THROTTLE

ONLY

STAT ION SELECT

SYNC

3433

b - Throttle only/station select button

Page 41

Section 2 - Getting to Know Your Power Package

17357

SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER

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

Zero Effort Features

a - Shift ever b - Throttle lever

Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position.

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

Electrical System Overload Protection

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

IMPORTANT: Always store spare fuses in the boat for replacement.

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.

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Section 2 - Getting to Know Your Power Package

33214

A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. Test the circuit breaker by pushing the red button. If the circuit breaker is functioning properly, the yellow lever appears. Push the yellow lever into the housing to reset the circuit breaker.

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

22529

A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs.

mc74907-1

Four fuses are located on the port side of the engine. These fuses protect the main power, fuel pump, ignition, and accessory circuits.

Page 34 90-899883173 DECEMBER 2007

Engine fuses

Page 43

Section 2 - Getting to Know Your Power Package

33177

32206

33179

Two 10 amp fuses protect the O2 (oxygen) sensors. These are located at the rear of the engine, near the 14‑pin connector.

Oxygen sensor fuses

A 15 amp accessory fuse protects the accessory circuits.

a - Fuse cover b - 15 amp fuse c - Power harness

A power harness, connected to the engine starting battery, minimizes voltage drop to the electrical system. This harness is protected by a 5 amp fuse. This connection is located at the rear of the engine, near the 14‑pin connector.

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Section 2 - Getting to Know Your Power Package

ON ON

OFF

33402

A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for a failed fuse if the ignition key is turned to the "START" position and nothing happens, and the circuit breaker is not tripped.

Audio Warning System

IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage.

Your Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.

There are three warning horn states:

• Caution

• Severe

• Onboard Diagnostic Marine (OBDM) fault

mc70525-1

Caution

Severe

If a caution is detected, the audio warning system will sound for six one‑second intervals.

a - Horn (on or off) b - Time (in seconds)

Below are some examples of a caution fault:

• Transmission fluid temperature is too hot

• Drive oil is low

• Sensor failure

IMPORTANT: If you experience a severe fault, contact your authorized Mercury MerCruiser dealer.

Page 36 90-899883173 DECEMBER 2007

Page 45

33403

ONON

6 6 6

OFF

OBDM

33404

OFF

5 60 60 60

½ ½ ½

ON ON ON

OFF OFF

Section 2 - Getting to Know Your Power Package

If a severe fault is detected, the audio warning system will sound for six seconds, turn off for six seconds, then sound for six more seconds.

a - Horn (on or off) b - Time (in seconds)

Below are some examples of a severe fault:

• Engine oil pressure is too low

• Engine temperature is too hot

• Seawater pressure is too low

• Transmission pressure is low (select models)

If an OBDM fault is detected, the audio warning system sound with one five‑second horn, then one short, 1/2‑second horn every 60 seconds for certain faults related to the emissions or fuel system. See your authorized Mercury MerCruiser dealer for assistance.

a - Horn (on or off) b - Time (in seconds)

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.

Guardian Strategy

Engine Guardian reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem. Below are some examples of what Engine Guardian monitors:

• Oil pressure

• Engine overspeed

• Exhaust manifold temperature IMPORTANT: Guardian can reduce power anywhere from 100% to idle, depending on the

severity of the problem. If forced to idle, boat speed might not respond to throttle operation. The PCM stores the fault for diagnostics. For example, if the water inlet becomes partially

blocked, Guardian reduces the available power level of the engine to help prevent damage from decreased water flow to the engine. If the debris passes through, and full water flow is restored, Guardian restores engine power to normal. To avoid recurrence of the problem,

90-899883173 DECEMBER 2007 Page 37

contact an authorized Mercury MerCruiser dealer.

Page 46

Section 2 - Getting to Know Your Power Package

As another example, Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage. To avoid possible recurrence of the problem, you should contact an authorized dealer. The ECM stores the fault and with this information the technician will be able to more rapidly diagnose problems.

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Page 47

Table of Contents

Section 3 - On the Water

Safe Boating Suggestions.................................. 40

Be Alert to Carbon Monoxide Poisoning............. 41

Good Ventilation ........................................... 41

Poor Ventilation ........................................... 42

Basic Boat Operation (Non-DTS Models)........... 42

Launching and Boat Operation.....................42

Operation Chart ...................................... 42

Starting and Stopping the Engine.................43

Starting the Engine ................................. 43

Stopping the Engine ............................... 44

Throttle-Only Operation.................................44

Freezing Temperature Operation..................44

Drain Plug and Bilge Pump...........................44

Basic Boat Operation (DTS Models)................... 44

Launching and Boat Operation.....................44

Operation Chart ...................................... 44

Starting and Stopping the Engine.................45

Starting the Engine ................................. 45

Stopping the Engine ............................... 46

Throttle-Only Operation.................................46

Freezing Temperature Operation..................47

Drain Plug and Bilge Pump...........................47

Protecting People in the Water........................... 47

While You Are Cruising ................................ 47

While Boat Is Stationary ............................... 47

High-Speed and High-Performance Operation

............................................................................ 48

Passenger Safety in Pontoon Boats and Deck Boats

............................................................................ 48

Boats Having An Open Front Deck .............. 48

Boats With Front-Mounted, Raised Pedestal

Fishing Seats ............................................... 48

Wave and Wake Jumping................................... 49

Impact with Underwater Hazards........................ 49

Conditions Affecting Operation........................... 50

Weight Distribution (Passengers and Gear)

