Mercury Racing Sterndrive 600SCi User Manual

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Declaration of Conformance – Mercury Racing Sterndrive 600SCi (600 HP)

Manufacturer:

Mercury Racing N7480 County Road UU Fond du Lac, WI 54935 USA

Authorized Representative:

Marine Power Europe, Inc. Parc Industriel de Petit-Rechain B-2800 Verviers, Belgium

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

Applicable Requirement Standards Applied

Owner’s manual (A.2.5) ISO 10240

Handling characteristics (A.4) ISO 8665

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

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

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

General Steering System (A.5.4.1)

Applicable portions of: ABYC P‑21; EN ISO 10592

Exhaust emission requirements (B.2)

ISO 8178‑1

Owner’s manual (B.4) ISO 8665

Module used for exhaust emission assessment: Modules B+C,

EC‑Type Examination Certificate No.: EXMERC001.

The notified body responsible for EC‑Type Examination for the engine exhaust emissions assessment is

IMCI Rue Abbe Cuypers 3 B – 1040, Brussels – Belgium

Notified Body No.: 0609

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Engine Type: Sterndrive

Fuel Type: Gasoline

Combustion Cycle: 4 Stroke

Engine Family Name: 600SCi

Starting Serial Number: 0M955821

Electromagnetic Compatibility Directive 89/336/EC

Generic emission standard BS EN 61000‑6‑3

Generic immunity standard BS EN 61000‑6‑1

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

SAE J551; CISPR 12

Electrostatic discharge testing BS EN 61000‑4‑2; BS EN 61000‑4‑3

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

Patrick C. Mackey

President ‑ Mercury Marine, Fond du Lac, WI USA

Regulatory contact: Engineering - Regulations Mercury Racing N7480 County Road UU Fond du Lac, WI 54935-9585 USA

Thank You

for your purchase of one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability.

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

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iii

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

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

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

7406

Warranty Message

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

WARNING

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

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WARNING

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

Safety Alerts and Notices

Throughout this publication, "Warnings" and "Cautions,"

accompanied by the international HAZARD symbol

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

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

WARNING

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

CAUTION

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

IMPORTANT: Indicates information or instructions that are necessary for a particular step or action.

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

Page 5

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

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TABLE OF CONTENTS

vii

Warranty Information

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

Transfer Of Warranty...................................................................1

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

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

3 Year Limited Warranty Against Corrosion................................7

Warranty Coverage and Exclusions for Mercury Racing Sterndrive

Products.....................................................................................10

General Information

Boater's Responsibilities............................................................12

Boat Horsepower Capacity........................................................12

High-Speed and High-Performance Boat Operation.................13

Paddle Wheel and Water Temperature Sensors.......................13

Lanyard Stop Switch..................................................................13

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

Protecting People In The Water.................................................15

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

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

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

Operating in Shallow Water.......................................................20

Safe Boating Suggestions.........................................................22

Stolen Power Package..............................................................25

Specifications

Engine Identification..................................................................26

General Engine Specifications...................................................27

Engine Operating Limitations (HP600)......................................28

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

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

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

California Emissions Regulations..............................................32

Engine Break-in.........................................................................32

After Break-In Period.................................................................33

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TABLE OF CONTENTS

viii

Operation

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

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

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

Remote Controls (Console Mounted Zero Effort)......................42

Remote Controls........................................................................43

Power Trim................................................................................46

Freezing Temperature Operation..............................................53

Starting, Shifting and Stopping..................................................53

Operation Chart.........................................................................55

Drain Plug and Bilge Pump........................................................56

Launching And Boat Operation Care.........................................57

Conditions Affecting Operation

Weight Distribution.....................................................................58

Bottom Of Boat..........................................................................58

Cavitation...................................................................................58

Ventilation..................................................................................59

Propeller Selection.....................................................................59

Conditions That Lower Engine Performance.............................60

Maintenance

Special Tools.............................................................................61

Servicing High Horsepower Engines.........................................62

Service Responsibilities.............................................................62

Replacement Service Parts.......................................................63

Do-It-Yourself Maintenance Suggestions..................................64

Engine Maintenance Charts......................................................65

Bravo Drive Maintenance Charts...............................................67

Checking Fluid Levels................................................................69

Changing Fluids.........................................................................76

Lubrication.................................................................................89

Propellers...................................................................................92

Flushing the Power Package.....................................................96

Seawater Pump Impeller Inspection..........................................99

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TABLE OF CONTENTS

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

Power Steering, and Fuel Coolers...........................................100

Serpentine and Supercharger Drive Belts...............................102

Fuel Filters...............................................................................107

Corrosion and Corrosion Protection........................................109

Battery.....................................................................................114

Bottom of Boat.........................................................................115

Inspection and Maintenance....................................................115

Attention Required After Submersion......................................116

Cold Weather or Extended Storage

Power Package Lay-up............................................................117

Draining Instructions................................................................119

Battery Winter Storage............................................................123

Power Package Recommissioning..........................................123

Troubleshooting

Engine Will Not Crank .............................................................127

Engine Cranks But Will Not Start.............................................128

Engine Hard to Start, Runs Rough, Misses, and/or Backfires. 128

Poor Performance....................................................................129

Engine Coolant Temperature Too Low....................................129

Engine Coolant Temperature Too High...................................130

Low Engine Oil Pressure.........................................................130

Power Trim Does Not Operate (Motor Doesn't Run)...............131

Battery Will Not Come Up On Charge.....................................131

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

Not Move)................................................................................131

Electrical Analog Trim Gauge Malfunction...............................132

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

or Makes Unusual Sounds.......................................................132

Steering Wheel Turns Hard or Jerky.......................................132

Seawater Pressure Is Below Specification..............................133

Seawater Pressure Is Above Specification..............................133

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TABLE OF CONTENTS

Owner Service Assistance

Local Repair Service................................................................134

Service Away From Home.......................................................134

Parts And Accessories Inquiries..............................................134

Service Assistance..................................................................134

Mercury Mercruiser Service Offices.........................................135

Ordering Literature

United States and Canada.......................................................137

Outside The United States and Canada..................................137

Maintenance Log

Maintenance Log.....................................................................138

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WARRANTY INFORMATION

Warranty Registration United States And Canada

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

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

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

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

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

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

Transfer Of Warranty

The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.

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WARRANTY INFORMATION

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

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

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

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

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

Mercury Racing Division One Year Limited Warranty

WHAT IS COVERED

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

DURATION OF COVERAGE

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

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WARRANTY INFORMATION

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

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

WHAT MERCURY WILL DO

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

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WARRANTY INFORMATION

HOW TO OBTAIN WARRANTY COVERAGE

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

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WARRANTY INFORMATION

WHAT IS NOT COVERED

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

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WARRANTY INFORMATION

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

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

Products Sold to Government Agencies

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

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

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WARRANTY INFORMATION

3 Year Limited Warranty Against Corrosion

WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing Outboard, Sport Jet, M2 Jet

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

DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to subsequent (non‑commercial use) purchaser upon proper re‑registration of the product.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat, and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants, and touch‑up of nicks and scratches) in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance.

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WARRANTY INFORMATION

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

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

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

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WARRANTY INFORMATION

Corrosion damage caused by stray electrical currents (on‑shore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty. If anti‑fouling protection is required, Tri‑Butyl‑Tin‑Adipate (TBTA) base anti‑fouling paints are recommended on Outboard and MerCruiser boating applications. In areas where TBTA base paints are prohibited by law, copper base paints can be used on the hull and transom. Do not apply paint to the outboard or MerCruiser product. In addition, care must be taken to avoid an electrical interconnection between the warranted product and the paint. For MerCruiser product, an unpainted gap of at least 38 mm (1.5 in.) should be left around the transom assembly. Refer to the Operation and Maintenance Manual for additional details.

For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty.

DISCLAIMERS AND LIMITATIONS:

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

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WARRANTY INFORMATION

Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products

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

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

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

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

GENERAL EXCLUSIONS FROM WARRANTY

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

2. Damage caused by lack of maintenance.

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

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

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WARRANTY INFORMATION

5. Labor performed by other than an authorized dealer may be covered only under following circumstances: When performed on emergency basis (providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility).

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

7. Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition, which could result in a failure, condition responsible for noise should be corrected under the warranty.

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

9. Water in the starter motor.

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

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

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GENERAL INFORMATION

Boater's Responsibilities

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

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

Boat Horsepower Capacity

WARNING

Avoid serious injury, death or property damage from overpowering a boat. Using a power package that exceeds the maximum horsepower limit of a boat can:

• Cause loss of boat control.

• Place too much weight at the transom altering the designed flotation characteristics of the boat

• Cause the boat to break apart, particularly around the transom area.

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

U.S. COAST GUARD CAPACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS) XXX

MAXIMUM WEIGHT CAPACITY XXX

ob00306

Page 23

GENERAL INFORMATION

High‑Speed and High‑Performance Boat Operation

If your power package is to be used on a high speed or high performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat/ power package combination. For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

Paddle Wheel and Water Temperature Sensors

Paddle wheels cannot be utilized on vessels that are capable of speeds in excess of 50 mph. Water temperature sensors cannot be connected to Race Sterndrive engines that are equipped with a Propulsion Control Module (PCM). The water temperatue sensor connection is utilized by the PCM for monitoring engine oil temperature.

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.

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GENERAL INFORMATION

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

21629

a - Lanyard cord b - Lanyard stop switch

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

WARNING

Should the operator fall out of the boat, the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both ends of the stop switch lanyard to the stop switch and the operator.

WARNING

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

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

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GENERAL INFORMATION

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

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

• Loss of control when docking.

Trailering Boat

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

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

Protecting People In The Water

WHILE YOU ARE CRUISING

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

21604

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

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

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GENERAL INFORMATION

WHILE BOAT IS STATIONARY

WARNING

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

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

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

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

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

WARNING

Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death.

POOR VENTILATION

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

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

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GENERAL INFORMATION

While Boat Is Stationary

21626

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

space.

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

While Boat is Moving

5449

a - Running the boat with the trim angle of the bow too high. b - Running the boat with no forward hatches open (station

wagon effect).

GOOD VENTILATION

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

5448

Page 28

GENERAL INFORMATION

Wave And Wake Jumping

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

5450

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

WARNING

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

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

Page 29

GENERAL INFORMATION

Impact With Underwater Hazards

WARNING

Avoid serious injury or death. When operating in shallow water or areas with underwater obstacles, maintain a minimum and safe speed.

Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the sterndrive or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed. Under these conditions, boat speed should be kept to a minimum planing speed 24 to 40 km/h (15 to 25 MPH)

7462

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

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

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

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

• Impact damage to the sterndrive and/or boat.

Page 30

GENERAL INFORMATION

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

WARNING

Avoid serious injury or death from loss of boat control due to sudden component failure. Do not operate a boat with impact damage. Have the power package inspected and repaired as necessary.

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

The boat should also be checked for any hull fractures, transom fractures, or water leaks.

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

Operating in Shallow Water

CAUTION

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

Page 31

GENERAL INFORMATION

Extreme care should be exercised when operating a boat equipped with only low water inlets while maneuvering in shallow water. Due to a small amount of total water inlet area, there is high suction at the water inlets. These inlets will easily clog with bottom contact and are susceptible to clogging when operated in shallow or weedy water.

23755

Low Water Inlet and Sportmaster Gearcase

a - Low water pick‑up

gearcase

b - Sportmaster gearcase

The design of the dual water inlet gear case reduces the risk of restricting or shutting off the water supply to the engine, but caution should still be used when operating in shallow or weedy water.

CLEARING A DUAL WATER INLET GEAR CASE

1. Idle the boat out to deep water.

2. Bring the boat up on plane but operate at a moderate speed until the engine temperature and block water pressure returns to normal.

Page 32

GENERAL INFORMATION

NOTE: Engine block pressure at the gauge can still be low if the line to the gauge is clogged.

7759

Dual Water Inlet Gear Case

a - Strut inlets b - Low water inlets

Safe Boating Suggestions

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

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

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

Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.

Check safety equipment on-board. Here are suggestions of the types of safety equipment to carry when boating:

• Approved fire extinguisher; paddle or oar.

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

• Spare propeller, thrust hubs and an appropriate wrench.

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

Page 33

GENERAL INFORMATION

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

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

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

• Transistor radio and drinking water.

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

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

Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by:

• The U.S. Coast Guard Auxiliary

• The Power Squadron

• The Red Cross

• Your state boating law enforcement agency

Direct all inquiries to the Boating Hotline, 1‑800‑368‑5647 or the Boat U.S. Foundation information number 1‑800‑336‑BOAT.

We strongly recommend that all powerboat operators attend one of these courses.

You should also review the NMMA Sources of Waterway Information booklet. It lists regional sources of safety, cruising and local navigation and is available at no charge by writing to:

Sources of Waterway Information

National Marine Manufacturers Association

410 N. Michigan Avenue

Chicago, IL 60611 U.S.A.

Make sure everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the back of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat; or anywhere that an unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the boat.

Page 34

GENERAL INFORMATION

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

Know your boating area and avoid hazardous locations.

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

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

Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operators view when operating the boat above idle speed.

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

Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to assist the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if:

1. There is loss of life or probable loss of life

2. There is personal injury requiring medical treatment beyond first aid

3. There is damage to boats or other property where the damage value exceeds $500.00

4. There is complete loss of the boat

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

Page 35

GENERAL INFORMATION

Stolen Power Package

If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This Stolen Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines.

Page 36

SPECIFICATIONS

Engine Identification

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

Spark Timing: Fuel Octane:

Engine Oil:

Engine Coolant:

**see owner's manual

HP600 SCi 502 C.I.D.

4800 - 5200 NGK BPR6ES

0.035 Inch **non-adjustable

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

**Kendall GT-1

Dex-Cool ®

SERIAL NUMBERS

ENGINE

DRIVE

TRANSOM

SAE 20W50

10013

a - Engine identification placard

Record the serial numbers from the engine placard in the space provided below.

Serial Numbers

Engine

Drive

Transom

Page 37

SPECIFICATIONS

General Engine Specifications

Horsepower 600 HP (447 kW)

Displacement 8.2 L (502 c.i.)

Cylinder arrangement V‑8

Bore 114 mm (4.47 in.)

Stroke 102 mm (4.00 in.)

Compression ratio 7.5:1

Supercharger 3.3 L Screw‑type compressor

Altenator 65 amp / 917 watt

Battery requirements 750 CCA 950 MCA

Ignition type PCM 03 Distributorless

Spark plug type NGK BPR6ES

Spark plug gap 0.889 mm (0.035 in.)

Fuel system Sequential Fuel Injection

Length (transom mount to front of engine) 907 mm (35.7 in.)

Width 838 mm (33.0 in.)

Height 691 mm (27.2 in.)

Weight 575 kg / 1267 lbs

Page 38

SPECIFICATIONS

Engine Operating Limitations (HP600)

Maximum wide open throttle (W.O.T.) RPM

4800 ‑ 5200 RPM

Rev limit 5400 RPM

Idle RPM in gear 700 RPM

Idle RPM out of gear 750 RPM

Maximum fuel system flow rate 211 L/hr (56 gals/hr) at 5200 RPM

Fuel pressure at idle 407 to 421 kPa (59 to 61 psi)

Fuel pressure at 5200 RPM 469 to 496 kPa (68 to 72 psi)

Coolant thermostat initially opens at temperature

62° C (143° F)

Coolant thermostat is at maximum open at temperature

70° C (158° F)

Minimum water pressure supplied to the engine

207 kPa (30 psi) at 5200 RPM (from oil cooler sensor)

Maximum water pressure supplied to the engine

290 kPa (42 psi) at 5200 RPM (from oil cooler sensor)

Minimum oil pressure at idle (Hot) 138 kPa (20 psi)

Minimum oil pressure at 5200 RPM (Hot) 331 kPa (48 psi)

Maxiumum oil temperature 85° C (185° F)

Fuel Requirements

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

WARNING

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

Page 39

SPECIFICATIONS

CAUTION

Use of improper fuel can seriously damage your engine. Engine damage resulting from use of improper fuel is considered misuse of the engine and damage caused thereby will not be covered under the Mercury Racing limited warranty.

OCTANE REQUIREMENTS (U.S./CANADA)

FUEL TYPE MINIMUM POSTED OCTANE

Premium Unleaded (R+M) ÷ 2 = 91 or RON = 98*

NOTE: *Research Octane Number

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

FUEL TYPE MINIMUM POSTED OCTANE

Premium Unleaded

(R+M) ÷ 2 = 91 or RON = 98*

NOTE: *Research Octane Number

USING REFORMULATED (OXYGENATED) FUELS (USA ONLY)

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

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

FUEL CONTAINING ALCOHOL

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

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

Page 40

SPECIFICATIONS

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

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

Fuel containing alcohol may increase:

• Corrosion of metal parts.

• Deterioration of rubber or plastic parts.

• Fuel permeation through rubber fuel lines.

• Starting and operating difficulties.

CAUTION

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

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

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

Page 41

SPECIFICATIONS

Oil Recommendations

ENGINE CRANKCASE OIL

Preferred Oils API Classification

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

Oil Filter Should Always Be Changed With Oil

SUPERCHARGER GEARCASE OIL

Preferred Oils API Classification

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

IMPORTANT OIL PRACTICES

Do Not Use

• Straight weight oils

• Non‑detergent oils

• Oils containing solid additives

• Multi‑viscosity oils other than the ones recommended

• Low quality oils

Do Not Mix

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

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

TEMPERATURE/OIL VISCOSITY CHART

Multi-viscosity

Oil

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

SJ, CF-2, CH-4

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

Kendall 20W 50

9160

Page 42

SPECIFICATIONS

Capacities

Model HP600 SCi

Crankcase Oil Capacity with New Filter

8 L (8.5 U.S. qts)

Supercharger Gearcase 177 ml ( 6 U.S. oz)

Bravo ‑ Drive Unit Oil Capacity (with Monitor)

2.65 L (2.8 U.S. qts)

Closed Cooling System 13 L (14 U.S. qts)

California Emissions Regulations

An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture.

EMISSION CONTROL INFORMATION

THIS ENGINE IS RATED AT GREATER THAN 500 HP

(CRANKSHAFT) AND IS THEREFORE EXEMPT FROM

CALIFORNIA EMISSIONS REGULATIONS FOR

SPARK - IGNITION MARINE ENGINES.

6104

Engine Break‑in

CAUTION

Severe damage to the engine can result by not complying with the engine break‑in proceedure. Engine damage may not be covered by the limited warranty.

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

Page 43

SPECIFICATIONS

5 Hr. Break‑in Procedure

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

• Do not exceed 3/4 throttle.

• Avoid full throttle acceleration from idle speed.

• Always vary throttle setting.

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

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

After Break‑In Period

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

After 5 hr. Break‑in

• Use a propeller that allows the engine to operate at or near the top of the maximum RPM range (See Specifications section) when at full throttle with a normal boat load.

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

• Follow the maintenance schedule in this manual.

Page 44

OPERATION

Instrumentation

It is important to monitor critical engine and boat functions while the boat is in operation. The SmartCraft boat information system uses gauges and/or a System View monitor screen to display the information.

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

• Oil pressure

• Engine RPM

• Oil temperature

• Water temperature

• System voltage

• Guardian fault messages

SmartCraft instruments display all of the above critical engine functions, as well as others not listed. SmartCraft instruments also display information about power train sensor faults and Guardian activation.

Warning System

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

CAUTION

Avoid engine damage. Do not operate the engine after a continous horn is heard, EXCEPT TO AVOID A HAZARDOUS SITUATION.

Page 45

OPERATION

ENGINE GUARDIAN SYSTEM

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

Fault Type and Related Warning Signal

• Critical ‑ Steady horn

• Severe ‑ 5 beeps, each 3 seconds long

• Warning ‑ 3 beeps, each 1.5 seconds long

• Caution ‑ 2 beeps, each 1 second long

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

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

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

WARNING SYSTEM TABLE

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

Page 46

OPERATION

Possible Cause Horn Monitor Display

Guardian

Activated and

Engine Power

Reduced

PCM Error Steady Horn Yes Forced Idle

Battery charging high

or low

Steady Horn Yes Yes

Low Seawater

Pressure

Steady Horn Yes Yes

Low Oil Pressure Steady Horn Yes Yes

Engine Overspeed Steady Horn Yes No

Charge Temperature

Overheat

Steady Horn Yes Yes

MAP Sensor Error Steady Horn Yes No

Oil Temperature High Steady Horn Yes No

Coil Pack Failure

5 Beeps‑3 Sec.

Long

Yes No

Fuel Injector Failure

5 Beeps‑3 Sec.

Long

Yes No

Fuel Pump Failure

5 Beeps‑3 Sec.

Long

Yes No

Idle Air Control

Failure

5 Beeps‑3 Sec.

Long

Yes No

Guardian Envoked

3 Beeps‑1.5 Sec.

Long

Yes No

Coolant Overheat

3 Beeps‑1.5 Sec.

Long

Yes Yes

Knock Sensor

3 Beeps‑1.5 Sec.

Long

Yes Yes

Charge Temperature

Sensor Failure

3 Beeps‑1.5 Sec.

Long

Yes No

Oil Temperature

Sensor Failure

3 Beeps‑1.5 Sec.

Long

Yes No

Cam Sensor

3 Beeps‑1.5 Sec.

Long

Yes No

Oil Pressure Sensor

Failure

3 Beeps‑1.5 Sec.

Long

Yes Yes

Page 47

OPERATION

Possible Cause Horn Monitor Display

Guardian

Activated and

Engine Power

Reduced

Fuel Pressure Sensor

Failure

3 Beeps‑1.5 Sec.

Long

Yes No

Block Pressure

Sensor Failure

3 Beeps‑1.5 Sec.

Long

Yes No

Charge Temperature

Sensor Failure

3 Beeps‑1.5 Sec.

Long

Yes No

Coolant Temperature

Sensor

3 Beeps‑1.5 Sec.

Long

Yes No

Throttle Position

Sensor

3 Beeps‑1.5 Sec.

Long

Yes Yes

Low Battery Voltage

2 Beeps‑1 Sec.

Long

Yes No

Low Drive Lube

2 Beeps‑1 Sec.

Long

Yes No

Electrical System Overload Protection

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

Page 48

OPERATION

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

7764

a - Reset button

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

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

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

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

10138

a - Ignition switch "I" terminal lead

Page 49

OPERATION

4. The power trim system is protected from overload by a 110 amp fuse and a 20 amp in‑line fuse on the power trim pump.

10121

a - 20 amp fuse holder b - 110 amp fuse

Page 50

OPERATION

5. The MerCathode system has a 20 amp in‑line fuse in the wire, which connects to the positive (+) terminal on the controller. If the fuse is open, the MerCathode system will not operate and a loss of corrosion protection will result.

MERCATHODE

7775

a - 20 amp in‑line fuse

6. A 90 amp fuse is located on the starter.

10309

a - Positive (+) battery cable b - 90 amp fuse c - Starter

Page 51

OPERATION

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

10310

a - Fuse holders (2)

Page 52

OPERATION

Fuse Holder ‑ C26 Fuse Holder ‑ C27

(1) ‑ 15 amp ‑ RED to RED/BLU constant power

(5) ‑ 20 amp ‑ RED/BLK to RED/PNK coil

(2) ‑ 5 amp ‑ PPL to PPL/WHT accessories

(6) ‑ 20 amp ‑ RED/GRN to RED/ WHT fuel injection

(3) ‑ 15 amp ‑ RED/GRN to RED/ORN hour meter

(7) ‑ 25 amp ‑ RED/BLK to RED/PNK fuel pump

(4) ‑ 15 amp ‑ RED to RED/PPL key switch/CAN power

(8) ‑ 20 amp ‑ RED/GRN to RED/BLU driver power

Remote Controls (Console Mounted Zero Effort)

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

CAUTION

Avoid possible engine damage. Never shift the unit into or out of gear unless the engine is at idle RPM.

Page 53

OPERATION

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

4090

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

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

Remote Controls

All controls feature an integral safety switch that allows starting the engine in neutral only. If the boat is equipped with a remote control other than that shown, consult your dealer for a description and/or demonstration of the control.

Page 54

OPERATION

7820

Page 55

OPERATION

1 - Neutral Lock Bar - Prevents accidental shift and throttle

engagement. The neutral lock bar must be pulled up to move the control handle out of neutral.

2 - Throttle Only Button - Allows throttle advancement

without shifting the engine by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position, and should only be used to assist in starting the engine.

3 - Power Trim Switch - See the Power Trim section for

detailed power trim operating procedures.

4 -

Trailer Switch (May not apply to all Bravo XR Drives) - See the Power Trim section for detailed trailer

switch operation.

5 - Lanyard Stop Switch - Turns the ignition off. See the

Lanyard Stop Switch section at the front of this manual for operation and safety warning on the use of this switch.

6 - Control Handle Tension Adjustment Screw - This

screw can be adjusted to increase or decrease the tension on the control handle. This will help prevent Creep of the remote control handle. Turn the screw clockwise to increase tension and Counter‑clockwise to decrease tension. Adjust to the tension desired.

7 - 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. Continue pulling back to increase speed.

8 - Power Trim Adjustment Switches - (Used on Three

Button Trim Control Only) ‑ See the Power Trim section for detailed power trim operating procedures.

Page 56

OPERATION

Power Trim

Power Trim allows the operator to adjust the drive unit(s) angle to provide the ideal boat angle for varying load and water conditions. The operator must use caution while underway to prevent trimming the drive unit up/out to far which could cause damage too the drive unit. Ideal drive unit trim angle while the boat is on plane is determined by boat transom and hull design. If the drive unit is trimmed up/out too far at high speeds, it could cause the boat to become extremely difficult to control.

Do not operate the engine over 1200 RPM when the drive unit's trim angle is greater than 12°. While operating the engine over 1200 RPM, a maximum trim angle of 12° beyond vertical is considered to be within mechanical limitations to prevent damage to the drive unit.

It is recommended that the boat is equipped with a trim indicator (s) in the dash so the operator is aware the drive unit's trim angle.

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

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

7418

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

Trimming Drive Unit Up/Out Can:

• Generally increase top speed.

Page 57

OPERATION

• Increase clearance over submerged objects or a shallow bottom.

• Cause the boat to accelerate and plane off slower.

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

7419

Trimming Drive Unit Down/In Can:

7420

• Help the boat accelerate and plane off quicker.

• Generally improve the ride in choppy water.

• In most cases, reduce boat speed.

• If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction, called bow steering or over steering, if any turn is attempted or if a significant wave is encountered.

Page 58

OPERATION

POWER TRIM OPERATION

Zero Effort Remote Control with Integral Trim Switch

WARNING

Avoid personal injury or damage to the sterndrive unit. Without trim limit protection, the drive unit can be trimmed up or out to a position where there is no drive unit side support from the gimbal ring.

Mercury recommends that a mechanical (cable actuated) or electrical trim position indicator be used to provide drive unit trim angle information to the operator, and that the trim gauge be marked clearly to indicate the maximum up or out position (12°) where side support is still provided.

The drive unit must not be trimmed to a position beyond the gimbal ring side support at engine speeds above 1200 RPM.

On boats equipped with multiple drives, each drive unit may be trimmed independently. There may be individual remote trim or trailer switches for each drive unit on the dash. It is important to equalize the units trim position by monitoring the trim position gauges or indicators. Or, if gauges/indicators are not available, trim the units fully down/in to equalize the units. Then, by operating the power trim with the integral trim switch on the Zero Effort Control handle, both drive units will trim simultaneously.

A boat builder may install a circuit breaker or fuse to protect the power trim equipment. Holding the trim switch or trailer button depressed after the drive unit reaches the end of its travel may cause the circuit overload protection to open.

Page 59

OPERATION

CAUTION

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

7868

1 - Trailering and trimming up/out position - Press the

(top) up/out portion of the switch until drive unit reaches desired trim/trailering position.

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

in/down portion of the switch until drive unit reaches desired trim position.

Page 60

OPERATION

Panel and Console Mount Remote Control Operation

WARNING

The drive unit must not be trimmed to a position beyond the gimbal ring side support at engine speeds above 1200 RPM.

On boats equipped with multiple drives, each drive unit may be trimmed independently. There may be individual remote trim or trailer switches for each drive unit. It is important to equalize the units trim position by monitoring the trim position gauges or indicators. Or, if gauges/indicators are not available, trim the units fully down/in to equalize the units. Then, by operating the power trim with the integral trim switch in the Console Mount Remote Control handle, both drive units will trim simultaneously.

CAUTION

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

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OPERATION

Page 62

OPERATION

7867

Page 63

OPERATION

1 - Integral Trim Control - Used to trim one or more drive

units simultaneously from the handle while the boat is underway. Press up on the switch to trim the drive unit (s) up/out. Press down on switch to trim drive unit(s) down/in.

2 - Trailer Button -Used to operate the power trim

through‑out its full range. This would be used to position the drive unit up/out to its trailering position. Press the button until drive unit reaches desired height for trailering drive units.

3 -

Independent Trim Control (Trim Adjustment Switches) - With a single integral trim switch in the

handle to control two drive units simultaneously, the independent trim control switches control each drive unit's trim independently. These switches can be used to fine tune the trim adjustment of each drive unit. Press the switches to set each drive unit to the desired trim angle. Then use the integral trim switch in the handle to control the trim of both drive units simultaneously.

Freezing Temperature Operation

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

Starting, Shifting and Stopping

WARNING

Avoid fire or explosion. Before starting the engine, operate the bilge blower for at least five minutes to remove any explosive fumes from the engine compartment. If the boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine.

NEW ENGINES OR ENGINES COMING OUT OF STORAGE

See Power Package Recommissioning.

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OPERATION

IMPORTANT: Observe the following:

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

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

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

Perform the following as appropriate:

Check all items listed in Operation Chart.

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

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

Place the control handle in neutral.

COLD OR WARM ENGINE

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

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

FLOODED ENGINE

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

STARTING PROCEDURE

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

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

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OPERATION

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

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

5. Ensure that the charging system is functioning correctly.

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

STARTING PROCEDURE IF ENGINE IS SHUT OFF OR STOPS WITH DRIVE UNIT IN GEAR

1. Pull/push remote control handle to neutral‑lock position (it will be necessary to exert force to move handle).

2. Turn the key to the "START" position momentarily, to release the clutch from gear.

3. Resume the normal starting procedure.

SHIFTING

1. To shift the drive unit into gear, move the control/shift lever with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse.

2. After shifting the drive unit, advance the throttle to the desired setting.

STOPPING

1. To shift the drive unit out of gear, throttle the engine back to idle speed, then move the control/shift lever to neutral. If the engine has been operating at high speed for a long period of time, allow the engine to cool by running at idle speed for three to five minutes.

2. Turn key switch to "OFF."

Operation Chart

Before Starting

Open the engine hatch.

Turn battery switch "ON," if equipped.

Operate bilge blowers, if equipped.

Open fuel shut off valve.

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OPERATION

Open seacock, if equipped.

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

After Starting

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

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

Check shift and throttle control operation.

Check steering operation.

While Underway

Observe all gauges to monitor engine condition.

After Stopping

Shift to neutral. Turn ignition key "OFF."

Turn battery switch "OFF," if equipped.

Close fuel valve.

Close seacock.

Flush cooling system if in saltwater area.

Drain Plug and Bilge Pump

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

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

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OPERATION

Launching And Boat Operation Care

CAUTION

Avoid product damage. The following situations could cause water to enter the engine

through the exhaust system, which could cause engine component failure:

• Unloading a boat from a trailer

• Slowing down rapidly or stopping suddenly

• Backing up rapidly

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

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CONDITIONS AFFECTING OPERATION

Weight Distribution

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

Shifting weight to rear (stern) may:

• Increase speed and engine RPM.

• Cause the boat to porpoise.

• Cause the bow to bounce in choppy water.

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

Shifting weight to front (bow) may:

• Improve ease of planing.

• Improve rough water ride.

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

Bottom Of Boat

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

• Clean and free of barnacles and marine growth.

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

• Straight and smooth both fore and aft.

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

Cavitation

Cavitation occurs when water flow cannot follow the contour of a fast‑moving, underwater object, such as a gear housing or propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housing or propeller. Common causes of cavitation are:

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

• Bent propeller blade or damaged gear housing skeg.

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

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CONDITIONS AFFECTING OPERATION

Ventilation

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

• A drive unit trimmed out too far.

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

• A drive unit installed too high on the transom.

Propeller Selection

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

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

IMPORTANT: All Mercury Racing engines have a RPM rev‑limiter that is set to an upper (or limited) RPM. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM. Once the RPM drops into the recommended operating RPM range, normal engine operation resumes.

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

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

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

• Operating in warmer weather and greater humidity

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CONDITIONS AFFECTING OPERATION

• Operating in a higher elevation

• Operating with a damaged propeller or dirty boat bottom

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

Conditions That Lower Engine Performance

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

• Above sea level elevations

• High temperature

• Low barometric pressure

• High humidity

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

• Boost pressure on supercharged engines

• Horsepower and torque throughout the RPM range

• Peak RPM

• Cranking compression

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

To compensate for power robbing conditions:

• Switch to a lower pitch propeller

• Change the gear ratio

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

Other advantages to propeller or gear ratio changes:

• Reduces the possibility of detonation

• Enhances overall reliability and durability of the engine

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MAINTENANCE

Special Tools

Dual Water Pick‑Up Flush Gear Case Seal Kit

91‑881150Q1

Description: Use to block‑off the front water inlet holes on the dual water inlet gearcases.

5321

Flushing Device 91‑44357Q2

Description: Attaches to the drive unit water intakes, provides a fresh water connection when flushing the cooling system or operating the engine.

4730

Flushing Kit 91‑849996T1

Description: Use for flushing drives with low water inlet gearcases.

5324

Flushing Attachment 91‑843122A01

14565

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

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MAINTENANCE

Servicing High Horsepower Engines

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

Service Responsibilities

OWNER/OPERATOR RESPONSIBILITIES

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

• Perform all safety checks.

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

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

• Perform normal maintenance service using authorized replacement parts.

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

DEALER RESPONSIBILITIES

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

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

• Properly equipping the boat.

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

• Making all necessary adjustments for maximum efficiency.

• Familiarizing the customer with the on‑board equipment.

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MAINTENANCE

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

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

Replacement Service Parts

WARNING

Avoid fire or explosion hazard. Electrical, ignition and fuel system components on Mercury Marine gasoline power packages are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize risks of fire or explosion.

Do not use replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations.

When servicing the electrical, ignition, and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks, if they existed.

Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in fresh and saltwater environments. These conditions require numerous special parts. Care should be exercised when replacing marine engine parts, as specifications are quite different from those of the standard automotive engine.

For example, one of the most important, and probably the least suspected special replacement part, is the cylinder head gasket. Since saltwater is highly corrosive, the steel‑type automotive head gasket cannot be used. A marine engine head gasket uses special materials to resist corrosive action.

Since marine engines must be capable of running at or near maximum RPM much of the time, special valve springs, valve lifters, pistons, bearings, camshafts and other heavy‑duty moving parts are required for long life and peak performance.

These are but a few of the many special modifications that are required in Mercury Marine engines to provide long life and dependable performance.

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MAINTENANCE

Do‑It‑Yourself Maintenance Suggestions

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

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

• Do not attempt any repairs that are not covered in this manual unless you are aware of the precautions (Cautions and Warnings) and procedures required. Your safety is of our concern.

• If you attempt to service the product yourself, we suggest you order the service manual for that model. This manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't understand. Do not attempt repairs if you do not understand the procedures.

• Special tools and equipment may be required to perform some repairs. Do not attempt these repairs unless you have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would charge you for the repair.

• If you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must re‑assemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem.

• Do not telephone the dealer, service office or the factory to attempt for them to diagnose a problem or request the repair procedure. It is difficult for them to diagnose a problem over the telephone.

• Your authorized Mercury Marine dealer is there to service your power package. They have qualified factory‑trained mechanics.

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MAINTENANCE

Mercury Marine recommends that you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble‑free boating pleasure.

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

Engine Maintenance Charts

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

Interval Task

Check prior to every use and every 3

hours of operation.

Engine crankcase oil ‑ Check level.

Engine ‑ Inspect

Seawater filter ‑ Check for debris or leakage.

Power steering fluid ‑ Check level.

After every use in salty, brackish, or

mineral‑laden water.

Flush the seawater section of the cooling system.

Every 25 hours of operation or once

every 30 days, whichever occurs first.

Crankcase oil and filter ‑ Change

Supercharger ‑ Check oil level in sight‑glass.

Check the oil level in the sea pump/ fuel pump and inspect for fuel contamination.

Battery ‑ Check water level and inspect for damage.

Fuel pump sight tube ‑ Ensure that no fuel is present. Vapor or condensation is acceptable.

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MAINTENANCE

Interval Task

Every 50 hours or once a year,

whichever occurs first.

Perform all 25 hour maintenance items.

Serpentine and Drive belts (All) ‑ Inspect condition and check tension.

Cooling system hoses and clamps ‑ Inspect for damage and deterioration. Check clamps for tightness.

Electrical system ‑ Check for loose or damaged wiring.

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

Throttle cable and linkage ‑ Lubricate and inspect for loose, damaged or missing parts.

Engine exhaust system ‑ Inspect for damage, deterioration and restrictions. Check clamps for tightness.

Water separator filter ‑ Inspect (If Installed on boat).

Freshwater use: Twice a year.

Power package exterior surfaces ‑ Spray with rust preventative.

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MAINTENANCE

Interval Task

Every 100 hours of operation or once a

year, whichever occurs first.

Supercharger ‑ Change oil.

Power package exterior surfaces ‑ Clean and paint.

Check engine cylinder compression.

Oil coolers for the engine and power steering ‑ Clean seawater section.

Replace positive crankcase ventilation (PCV) valve.

Flame arrestor and crankcase ventilation hose ‑ Inspect, clean or replace.

Engine alignment ‑ Check.

Exhaust ‑ Check for signs of water leakage.

Exhaust system internal and external shutters ‑ Inspect.

Engine output shaft, bearing, and pilot bushing ‑ Inspect and lubricate.

Rear bearing support block ‑ Check alignment.

MerCathode system ‑ Test output.

Every 100 hours of operation or

recommissioning after storage.

Fuel filters ‑ Replace.

Every 100 hours of operation or once a

season and whenever insufficient seawater flow is suspected (if the

operating temperature exceeds

normal).

Seawater pick‑up pump ‑ Disassemble and inspect.

Every 200 hours of operation.

Ignition system ‑ Clean and inspect condition. Adjust or replace spark plugs as needed.

Every 5 years.

Flush the closed cooling system and refresh coolant.

Bravo Drive Maintenance Charts

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

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MAINTENANCE

Interval Task

Check prior to every use and every 3

hours of operation.

Drive, transom, and propeller ‑ Inspect

Every 25 hours of operation or once

every 30 days, whichever occurs

first.

Gear housing water pickups ‑ Check for marine growth or debris.

Anodes ‑ Inspect for erosion.

Sterndrive unit oil ‑ Check level.

Saltwater use: Every 50 hours of

operation or 60 days, whichever

occurs first.

Propeller Shaft ‑ Lubricate.

Every 50 hours or once a year,

whichever occurs first.

Perform all 25 hour maintenance items.

Shift cable and linkage ‑ Lubricate and inspect for loose, damaged or missing parts.

Water separator filter ‑ Inspect (If Installed on boat).

Engine coupling, universal joint shaft spline ‑ Lubricate.

Sterndrive unit ‑ Oil change.

Every 50 hours or once a year,

whichever occurs first.

Sterndrive unit universal joint cross bearings ‑ Inspect and lubricate.

Gimbal ring clamping screws ‑ Re‑torque to 67‑74 Nm (50‑55 lb. ft.).

Gimbal bearing ‑ Lubricate.

Transom gimbal housing assembly swivel shaft and gimbal bearing ‑ Lubricate.

Engine driveshaft ‑ Lubricate (drive line models).

Engine output shaft bearings ‑ Lubricate.

Input shaft/rear bearing support block bearing ‑ Lubricate.

Steering system ‑ Lubricate and inspect for loose, damaged or missing parts.

Propeller shaft ‑ Inspect for bending.

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MAINTENANCE

Interval Task

Every 100 hours of operation or once

a year, whichever occurs first.

Supercharger ‑ Change oil.

Power package exterior surfaces ‑ Clean and paint.

Check engine cylinder compression.

Oil coolers for the engine and power steering ‑ Clean seawater section.

Replace positive crankcase ventilation (PCV) valve.

Flame arrestor and crankcase ventilation hose ‑ Inspect, clean or replace.

Engine alignment ‑ Check.

Exhaust ‑ Check for signs of water leakage.

Exhaust system internal and external shutters ‑ Inspect.

Engine output shaft, bearing, and pilot bushing ‑ Inspect and lubricate.

Rear bearing support block ‑ Check alignment.

MerCathode system ‑ Test output.

Steering head and remote control ‑ Inspect and lubricate.

Drive unit bellows and clamps ‑ Inspect.

Propeller shaft bearing ‑ Inspect by measuring shaft deflection.

Drive bearing carrier ‑ Check bore for evidence of friction with the propeller shaft.

Checking Fluid Levels

CRANKCASE OIL

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

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MAINTENANCE

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

1. Stop the engine.

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

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

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

5. If the oil level is below the "ADD" mark, remove the oil filler cap (port or starboard). Add the specified oil to bring the level up to, but not over, the "OK RANGE" mark on the dipstick.

IMPORTANT: Do not overfill the crankcase oil.

ADD

OK RANGE

9987

a - Oil level dipstick b - Crankcase oil filler cap

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MAINTENANCE

Tube Ref No. Description Where Used Part No.

Kendall GT-1 SAE 20W50

Engine crankcase Obtain Locally

SUPERCHARGER GEARCASE OIL

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

1. Stop the engine.

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

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

7356

a - Sight‑glass

POWER STEERING PUMP

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

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MAINTENANCE

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

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

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

21834

a - Power steering reservoir fill/dipstick cap b - Add fluid mark c - Full fluid mark

Tube Ref No. Description Where Used Part No.

114

Power Trim and Steering Fluid

Power steering pump

92-858074K0

4. Re‑install the cap/dipstick.

SEAWATER/FUEL PUMP OIL

IMPORTANT: Oil must be changed at specified intervals. Refer to the Maintenance Chart for specific requirements. Use only High Performance Gear Lube in the pump.

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

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MAINTENANCE

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

10073

a - Oil level screw

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Seawater/fuel pump 92-802854A1

ENGINE COOLANT

WARNING

Avoid personal injury and burns from hot engine coolant. Allow the engine to cool down before removing the coolant pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently.

IMPORTANT: Check engine coolant before starting engine.

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MAINTENANCE

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

COLD FILL

10140

122

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

Tube Ref No. Description Where Used Part No.

122

Extended Life Antifreeze/Coolant

Closed cooling

system

92-877770K1

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

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

CHANGING ENGINE COOLANT

Contact your authorized Mercury Marine dealer.

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MAINTENANCE

DRIVE UNIT OIL

NOTE: Oil level will fluctuate during operation. Oil level should be checked with the cold engine before starting.

1. Check gear lube monitor oil level; keep oil level at or near the "FULL" line.

2. Check for water at the bottom of the monitor and/or if the oil appears a milky tan color. Contact your authorized Mercury Marine dealer immediately because both conditions indicate a water leak somewhere in the drive unit.

IMPORTANT: If more than 59ml (2 fl oz) of High Performance Gear Lube is required to fill the monitor, a seal may be leaking. Damage to the drive unit may occur due to lack of lubrication. Contact your authorized Mercury Marine dealer for service.

7333

a - Gear lube monitor

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Gear lube monitor 92-802854A1

POWER TRIM PUMP FLUID

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

2. The oil level should be between the "MAX" and "MIN" marks on the plastic reservoir.

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MAINTENANCE

3. If the oil level is below the "MIN" mark, remove the fill cap and add Power Trim and Steering Fluid to bring the oil level up to the "MAX" mark on the reservoir.

10160

a - Vented trim pump fill cap b - Trim pump filter and vents (4)

Tube Ref No. Description Where Used Part No.

114

Power Trim and Steering Fluid

Power trim pump

reservoir

92-858074K0

4. Inspect the fill cap vent slots to ensure that they are clean. Re‑install the fill cap.

Changing Fluids

See the Maintenance Chart for lubricant change frequency. Lubricant should be changed before placing the boat in storage.

Power trim or power steering fluids do not require changing.

CRANKCASE OIL AND FILTER (BOAT IN THE WATER)

CAUTION

ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as directed by local authorities.

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MAINTENANCE

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

Specifications

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

10449

a - Crankcase oil filter

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

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

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MAINTENANCE

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

10460

a - Crankcase oil pump b - Crankcase oil pump hose

4. Remove the crankcase oil pump.

5. Place a container below the oil filter.

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

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

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MAINTENANCE

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

9998

a - Oil filter sealing ring

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

10.Add oil to bring level up to, but not over, the "OK RANGE" mark on the dipstick.

IMPORTANT: Always use the dipstick to determine exactly how much oil is required.

10152

a - Crankcase oil fill cap

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MAINTENANCE

Tube Ref No. Description Where Used Part No.

Kendall GT-1 SAE 20W50

Engine crankcase

Obtain

Locally

11.Start the engine and check for acceptable oil pressure. Allow the engine to idle for at least one minute. Shut off the engine. Wait a few minutes for the engine oil to return to the crankcase and then check the oil level. Add the specified oil to bring the level up to, but not over, the "OK RANGE" mark on the dipstick.

NOTE: It is normal for the oil level to be low after changing the oil and filter because the filter is empty and gets filled at start up.

CRANKCASE OIL AND FILTER (BOAT OUT OF THE WATER)

WARNING

If the engine is to be tested with boat out of the water, the propeller must be removed to avoid injury.

CAUTION

Avoid engine damage from overheating. If the engine is operated above 1500 RPM during flushing, suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat.

CAUTION

IMPORTANT: Change oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use Mercury Precision Parts or flushing attachment(s) over the water intake holes and attach a water hose. Use only recommended motor oil, see

Specifications.

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MAINTENANCE

1. Install the appropriate flushing attachment(s) over the water intake holes and attach a water hose.

6155

a - Flushing attachment over water intake holes

(SportMaster Gearcase)

b - Fresh water source c - Flushing attachment for dual water inlet drives d - Nose cone water pickup cover for dual water inlet

drives

2. With the drive unit in normal operating position, partially open the water tap (about 1/2 maximum).

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

4. Stop the engine and shut off the water.

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MAINTENANCE

10449

a - Crankcase oil filter

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

6150

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

d - Bilge drain flange e - Oil drain hose

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

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

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

9. Place a container below the oil filter.

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MAINTENANCE

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

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

9998

a - Oil filter sealing ring

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

13.Tighten the bilge drain plug.

14.Remove the oil filler cap (port or starboard). Add oil to bring level up to, but not over the "FULL" mark on the dipstick.

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MAINTENANCE

IMPORTANT: Always use dipstick to determine exactly how much oil is required.

10152

a - Crankcase oil filler cap

Tube Ref No. Description Where Used Part No.

Kendall GT-1 SAE 20W50

Engine crankcase

Obtain

Locally

15.Turn on the water to the flushing attachment.

16.Start the engine and check for acceptable oil pressure. Allow the engine to idle for at least one minute. Shut off the engine and the water to the flushing attachment. Wait a few minutes for the engine oil to return to the crankcase and then check the oil level. Add the specified oil to bring the level up to, but not over, the "OK range" mark on the dipstick.

NOTE: It is normal for the oil level to be low after changing the oil and filter because the filter is empty and gets filled at start up.

17.Remove the flushing attachment(s).

SUPERCHARGER GEARCASE OIL

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

Specifications.

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

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

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MAINTENANCE

2. Place a catch pan under the drain plug in the bottom of the supercharger gearcase.

3. Remove the drain plug and drain the oil.

4. Clean and inspect the plug o‑rings, the gearcase fill and drain hole threads and the plug threads.

5. Install the drain plug in the gearcase and torque to specifications.

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

7. Install the fill plug and torque to specifications.

10567

a - Drain plug b - Sight‑glass

c - Fill plug

Description Nm lb. in. lb. ft.

Fill and drain plugs, supercharger gearcase

13.5 10

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MAINTENANCE

Tube Ref No. Description Where Used Part No.

Castrol Syntec 5W-50 Synthetic Oil

Supercharger

gearcase

Obtain Locally

DRIVE UNIT OIL (XR MODELS)

IMPORTANT: Use only High Performance Gear Lube in drive unit.

1. Remove the propeller and place the drive unit in the full down position.

2. Place a suitable container below the drive fill/drain screw.

3. Remove the fill/drain screw and sealing washer and drain the oil.

IMPORTANT: If any water drained from the oil fill/drain hole, or if oil appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury Marine dealer.

7986

a - Oil fill/drain plug

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MAINTENANCE

4. Remove the oil vent screw and sealing washer. Allow oil to drain completely.

7987

a - Sealing washer b - Oil vent screw

5. Adjust the drive unit so that the propeller shaft is level.

6. Fill the drive unit through the oil fill/drain hole with High Performance Gear Lube until an air‑free stream of lubricant flows from the oil vent hole.

7988

a - Oil fill/drain screw

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Drive unit 92-802854A1

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MAINTENANCE

7. Remove the tube from the oil fill/drain hole and quickly install the sealing washer and the oil fill/drain screw. Tighten securely.

8. Add specified gear lube to the monitor bottle.

9. When oil starts to run out of the oil vent hole of the drive, re‑install the oil vent screw and sealing washer. Tighten securely.

7333

a - Gear lube monitor bottle

Tube Ref No. Description Where Used Part No.

High Performance Gear Lubricant

Gear lube monitor 92-802854A1

10.Continue adding gear lube to the monitor bottle until the oil level is at the "FULL" line mark on the bottle.

11.Lubricate the O‑ring on the bottle neck with sterndrive oil to ensure ease of installation and removal of the cap.

12.Install the filler cap, and be careful to not overtighten.

IMPORTANT: Re‑check the reservoir bottle oil level after the first use.

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MAINTENANCE

13.Grease the propeller shaft with anti‑corrosion grease. Re‑install the propeller and torque the prop nut to specification.

7990

Tube Ref No. Description Where Used Part No.

Anti-Corrosion Grease

Propeller shaft 92-802867A1

Description Nm lb. in. lb. ft.

Propeller nut 75 55

IMPORTANT: Oil level in the gear lube monitor will rise and fall during drive operation. Always check the oil level when the drive is cool and the engine is shut down.

Lubrication

SHIFT CABLE

Lubricate the pivot points with 4 Cycle 25W40 motor oil.

7997

Tube Ref No. Description Where Used Part No.

MerCruiser 4-cycle 25W40 Engine Oil

Pivot points 92-802837A1

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MAINTENANCE

THROTTLE CABLE

Lubricate pivot points with 4 Cycle 25W40 motor oil.

10305

a - Lubrication points

Tube Ref No. Description Where Used Part No.

MerCruiser 4-cycle 25W40 Engine Oil

Pivot points 92-802837A1

DRIVE UNIT AND TRANSOM ASSEMBLY

CAUTION

Avoid speedometer hose fitting damage. Disconnect the speedometer hose fitting from the driveshaft housing before removing the sterndrive unit.

IMPORTANT: The sterndrive must be removed to lubricate the U‑joints. Contact your authorized Mercury Marine dealer for this service.

NOTE: The engine coupling and shaft splines are greased with engine coupler spline grease. Universal joints are greased with 2‑4‑C with Teflon lubricant. Contact your authorized Mercury Marine dealer for this service.

Mercury Racing Sterndrive 600SCi User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual