Mercury MerCruiser 8.2 Horizon ECT Maintance Manual

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8.2

H.O.

Horizon

ECT

OPERATION &

MAINTENANCE

MANUAL

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Welcome

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

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

The Operation and Maintenance 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 products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:

John Pfeifer, President, Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a demonstration of actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the

8M0113925 1215 eng

International Hazard Symbol !, may be used to alert the installer and user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

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

WARNING

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

CAUTION

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

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.

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

WARNING

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

8.2 H.O./Horizon ECT

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

Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.

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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 Manual included with the product. The Warranty Manual 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.

Copyright and Trademark Information

Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.

Identification Records

Please record the following applicable information:

MerCruiser

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 (Europe Only)

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Section 1 - Getting to Know Your Power Package

Identification............................................................................... 2

Information Decal................................................................ 2

Quick Response (QR) Code............................................... 2

Engine Serial Number ........................................................ 3

Lanyard Stop Switch.................................................................. 3

Keep the Lanyard Stop Switch and Lanyard Cord in Good

Operating Condition............................................................. 4

Instrumentation.......................................................................... 4

VesselView......................................................................... 4

Front Controls................................................................. 5

Troll Control Speed Range Specification............................ 5

Digital Gauges.................................................................... 5

Analog Gauges................................................................... 6

Remote Controls (DTS Models)................................................. 7

Remote Controls................................................................. 7

Panel Mount Features........................................................ 7

DTS Slim Binnacle Single Handle Console Features and

Operation............................................................................ 7

Special Digital Throttle and Shift (DTS) Features...........8

Dual‑Handle Electronic Remote Control (ERC)—Operation

and Adjustment................................................................... 9

Section 2 - On the Water

Safe Boating Recommendations............................................. 20

Carbon Monoxide Exposure.................................................... 21

Be Alert To Carbon Monoxide Poisoning........................... 21

Stay Clear of Exhaust Areas.............................................. 21

Good Ventilation ................................................................ 21

Poor Ventilation ................................................................. 22

Basic Boat Operation (DTS Models)........................................ 22

Launching and Boat Operation......................................... 22

Operation Chart............................................................ 22

Starting and Stopping the Engine..................................... 23

Starting the Engine....................................................... 23

Stopping the Engine..................................................... 23

Throttle Only Operation.................................................... 24

Freezing Temperature Operation..................................... 24

Drain Plug and Bilge Pump............................................... 24

Protecting People in the Water................................................ 24

While You Are Cruising...................................................... 24

While Boat Is Stationary..................................................... 25

Operation........................................................................ 9

Adjustment......................................................................9

Special Digital Throttle and Shift (DTS) Features............. 10

Dock............................................................................. 11

Throttle Only................................................................. 11

1 Lever..........................................................................12

Sync..............................................................................12

Transfer (Boats equipped with dual helms).................. 13

Helm Transfer................................................................... 13

Zero Effort Features.......................................................... 13

Electrical System Overload Protection..................................... 14

Visual and Audio Warning Systems......................................... 15

Service Engine Light and OBD‑M MIL Kit......................... 15

Testing the OBD‑M Malfunction Indicator Lamp (MIL). 16

Audio Warning System..................................................... 16

Caution......................................................................... 16

Critical...........................................................................16

Nonconfigured Alarm–DTS Only.................................. 16

Testing the Audio Warning System.............................. 17

Guardian Strategy............................................................. 17

Transmission Guardian Strategy............................................. 17

High‑Speed and High‑Performance Operation........................ 25

Passenger Safety in Pontoon Boats and Deck Boats.............. 25

Boats Having an Open Front Deck.....................................25

Boats With Front‑Mounted, Raised Pedestal Fishing Seats

........................................................................................... 25

Wave and Wake Jumping........................................................ 26

Impact with Underwater Hazards............................................. 26

Conditions Affecting Operation................................................ 27

Weight Distribution (Passengers and Gear) Inside the

Boat.................................................................................. 27

The Bottom of the Boat..................................................... 27

Cavitation.......................................................................... 27

Elevation and Climate....................................................... 27

Getting Started......................................................................... 27

20‑Hour Break‑In Period................................................... 27

After the Break‑In Period.................................................. 28

End of First Season Checkup........................................... 28

Section 3 - Specifications

Cruising RPM........................................................................... 30

Fuel Requirements................................................................... 30

Fuel Ratings....................................................................... 30

Using Reformulated (Oxygenated) Gasoline (USA Only).. 30

Gasoline Containing Alcohol.............................................. 30

Bu16 Butanol Fuel Blends............................................ 30

Methanol and Ethanol Fuel Blends...............................30

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Engine Oil................................................................................ 31

Engine Specifications............................................................... 31

Horizon 8.2 ECT and 8.2 H.O. ECT.................................. 31

Fluid Specifications.................................................................. 32

Engine............................................................................... 32

Transmission.................................................................... 32

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Section 4 - Maintenance

Owner/Operator Responsibilities............................................ 34

Dealer Responsibilities........................................................... 34

Maintenance........................................................................... 34

Do‑It‑Yourself Maintenance Suggestions............................... 34

Inspection............................................................................... 35

MerCruiser Gas Inboard Inspection and Maintenance

Schedule................................................................................. 35

Daily Checks..................................................................... 35

After Each Use.................................................................. 35

Weekly Checks................................................................. 35

20 Hour Break In............................................................... 35

Annually or 100 Hours...................................................... 35

Three Years or 300 Hours................................................ 36

Five Years or 500 Hours................................................... 36

Engine Oil............................................................................... 36

Checking......................................................................... 36

Oil Level—Overfilled................................................... 37

Filling............................................................................... 37

Changing Oil and Filter.................................................... 38

Oil Removal with Drain Pump......................................... 38

Changing the Oil Filter..................................................... 38

Transmission Fluid................................................................. 39

Checking While Engine is Warm...................................... 39

Checking While Engine is Cold......................................... 39

Section 5 - Storage

Transmission Fluid............................................................ 39

Changing.......................................................................... 39

Closed Cooling System.......................................................... 40

Coolant Requirement...................................................... 40

Checking Coolant Level.................................................. 40

.................................................................................... 40

Filling the Closed Cooling System................................... 40

Draining........................................................................... 41

Cleaning.......................................................................... 41

Battery.................................................................................... 41

Multiple EFI Engine Battery Precautions......................... 41

Cleaning the Flame Arrestor................................................... 42

Changing the Positive Crankcase Ventilation Valve (PCV).... 43

Water‑Separating Fuel Filter.................................................. 43

Removal and Installation................................................. 44

Removal...................................................................... 44

Installation................................................................... 44

Serpentine Drive Belt.............................................................. 45

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

Checking......................................................................... 45

Replacing........................................................................ 46

Flushing the Seawater System—Inboard Models.................. 47

The Boat Out of the Water—Inboard Models.................. 47

The Boat in the Water—Inboard Models......................... 48

Cold Weather or Extended Storage........................................ 50

Reformulated (Oxygenated) Gasolines (U.S.A. Only)..... 50

Fuel Containing Alcohol.................................................. 50

Preparing Power Package for Storage—MPI Models..... 50

Special Fuel Mix.......................................................... 51

Engine and Fuel System Preparation......................... 51

Draining the Seawater System............................................... 52

Drain System Identification.............................................. 52

Air‑Actuated Single‑Point Drain System..................... 52

Manual Drain System.................................................. 53

Section 6 - Troubleshooting

Diagnosing EFI Problems....................................................... 60

Diagnosing DTS Problems..................................................... 60

Engine Guardian System........................................................ 60

Troubleshooting Charts.......................................................... 60

Starter Motor Will Not Crank Engine, or Cranks Slowly.. 60

Engine Will Not Start or Is Hard to Start.......................... 60

Engine Runs Rough, Misses, or Backfires...................... 61

Poor Performance........................................................... 61

Air‑Actuated Single‑Point Drain System.......................... 53

Boat in the Water........................................................ 53

Boat Out of the Water................................................. 54

Manual Drain System...................................................... 56

Boat in the Water........................................................ 56

Boat Out of the Water................................................. 56

Draining Water from the Cool Fuel Module..................... 57

Battery Storage....................................................................... 57

Recommissioning the Power Package................................... 57

Excessive Engine Temperature...................................... 61

Insufficient Engine Temperature..................................... 61

Low Engine Oil Pressure................................................. 62

Battery Will Not Recharge............................................... 62

Remote Control Is Difficult to Move or Makes Unusual

Sounds............................................................................ 62

Steering Wheel Jerks or Is Difficult to Turn..................... 62

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Page 7

Section 7 - Customer Assistance Information

Owner Service Assistance....................................................... 64

Local Repair Service.......................................................... 64

Service Away From Home..................................................64

Stolen Power Package....................................................... 64

Attention Required After Submersion................................. 64

Replacement Service Parts................................................ 64

Parts and Accessories Inquiries................................... 64

Resolving a Problem.......................................................... 64

Contact Information for Mercury Marine Customer Service

........................................................................................... 65

Customer Service Literature.................................................... 65

English Language.............................................................. 65

Other Languages................................................................66

Ordering Literature................................................................... 66

United States and Canada................................................. 66

Outside the United States and Canada.............................. 66

Section 8 - Checklists

Predelivery Inspection (PDI).................................................... 68 Customer Delivery Inspection (CDI)........................................ 69

Section 9 - Maintenance Log

Scheduled Maintenance Log................................................... 72 Vessel Maintenance Notes...................................................... 73

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Section 1 - Getting to Know Your Power Package

Table of Contents

Identification........................................................................... 2

Information Decal.............................................................2

Quick Response (QR) Code............................................ 2

Engine Serial Number .....................................................3

Lanyard Stop Switch............................................................... 3

Keep the Lanyard Stop Switch and Lanyard Cord in

Good Operating Condition .............................................. 4

Instrumentation....................................................................... 4

VesselView...................................................................... 4

Front Controls .......................................................... 5

Troll Control Speed Range Specification......................... 5

Digital Gauges................................................................. 5

Analog Gauges................................................................ 6

Remote Controls (DTS Models)............................................. 7

Remote Controls.............................................................. 7

Panel Mount Features..................................................... 7

DTS Slim Binnacle Single Handle Console Features and

Operation......................................................................... 7

Special Digital Throttle and Shift (DTS) Features ... 8 Dual‑Handle Electronic Remote Control (ERC)—

Operation and Adjustment............................................... 9

Operation ................................................................. 9

Adjustment .............................................................. 9

Special Digital Throttle and Shift (DTS) Features.......... 10

Dock ...................................................................... 11

Throttle Only .......................................................... 11

1 Lever .................................................................. 12

Sync ...................................................................... 12

Transfer (Boats equipped with dual helms) ........... 13

Helm Transfer................................................................ 13

Zero Effort Features.......................................................13

Electrical System Overload Protection................................. 14

Visual and Audio Warning Systems..................................... 15

Service Engine Light and OBD‑M MIL Kit......................15

Testing the OBD‑M Malfunction Indicator Lamp (MIL)

.............................................................................. 16

Audio Warning System.................................................. 16

Caution .................................................................. 16

Critical ................................................................... 16

Nonconfigured Alarm–DTS Only ........................... 16

Testing the Audio Warning System ....................... 17

Guardian Strategy..........................................................17

Transmission Guardian Strategy.......................................... 17

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Section 1 - Getting to Know Your Power Package

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Identification

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

Information Decal

The information decal is located on the coolant reservoir.

a - Quick response code b - Service point information c - Engine serial number d - Transom serial number e - Sterndrive serial number f - Specifications

Quick Response (QR) Code

Scan the QR code link with a smartphone to access additional product information.

QR code

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Section 1 - Getting to Know Your Power Package

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53910

OFF

RUN

ATTACH LANYARD

Engine Serial Number

The engine serial number stamp is located on the starboard side of the engine block next to the flywheel housing cover.

a - Flywheel housing cover b - Engine serial number stamp c - Engine block

Lanyard Stop Switch

A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.

A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.

a - Lanyard cord clip b - Lanyard decal c - Lanyard stop switch

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

• Carelessness caused by consuming alcohol or drugs

• High‑speed boating maneuvers The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long 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 operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying 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 its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.

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Section 1 - Getting to Know Your Power Package

Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an emergency.

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.

WARNING

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

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

Instrumentation

VesselView

Your power package may have a SmartCraft VesselView display. VesselView is a comprehensive boat information center that can display information for up to four gasoline or diesel engines. It continuously monitors and reports basic operating data, such as information on fuel, oil, water and waste tanks, and will alert the operator if certain problems arise.

VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible devices to provide up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.

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Front Controls

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Section 1 - Getting to Know Your Power Package

a - Touch screen b - Mark–Menu button c - Standby–Auto button d - Exit button e - Rotary knob (press for enter function) f - Goto–Pages button g - In/out zoom, man overboard (MOB) button h - Power/brightness i - Card reader door

Troll Control Speed Range Specification

Engine Model RPM

Horizon 8.2 with Emissions Control 600–1000

8.2 H.O. with Emissions Control 650–1200

Digital Gauges

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

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Section 1 - Getting to Know Your Power Package

OIL

C H

TEMP

R P M

X 1000

MPH

KPH

100

120

110

10 16

BATT

FUEL

CRUISELOG

0 0 0 0

17352

26238

SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between the specified RPM range.

SmartCraft gauges

a - Tachometer b - Speedometer c - LCD system view display

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.

Analog Gauges

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

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.

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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.

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Section 1 - Getting to Know Your Power Package

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 (DTS) system 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

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

Control handle ‑ Operation of the shift and throttle are controlled by the movement of the control handle. Push the control

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

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

Trim/tilt switch (if equipped) ‑ Refer to Power Trim. Throttle only button ‑ Allows engine throttle advancement without shifting the engine. The throttle only button can be

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

Start/stop button ‑ Allows the boat operator to start or stop the engine without using the ignition key. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort required to move the control

handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control handle friction adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control

handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.

3409

a - Lanyard stop switch b - Control handle c - Shift lock d - Trim/tilt switch e - Throttle only button

f - Start/stop button g - Detent tension adjustment screw h - Control handle friction adjustment screw

DTS Slim Binnacle Single Handle Console Features and Operation

1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear. Continue pushing back to increase speed.

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Section 1 - Getting to Know Your Power Package

STOP/ START

THROTTLE - ONLY

DOCK TRANSFER

bcd

52365

abc

52360

abc

52313

2. Trim Switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The PCM closes the ground circuit to the up or down trim relay.

a - Forward b - Neutral c - Reverse d - Trim switch

3. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle out of detent positions. Turning screw clockwise will increase tension. Adjust to tension desired.

4. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

a - Caps (2) b - Detent tension adjustment c - Control handle tension adjustment

NOTE: The control handle tension and detent tension screws may require periodic maintenance adjustment.

Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers.

Slim binnacle ERC

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Section 1 - Getting to Know Your Power Package

abc

51902

Item Control Function

a Trim control (handle)

b "Stop/Start"

c "Transfer" Allows boat control to be transferred to a different helm.

d "Throttle‑only"

e "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.

f "–" Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.

g "Dock"

h Neutral light

Raises and lowers the engine for best efficiency, or for conditions such as shallow water, trailering, etc.

Allows the operator to start or stop the engine without the use of the key switch. The key switch must be in the run position for the start/stop switch to function.

Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into gear.

Reduces control lever operation throttle capacity to approximately 50% of normal control lever throttle demand.

Illuminates when the drive is in the neutral gear position. The lights flash when the engine is in throttle only mode.

Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment

Operation

The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling the handle back to increase speed in reverse.

NOTE: In certain modes, the gear position is determined by the electronic shift control (ESC), not the position of the ERC levers. When using the joystick or while in Skyhook, the computer controls the shifting in and out of gears even though the handles are in neutral.

a - Forward b - Neutral c - Reverse

The amount of force needed to move the handles and to move the handles through the detents is adjustable to help prevent unwanted motion.

Adjustment

NOTE: The control handle tension and detent tension may require periodic maintenance using the adjustment screws.

To adjust the handle detent tension:

1. Remove the side cover plugs of the handle that needs adjustment.

2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.

3. Adjust to the tension desired. To adjust handle tension:

1. Remove the side cover plugs of the handle that needs adjustment.

2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.

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Section 1 - Getting to Know Your Power Package

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51901

3. Adjust to the tension desired.

a - Detent tension adjustment screw b - Handle tension adjustment screw

Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously.

Dual-engine ERC

Item Control Function

a Trim control (handle)

Trim control (CAN

pad)

c "NEUTRAL" lights

d "TRANSFER"

e "DOCK"

Page 10 90-8M0113925 eng DECEMBER 2015

Raises and lowers the engines for best efficiency, or for conditions such as shallow water, trailering, etc.

Raises and lowers all the engines.

Illuminate when the drive is in the neutral gear position. The lights flash when the engine is in throttle only mode.

Allows boat control to be transferred to a different helm. Refer to Helm Transfer.

Available with joystick operation and the control levers. Joystick operation reduces throttle capacity to approximately 70% of normal joystick throttle demand. Control lever operation reduces throttle capacity to approximately 50% of normal control lever throttle demand.

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Section 1 - Getting to Know Your Power Package

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Item Control Function

f "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.

g "THROTTLE ONLY"

h "–" Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.

i "1 LEVER" Enables the throttle and shift functions of both engines to be controlled by the port lever.

j "SYNC" Turns off or on the auto‑synchronization feature.

Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into gear.

NOTE: Not all functions may be active.

Dock

Dock mode is available with joystick operation and remote control lever operation. Dock mode reduces throttle capacity to approximately 70% of normal joystick throttle demand, allowing finer control of engine power in close quarter situations. If more power is needed for vessel maneuvering when environmental conditions require more thrust, use the electronic remote control levers.

"DOCK" button

Throttle Only

NOTE: The joystick can become active when it is moved any time the engines are running and the ERC levers are in the neutral position. Throttle only mode should be used to disable the joystick if the captain is not in command at the helm. Placing the ERC in throttle only will avoid unintended gear engagement. The engines will turn using the steering wheel or the joystick and the RPM of the engines can be increased while in the throttle only mode, but the gear position will remain in neutral.

"THROTTLE ONLY" button

To engage throttle only mode:

1. Place both ERC levers in neutral.

2. Press the "THROTTLE ONLY" button. The button light will turn on and the neutral lights will blink.

3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in

throttle only, but will remain in neutral.

4. The RPM of the engines can be increased.

5. Throttle only mode also affects the joystick. The engines will move and the RPM can be increased, but will remain in

neutral.

NOTE: Pressing the "THROTTLE ONLY" button while the ERC levers are not in the neutral position, turns the button light off and remains in throttle only mode. You must place the ERC levers into the neutral position to disengage throttle only mode.

To disengage throttle only mode:

1. Place both ERC levers into neutral. Throttle only will not disengage unless the ERC levers are in neutral.

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2. Press the "THROTTLE ONLY" button. The button light will turn off.

3. The neutral lights stop flashing and remain illuminated. The joystick can now be used.

1 Lever

The outboard joystick system features the ability to command both engines with a single lever on a dual‑engine application. This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both engines simultaneously. It has no affect on the joystick function. It is not the same as the system feature called Sync.

"1 LEVER" button

To engage 1 Lever mode:

1. Place both ERC levers in neutral.

2. Press the "1 LEVER" button. The button light will turn on.

3. Place the starboard ERC lever into gear.

4. When the handle is moved, the engines RPM and gear position is synchronized.

To disengage 1 lever mode:

1. Place both ERC levers in neutral.

2. Press the "1 LEVER" button. The button light turns off.

Sync

Sync is an automatic engine synchronization feature that is always on unless it is turned off. Sync monitors the position of both ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM. The SmartCraft system will automatically disengage sync after 95% of throttle position range to allow each engine the ability to reach maximum available RPM. Sync cannot engage until the engines are at a minimum speed.

The indicator light on the "SYNC" button is on when both engines are on. The light is yellow at idle and 95% of throttle and when the engines are not synchronized. The light turns red when the engines are synchronized.

"SYNC" button

The RPM display of VesselView also shows an orange icon under the RPM numbers if the engines RPMs differ more than 10% of each other, and the icon turns red when they are synchronize.

To disengage sync mode:

1. Place the ERC levers in any detent.

2. Press the "SYNC" button. The button light turns off.

To engage Sync mode, press the "SYNC" button at any time.

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Transfer (Boats equipped with dual helms)

The "TRANSFER" button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer.

"TRANSFER" button

Helm Transfer

Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to another helm.

WARNING

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.

The helm transfer function allows the boat operator to select which helm is in control of the vessel. Before a transfer can be initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position.

NOTE: If you attempt to transfer helm control when the ERC levers are not in neutral, a beep will sound and the helm transfer will not succeed until the levers at the helms are moved to neutral and transfer is requested again.

Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the helm transfer procedure. Ensure that other control and navigation inputs are performed after helm transfer is complete to avoid setting fault codes.

NOTICE

The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects nearby resulting in damage. Keep an adequate look out while performing the helm transfer.

To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items or when near other vessels.

Zero Effort Features

a - Shift lever b - Throttle lever c - Trim/tilt switch

5656

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

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

Trim/tilt switch ‑ Refer to Power Trim.

Electrical System Overload Protection

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

NOTE: In an emergency, when you must operate the engine and cannot locate the cause for the high current draw, 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. Contact your authorized dealer as soon as possible.

The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. To reset the circuit breaker, push the red button. The circuit breaker is located at the starboard rear of the engine.

A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.

a - Starter b - Starter solenoid c - 90‑amp fuse—do not remove d - Positive (+) starter stud

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Four fuses protect the main power, fuel pump, ignition, and accessory circuits. These are located on the top of the engine near the PCM. Fuses protect the O2 sensors. These are located near the 14‑pin harness connector.

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

a - Fuse cover b - 15‑amp fuse c - Accessory harness

The DTS control system is protected by a 5‑amp fuse located near the battery.

a - 5‑amp fuse b - Positive battery terminal (harness lead with fuse) c - Negative battery terminal

Visual and Audio Warning Systems

Service Engine Light and OBD‑M MIL Kit

Boats powered by emissions control technology (ECT) catalyzed engines must be equipped with a SmartCraft‑enabled gauge capable of displaying the service engine icon, or a dash‑mounted service engine light. Malfunction indicator lamp (MIL) kits containing a dash‑mounted service engine light and a special harness that connects to the engine harness may be purchased separately.

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ON ON

OFF

33402

53403

OFF

ON ON

OFF

53402

The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and will remain illuminated while the OBD‑M fault is active.

SC 1000 gauge and service engine light

Testing the OBD-M Malfunction Indicator Lamp (MIL)

1. Turn the ignition switch to the on position without cranking the engine.

2. The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning correctly.

Audio Warning System

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

Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem. There are two warning horn states:

• Caution

• Critical

There is also an alarm that sounds if the helm has not been properly configured using the G3 service tool.

Caution

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

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

Critical

If a critical state is detected, the audio warning system sounds for six seconds and then turns off.

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

Nonconfigured Alarm–DTS Only

If the helm has not been properly configured using the G3 service tool, the audio warning system will sound for five one‑second intervals.

Horn (on or off)

a b - Time (in seconds)

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Testing the Audio Warning System

1. Turn the key 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

The MerCruiser Engine Guardian system 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: Engine 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, Engine 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, Engine Guardian restores engine power to normal.

Transmission Guardian Strategy

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

The ECM stores the fault and with this information the technician will be able to rapidly diagnose problems.

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Notes:

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Table of Contents

Section 2 - On the Water

Safe Boating Recommendations.......................................... 20

Carbon Monoxide Exposure................................................. 21

Be Alert To Carbon Monoxide Poisoning ..................... 21

Stay Clear of Exhaust Areas ........................................ 21

Good Ventilation .......................................................... 21

Poor Ventilation ........................................................... 22

Basic Boat Operation (DTS Models).................................... 22

Launching and Boat Operation...................................... 22

Operation Chart ..................................................... 22

Starting and Stopping the Engine.................................. 23

Starting the Engine ................................................ 23

Stopping the Engine .............................................. 23

Throttle Only Operation................................................. 24

Freezing Temperature Operation.................................. 24

Drain Plug and Bilge Pump............................................24

Protecting People in the Water............................................. 24

While You Are Cruising ................................................ 24

While Boat Is Stationary ............................................... 25

High‑Speed and High‑Performance Operation..................... 25

Passenger Safety in Pontoon Boats and Deck Boats.......... 25

Boats Having an Open Front Deck ............................... 25

Boats With Front‑Mounted, Raised Pedestal Fishing

Seats ............................................................................ 25

Wave and Wake Jumping..................................................... 26

Impact with Underwater Hazards......................................... 26

Conditions Affecting Operation............................................. 27

Weight Distribution (Passengers and Gear) Inside the

Boat............................................................................... 27

The Bottom of the Boat.................................................. 27

Cavitation....................................................................... 27

Elevation and Climate.................................................... 27

Getting Started..................................................................... 27

20‑Hour Break‑In Period................................................ 27

After the Break‑In Period............................................... 28

End of First Season Checkup........................................ 28

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Safe Boating Recommendations

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 U.S., 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 U.S., 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 onboard.

• 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

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

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 onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

• Instruct at least one person onboard 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's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride 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 operate a boat while under the influence of alcohol or drugs. It is the law.

• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

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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 operator's 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.

• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.

Watch fallen skiers.

• When using your boat for waterskiing 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.

Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning

Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.

Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness, drowsiness, and nausea.

WARNING

Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide.

Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.

Stay Clear of Exhaust Areas

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the possibility of injury from the boat propeller.

Good Ventilation

Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat:

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Poor Ventilation

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

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

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

a - Operating the engine when the boat

is moored in a confined space

b - Mooring close to another boat that

has its engine operating

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

a - Operating the boat with the

trim angle of the bow too high

b - Operating the boat with no

forward hatches open (station wagon effect)

Basic Boat Operation (DTS Models)

Launching and Boat Operation

IMPORTANT: Install bilge drain plug prior to launching boat. Follow these guidelines when operating your boat to avoid possible water ingestion:

• Do not turn the key off when the engine is above idle speed.

• Do not use the lanyard stop switch to shut off the engine when operating above idle speed.

• Enter the water slowly when launching your boat from a steep ramp.

• Do not shift into reverse while on plane.

• When coming off plane, avoid impact with large waves by applying short, light bursts of power to minimize the wave action against the stern of the boat.

• Do not come off plane quickly and immediately shut of the engine.

Operation Chart

BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING

Observe all gauges to

Install bilge drain plug.

Open engine hatch.

Turn battery switch on.

Operate bilge blowers. Check steering operation. Close seacock, if equipped.

Open fuel shut off valve.

Open seacock, if equipped. Drain bilge.

Close the drain system.

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

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

Check shift and throttle control operation.

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

Listen for the audio alarm.

Turn ignition key to the "OFF" position.

Turn battery switch to the "OFF" position.

Close fuel shut off valve.

Flush cooling system if in saltwater.

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Operation Chart

BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING

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

Check all items listed in the Operation Chart.

2. Place the remote control handle in neutral.

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.

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

3. Turn ignition key to "RUN" position.

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

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

a. Push the throttle‑only button and position the remote control handle or throttle lever to the 1/4 throttle position. b. Turn the ignition key to "START." Release key when the engine starts and allow the switch to return to the "ON"

position.

6. If the engine does not start after step 5:

a. Move the remote control handle.throttle lever to the full throttle position, then return to 1/4 throttle. b. Turn the ignition key to "START." Release key when the engine starts and allow the switch to return to the "ON"

position.

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

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

NOTICE

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. 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 will stop and the control system will

be deactivated.

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

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

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

WARNING

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: Panel mount and console mount remote controls are equipped with a throttle only button. To activate throttle only mode:

Refer to Remote Controls section for remote control features.

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

3. Depress the throttle only button, and move the control lever to the idle/forward or idle/reverse position. The DTS control system will sound two beeps on the audio warning horn to indicate throttle only mode is active. On console mount remote controls, the neutral light will begin to blink.

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

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

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.

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.

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While Boat Is Stationary

WARNING

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

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

High‑Speed and High‑Performance Operation

If your boat is considered a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to Hi‑Performance Boat Operation booklet (90‑849250‑R03) 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 the 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.

mc79555-1

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.

mc79557-1

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Wave and Wake Jumping

WARNING

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

mc79680-1

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 reenters 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.

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.

7576

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 24–40 km/h (15–25 mph).

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

• The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

• A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.

• Impact damage to the underwater drive components, rudder, and/or boat.

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

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

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

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

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Section 2 - On the Water

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

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.

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 (five minutes at a time maximum).

• Avoid full throttle acceleration from idle speed.

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Section 2 - On the Water

• 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 the Break‑In Period

To help extend the life of your Mercury MerCruiser power package, follow these recommendations:

• Ensure that the propeller allows the engine to operate at or near the top of the specified wide‑open throttle (WOT) RPM range. Refer to Specifications and Maintenance.

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

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.

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Table of Contents

Section 3 - Specifications

Cruising RPM....................................................................... 30

Fuel Requirements............................................................... 30

Fuel Ratings ................................................................. 30

Using Reformulated (Oxygenated) Gasoline (USA Only)

...................................................................................... 30

Gasoline Containing Alcohol ........................................ 30

Bu16 Butanol Fuel Blends ..................................... 30

Methanol and Ethanol Fuel Blends ....................... 30

Engine Oil............................................................................. 31

Engine Specifications........................................................... 31

Horizon 8.2 ECT and 8.2 H.O. ECT...............................31

Fluid Specifications............................................................... 32

Engine............................................................................32

Transmission................................................................. 32

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Section 3 - Specifications

Cruising RPM

Material and design advancements allow modern inboard engines to 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. Overpropping the boat to reduce its cruising RPM to previous levels increases the engine's susceptibility to engine damage from detonation and preignition. The recommended cruising RPM ranges are:

Cruising RPM for Peak Efficiency

Model RPM range

Horizon 8.2 3200–3600

8.2 H.O. 3400–3800

Fuel Requirements

NOTICE

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.

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, for all models. Premium gasoline 91 (R+M)/2 octane is also acceptable for all models. Do not use leaded gasoline.

Outside USA and Canada ‑ A posted pump octane rating of 91 RON, minimum, for all models. Premium gasoline (95 RON) is also acceptable for all models. Do not use leaded gasoline.

Using Reformulated (Oxygenated) Gasoline (USA Only)

Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).

Gasoline Containing Alcohol

Bu16 Butanol Fuel Blends

Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

Methanol and Ethanol Fuel Blends

IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol. 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 methanol or ethanol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through the rubber fuel lines

• Likelihood of phase separation (water and alcohol separating from the gasoline in the fuel tank)

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 methanol or ethanol, you must increase the frequency of inspection for leaks and abnormalities.

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Section 3 - Specifications

Mercury/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W Catalyst Compatible rated 4-cycle oil

Other recognized brands of NMMA FC-W Catalyst Compatible rated 4-cycle oil

SAE 20W

SAE30W

SAE40W

AIR TEMPERATURE

ORDER OF PREFERENCE

(32° F)

0° C

(50° F)

10° C

Mercury/Quicksilver 25W-40 Mineral NMMA FC-W Catalyst Compatible rated 4-cycle oil

53574

Other recognized brands of NMMA FC-W rated 4-cycle oil

IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble; boats often sit idle long enough for phase separation to take place. Internal corrosion may occur during storage if alcohol has washed protective oil films from internal components.

Engine Oil

For optimum engine performance and maximum protection, use the following oil:

Application Recommended Oil

All MerCruiser engines Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst Compatible rated

IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for noncatalyzed engines. Some marine‑grade lubricants contain high levels of phosphorus. Although these high‑phosphorus lubricants may allow 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 Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation.

1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible.

IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.

2. Other recognized brands of NMMA FC‑W Catalyst Compatible rated 4‑cycle oil.

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

4. A good‑grade, straight‑weight detergent automotive oil according to the last row of the operating chart below.

NOTE: We do not recommend nondetergent oils, multi‑viscosity oils (other than as specified), non‑FC‑W rated synthetic oils, low‑quality oils, or oils that contain solid additives.

Use the following information for selecting the type of oil according to the order of preference.

Engine Specifications

Horizon 8.2 ECT and 8.2 H.O. ECT

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 was measured using an accurate service tachometer with the engine at normal operating temperatures. NOTE: Oil pressure specifications are for reference and may vary.

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Section 3 - Specifications

Propeller shaft power

Displacement

Alternator amps

RPM

Idle RPM

Minimum oil pressure

Thermostat

Timing at idle

Firing order

Minimum battery rating

Spark plug type

Spark plug gap

Emission control system

Horizon 8.2 ECT 8.2 H.O. ECT

280 kW (375 hp) 317 kW (425 hp)

8.2 L (502 cid)

Hot 72 A

Cold 65 A

WOT 4200–4600 4400–4800

Rev limiter 4750 4950

Mechanical

DTS

At 2000 RPM 431 kPa (62 psi)

At idle 207 kPa (30 psi)

MPI models with closed cooling 76° C (170° F)

DTS models 800 CCA, 1000 MCA, 190 Ah

0.83 mm (0.033 in.)

Electronic control (EC), heated oxygen sensor

650

Not adjustable

1‑8‑4‑3‑6‑5‑7‑2

NGK BPR6ES

(HO2S), catalyst

Fluid Specifications

Engine

IMPORTANT: All capacities are approximate fluid measures.

All Models

Engine oil (with filter) 6.5 L (7 US qt)

Seawater cooling system (winterization use only)

Closed cooling system 17.4 L (18.4 US qt)

Transmission

Model

63A 4.3 L (4.5 US qt)

63V 4.3 L (4.5 US qt)

80A 5.7 L (6 US qt)

Capacity Fluid Type

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

Capacity Fluid Type

Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA

FC‑W

Mercury Extended Life Antifreeze/Coolant or extended life

ethylene glycol 5/100 antifreeze mixed 50/50 with purified water

Dexron III Automatic Transmission

Fluid

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Table of Contents

Section 4 - Maintenance

Owner/Operator Responsibilities.......................................... 34

Dealer Responsibilities......................................................... 34

Maintenance......................................................................... 34

Do‑It‑Yourself Maintenance Suggestions............................. 34

Inspection............................................................................. 35

MerCruiser Gas Inboard Inspection and Maintenance

Schedule............................................................................... 35

Daily Checks ................................................................. 35

After Each Use ............................................................. 35

Weekly Checks ............................................................. 35

20 Hour Break In .......................................................... 35

Annually or 100 Hours .................................................. 35

Three Years or 300 Hours ............................................ 36

Five Years or 500 Hours ............................................... 36

Engine Oil............................................................................. 36

Checking........................................................................ 36

Oil Level—Overfilled .............................................. 37

Filling............................................................................. 37

Changing Oil and Filter.................................................. 38

Oil Removal with Drain Pump........................................ 38

Changing the Oil Filter................................................... 38

Transmission Fluid............................................................... 39

Checking While Engine is Warm .................................. 39

Checking While Engine is Cold .................................... 39

Transmission Fluid ....................................................... 39

Changing ...................................................................... 39

Closed Cooling System........................................................ 40

Coolant Requirement..................................................... 40

Checking Coolant Level................................................. 40

.............................................................................. 40

Filling the Closed Cooling System................................. 40

Draining......................................................................... 41

Cleaning.........................................................................41

Battery.................................................................................. 41

Multiple EFI Engine Battery Precautions....................... 41

Cleaning the Flame Arrestor................................................. 42

Changing the Positive Crankcase Ventilation Valve (PCV).. 43

Water‑Separating Fuel Filter................................................ 43

Removal and Installation............................................... 44

Removal ................................................................ 44

Installation ............................................................. 44

Serpentine Drive Belt............................................................ 45

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

Checking........................................................................ 45

Replacing....................................................................... 46

Flushing the Seawater System—Inboard Models................ 47

The Boat Out of the Water—Inboard Models................ 47

The Boat in the Water—Inboard Models....................... 48

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Section 4 - 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 onboard 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 register the product on‑line or, 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 the complete listing of all scheduled maintenance to be performed. Some items should be performed only by an authorized Mercury MerCruiser dealer only. 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.

Maintenance Point Color Codes

Yellow Engine Oil

Red ATF (Transmission)

Orange Coolant

Blue Raw Water Flush

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.

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Section 4 - Maintenance

• 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.

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.

MerCruiser Gas Inboard Inspection and Maintenance Schedule

Daily Checks

• Check the engine oil level

• Check the transmission fluid level

• Check the lanyard stop switch

After Each Use

• Flush the engine with fresh water, brackish or saltwater use only

Weekly Checks

• Check the seawater inlets for marine growth

• Clean the seawater strainer, if equipped

• Check the coolant level, if equipped

• Check the transmission fluid level

20 Hour Break In

• Change the transmission fluid and filter—ZF requirement to maintain warranty—dealer item

Annually or 100 Hours

• Check the battery condition and connections—dealer item

• Lubricate the propeller shaft splines

• Check the torque of the proper nut

• Clean the gauges and check wire connection—dealer item

• Touch up any paint nicks and spray the power package with Corrosion Guard

• Change the engine oil and filter

• Change transmission fluid and filter—dealer item

• Check the closed cooling fluid level and concentration for freeze protection, if equipped

• Replace the water‑separating fuel filter

• Check the crankcase vent—8.2L only

• Check the IAC muffler—8.2L only

• Clean the flame arrestor—8.2L only

• 6.2L MIE models, inspect the exhaust system. If the power package is equipped with water shutters, verify they are not missing or worn—dealer item.

90-8M0113925 eng DECEMBER 2015 Page 35

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Section 4 - Maintenance

• Inspect the condition of the accessory drive belt—dealer item

• Replace the PCV valve

• Spray the power package with Corrosion Guard

• Inspect anodes, if equipped

Three Years or 300 Hours

•

Inspect the spark plugs and spark plug wires

• Clean the flame arrestor and crankcase vent hoses

• Check the engine mount fasteners for tightness and tighten to the specified torque—dealer item

• Check the electrical system for loose, damaged, or corroded fasteners—dealer item

• Check the exhaust and cooling system hose clamps for tightness. Inspect for damage or leaks—dealer item.

• Inspect and clean seawater side of closed cooling system, if equipped—dealer item

• Clean, inspect, and test the closed cooling pressure cap, if equipped—dealer item

• Inspect seawater pump. Replace worn components—dealer item.

• Inboard models, inspect the exhaust system. If the power package is equipped with water shutters, verify they are not missing or damaged—dealer item.

• Replace the vent valve on each exhaust elbow, port and starboard, if equipped—dealer item

• TowSport models, check the neutral position on manual shift transmission. Adjust the control cable if necessary—dealer item.

Five Years or 500 Hours

• Replace the antifreeze—replace the antifreeze every two years if not using extended life antifreeze—dealer item

Engine Oil

Checking

NOTICE

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

1. With the engine warm but not running, wait five minutes to allow the oil to drain into the oil pan.

1. Inspect the condition of the spark plugs and spark plug wires. Replace as necessary. If the condition of these components is satisfactory at the time of inspection, repeat the inspection every 100 hours or once a year, whichever occurs first.

2. After the three year or 300 hour inspection, repeat the inspection every 100 hours or once a year, whichever occurs first.

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Section 4 - Maintenance

43692

50388

2. Remove the dipstick, wipe it clean, and install it fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.

a - Oil dipstick handle b - Operating range

3. Remove the dipstick and verify that the oil level is in the operating range (cross markings) on the dipstick. Install the dipstick into the dipstick tube. If the oil level is low, refer to Filling.

Oil Level—Overfilled

IMPORTANT: Do not overfill the engine with oil. An overfilled crankcase can cause a fluctuation or drop in oil pressure and rocker arm clatter, and result in a loss of engine performance.

An overfilled crankcase (oil level too high) can cause a fluctuation or drop in oil pressure, and rocker arm clatter. This condition results in the engine crankshaft splashing and agitating the oil, causing it to foam (become aerated). The aerated oil causes the hydraulic valve lifters to bleed down. This results in rocker arm clatter and loss of engine performance.

Care must be taken when checking the engine oil level. The oil level must be maintained between the "ADD" mark and the "FULL" or "OK RANGE" mark on the dipstick. To avoid getting a false reading, adhere to the following procedures.

Filling

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

1. Remove the oil fill cap.

a - Oil fill cap b - Oil filter

2. Add the specified engine oil to bring the level up to, but not over, the operating range cross markings on the dipstick.

All Models

Engine oil (with filter) 6.5 L (7 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W

3. Check the oil level and replace the fill cap.

Capacity Fluid Type

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Section 4 - Maintenance

50335

50318

Changing Oil and Filter

Refer to 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).

Oil Removal with Drain Pump

1. Loosen the oil filter to vent the system.

2. Remove the dipstick.

3. Install the oil drain pump onto the dipstick tube.

a - Oil drain hose b - Oil drain pump

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

5. Remove the pump.

6. Install the dipstick.

Changing the Oil Filter

NOTE: Keep oil off the exhaust manifold and also the serpentine belt.

1. Remove and discard the oil filter. If any oil escapes from the oil filter, it will exit the oil drain slot. Place a container below the oil drain slot to catch any oil.

a - Oil fill cap b - Oil filter c - Oil drain slot

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 the 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 bottom of the operating range to the top of the operating range.

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Section 4 - Maintenance

43702

All Models Capacity Fluid Type

Engine oil (with filter) 6.5 L (7 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil

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 Engine is Warm

1. Stop the engine.

2. Remove the dipstick from the transmission.

3. If the fluid level is below the add mark on the dipstick, add the specified fluid through the dipstick hole. Do not overfill.

4. Install the dipstick, hand tighten the T‑handle to seat the O‑ring. Do not overtighten.

Typical ZF Marine Transmission

a - Dipstick b - O‑ring c - Dipstick hole d - Full mark e - Add mark

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. Install the dipstick, hand tighten the T‑handle to seat the O‑ring. Do not overtighten.

Transmission Fluid

Model

63A 4.3 L (4.5 US qt)

80A 5.7 L (6 US qt)

Capacity Fluid Type

Dexron III Automatic Transmission Fluid63V 4.3 L (4.5 US qt)

Changing

Contact your authorized Mercury MerCruiser dealer.

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Page 48

Section 4 - Maintenance

HOT

FILL

COLD

50916

Closed Cooling System

Coolant Requirement

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.

NOTE: All factory‑installed closed cooling systems come filled with Extended Life Coolant. This antifreeze requires draining and replacing every five years or 1000 hours of operation, whichever comes first. The color of this antifreeze is orange. Any "top‑off" fluid used must be Extended Life Coolant.

Tube Ref No. Description Where Used Part No.

122

Checking Coolant Level

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

IMPORTANT: Tighten the pressure cap securely. The coolant level should be at the full mark on the coolant reservoir when the engine is cold.

Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1

CAUTION

Coolant recovery bottle

a - Coolant reservoir cap b - Sight window c - Coolant reservoir d - Full mark (engine hot) e - Full mark (engine cold)

Filling the Closed Cooling System

IMPORTANT: The engine must be cooled to ambient temperature to correctly perform the following procedure.

NOTICE

The coolant section of the closed cooling system must be filled with a 50/50 mixture of Extended Life Antifreeze/Coolant and distilled water.

Tube Ref No.

122

Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1

Description Where Used Part No.

NOTE: Coolant section capacity is approximate.

8.2 Models

Closed cooling system 17.4L (18.4 US qt) Extended Life Antifreeze/Coolant

Capacity Fluid Type

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Section 4 - Maintenance

CAUTION

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

IMPORTANT: When filling the coolant section after it has been completely drained, the engine should be level or slightly lower at the flywheel end.

1. Remove the pressure cap from the coolant reservoir.

2. Fill the reservoir to the full mark with the recommended coolant solution.

3. When refilling the coolant section after it has been completely drained, fill the reservoir to within 12 mm (0.50 in.) of the top of the reservoir neck before starting the engine.

4. Replace the pressure cap.

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.

5. Supply cooling water to the engine.

6. With the engine running, check the hose connections, fittings, and gaskets for leaks. Also observe the engine temperature gauge to ensure that the engine operating temperature is normal. If the gauge indicates excessive temperature, stop the engine immediately and determine the cause.

CAUTION

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

7. After the engine has cooled completely, recheck the coolant level and add coolant, if necessary.

8. If the reservoir was completely emptied of coolant, a significant amount of air remains in the cooling system. Refill the reservoir to the "FULL" mark, repeat the warm‑up/cool‑down cycle, and check the coolant level again.

9. Maintain the coolant level in the reservoir at or near the "FULL" mark with the engine cold.

Draining

Contact your authorized Mercury MerCruiser dealer.

Cleaning

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.

WARNING

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.

WARNING

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

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 ECMs 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.

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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 multiengine 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 generator's battery should be considered another engine's battery.

Cleaning the Flame Arrestor

WARNING

Fuel is flammable and explosive. Ensure that 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. Gently lift the top back edge of the silencer and pull forward to remove.

a - Silencer b - Flame arrestor

2. Loosen the flame arrestor clamp and remove the flame arrestor.

a - Flame arrestor b - Flame arrestor clamp

3. Clean the flame arrestor with solvent and dry with compressed air or set aside and allow to air dry completely.

4. Install the flame arrestor and tighten the clamp to the specified torque.

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43215

Description Nm lb‑in. lb‑ft

Flame arrestor clamp 6.2 55 –

5. Install the silencer.

Changing the Positive Crankcase Ventilation Valve (PCV)

This engine is equipped with a positive crankcase ventilation valve (PCV). We recommend changing it every 100 hours of operation or at least once a year, whichever occurs first.

1. Pull the PCV valve out of the intake manifold and remove the PCV valve from the hose.

a - Hose from plenum to PCV valve b - PCV valve

2. Inspect the PCV valve and replace if necessary.

3. Install the PCV valve into the intake manifold.

4. Ensure that the PCV valve is tightly seated into the intake manifold.

We recommend the use of Mercury MerCruiser replacement parts.

Water‑Separating Fuel Filter

WARNING

CAUTION

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.

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Removal and Installation

a - Filter assembly retaining screw b - Filter cap c - Fuel filter element d - O‑ring e - Filter cup f - Cool Fuel Module g - Cool Fuel Module harness

Removal

1. Allow the engine to cool down.

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

2. Close fuel supply valve, if equipped.

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

4. Turn the key switch to the start position and allow the starter to operate for five 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 cap 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.

Installation

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 counterclockwise direction while holding

4. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel, and align the screws retained in the

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

6. Open the fuel supply valve, if equipped.

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

8. Properly ventilate the engine compartment.

Page 44 90-8M0113925 eng DECEMBER 2015

the filter cup stationary, until the filter cap locks securely into place.

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

Description

Filter assembly retaining screw 6 53 –

Nm lb‑in. lb‑ft

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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. Check 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.

Serpentine Drive Belt

Inspection

WARNING

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

a - Alternator pulley b - Idler pulley c - Water circulating pump pulley d - Crankshaft pulley e - Seawater pump pulley f - Tensioner pulley

Checking

Inspect the drive belt for:

• Proper belt tension deflection

• Excessive wear

• Cracks

• Fraying

• Glazed surfaces

• Proper tension

Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys.

Description

Deflection 13 mm (1/2 in.)

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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.

Replacing

IMPORTANT: If reusing a belt, install it in the same direction of rotation as before. The belt tensioner operates within the limits of movement provided by the cast stops when the belt length and geometry are

correct. If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length. Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist.

CAUTION

Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage. Relieve the spring tension slowly.

1. Use a breaker bar and appropriate socket to relieve the tensioner. Rotate the tensioner away from the belt until it stops.

2. Remove the belt from the idler pulley and slowly relieve the tension on the breaker bar.

a - Tensioner pulley b - Socket and breaker bar c - Water circulating pump pulley d - Idler pulley

3. Remove the belt and route the replacement belt according to the belt routing diagram.

4. Carefully release the tensioner and ensure that the belt stays positioned properly.

5. Check the belt tension.

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NOTE: Proper tension is a measurement of deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys.

Deflection measurement point

Description

Deflection 13 mm (½ in.)

Flushing the Seawater System—Inboard Models

The Boat Out of the Water—Inboard Models

IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water. IMPORTANT: We recommend flushing after each outing in salty, brackish, mineral‑laden, or polluted water and before cold weather and extended storage.

WARNING

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

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

2. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump and immediately plug the hose.

3. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.

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

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

6. 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.

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

8. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

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

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10.

For power packages operated in salty, brackish, mineral‑laden, or polluted water: Continue to operate the engine until the discharge water is clear.

11. Slowly return the throttle to idle speed position.

12. Stop the engine.

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

14. Install the water inlet hose to the seawater inlet of the seawater pump. Tighten the hose clamp securely.

The Boat in the Water—Inboard Models

IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water. IMPORTANT: We recommend flushing the engine after each outing in salty, brackish, mineral‑laden, or polluted water and before cold weather and extended storage.

NOTICE

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.

1. Close the seacock, if equipped, then disconnect the seawater inlet hose to prevent water from siphoning into the engine or boat.

2. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump, and immediately plug the hose to prevent water from siphoning into the engine or boat.

3. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.

NOTICE

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

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

6. Immediately start the engine.

NOTICE

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

8. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

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

10.

For power packages operated in salty, brackish, mineral‑laden, or polluted water: Continue to operate the engine until the discharge water is clear.

11. Slowly return the throttle to idle speed position.

12. Stop the engine.

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

14. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose to be reconnected prior to operating the engine.

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Table of Contents

Section 5 - Storage

Cold Weather or Extended Storage...................................... 50

Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 50

Fuel Containing Alcohol................................................. 50

Preparing Power Package for Storage—MPI Models....50

Special Fuel Mix .................................................... 51

Engine and Fuel System Preparation .................... 51

Draining the Seawater System............................................. 52

Drain System Identification............................................ 52

Air‑Actuated Single‑Point Drain System ................ 52

Manual Drain System ............................................ 53

Air‑Actuated Single‑Point Drain System........................ 53

Boat in the Water ................................................... 53

Boat Out of the Water ............................................ 54

Manual Drain System.................................................... 56

Boat in the Water ................................................... 56

Boat Out of the Water ............................................ 56

Draining Water from the Cool Fuel Module................... 57

Battery Storage..................................................................... 57

Recommissioning the Power Package................................. 57

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Cold Weather or Extended Storage

Reformulated (Oxygenated) Gasolines (U.S.A. Only)

This type of gasoline is required throughout most of the U.S.A. There are two types of oxygenates used in fuels: alcohol (ethanol) or ether (MTBE or ETBE). Gasoline containing ethanol is especially subject to absorbing atmospheric moisture, forming gums or solids, or it may separate into a layer of fuel floating on top of a layer of water and alcohol. To reduce the potential for separation, storage should be in containers that prevent oxidation or water vapors mixing. If ethanol is used in the gasoline in your area, refer to Fuel Containing Alcohol.

Fuels for your Mercury Marine engine may contain up to 10% of ethanol or ether.

Fuel Containing Alcohol

Fuels containing either methanol (methyl alcohol) or ethanol (ethyl alcohol) may cause certain adverse effects. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.

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

The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

WARNING

Because of possible adverse effects of alcohol in gasoline, only alcohol‑free gasoline should be used. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required.

IMPORTANT: When operating a Mercury Marine 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 problems. Conversely, boats may not be used for days, weeks, or months, 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.

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.

NOTICE

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 freezing temperatures. 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 manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure 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.

Preparing Power Package for Storage—MPI Models

Multipoint fuel injection (MPI) systems must have a special mix of fuel, stabilizer, and lubricant, completely fill the fuel delivery system. This fuel mix stabilizes the fuel and lubricates the fuel pumps, fuel pressure regulator, fuel injectors and, reduces internal oxidation of the fuel system metal components.

IMPORTANT: This special fuel mix can be used on Mercury Marine catalyzed gasoline engines.

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Special Fuel Mix

WARNING

1. Fill a 23 liter (6 US gal) remote fuel tank with 19 L (5 US gal) regular unleaded 87 octane (90 RON) gasoline.

2. Pour into the remote fuel tank 1.89 L (2 US qt) of Premium Plus 2‑Cycle TC‑W3 Outboard Oil and 29.5 ml (1 oz) of Mercury Quickstor Fuel Stabilizer.

Tube Ref No. Description Where Used Part No.

115

124

Premium Plus 2-Cycle TC-W3 Outboard Oil

Quickstor Fuel Stabilizer Fuel system 92-8M0047932

Fuel system 92-858026K01

3. Install the remote fuel tank cap and ensure the added ingredients are thoroughly mixed with the fuel.

Engine and Fuel System Preparation

WARNING

NOTICE

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

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

2. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following:

a. Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add

a sufficient amount of Mercury Quickstor Fuel Stabilizer to treat the gasoline. Follow the instructions on the container.

b. Vessels using fuel containing alcohol—drain the fuel tanks as low as possible and add a sufficient amount of Mercury

Quickstor Fuel Stabilizer to treat the remaining gasoline. Follow the instructions on the container.

Flush the cooling system. Refer to the Maintenance section.

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

5. Close the fuel shut off valve, if equipped, or disconnect and plug the boat fuel tank hose.

6. Connect the remote fuel tank with the special fuel mix to the fuel inlet fitting.

7. Start the engine and run the engine at 1300 RPM for five minutes. This is usually enough time for the special fuel mix to circulate through the fuel system. Check to ensure there are no oil leaks. Shut the engine off.

IMPORTANT: Do not allow the engine to run out of fuel.

8. Disconnect the special fuel mix hose from the inlet fitting. Connect the boat fuel tank hose to the inlet fitting. Open the fuel shut off valve, if equipped.

9. Change the oil and oil filter.

10. Replace the water separating fuel filter element where applicable.

11.

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

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NOTICE

12. Fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect the engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage. This will also prevent the formation of exfoliating rust in the cooling system passages.

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

Draining the Seawater System

CAUTION

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. Ensure 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.

Drain System Identification

Air-Actuated Single-Point Drain System

a - Manual pressure release valve b - Threaded cap for air connection c - Green indicators

a - Starboard side

air‑actuated drain location

b - Port side

air‑actuated drain location

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aba

50412

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Manual Drain System

a - Starboard side blue

drain plugs

b - Port side blue drain

plug

Air‑Actuated Single‑Point Drain System

Boat in the Water

NOTE: This procedure is written for the air pump that was shipped with the engine from the factory. However, any air source can be used.

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

2. Obtain the air pump.

3. Remove the threaded cap from the air connection.

4. Ensure that the lever on top of the air pump is against the handle (horizontal).

5. Install the air pump on the air connection.

a - Lever b - Air pump c - Air connection

6. Pull the lever on the air pump (vertical) to seal the pump to the connection.

7. 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 - Manual release valve b - Air pump lever (locked) c - Air connection d - Green indicators extended

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

a - Starboard side

air‑actuated drain location

b - Port side

air‑actuated 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. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit by pulling the fuse marked "CD."

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

12. Remove the air pump from the air connection 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.

14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a - Manual release valve pull ring b - Threaded cap on air connection c - 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 air pump that is attached to the engine. However, any air source can be used.

1. Place the boat on a level surface and ensure the boat is level.

2. Obtain the air pump.

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

4. Install the air pump on the air connection.

Lever

a b - Air pump c - Air connection

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5. Pull the lever on the air pump (vertical) to seal the pump to the air connection.

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 - Manual release valve b - Air pump lever (locked) c - Air connection d - Green indicators extended

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

a - Starboard side

air‑actuated drain location

b - Port side

air‑actuated 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. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit by pulling the fuse marked "CD."

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

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

12. 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.

13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a - Manual release valve pull ring b - Threaded cap c - Green indicators

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aba

50412

aba

50412

Manual Drain System

Boat in the Water

NOTE: Use this procedure if the air‑actuated single‑point drain system fails to drain the system. NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are disconnected.

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

2. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

a - Starboard side blue

drain plugs

b - Port side blue drain

plug

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.

5. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit by pulling the fuse marked "CD."

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

7. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain plugs.

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

Boat Out of the Water

NOTE: Use this procedure if the air‑actuated single‑point drain system fails. NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are disconnected.

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

2. Remove two blue drain plugs from the seawater pickup pump (front, starboard side).

a - Starboard side blue

drain plugs

b - Port side blue drain

plug

3. Verify that water is draining from each opening.

5. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit by pulling the fuse marked "CD."

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

7. Prior to launching the boat or starting the engine, close the drain system by installing the two blue drain plugs.

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Draining Water from the Cool Fuel Module

Mercury MerCruiser recommends draining the Gen 3 Cool Fuel Module if it is equipped with a drain plug.

1. Remove the drain plug from the Gen 3 Cool Fuel Module and allow the water to completely drain from the module.

2. Inspect the drain plug and the O‑ring for damage. Replace if needed.

3. Place the O‑ring on the drain plug and apply Perfect Seal to the threads. Install the drain plug in the module drain hole. Tighten the drain plug to finger‑tight.

a - Gen 3 Cool Fuel Module b - Drain plug c - O‑ring

Tube Ref No. Description Where Used Part No.

Perfect Seal Drain plug threads 92-34227Q02

Battery Storage

Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for storage.

Recommissioning the Power Package

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.

CAUTION

Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.

2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable clamp securely when connecting.

3. Coat the terminal connections with a battery terminal anticorrosion agent.

Perform all the checks in the Operation Chart.

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.

5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly.

6. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.

7. Inspect the steering system, shift and throttle control for proper operation.

90-8M0113925 eng DECEMBER 2015 Page 57

Page 66

Section 5 - Storage

Notes:

Page 58 90-8M0113925 eng DECEMBER 2015

Page 67

Table of Contents

Section 6 - Troubleshooting

Diagnosing EFI Problems..................................................... 60

Diagnosing DTS Problems................................................... 60

Engine Guardian System...................................................... 60

Troubleshooting Charts........................................................ 60

Starter Motor Will Not Crank Engine, or Cranks Slowly.60

Engine Will Not Start or Is Hard to Start........................ 60

Engine Runs Rough, Misses, or Backfires.................... 61

Poor Performance..........................................................61

Excessive Engine Temperature..................................... 61

Insufficient Engine Temperature.................................... 61

Low Engine Oil Pressure............................................... 62

Battery Will Not Recharge............................................. 62

Remote Control Is Difficult to Move or Makes Unusual

Sounds...........................................................................62

Steering Wheel Jerks or Is Difficult to Turn................... 62

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Section 6 - Troubleshooting

Diagnosing EFI Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on electronic fuel injection (EFI) systems. The engine control module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECMs memory. This code can then be read later by a service technician using a special diagnostic tool.

Diagnosing DTS Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory. This code can then be read later by a service technician using a special diagnostic tool.

Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. The system will respond to a problem by emitting a continuous beep and/or reducing engine power in order to provide engine protection.

If Guardian System has been activated, reduce throttle speed. The horn will turn off when throttle speed is within the allowable limit. Consult an authorized Mercury MerCruiser dealer for assistance.

Troubleshooting Charts

Starter Motor Will Not Crank Engine, or Cranks Slowly

Possible Cause

Battery switch turned off. Turn the switch on.

Remote control not in neutral position. Position the control lever in neutral.

Check and reset the main power circuit breaker or replace the fuse. Check the

Open circuit breaker or fuse.

Loose or dirty electrical connections or damaged wiring.

Bad battery or low battery voltage. Test the battery and charge if necessary; replace if bad.

Lanyard stop switch activated. Check the lanyard stop switch.

5‑amp fuse on the power harness connected to the battery, and replace if necessary.

Check all electrical connections and wires (especially battery cables). Clean and tighten all faulty connections.

Remedy

Engine Will Not Start or Is Hard to Start

Possible Cause

Lanyard stop switch activated. Check the lanyard stop switch.

Improper starting procedure. Read the starting procedure.

Insufficient fuel supply. Fill fuel tank or open valve.

Faulty ignition system component. Service the ignition system.

Clogged fuel filter. Replace fuel filter.

Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.

Fuel line or tank vent line kinked or clogged.

Faulty wire connections. Check wire connections.

EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer.

Replace kinked lines or blow out lines with compressed air to remove obstruction.

Remedy

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Section 6 - Troubleshooting

Engine Runs Rough, Misses, or Backfires

Possible Cause Remedy

Clogged fuel filter. Replace filter.

Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.

Kinked or clogged fuel line or fuel tank vent line.

Flame arrestor dirty. Clean the flame arrestor.

Faulty ignition system component. Service ignition system.

Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer.

EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer.

Replace kinked lines or blow out lines with compressed air to remove obstruction.

Poor Performance

Possible Cause

Throttle not fully open. Inspect the throttle cable and linkages for proper operation.

Damaged or improper propeller. Replace the propeller.

Excessive bilge water. Drain and check for cause of entry.

Boat overloaded or load improperly distributed. Reduce load or redistribute load more evenly.

Flame arrestor dirty. Clean the flame arrestor.

Boat bottom fouled or damaged. Clean or repair as necessary.

Ignition problem.

Engine overheating.

EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer.

See Engine Runs Rough, Misses, or Backfires.

See Excessive Engine Temperature.

Remedy

Excessive Engine Temperature

Possible Cause

Water inlet or seacock closed. Open.

Drive belt loose or in poor condition. Replace or adjust belt.

Seawater pickups or sea strainer obstructed. Remove obstruction.

Faulty thermostat. Replace.

Coolant level (if equipped) low in closed cooling section.

Heat exchanger or fluid cooler plugged with foreign material.

Loss of pressure in closed cooling section. Check for leaks. Clean, inspect, and test pressure cap.

Faulty seawater pickup pump. Repair.

Seawater discharge restricted or plugged. Clean exhaust elbows.

Check for cause of low coolant level and repair. Fill system with proper coolant solution.

Clean heat exchanger, engine oil cooler, and transmission oil cooler (if equipped).

Remedy

Insufficient Engine Temperature

Possible Cause

Faulty thermostat. Replace.

90-8M0113925 eng DECEMBER 2015 Page 61

Remedy

Page 70

Section 6 - Troubleshooting

Low Engine Oil Pressure

Possible Cause Remedy

Insufficient oil in crankcase. Check and add oil.

Excessive oil in crankcase (causing it to become aerated).

Diluted or improper viscosity oil.

Check and remove required amount of oil. Check for cause of excessive oil (improper filling).

Change oil and oil filter, using correct grade and viscosity oil. Determine cause for dilution (excessive idling).

Battery Will Not Recharge

Possible Cause Remedy

Excessive current draw from battery. Turn off nonessential accessories.

Alternator drive belt loose or in poor condition. Replace and/or adjust.

Unacceptable battery condition. Test battery, replace if necessary.

Loose or dirty electrical connections or damaged wiring.

Faulty alternator. Test alternator output, replace if necessary.

Check all associated electrical connections and wires (especially battery cables). Clean and tighten faulty connections. Repair or replace damaged wiring.

Remote Control Is Difficult to Move or Makes Unusual Sounds

Possible Cause

Incorrect friction adjustment. Change friction adjustment.

Incorrect detent adjustment. Change detent adjustment.

Friction pad in the remote control worn. Replace the remote control.

Steering Wheel Jerks or Is Difficult to Turn

Possible Cause

Low power steering pump fluid level. Check for leak. Refill system with fluid.

Drive belt loose or in poor condition. Replace and/or adjust.

Insufficient lubrication on steering components. Lubricate.

Loose or missing steering fasteners or parts.

Contaminated power steering fluid. See authorized Mercury MerCruiser dealer.

Check all parts and fasteners. If any are loose or missing, see authorized Mercury MerCruiser dealer immediately.

Remedy

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Page 71

Section 7 - Customer Assistance Information

Table of Contents

Section 7 - Customer Assistance Information

Owner Service Assistance.................................................... 64

Local Repair Service .................................................... 64

Service Away From Home ............................................ 64

Stolen Power Package ................................................. 64

Attention Required After Submersion ........................... 64

Replacement Service Parts .......................................... 64

Parts and Accessories Inquiries ............................ 64

Resolving a Problem .................................................... 64

Contact Information for Mercury Marine Customer

Service ......................................................................... 65

Customer Service Literature................................................. 65

English Language ......................................................... 65

Other Languages .......................................................... 66

Ordering Literature............................................................... 66

United States and Canada ........................................... 66

Outside the United States and Canada ........................ 66

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Section 7 - Customer Assistance Information

Owner Service Assistance

Local Repair Service

If you need service for your Mercury MerCruiser‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.

NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser sterndrives and inboards.

Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. If, for any reason, you cannot obtain service, contact the nearest regional service center. Outside the United States and Canada, contact the nearest Marine Power International service center.

Stolen Power Package

If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

Attention Required After Submersion

1. Before recovery, contact an authorized Mercury MerCruiser dealer.

2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage.

Replacement Service Parts

WARNING

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

Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both fresh and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine engine parts because specifications are different from those of the standard automotive engine. For example, one of the most important special replacement parts is the cylinder head gasket. Marine engines cannot use steel‑type automotive head gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.

Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve springs, valve lifters, pistons, bearings, camshafts, and other heavy‑duty moving parts.

Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.

Parts and Accessories Inquiries

Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has the necessary information to order parts and accessories for you. Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring about parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.

Resolving a Problem

Satisfaction with your Mercury MerCruiser product is important to your dealer and to us. If you ever have a problem, question, or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need additional assistance:

1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem.

2. If your question, concern, or problem cannot be resolved by your dealership, please contact a Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.

The following information will be needed by Customer Service:

• Your name and address

• Daytime telephone number

• Model and serial numbers for your power package

• The name and address of your dealership

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Section 7 - Customer Assistance Information

• Nature of the problem

Contact Information for Mercury Marine Customer Service

For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.

United States, Canada

Telephone

Fax

Website www.mercurymarine.com

Australia, Pacific

Telephone +61 3 9791 5822 Brunswick Asia Pacific Group

Fax +61 3 9706 7228

Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe

Fax +32 87 31 19 65

English +1 920 929 5040 Français +1 905 636 4751

English +1 920 929 5893 Français +1 905 636 1704

41–71 Bessemer Drive Dandenong South, Victoria 3175 Australia

Parc Industriel de Petit-Rechain B-4800 Verviers, Belgium

Mercury Marine W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939

Mexico, Central America, South America, Caribbean

Telephone +1 954 744 3500 Mercury Marine

11650 Interchange Circle North

Fax +1 954 744 3535

Japan

Telephone +072 233 8888 Kisaka Co., Ltd.

4-130 Kannabecho Sakai-shi Sakai-ku

Fax +072 233 8833

Asia, Singapore

Telephone +65 65466160 Brunswick Asia Pacific Group

Fax +65 65467789

5900984 Osaka, Japan

T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore, 508944

Miramar, FL 33025 U.S.A.

Customer Service Literature

English Language

English language publications are available from: Mercury Marine Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939

Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information.

When ordering be sure to:

• List your product, model, year, and serial numbers.

• Check the literature and quantities you want.

90-8M0113925 eng DECEMBER 2015 Page 65

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Section 7 - Customer Assistance Information

• Enclose full remittance in check or money order (NO COD).

Other Languages

To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.

Ordering Literature

Before ordering literature, have the following information about your power package available:

Model Serial Number

Horsepower Year

United States and Canada

For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:

Mercury Marine

Telephone Fax Mail

Mercury Marine

(920) 929‑5110

(USA only)

(920) 929‑4894

(USA only)

Attn: Publications Department

P.O. Box 1939

Fond du Lac, WI 54936-1939

Outside the United States and Canada

Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package.

Mercury Marine Submit the following order form with payment to:

Ship To: (Copy this form and print or type–This is your shipping label)

Name

Address

City, State, Province

ZIP or postal code

Country

Quantity Item Stock Number Price Total

Attn: Publications Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54936-1939

. .

Total Due .

Page 66 90-8M0113925 eng DECEMBER 2015

Page 75

Section 8 - Checklists

Table of Contents

Predelivery Inspection (PDI)................................................. 68 Customer Delivery Inspection (CDI)..................................... 69

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Page 76

Section 8 - Checklists

Predelivery Inspection (PDI)

IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI).

Check/

N/A

Adjust

  Service bulletin updates or repairs completed

  Seawater inlet valve open

  Engine alignment

  Drive unit fasteners tightened to specifications

  Power trim cylinders fasteners tight

  Test OBDM warning system and MIL (light) operation (EC models only)

  Power trim oil level

  Sterndrive unit oil level

  Power steering fluid level

  Closed cooling fluid level

  Transmission fluid level

  V‑engines: serpentine belt tension

  Alternator belt tension (3.0L)

  Power steering pump belt tension (3.0L)

  SmartCraft gauges calibrated, if equipped

  Warning system operation

  Trim limit switch operation

Item

 Drain plug installed and drain valves closed

 Engine mounts tight

 Battery of proper rating, fully charged, secured, with protective covers in place

 All electrical connections tight

 Exhaust system hose clamps tight

 All fuel connections tight

 Correct propeller selected, installed, and tightened to specifications

 Throttle, shift, and steering system fasteners tightened to specifications

 Steering operation throughout range

 Throttle plates open and close completely

 Crankcase oil level

Page 68 90-8M0113925 eng DECEMBER 2015

Page 77

Section 8 - Checklists

Predelivery Inspection Checklist, Continued

Check/

N/A

Adjust

  Engine alignment (Inboard models only)

  EC models: run two full operating cycles (key on/off) to WOT with engine at normal operating temperature

  Power trim operation

  Boat handling

  CARB hang tag in boat

  CARB decal properly affixed to boat hull

Item

On‑the‑Water Test

 Starter neutral safety switch operation

 E‑stop switch/lanyard stop switch operation (all helms)

 Seawater pump operation

 Operation of instruments

 Fuel, oil, and water leaks

 Exhaust leaks

 Ignition timing

 Forward, neutral, and reverse gear operation

 Steering operation throughout range

 Acceleration from idle RPM is normal

 WOT________ RPM within specification (in forward gear)

while monitoring engine with G3 CDS to verify engine goes into closed‑loop engine control.

After On‑the‑Water Test

 Propeller nut tightened to specification

 Fuel, oil, coolant, water, and fluid leaks

 Oil and fluid levels

 Apply Quicksilver Corrosion Guard to engine package

 Operation, Maintenance & Warranty manual in boat

If Boat Is Registered to a Resident of California

Customer Delivery Inspection (CDI)

N/A

Completed Item

 Operation and Maintenance manual—provide and review with customer. Emphasize the importance of

safety warnings and Mercury engine testing procedures.

 Approve the external appearance of the product (paint, cowl, decals, etc.)

 Warranty—provide and explain the limited warranty to the customer. Explain dealer services.

  Explain the optional Mercury Product Protection Plan (North America only)

Operation of equipment—explain and demonstrate:

 E‑stop switch/lanyard stop switch operation (all helms)

 Cause and effect of steering torque or pull; instruct on using a firm steering grip; explain boat spin‑out and

how to trim for neutral steering

  U.S. Coast Guard capacity plate

 Proper seating

 Importance of personal flotation devices (PFDs or life vests) and throwable PFDs (throw cushions)

90-8M0113925 eng DECEMBER 2015 Page 69

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Section 8 - Checklists

N/A Completed Item

  Functions of SmartCraft accessories (if applicable)

 Off‑season storage and maintenance schedule

 Engine (starting, stopping, shifting, using throttle)

 Boat (lights, battery switch location, fuses/breakers)

  Trailer (if applicable)

Registration:

 Complete and submit warranty registration—provide the customer with a copy

Page 70 90-8M0113925 eng DECEMBER 2015

Page 79

Section 9 - Maintenance Log

Table of Contents

Scheduled Maintenance Log................................................ 72 Vessel Maintenance Notes................................................... 73

90-8M0113925 eng DECEMBER 2015 Page 71

Page 80

Section 9 - Maintenance Log

Scheduled Maintenance Log

Actual Hours

Service Notes

Dealer Name

Actual Hours

Service Notes

Dealer Name

Actual Hours

Service Notes

Dealer Name

100 Hours

Signature

200 Hours

Signature

300 Hours

Signature

Date

Actual Hours

Service Notes

Dealer Name

Actual Hours

Service Notes

Dealer Name

Actual Hours

Service Notes

Dealer Name

400 Hours

Signature

500 Hours

Signature

600 Hours

Signature

Date

Page 72 90-8M0113925 eng DECEMBER 2015

Page 81

Section 9 - Maintenance Log

Vessel Maintenance Notes

Record all general maintenance performed on your power package here. Save all work orders and receipts.

Date

Engine

Hours

Maintenance Completed Servicing Dealer

90-8M0113925 eng DECEMBER 2015 Page 73

Page 82

Page 83

www.mercurymarine.com.au

41-71 Bessemer Drive

Dandenong South, Victoria 3175 Australia

www.mercurymarine.com

P.O. Box 1939

Fond du Lac, WI 54936-1939 USA

www.brunswick-marine.com

Parc Industriel de Petit-Rechain

B-4800 Verviers, Belgium

Printed in U.S.A.

90-8M0113925 NOVEMBER 2015

Mercury MerCruiser 8.2 Horizon ECT Maintance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Welcome

Read This Manual Thoroughly

Notice

8.2 H.O./Horizon ECT

Warranty Message

Copyright and Trademark Information

Identification Records

TABLE OF CONTENTS

Identification

Information Decal

Quick Response (QR) Code

Engine Serial Number

Lanyard Stop Switch

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Instrumentation

VesselView

Front Controls

Troll Control Speed Range Specification

Digital Gauges

Analog Gauges

Remote Controls (DTS Models)

Remote Controls

Panel Mount Features

DTS Slim Binnacle Single Handle Console Features and Operation

Special Digital Throttle and Shift (DTS) Features

Operation

Adjustment

Special Digital Throttle and Shift (DTS) Features

Dock

Throttle Only

1 Lever

Sync

Transfer (Boats equipped with dual helms)

Helm Transfer

Zero Effort Features

Electrical System Overload Protection

Visual and Audio Warning Systems

Testing the OBD-M Malfunction Indicator Lamp (MIL)

Audio Warning System

Caution

Critical

Nonconfigured Alarm–DTS Only

Testing the Audio Warning System

Guardian Strategy

Transmission Guardian Strategy

Safe Boating Recommendations

Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning

Stay Clear of Exhaust Areas

Good Ventilation

Poor Ventilation

Basic Boat Operation (DTS Models)

Launching and Boat Operation

Operation Chart

Starting and Stopping the Engine

Starting the Engine

Stopping the Engine

Throttle Only Operation

Freezing Temperature Operation

Drain Plug and Bilge Pump

Protecting People in the Water

While You Are Cruising

While Boat Is Stationary

Passenger Safety in Pontoon Boats and Deck Boats

Boats Having an Open Front Deck

Wave and Wake Jumping

Impact with Underwater Hazards

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat

The Bottom of the Boat

Cavitation

Elevation and Climate

Getting Started

End of First Season Checkup

Cruising RPM

Fuel Requirements