Inside the Boat..............................................50

The Bottom of the Boat.................................50

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

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

Elevation and Climate...................................51

Getting Started.................................................... 51

20-Hour Break-In Period...............................51

After Break-In Period.....................................51

End of First Season Checkup.......................52

90-899883173 DECEMBER 2007 Page 39

Page 48

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.

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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.

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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 (Non‑DTS Models)

Launching and Boat Operation

IMPORTANT: Install bilge drain plug prior to launching boat.

OPERATION CHART

Operation Chart

BEFORE STARTING AFTER STARTING

Observe all gauges to

Install bilge drain plug.

Open engine hatch.

Turn battery switch on.

Operate bilge blowers.

check condition of engine. If not normal, stop engine.

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

Check shift and throttle control operation.

Check steering operation.

mc79554-1

b - Mooring close to another boat with

its engine operating

mc79556-1

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.

Close fuel shut off valve.

Close seacock, if equipped.

Page 42 90-899883173 DECEMBER 2007

Page 51

BEFORE STARTING AFTER STARTING

Open fuel shut off valve.

Open seacock, if equipped. Drain bilge.

Close the drain system.

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.

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.

Operation Chart

WHILE

UNDERWAY

Section 3 - On the Water

AFTER STOPPING

Flush cooling system if in saltwater.

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.

WARNING

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

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

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

4. If engine does not start after 3 attempts:

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

to the 1/4 throttle position.

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.

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.

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Section 3 - On the Water

Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is operating at idle.

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.

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.

NOTICE

Freezing Temperature Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty.

Drain Plug and Bilge Pump

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

Basic Boat Operation (DTS Models)

Launching and Boat Operation

IMPORTANT: Install bilge drain plug prior to launching boat.

OPERATION CHART

BEFORE STARTING AFTER STARTING

Observe all gauges to

Install bilge drain plug.

Open engine hatch.

check condition of engine. If not normal, stop engine.

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

Operation Chart

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

Listen for the audio alarm.

WHILE

UNDERWAY

AFTER STOPPING

Turn ignition key to the "OFF" position.

Turn battery switch to the "OFF" position.

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BEFORE STARTING AFTER STARTING

Turn battery switch on.

Operate bilge blowers.

Open fuel shut off valve.

Open seacock, if equipped. Drain bilge.

Close the drain system.

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.

Starting and Stopping the Engine

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

STARTING THE ENGINE

1. Check all items listed in the Operation Chart.

2. Place the remote control handle in neutral.

Operation Chart

Check shift and throttle control operation.

Check steering operation.

WHILE

UNDERWAY

Section 3 - On the Water

AFTER STOPPING

Close fuel shut off valve.

Close seacock, if equipped.

Flush cooling system if in saltwater.

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.

WARNING

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

3. Turn ignition key to "RUN" position.

4. Turn the ignition key switch to the "START" position then release, or depress the start/

stop button and release. If the engine is cold, allow the engine to operate at idle for 6– 10 minutes or until the engine temperature reaches 60° C (140° F).

5. If the engine does not start after three attempts:

a. Push the throttle‑only button and position the remote control handle or throttle

lever to the 1/4 throttle position.

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Section 3 - On the Water

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

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

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

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

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

Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is operating at idle.

STOPPING THE ENGINE

2. The engine can be stopped by any one of the following 4 methods: a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine

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

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

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

switch to return to the "on" position.

to 1/4 throttle.

the switch to return to the "on" position.

NOTICE

will stop and the control system will be deactivated.

system will remain active.

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

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

Throttle‑Only Operation

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

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

The Digital Throttle and Shift (DTS) Zero Effort control can shift the engine or transmission at speeds greater than idle, causing unexpected boat movement, which may result in injury, death, or property damage due to loss of boat control. Always place the throttle control lever in the idle position before moving the shift control lever into forward or reverse gear position.

Panel Mount and Console Mount Remote Controls:

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

Page 46 90-899883173 DECEMBER 2007

WARNING

Panel mount and console mount

Page 55

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

21604

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

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

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

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

engine speed to increase.

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

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.

Freezing Temperature Operation

Drain Plug and Bilge Pump

Section 3 - On the Water

Protecting People in the Water

While You Are Cruising

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

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

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

While Boat Is Stationary

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.

WARNING

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Section 3 - On the Water

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.

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

mc79557-1

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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.

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

WARNING

mc79680-1

Section 3 - On the Water

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.

7576

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Section 3 - On the Water

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.

WARNING

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

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:

• 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

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

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Page 59

Ventilation

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.

Section 3 - On the Water

Getting Started

20‑Hour Break‑In Period

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

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

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

• 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, follow these recommendations:

• Ensure that propeller allows the engine to operate at or near the top of the specified

WOT RPM range. Refer to Specifications and Maintenance.

• Operate the engine at 3/4 throttle or lower. Refrain from prolonged operation at

wide‑open‑throttle RPM.

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Section 3 - On the Water

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

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

End of First Season Checkup

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

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

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Table of Contents

Section 4 - Specifications

Cruising RPM...................................................... 54

Fuel Requirements............................................. 54

Fuel Ratings ................................................. 54

Using Reformulated (Oxygenated) Gasoline

(USA Only) ................................................... 54

Gasoline Containing Alcohol ........................ 54

Engine Oil........................................................... 55

Engine Specifications......................................... 56

Fluid Specifications............................................. 57

Engine...........................................................57

Transmission.................................................57

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Section 4 - Specifications

Cruising RPM

Material and design advancements allow modern inboard engines operate at higher engine speeds than their predecessors. Increased RPM significantly increases the horsepower of these new engines and is a critical part performance and efficiency. The materials and design of the new engines allow these higher speeds without durability penalty. Over‑propping the boat to reduce its cruising RPM to previous levels increases the engine's susceptibility to engine damage from detonation and pre‑ignition. The recommended cruising RPM ranges are:

Model RPM range

5.7 MPI and Horizon 5.7 3400–3800

Fuel Requirements

Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.

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 will not be covered under the limited warranty.

Cruising RPM for peak efficiency

NOTICE

Fuel Ratings

Mercury MerCruiser engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following specifications:

USA and Canada ‑ 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 ‑ 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) Gasoline (USA Only)

Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.

Gasoline Containing Alcohol

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), be aware of possible adverse effects. These adverse effects are more severe with methanol and worsen according to the percentage of alcohol in the fuel.

Alcohol in gasoline can absorb moisture from the air, causing the water and the alcohol to separate from the gasoline in the fuel tank.

IMPORTANT: 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 your boat's fuel system components (fuel tanks, fuel lines, and fittings).

Be aware that gasoline containing alcohol may cause increased:

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Section 4 - Specifications

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

WARNING

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

IMPORTANT: If you use gasoline that contains or might contain alcohol, you must increase the frequency of inspection for leaks and abnormalities.

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

Engine Oil

To maintain optimum engine performance and to provide maximum protection, we recommend the following oil:

Application Recommended Oil

All MerCruiser engines with Emissions Control

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

IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for non‑catalyzed engines. Some marine‑grade lubricants contain high levels of phosphorus, which can damage the catalyst system on MerCruiser engines. Although these high‑phosphorus lubricants may allow for acceptable engine performance, exposure over time will damage the catalyst. Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty.

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

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

2. Other recognized brands of NMMA FC‑W–rated oils

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Section 4 - Specifications

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

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

31655

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.

Engine Specifications

NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. All measurements are taken with the engine at normal operating temperature. RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures. Oil pressure must be checked with the engine at normal operating temperature.

Model 5.7 MPI and Horizon 5.7

Power 224 kW (300 hp)

Displacement 5.7 L (350 cid)

Specified WOT RPM range 4600–5000

Idle RPM in neutral 600

Minimum oil pressure at idle 41 kPa (6 psi)

Thermostat (seawater cooled models) 71° C (160° F)

Thermostat (closed cooled models) 77° C (170° F)

Timing at idle Not Adjustable

Firing order 1‑8‑4‑3‑6‑5‑7‑2

Electrical system 12 V negative (–) ground

Alternator rating 65 A

Minimum battery rating (non‑DTS models) 750 CCA, 950 MCA, or 180 Ah

Minimum battery rating (DTS models) 800 CCA, 1000 MCA, or 190 Ah

Spark plug type AC Platinum (AC 41‑993)

Spark plug gap 1.5 mm (0.060 in.)

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Fluid Specifications

Engine

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

All Models Capacity Fluid Type

Engine oil (with filter) 4.25 L (4.50 US qt)

Seawater cooling system (winterization use only)

Closed cooling system 18 L (19 US qt)

Transmission

Model Capaci Fluid Type

5000A 2.84 L (3.00 US qt)

5000V 3.30 L (3.50 US qt)

71C In‑Line 1.66 L (1.75 US qt)

71C Remote V‑Drive 1.66 L (1.75 US qt)

72C In‑Line 1.66 L (1.75 US qt)

72C Gear Reduction 1.66 L (1.75 US qt)

72C Remote V‑Drive 1.66 L (1.75 US qt)

72C V‑Drive 3.79 L (4.00 US qt)

63A 4.00 L (4.5 US qt)

63V 4.00 L (4.5 US qt)

Section 4 - Specifications

Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40

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

Mercury Extended Life Coolant Antifreeze or extended life ethylene glycol 5/100 antifreeze mixed 50/50 with purified water

Dexron III Automatic Transmission Fluid

Dexron III Automatic Transmission Fluid71C Gear Reduction 2.84 L (3.00 US qt)

Dexron III Automatic Transmission Fluid

NOTE: Walters V‑Drive applications have two fluid service points: the transmission and the v‑drive gear box. Refer to the Walters owner's manual for capacity and intervals.

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Section 4 - Specifications

Notes:

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Table of Contents

Section 5 - Maintenance

Owner/Operator Responsibilities........................ 60

Dealer Responsibilities....................................... 60

Maintenance....................................................... 60

Do-It-Yourself Maintenance Suggestions........... 61

Inspection........................................................... 61

Maintenance Schedule—Inboard Models........... 62

Routine Maintenance....................................62

Scheduled Maintenance................................62

Maintenance Log................................................ 63

Engine Oil........................................................... 64

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

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

Changing Oil and Filter.................................65

Easy Engine Oil Drain System......................65

Engine Oil Drain Pump..................................66

Changing the Oil Filter..................................67

Transmission Fluid.............................................. 67

Checking While the Engine is Warm ............ 67

Checking While Engine is Cold .................... 68

Changing ...................................................... 68

Engine Coolant................................................... 68

Checking.......................................................68

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

Changing ......................................................70

Battery................................................................ 70

Multiple EFI Engine Battery Precautions.......70

Cleaning the Flame Arrestor............................... 71

Positive Crankcase Ventilation Valve

(PCV) ........................................................... 72

Changing ................................................ 72

Cleaning The IAC Muffler................................... 72

Water-Separating Fuel Filter............................... 73

GEN III Models..............................................74

Removal ................................................. 74

Installation .............................................. 75

Lubrication.......................................................... 75

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

Transmission Linkage...................................76

Serpentine Drive Belt.......................................... 77

Checking ...................................................... 77

Replacing Belt and/or Adjusting Tension ..... 77

Flushing The Power Package............................. 78

Horizon Models ............................................ 78

The Boat Out of the Water ........................... 80

The Boat In the Water .................................. 81

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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.

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Maintenance Point Color Codes

Blue Coolant

Yellow Engine oil

Orange Fuel

Brown Transmission

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.

90-899883173 DECEMBER 2007 Page 61

Page 70

Section 5 - Maintenance

Maintenance Schedule—Inboard 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

Each day start

Each day end

Weekly

Every two months or 50

hours

with the product.

• Check the transmission fluid level.

• 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.

• Check the transmission fluid.

• 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.

• Change the engine oil and filter.

• Change the transmission fluid and filter. ZF Marine requires changing the transmission fluid and filter maintain warranty.

• Touch up the paint on the power package.

• Change the engine oil and filter.

• Change the transmission fluid (ZF Transmission Models).

• If the condition of the spark plugs, spark plug wires, and the distributor cap and rotor was satisfactory at the initial inspection (as listed in Every 300 hours or 3 years), inspect the condition of these components. Replace as necessary.

• Replace the water‑separating fuel filter element.

• 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.

Page 62 90-899883173 DECEMBER 2007

Page 71

Task Interval Maintenance to Be Performed

Every 300 hours or 3

(whichever occurs first)

Every 5 years

Maintenance Log

Record all maintenance performed on your power package here. Be sure to save all work orders and receipts.

years

Section 5 - Maintenance

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

necessary.

• Inspect the condition of the spark plugs, spark plug wires, and the distributor

cap and rotor, if equipped. Replace as necessary. If the condition of these components is satisfactory at inspection, repeat inspection every 100 hours or once a year, whichever occurs first.

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

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

Inspect both systems for damage or leaks.

• Disassemble and inspect the seawater pump and replace worn components.

• Clean the seawater section of the closed‑cooling system. Clean, inspect,

and test the pressure cap.

• Inspect the exhaust system components. 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.

Date Maintenance Performed Engine Hours

90-899883173 DECEMBER 2007 Page 63

Page 72

Section 5 - Maintenance

33139

Engine Oil

Checking

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.

1. Stop the engine. Allow the oil to drain into the oil pan for approximately five minutes

2. Remove the dipstick, wipe clean, and reinstall fully into the dipstick tube. Wait 60

NOTE: Install the dipstick with oil level indication marks facing the rear of the engine (flywheel end).

NOTICE

with the boat at rest in the water.

seconds to allow trapped air to vent.

Filling

Possible dipstick locations

3. Inspect the dipstick reading, which should indicate a level between the full or "OK" mark and the "ADD" mark. Reinstall the dipstick into the dipstick tube. If the oil level is low, refer to Filling.

IMPORTANT: Do not overfill the engine with oil. Always use the dipstick to determine the exact quantity of oil or fluid required.

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Section 5 - Maintenance

33140

1. Remove oil fill cap.

Oil fill cap

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

2. Add the specified engine oil to bring the level up to, but not over, the full or OK range

mark on the dipstick. Recheck oil level.

3. Replace the fill cap.

All Models Capacity Fluid Type

Engine oil (with filter)

Changing Oil and Filter

See 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 the Specifications section).

Easy Engine Oil Drain System

NOTE: The boat must be out of water to perform this procedure.

1. Loosen the oil filter to vent the system.

2. Allow sufficient time for the oil to drain from the filter down into the engine block.

3. Remove the bilge drain plug.

4.25 L

(4.5 US qt)

Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40

90-899883173 DECEMBER 2007 Page 65

Page 74

Section 5 - Maintenance

7284

4. Pull tether through the bilge drain.

5. Place the oil drain hose in a suitable container.

6. Remove the drain plug from the oil drain hose.

7. After oil has drained completely, install the drain plug in the oil drain hose.

8. Push the hose through bilge drain and install the plug.

9. Replace the engine oil filter. See Changing the Oil Filter.

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.

a - Bilge drain plug b - Tether c - Clip

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

a - Oil pump b - Dipstick tube c - Oil drain hose

4. Insert the hose end of the crankcase oil pump onto an appropriate container and usie the handle to pump until the crankcase is empty.

5. Remove the pump.

6. Install the dipstick.

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mc70571-1

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Changing the Oil Filter

33141

1. Remove and discard oil filter.

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

3. Install and tighten the oil filter securely following the filter manufacturer's instructions.

Do not overtighten.

4. Remove oil fill cap.

5. Use the dipstick to determine the amount of engine oil required. Replace the dipstick.

6. Add the required amount of the recommended oil to bring the level up to the bottom of

the OK range on the dipstick.

7. With the boat at rest in the water, repeat steps 5 and 6 if necessary.

NOTE: Adding 0.95 L (1 US qt) of engine oil raises the level from the add mark to the top of the OK range.

Section 5 - Maintenance

a - Oil filter (in‑line exhaust) b - Oil filter (V‑drive exhaust)

All Models Capacity Fluid Type

Engine oil (with filter)

8. Start the engine and operate for three minutes, checking for leaks.

9. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes

with the boat at rest in the water.

Transmission Fluid

Checking While the Engine is Warm

1. Velvet Drive Transmissions ‑ Stop the engine and immediately check fluid level by

turning T‑handle counterclockwise, to remove dipstick. Fluid level should be up to full mark. If low, add specified fluid through dipstick tube on transmissions.

2. ZF Marine Transmissions ‑ Stop the engine and remove the dipstick to check level. If

fluid is below top (full) line, add specified fluid through dipstick hole. Do not overfill. Reinstall dipstick with cap fully seated.

3. Walter V‑Drive Transmissions ‑ Stop the engine and remove the dipstick to check the

level. If the fluid is below the top (full) line, add the specified fluid through the breather elbow. Do not overfill. Reinstall the dipstick with the cap fully seated.

4.25 L

(4.50 US qt)

Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40

90-899883173 DECEMBER 2007 Page 67

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Section 5 - Maintenance

33172

Checking While Engine is Cold

NOTE: Cold fluid level check: To ease checking the fluid level, the dipstick can be marked or scribed with a cold level mark.

1. Follow the procedure for the warm fluid level check, then allow the boat to sit overnight.

IMPORTANT: Be sure to push the dipstick all the way down into the dipstick tube when checking the fluid level.

2. Remove the dipstick, wipe clean and reinsert.

3. Remove the dipstick, observe the fluid level and mark the cold fluid level.

4. Reinstall the dipstick, tighten the T‑handle securely. Do not overtighten.

Changing

Contact your authorized Mercury MerCruiser dealer.

Engine Coolant

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.

CAUTION

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

Heat exchanger cap

2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer.

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 recovery bottle.

Page 68 90-899883173 DECEMBER 2007

Page 77

Filling

Section 5 - Maintenance

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

6102

6. Add the specified fluid as necessary.

Tube Ref No. Description Where Used Part No.

122

Extended Life Antifreeze/ Coolant

Closed Cooling System 92-877770K1

NOTICE

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.

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:

1. Remove the fill cap from the coolant recovery bottle. Inspect the gasket and replace if

IMPORTANT: Coolant flows at a high rate of speed in this closed cooling system. Higher idle speeds can trap air in the system and make purge procedures more difficult. Operate at idle when filling the system or purging air.

2. Fill to the full mark with the specified coolant.

Add coolant only when the engine is at normal operating temperature.

necessary.

Tube Ref No.

122

3. Check the antifreeze concentration for adequate freeze protection and correct if

necessary. Refer to the Specifications section.

4. Install the fill cap to the coolant recovery bottle.

90-899883173 DECEMBER 2007 Page 69

Description Where Used Part No.

Extended Life Antifreeze/ Coolant

Closed cooling system 92-877770K1

Page 78

Section 5 - Maintenance

Changing

Contact your authorized Mercury MerCruiser dealer.

Battery

Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

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.

Multiple EFI Engine Battery Precautions

Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for 2 different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine's alternator will not be required to supply any charging current.

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

In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself, and the engine will operate normally. The ECM shuts off and resets itself so quickly that the engine may only seem to have an ignition miss.

Batteries: Boats with multi‑engine EFI power packages require each engine be connected to its own battery. This ensures that the engine's ECM has a stable voltage source.

Battery Switches: Battery switches should always be positioned so each engine is operating off of its own battery. Do not operate engines with switches in both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.

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

Generators: The generators battery should be considered another engine's battery.

WARNING

Page 70 90-899883173 DECEMBER 2007

Page 79

Cleaning the Flame Arrestor

33180

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. Remove the engine cover.

2. Disconnect and remove the crankcase ventilation hose from the fitting on the flame

arrestor and valve cover.

3. Remove the flame arrestor.

WARNING

Section 5 - Maintenance

a - Engine cover knob b - Engine cover c - Nuts, flame arrestor

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

90-899883173 DECEMBER 2007 Page 71

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

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

7. Clean the crankcase ventilation hose with warm water and a mild detergent. Dry with

compressed air or allow to air dry completely.

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

9. Install the flame arrestor and flame arrestor bracket. Torque the flame arrestor bracket

nuts.

Description

Flame arrestor bracket nut 12 106 –

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

cover.

d - Cover mount bracket e - Flame arrestor f - Crankcase ventilation hose

Nm lb‑in. lb‑ft

Page 80

Section 5 - Maintenance

33143

11. Install the engine cover.

Positive Crankcase Ventilation Valve (PCV)

CHANGING

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

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

a - PCV valve (hose not shown)

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 that the PCV valve is tightly seated in the valve cover.

Cleaning The IAC Muffler

NOTE: The IAC muffler may be installed in the throttle body or in the IAC adapter. Locate your IAC muffler by removing the engine cover.

1. Remove the engine cover.

WARNING

Page 72 90-899883173 DECEMBER 2007

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Section 5 - Maintenance

33269

2. Remove the IAC muffler.

IAC muffler installed in the IAC adapter

3. Inspect the IAC muffler for holes, cracks, or deterioration. Replace the IAC muffler if

damaged.

IMPORTANT: Do not get cleaner on electrical connections and do not use cleaner containing methyl ethyl ketone.

4. Clean the IAC muffler with warm water and a mild detergent. Replace if necessary.

5. Allow the IAC muffler to completely, then install.

Water‑Separating Fuel Filter

Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and skin from pressurized fuel and vapors.

WARNING

CAUTION

90-899883173 DECEMBER 2007 Page 73

Page 82

Section 5 - Maintenance

GEN III Models

REMOVAL

8837

a - Cool Fuel Module b - Cool Fuel Module harness c - Filter cap d - Filter assembly retaining screw

1. Allow the engine to cool down.

e - Fuel filter element f - Filter cup g - Cool Fuel Module filter reservoir h - O‑ring

NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal.

2. Close fuel supply valve, if equipped.

3. Disconnect the Cool Fuel Module harness from the engine wiring harness.

4. Turn the key switch to the start position and allow the starter to operate for 5 seconds.

5. Turn key switch to off position.

6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap.

7. Unseat the filter assembly by grasping the filter assembly handle and pulling upward. Do not remove the filter assembly from the Cool Fuel Module at this time.

8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool Fuel Module filter reservoir.

9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a clockwise direction while holding the filter cup stationary.

10. Remove the used water‑separating fuel filter element from the filter cup, place it in a clean, approved container.

11. Dispose of any water or debris that may be in the filter cup.

Page 74 90-899883173 DECEMBER 2007

Page 83

INSTALLATION

Section 5 - Maintenance

1. Install a new water‑separating fuel filter element into the filter cup. Push the element

into the cup until completely seated.

2. Install new O‑ring on the filter cup.

3. Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter

clockwise direction while holding the filter cup stationary, until the filter cap locks securely into place.

4. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel,

and align the screws retained in the filter cap with the screw holes in the Cool Fuel Module. Tighten the filter assembly retaining screws until hand tight.

5. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each

filter assembly retaining screw.

Description Nm lb. in. lb. ft.

Filter assembly retaining screw 6 53

6. Open fuel supply valve, if equipped.

7. Reconnect the Cool Fuel Module harness to the engine wiring harness.

8. Properly ventilate the engine compartment.

Lubrication

Throttle Cable

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.

9. Supply cooling water to the engine.

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

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

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

a - Pivot points

90-899883173 DECEMBER 2007 Page 75

5577

b - Guide contact surfaces

Page 84

Section 5 - Maintenance

Tube Ref. No. Description Where Used Part No.

Transmission Linkage

IMPORTANT: The poppet ball must be centered in the detent hole for each F‑N‑R position.

1. Lubricate the detent ball and the holes in the shift lever.

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Throttle cable pivot points &

guide contact surfaces

92‑883725K01

5934

In‑Line Transmission

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Detent ball and shift lever

holes

92‑883725K01

2. Lubricate the shift cable pivot points.

5935

a - Pivot points

Tube Ref. No. Description Where Used Part No.

Page 76 90-899883173 DECEMBER 2007

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

Shift cable pivot points 92‑883725K01

Page 85

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

Section 5 - Maintenance

Checking

a - Idler pulley b - Circulating pump pulley c - Crankshaft pulley

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

• Excessive wear

• Cracks

6089

d - Alternator pulley e - Seawater 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.

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.

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.

90-899883173 DECEMBER 2007 Page 77

mc75130-1

Page 86

Section 5 - Maintenance

COLOR GUIDE

for

PATENT

2.83918

NEWTONE

14980

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.

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

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

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

ranges for new and used belts.

(5/8 in.) locking nut.

a - 8 mm (1/16 in.) adjusting stud

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

Flushing The Power Package

Horizon Models

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

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

2. Attach the quick connect fitting to a water hose.

3. Remove the blue cap from the flush socket on the engine

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.

6119

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

NOTICE

Page 78 90-899883173 DECEMBER 2007

Page 87

Section 5 - Maintenance

33389

NOTICE

Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating.

4. Snap the quick connect fitting and the water hose into the flush socket on the engine.

V‑drive shown (inline similar)

5. Open the water source completely.

6. Start the engine within 15 seconds.

7. Operate the engine at 1300 RPM, +/‑ 100 RPM.

8. Allow engine to reach normal operating temperature. Watch the temperature gauge on the dash to ensure that the engine does not overheat.

9. Flush the engine for a minimum of 10 minutes or until the discharge water is clear.

10. Shut off the engine.

NOTICE

11. Turn off water source within 15 seconds of shutting off engine.

12. Disconnect the quick connect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket

13. Attach to the next engine, if equipped, and repeat procedure.

14. Turn off the water source.

15. Remove the quick connect fitting from the water hose.

16. Replace the blue cap into the flush socket on the engine.

17. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.

NOTE: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock.

90-899883173 DECEMBER 2007 Page 79

Page 88

Section 5 - Maintenance

The Boat Out of the Water

IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water.

IMPORTANT: Flushing is needed If the engine package has been operated in salty, brackish, mineral‑laden or polluted water. For best results flushing is recommended after each outing and before cold weather and extended storage.

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.

Models with Walter V-Drive Transmissions:

1. a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from

the transmission seawater inlet fitting.

b. If not equipped with a seacock, disconnect the seawater inlet hose from the

transmission seawater inlet fitting and plug the seawater inlet hose.

WARNING

6091

c. Using appropriate connector, connect the flushing water hose to the transmission

seawater inlet fitting.

d. Proceed to step 3

All other models:

2. a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from

the seawater pump inlet fitting..

b. If not equipped with a seacock, disconnect the seawater inlet hose from the

seawater pump and plug the hose.

10839

Page 80 90-899883173 DECEMBER 2007

Page 89

Section 5 - Maintenance

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

water inlet of the seawater pump.

d. Proceed to step 3.

NOTICE

3. Completely open the water source to provide maximum water supply.

4. Place the remote control in the neutral idle speed position.

5. Immediately start the 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.

6. Depress the throttle only button and slowly advance the throttle until the engine reaches

1300 RPM (± 100 RPM).

7. Observe the water temperature gauge to ensure that the engine is operating in the

normal range.

8. Operate the engine with the transmission in neutral for a minimum of 10 minutes.

For power packages operated in salty, brackish, mineral‑laden or polluted water:

Continue to operate the engine until the discharge water is clear.

10. Slowly return the throttle to idle speed position.

11. Stop the engine.

12. Immediately shut off the supply water and remove the flushing attachment.

13. Install the water inlet hose to the seawater inlet of the seawater pump or V‑Drive water

inlet.

14. Tighten hose clamp securely.

15. Attach to the next engine, if equipped, and repeat procedure.

The Boat In the Water

IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water.

NOTICE

90-899883173 DECEMBER 2007 Page 81

Page 90

Section 5 - Maintenance

Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug the seawater inlet hose immediately after disconnecting it.

NOTICE

Models with Walter V-Drive Transmissions:

a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from

the transmission seawater inlet fitting.

NOTICE

b. If not equipped with a seacock, disconnect the seawater inlet hose from the

transmission seawater inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat.

6091

c. Using suitable adapter, connect the flushing water hose to the transmission

seawater inlet fitting.

d. Proceed to step 3

All other models:

2. a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from

the seawater pump inlet fitting.

NOTICE

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Section 5 - Maintenance

b. If not equipped with a seacock, disconnect the seawater inlet hose from the

seawater pump inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat.

10839

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

water inlet of the seawater pump.

d. Proceed to step 3.

NOTICE

3. Completely open the water source to provide maximum water supply.

4. Place the remote control in the neutral idle speed position.

5. Immediately start the engine.

NOTICE

6. Depress the throttle only button and slowly advance the throttle until the engine reaches

1300 RPM (± 100 RPM).

7. Observe the water temperature gauge to ensure that the engine is operating in the

normal range.

8. Operate the engine with the transmission in neutral for a minimum of 10 minutes.

For power packages operated in salty, brackish, mineral‑laden or polluted water:

Continue to operate the engine until the discharge water is clear.

10. Slowly return the throttle to idle speed position.

11. Stop the engine.

12. Immediately shut off the water supply and remove the flushing attachment.

13. Remove the flushing connector from the water inlet.

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NOTICE

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Section 5 - Maintenance

14. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or

15. Repeat the flushing procedure on the next engine, if equipped.

the seawater inlet hose to be reconnected prior to operating the engine.

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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...........................88

Air Actuated Single Point Drain System

............................................................... 88

Three Point Manual Drain System ......... 89

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

Boat in the Water ................................... 89

Boat out of the Water ............................. 91

Three-Point Manual Drain System................93

Boat in the Water ................................... 93

Boat out of the Water ............................. 94

Battery Storage................................................... 95

Power Package Recommissioning..................... 95

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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. Check the antifreeze concentration. Refer to the Specifications section.

3. 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.

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

5. Supply cooling water to engine. Refer to the Maintenance section

6. 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.

7. Change the oil and oil filter.

8. Prepare the engine and fuel system for storage. See Engine and Fuel System Preparation.

9. Drain the engine seawater cooling system. See Draining the Seawater System.

NOTICE

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

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.

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

ENGINE AND FUEL SYSTEM PREPARATION

WARNING

Section 6 - Storage

NOTICE

Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.

1. In a 23 liter (6 US gal.) remote fuel tank mix:

a. 19 liter (5 US gal.) regular unleaded 87 octane (90 RON) gasoline b. 1.89 liter (2 US qt.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil c. 150 ml (5 oz) Fuel System Treatment and Stabilizer or 30 ml (1 oz) Fuel System

Treatment and Stabilizer Concentrate

Tube Ref No. Description Where Used Part No.

115

124

2. Allow the engine to cool. IMPORTANT: Immediately wipe up any fuel spills or sprays.

3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not

equipped with a fuel shut off valve.

4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting. IMPORTANT: Supply cooling water to the engine.

5. Start and operate the engine at 1300 RPM for five minutes.

6. After the specified operating time is complete, slowly return the throttle to idle and shut

the engine off.

IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the engine's fuel system to become completely dry.

7. Replace the water separating fuel filter element. Refer to Section 5.

Premium Plus 2-cycle TC-W3 Outboard Oil

Fuel System Treatment & Stabilizer

Fuel system 92-858026K01

Fuel system 858071K01

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Section 6 - Storage

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33150

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

Drain System Identification

NOTE: All drain plugs are fitted with blue wing nuts.

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

Closed‑cooled models

a - Blue drain plug location b - Blue air pump

Seawater-cooled models

c - Air manifold d - Green indicators

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THREE POINT MANUAL DRAIN SYSTEM

Section 6 - Storage

a - Blue drain plug

Air Actuated Single Point Drain System

BOAT IN THE WATER

NOTE: This procedure is written for the blue 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 blue 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.

6126

a - Actuator fitting b - Green indicators 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.

90-899883173 DECEMBER 2007 Page 89

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d - Blue air pump e - Lever (locking)

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Section 6 - Storage

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33150

6133

Closed Cooled Models Seawater Cooled Models

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.

a - Blue drain plug location b - Blue air pump

c - Air manifold d - Green indicators

8. Verify that water is draining from each opening. If not, use the Three Point Manual Drain System instructions.

a - Port side drain location

b - Starboard side drain location

9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.

10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow engine to start.

11. Reinstall the blue drain plug in the thermostat housing or heat exchanger.

12. Remove the blue air pump from the air manifold and return it to the mounting bracket.

13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

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14. Before launching the boat, pull up on the manual release valve. Verify that the green

indicators are no longer extended.

a - Green indicators

15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to

operating the engine.

BOAT OUT OF THE WATER

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

1. Place the boat on a lever surface to ensure complete draining of system.

2. Remove the blue 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

6135

a - Actuator fitting b - Green indicators

8293

d - Air pump e - Lever (locking)

c - Manual release valve

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Section 6 - Storage

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6133

Closed Cooled Models Seawater Cooled Models

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.

a - Blue drain plug location b - Blue air pump

c - Air manifold d - Green indicators

7. Verify that water is draining from each opening. If not, use the Three Point Manual Drain System instructions.

a - Port side drain location

b - Starboard side drain location

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.

9. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump. Do not allow engine to start.

10. Remove the air pump from the air manifold and return it to the mounting bracket.

11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

Page 92 90-899883173 DECEMBER 2007

Mercury MerCruiser 5.7 MPI, MerCruiser 5.7 Horizon User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual