Mercury TowSport Inboards User Manual
2002, Mercury Marine
Tow Sports / Inboard MPI Models
90Ć864197020 302
0001
Identification Record
PLEASE RECORD THE FOLLOWING INFORMATION:
1.
Engine Model and Horsepower
Engine Serial Number
2.
Transom Assembly Serial Number
(Sterndrive)
Gear Ratio Sterndrive Unit Serial
Number
3.
Transmission Model (Inboard)
Gear Ratio Transmission Serial
Number
4.
Propeller Number
Pitch Diameter
5.
Hull Identification Number (HIN)
Purchase Date
6.
Boat Manufacturer
Boat Model Length
7.
Exhaust Gas Emissions Certificate Number (Europe Only)
The serial numbers are the manufacturer’s keys to numerous engineering details which apply
to your Mercury MerCruiser
power package. When contacting your Authorized Mercury
MerCruiser Dealer about service, always specify model and serial numbers.
The description and specifications contained herein were in effect at the time this guide was
approved for printing. Mercury Marine, whose policy is one of continuous improvement,
reserves the right to discontinue models at any time, or to change specifications or designs,
without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
2002, Mercury Marine
The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop,
Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide,
Thruster and Mercury Precision Parts.
7
1
3
71452
0002
Welcome!
You have selected one of the finest marine power packages available. It incorporates
numerous design features to assure operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many
boating seasons. To ensure maximum performance and carefree use, we ask that you
thoroughly read this manual.
The Operation, Maintenance and Warranty Manual contains specific instructions for using
and maintaining your product. We suggest that this manual remain with the product for ready
reference whenever you are on the water.
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your
boating will be pleasant!
Consumer Affairs Department
0003
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the
terms of the warranty are set forth in the Warranty Sections of this manual. The warranty
statement contains a description of what is covered, what is not covered, the duration of
coverage, how to best obtain warranty coverage, important disclaimers and limitations of
damages and other related information. Please review this important information.
0004
Read This Manual Thoroughly
IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A
DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES.
NOTICE
Throughout this publication, and on your power package, WARNINGS and CAUTIONS,
accompanied by the International Hazard Symbol
to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully.
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance
with these special instructions while performing the service, plus common sense operation,
are major accident prevention measures.
WARNING - Hazards or unsafe practices which could result in severe personal injury
or death.
!
WARNING
CAUTION
, may be used to alert the installer/user
CAUTION - Hazards or unsafe practices which could result in minor personal injury
or product or property damage.
IMPORTANT: - Indicates information or instructions that are necessary for proper
operation and/or maintenance.
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.
WARRANTY
Warranty Information 2. . . . . . . . . . . . . . . .
Owner Warranty Registration 2. . . . . . .
International Owner Registration 3. . . .
Warranty Policies 4. . . . . . . . . . . . . . . . . . .
Mercury MerCruiser One Year
Limited Warranty
(Gasoline Fueled Products Only) 4. . .
GETTING TO KNOW YOUR POWER PACKAGE
Features And Controls 12. . . . . . . . . . . . . . .
Lanyard Stop Switch 12. . . . . . . . . . . . . .
Instrumentation 14. . . . . . . . . . . . . . . . . . .
Remote Controls 15. . . . . . . . . . . . . . . . .
Electrical System Overload Protection 18
Audio Warning System 19. . . . . . . . . . . .
Engine Guardian Strategy 20. . . . . . . . .
ON THE WATER
Safe Boating Suggestions 24. . . . . . . . . . . .
Be Alert To Carbon Monoxide
Poisoning 26. . . . . . . . . . . . . . . . . . . . . . . .
Basic Boat Operation 28. . . . . . . . . . . . . . . .
Launching And Boat Operation Care 28
Starting And Stopping The Engine 29. .
Freezing Temperature Operation 29. . .
Drain Plug and Bilge Pump 29. . . . . . . .
Protecting People In The Water 30. . . . . . .
While You Are Cruising 30. . . . . . . . . . . .
While Boat Is Stationary 30. . . . . . . . . . .
High-Speed And High-Performance
Boat Operation 30. . . . . . . . . . . . . . . . . . . . . .
Wave And Wake Jumping 31. . . . . . . . . . . .
3 Year Limited Warranty
Against Corrosion (Worldwide) 6. . . . .
Transferable Warranty 8. . . . . . . . . . . . . . .
Direct Sale By Owner 8. . . . . . . . . . . . .
Mercury Product Protection Plan 8. . . . . .
United States And Canada Only 8. . . .
Impact With Underwater Hazards 32. . . . .
Conditions Affecting Operation 33. . . . . . . .
Weight Distribution (Passengers
And Gear) Inside The Boat 33. . . . . . . .
Bottom Of Boat 33. . . . . . . . . . . . . . . . . . .
Cavitation 33. . . . . . . . . . . . . . . . . . . . . . .
Elevation And Climate 34. . . . . . . . . . . . .
Propeller Selection 34. . . . . . . . . . . . . . . .
Getting Started 35. . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 35. . . . . . . . . . .
After Break-In Period 35. . . . . . . . . . . . . .
End of First Season Checkup 35. . . . . .
90-864197020 MARCH 2002 Page i
SPECIFICATIONS AND MAINTENANCE
Specifications 38. . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 38. . . . . . . . . . .
Engine Oil 40. . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 41. . . . . . . . . . . . .
Fluid Specifications 42. . . . . . . . . . . . . . .
Owner/Operator Responsibilities 43. . . . . .
Dealer Responsibilities 43. . . . . . . . . . . . . . .
Maintenance 44. . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance
Suggestions 45. . . . . . . . . . . . . . . . . . . . .
Inspection 46. . . . . . . . . . . . . . . . . . . . . . .
Inboard Maintenance Chart 46. . . . . . . .
Maintenance Record 49. . . . . . . . . . . . . .
Engine Oil 50. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking 50. . . . . . . . . . . . . . . . . . . . . . . .
Filling 51. . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Oil and Filter 52. . . . . . . . . . . .
Transmission Fluid 54. . . . . . . . . . . . . . . .
Lubrication 55. . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable 55. . . . . . . . . . . . . . . . . . . .
Transmission Linkage 55. . . . . . . . . . . .
Engine Coolant - Closed Cooled
Models Only 56. . . . . . . . . . . . . . . . . . . . . . . .
Checking 56. . . . . . . . . . . . . . . . . . . . . . . .
Filling 57. . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing 57. . . . . . . . . . . . . . . . . . . . . . . .
Flame Arrestor and
Related Components 58. . . . . . . . . . . . . . . .
Cleaning 58. . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase
Ventilation Valve (PCV) 59. . . . . . . . . . . .
Water Separating Fuel Filter 60. . . . . . . . . .
Changing 60. . . . . . . . . . . . . . . . . . . . . . . .
In-line Fuel Filter 62. . . . . . . . . . . . . . . . . . . .
Changing 62. . . . . . . . . . . . . . . . . . . . . . . .
Battery 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple EFI Engine
Battery Precautions 64. . . . . . . . . . . . . . .
Serpentine Drive Belt 65. . . . . . . . . . . . . . . .
Cold Weather Or Extended Storage 68. . .
Preparing Your Power
Package For Storage 68. . . . . . . . . . . . .
Draining Instructions 70. . . . . . . . . . . . . . . . .
Identification 71. . . . . . . . . . . . . . . . . . . . .
Boat In Water 72. . . . . . . . . . . . . . . . . . . .
Boat Out Of The Water 76. . . . . . . . . . . .
All Models 78. . . . . . . . . . . . . . . . . . . . . . .
Flushing The Power Package 79. . . . . . . . .
Inboards 79. . . . . . . . . . . . . . . . . . . . . . . . .
Tow Sports 81. . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 83. . . . .
Emissions (Europe Only) 84. . . . . . . . . . . . .
Emissions Testing 84. . . . . . . . . . . . . . . .
Installing Test Probes 84. . . . . . . . . . . . .
TROUBLESHOOTING
Diagnosing EFI Problems 88. . . . . . . . . . . .
Troubleshooting Charts 88. . . . . . . . . . . . . .
Starter Motor Will Not Crank
Engine Or Cranks Slow 88. . . . . . . . . . .
Engine Will Not Start,
Or Is Hard To Start 88. . . . . . . . . . . . . . . .
Engine Runs Rough, Misses
And/Or Backfires 89. . . . . . . . . . . . . . . . .
Poor Performance 89. . . . . . . . . . . . . . . .
Excessive Engine Temperature 90. . . . .
CUSTOMER ASSISTANCE INFORMATION
Owner Service Assistance 94. . . . . . . . . . . .
Local Repair Service 94. . . . . . . . . . . . . .
Service Away From Home 94. . . . . . . . .
Stolen Power Package 94. . . . . . . . . . . .
Attention Required After Submersion 94
Replacement Service Parts 95. . . . . . . .
Resolving A Problem 96. . . . . . . . . . . . . .
Mercury Marine Service Offices 97. . . .
Customer Service Literature 98. . . . . . . . . .
English Language 98. . . . . . . . . . . . . . . .
Other Languages 98. . . . . . . . . . . . . . . . .
Andre sprog 98. . . . . . . . . . . . . . . . . . . . .
Andere talen 98. . . . . . . . . . . . . . . . . . . . .
Insufficient Engine Temperature 90. . . .
Low Engine Oil Pressure 90. . . . . . . . . .
Excessive Transmission Fluid
Temperature or Slipping Transmission 91
Battery Will Not Come
Up On Charge 91. . . . . . . . . . . . . . . . . . .
Remote Control Operates Hard,
Binds, Has Excessive Free-play
Or Makes Unusual Sounds 91. . . . . . . .
Muut kielet 98. . . . . . . . . . . . . . . . . . . . . . .
Autres langues 98. . . . . . . . . . . . . . . . . . .
Andere Sprachen 99. . . . . . . . . . . . . . . . .
Altre lingue 99. . . . . . . . . . . . . . . . . . . . . .
Andre språk99. . . . . . . . . . . . . . . . . . . . . .
Outros Idiomas 99. . . . . . . . . . . . . . . . . . .
Otros idiomas 99. . . . . . . . . . . . . . . . . . . .
Andra språk99. . . . . . . . . . . . . . . . . . . . . .
Allej gl
Ordering Literature 100. . . . . . . . . . . . . . . . . .
United States and Canada 100. . . . . . . . .
Outside The United States
and Canada 100. . . . . . . . . . . . . . . . . . . . .
ssej 99. . . . . . . . . . . . . . . . . . . . .
Page ii 90-864197020 MARCH 2002
Table of Contents
WARRANTY
WARRANTY
1
Warranty Information 2. . . . . . . . . . . . . . . .
Owner Warranty Registration 2. . . . . . . .
International Owner Registration 3. . . . .
Warranty Policies 4. . . . . . . . . . . . . . . . . . .
Mercury MerCruiser One Year
Limited Warranty
(Gasoline Fueled Products Only) 4. . . . .
3 Year Limited Warranty
Against Corrosion (Worldwide) 6. . . . . .
Transferable Warranty 8. . . . . . . . . . . . . . .
Direct Sale By Owner 8. . . . . . . . . . . . . . .
Mercury Product Protection Plan 8. . . . . .
United States And Canada Only 8. . . . .
90-864197020 MARCH 2002 Page 1
WARRANTY
0005
Warranty Information
Owner Warranty Registration
UNITED STATES AND CANADA ONLY
• It is important that your selling dealer fills out the Warranty Registration Card
completely and mails it to the factory immediately upon sale of the new product.
• It identifies name and address of the original purchaser, product model and serial
number(s), date of sale, type of use and selling dealer’s code, name and address.
The dealer also certifies that you are the original purchaser and user of the product.
• Upon receipt of the Warranty Registration Card at the factory, you will be issued a
plastic Owner Warranty Registration Card which is your only valid registration
identification. It must be presented to the servicing dealer should warranty service be
required. Warranty claims will not be accepted without presentation of this card.
• A temporary Owner Warranty Registration Card will be presented to you when you
purchase the product. It is valid only for 30 days from date of sale while your plastic
Owner Warranty Registration Card is being processed. Should your product need
service during this period, present the temporary registration card to the dealer. He
will attach it to your warranty claim form.
• Because of your selling dealer’s continuing personal interest in your satisfaction, the
product should be returned to him for warranty service.
• If your plastic card is not received within 30 days from date of new product sale,
please contact your selling dealer.
• The product warranty is not effective until the product is registered at the factory.
• NOTICE: Registration lists must be maintained by factory and dealer on marine
products sold in the United States, should notification under the Federal Boat Safety
Act be required.
Page 2 90-864197020 MARCH 2002
International Owner Registration
OUTSIDE THE UNITED STATES AND CANADA
• It is important that your selling dealer fills out the Warranty Registration Card
completely and mails it to the distributor or Marine Power Service Center responsible
for administering the warranty registration/claim program for your area.
• The Warranty Registration Card identifies your name and address, product model
and serial number(s), date of sale, type of use and the selling distributor’s/dealer’s
code number, name and address. The distributor/dealer also certifies that you are
the original purchaser and user of the product.
• A copy of the Warranty Registration Card, designated as the “Purchaser’s Copy”,
MUST be given to you immediately after the card has been completely filled out by
the selling distributor/dealer. This card represents your factory registration
identification, and should be retained by you for future use when required. Should
you ever require warranty service on this product, your dealer may ask you for the
Warranty Registration Card to verify date of purchase and to use the information on
the card to prepare the warranty claim form(s).
• In some countries, the Marine Power Service Center will issue you a permanent
(plastic) Warranty Registration Card within 30 days after receiving the “Factory Copy”
of the Warranty Registration Card from your distributor/dealer. If you receive a plastic
Warranty Registration Card, you may discard the “Purchaser’s Copy” that you
received from the distributor/dealer when you purchased the product. Ask your
distributor/dealer if this plastic card program applies to you.
WARRANTY
• For further information concerning the Warranty Registration Card and its
relationship to Warranty Claim processing, refer to the “International Warranty.” Refer
to “Table of Contents.”
IMPORTANT: Registration lists must be maintained by the factory and dealer in some
countries by l a w. It is our desire to have ALL products registered at the factory should
it ever be necessary to contact you. Make sure your dealer/distributor fills out the
warranty registration card immediately and sends the factory copy to the Marine
Power International Service Center for your area.
90-864197020 MARCH 2002 Page 3
WARRANTY
0006
Warranty Policies
Mercury MerCruiser One Year Limited Warranty
(Gasoline Fueled Products Only)
WHAT IS COVERED
Mercury Marine warrants its new products to be free of defects in material and workmanship
during the period described below.
DURATION OF COVERAGE
This Limited Warranty provides coverage for either one (1) year from the date the product
is first sold to a recreational use retail purchaser, or the date on which the product is first put
into service, whichever occurs first. Commercial users of these products receive warranty
coverage of either one (1) year from the date of first retail sale, or the accumulation of 500
hours of operation, whichever occurs first. Commercial use is defined as any work or
employment related use of the product, or any use of the product which generates income,
for any part of the warranty period, even if the product is only occasionally used for such
purposes. The repair or replacement of parts, or the performance of service under this
warranty, does not extend the life of this warranty beyond its original expiration date.
Unexpired warranty coverage can be transferred from one recreational use customer to a
subsequent recreational use customer upon proper re-registration of the product.
Unexpired warranty coverage cannot be transferred either to or from a commercial use
customer.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE
Warranty coverage is available only to retail customers that purchase from a Dealer
authorized by Mercury Marine to distribute the product in the country in which the sale
occurred, and then only after the Mercury Marine specified pre-delivery inspection process
is completed and documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Inaccurate warranty registration
information regarding recreational use, or subsequent change of use from recreational to
commercial (unless properly re-registered) 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 obtain warranty coverage. Mercury Marine reserves
the right to make any 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.
Page 4 90-864197020 MARCH 2002
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. The
warranty registration card is the only valid registration identification and must be presented
to the dealer at the time warranty service is requested in order to obtain coverage.
WHAT IS NOT COVERED
This limited warranty does not cover routine maintenance items, tune ups, adjustments,
normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear
ratio that does not allow the engine to run in its recommended RPM range (see the
Operation and Maintenance Manual), operation of the product in a manner inconsistent with
the recommended operation/duty cycle section of the Operation and Maintenance Manual,
neglect, accident, submersion, improper installation (proper installation specifications and
techniques are set forth in the installation instructions for the product), improper service, use
of an accessory or part which damages the Mercury product and was not manufactured or
sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are
not suitable for use with the product (see the Operation and Maintenance Manual),
alteration or removal of parts, water entering the engine through the fuel intake, air intake
or exhaust system or damage to the product from insufficient cooling water caused by
blockage of the cooling system by a foreign body, running the engine out of water, mounting
the engine too high on the transom, or running the boat with the engine trimmed out too far.
Use of the product for racing or other competitive activity, or operating with a racing type
lower unit, at any point, even by a prior owner of the product, voids the warranty.
WARRANTY
Expenses related to haul-out, launch, towing, storage, telephone, rental, inconvenience,
slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type
of incidental or consequential damages are not covered by this warranty. Also, expenses
associated with the removal and/or replacement of boat partitions or material caused by
boat design for access to the product are not covered by this warranty.
No individual or entity, including Mercury Marine authorized dealers, has been given
authority by Mercury Marine to mak e a ny a ffirmation, representation or warranty regarding
the product, other than those contained in this limited warranty, and if made, shall not be
enforceable against Mercury Marine.
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT
THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND
CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS
WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE
DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A
RESULT, THEY MAY NOT APPL Y 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.
90-864197020 MARCH 2002 Page 5
WARRANTY
0007
3 Year Limited Warranty Against Corrosion (Worldwide)
WHAT IS COVERED
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M
Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine
(Product) will not be rendered inoperative as a direct result of corrosion for the period of time
described below.
DURATION OF COVERAGE
This limited corrosion warranty provides coverage for three (3) years from either the date
the product is first sold, or the date on which the product is first put into service, whichever
occurs first. The repair and replacement of parts, or the performance of service under this
warranty does not extend the life of this warranty beyond its original expiration date.
Unexpired warranty coverage can be transferred to subsequent (noncommercial use)
purchaser upon proper re-registration of the product.
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.
2
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.
Page 6 90-864197020 MARCH 2002
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. The
warranty registration card is the only valid registration identification and 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; product sold with less than a one year limited
Product warranty; replacement parts (parts purchased by the Customer); products used in
a commercial application. Commercial use is defined as any work or employment related
use of the product, or any use of the product which generates income, for any part of
warranty period, even if the product is only occasionally used for such purposes.
WARRANTY
90-864197020 MARCH 2002 Page 7
WARRANTY
0008
Transferable Warranty
The product 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.
Direct Sale By Owner
• The second owner can be registered as the new owner and retain the unused
portion of the limited warranty by sending the former owner’s plastic Owner Warranty
Registration Card and a copy of the bill of sale to show proof of ownership. In the
United States and Canada, mail to:
• A new Owner Warranty Registration Card will be issued with the new owner’s name
and address. Registration records will be changed on the factory computer
registration file.
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939
• There is no charge for this service.
Outside the United States and Canada, please contact the distributor in your country, or the
Marine Power International Service Center closest to you, for the transferable warranty
procedure that would apply to you.
0009
Mercury Product Protection Plan
United States And Canada Only
(Certain performance products, triple engine installations, and commercial applications are
excluded.)
The Mercury Product Protection Plan provides coverage against unexpected mechanical
and electrical breakdowns that may occur beyond the standard limited warranty.
The optional Mercury Product Protection Plan is the only Factory Plan available for your
engine.
Two, three or four - year term plans can be purchased up to 12 months after the original
engine registration date.
See your participating Mercury MerCruiser dealer for complete program details.
Page 8 90-864197020 MARCH 2002
THIS PAGE IS INTENTIONALLY BLANK
WARRANTY
90-864197020 MARCH 2002 Page 9
WARRANTY
THIS PAGE IS INTENTIONALLY BLANK
Page 10 90-864197020 MARCH 2002
GETTING TO KNOW YOUR POWER PACKAGE
Table of Contents
GETTING TO KNOW YOUR POWER PACKAGE
Features And Controls 12. . . . . . . . . . . . . . .
Lanyard Stop Switch 12. . . . . . . . . . . . . .
Instrumentation 14. . . . . . . . . . . . . . . . . . .
Remote Controls 15. . . . . . . . . . . . . . . . .
Electrical System Overload Protection 18
Audio Warning System 19. . . . . . . . . . . .
Engine Guardian Strategy 20. . . . . . . . .
2
90-864197020 MARCH 2002 Page 11
GETTING TO KNOW YOUR POWER PACKAGE
0010
Features And Controls
0011
Lanyard Stop Switch
The purpose of a lanyard stop switch is to turn off the engine when the operator moves
outside the operator’s position (as in accidental ejection from the operator’s position).
b
c
74608
a-Stop Switch
b-Lanyard
c-Clips To The Operator
Accidental ejections, such as falling overboard, are more likely to occur in:
• low sided sport boats
• bass boats
• high performance boats
Accidental ejections can also occur from:
• poor operating practices
• sitting on the seat or gunwale at planing speeds
• standing at planing speeds
a
• operating at planing speeds in shallow or obstacle infested waters
• releasing your grip on the steering wheel that is pulling in one direction
• consuming alcohol or drugs
• high speed boating maneuvers
Some remote control units are equipped with a lanyard stop switch, if your remote control
is not equipped with a lanyard stop switch one can be installed on the dashboard or side
adjacent to th e o p e r a tor’s position. The lanyard is a cord usually 4-5 ft (1.2-1.5 m) long when
stretched out with an element on one end made to be inserted into the switch and a snap
on the other end for attaching to the operator. The lanyard is coiled to make it as short as
possible to minimize the likelihood of entanglement with nearby objects. It stretches to
minimize the likelihood of accidental activation should the operator choose to move around
in an area close to the normal operator’s position. To shorten the lanyard, wrap it around
the operator’s wrist or leg, or tie a knot in the lanyard.
Page 12 90-864197020 MARCH 2002
GETTING TO KNOW YOUR POWER PACKAGE
Activation of the lanyard stop switch will stop the engine immediately, but the boat will
continue to coast for some distance depending upon the velocity and degree of any turn at
shut down. However , the boat will not complete a full circle. While the boat is coasting, it can
cause injury to anyone in the boat’s path as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting and operating
procedures should they be required to operate the engine in an emergency (e.g. if the
operator is accidentally ejected).
WARNING
Avoid contact with the boat hull and propeller from accidental ejection. Personal
injury or death could occur. Always properly connect both ends of the lanyard stop
switch.
Accidental or unintended activation of the switch during normal operation is also a
possibility. This could cause any, or all, of the following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward motion, a par-
ticular 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.
WARNING
Avoid abrupt deceleration of the boat from lanyard stop switch activation. Boat
damage and personal injury or death could occur. NEVER leave the operator’s sta-
tion with the engine operating and in gear.
90-864197020 MARCH 2002 Page 13
GETTING TO KNOW YOUR POWER PACKAGE
0012
Instrumentation
The following is a brief explanation of the instrumentation typically found on some boats.
The owner/operator should be familiar with all instruments and their functions. Because of
the large variety of instrumentation and manufacturers, you should have your boat dealer
explain the particular gauges and normal readings for your boat.
1
1. Speedometer: Indicates boat speed.
2. Tachometer: Indicates engine rpm.
3. Oil Pressure Gauge: Indicates engine oil pressure.
4. Battery Meter: Indicates battery voltage.
5. Water Temperature Gauge: Indicates engine operating temperature.
6. Fuel Gauge: Indicates quantity of fuel in tank.
7. Hour Meter: Records engine running time.
8. Bilge Blower Switch: Operates bilge blower.
9. Ignition Switch: Allows operator to start and stop engine.
0013
SMARTCRAFT PRODUCT
70514
6
2
70515 70516
70519
7
3
70521
8
4
70522
70517
9
5
70523
70518
A Mercury SmartCraft System instrument package can be purchased for this product. A few
of the functions the instrument package will display are engine rpm, coolant temperature,
water pressure, battery voltage, fuel consumption and engine operating hours.
The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The
SmartCraft Instrument package will display critical engine alarm data and potential
problems.
Refer to the Mercury SmartCraft Operator ’s Supplement (90-10229021) for the warning
functions monitored and basic operation of the SmartCraft Instrument package.
Page 14 90-864197020 MARCH 2002
0014
Remote Controls
Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls.
All controls may not have all features shown. Consult your dealer for a description and/or
demonstration of your remote control.
0015
PANEL MOUNTED
GETTING TO KNOW YOUR POWER PACKAGE
1
5
2
3
4
77019
1. Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock
button must be pushed IN to move the control handle out of NEUTRAL.
2. Throttle Only Button - Allows engine throttle advancement without shifting the engine.
This is done by disengaging the shift mechanism from the control handle. The throttle
only button can be depressed only when the remote control handle is in the NEUTRAL
position, and should only be used to assist in starting the engine.
3. Lanyard Stop Switch - Turns the ignition OFF whenever the operator (when attached
to the lanyard) moves far enough away from the operator’s position to activate the
switch. Refer to Lanyard Stop Switch for information on the use of this switch.
4. Control Handle Throttle Friction Screw - This screw (located behind the bezel cover)
can be adjusted to increas or decrease the tension on the control handle. This will help
prevent slipping of the remote control handle. Turn screw clockwise to increase tension
and counterclockwise to decrease tension. Adjust to tension desired.
5. Control Handle - Operation of the shift and throttle are controlled by the movement of
the control handle. Push the control handle forward from NEUTRAL with a quick firm
motion to the first detent for FORWARD gear. Continue pushing forward to increase
speed. Pull the control handle back from NEUTRAL with a quick firm motion to the first
detent for REVERSE gear and continue pushing back to increase speed.
90-864197020 MARCH 2002 Page 15
GETTING TO KNOW YOUR POWER PACKAGE
0016
CONSOLE MOUNTED
Avoid possible boat and power package damage. Never shift unit into or out of gear
unless throttle lever is at idle rpm.
IMPORTANT: Boats equipped with dual power packages may have both shift levers
on one control and both throttle levers on the other control.
CAUTION
4
1
2
71339
3
70537
1. Shift Lever - shifts unit into gear with full lever movement. Move lever forward to shift
to FORWARD gear . Move lever backward to shift to REVERSE gear. Lever in full vertical
position shifts to NEUTRAL.
2. Throttle Lever - allows engine rpm to be increased or decreased.
3. FRICTION Screw - adjusts control handle friction so motor speed can be set and driver
does not have to hold handle. Turn screw clockwise to increase friction. Do not thread
screw all the way out.
4. DETENT Screw - controls the effort needed to move control handle out of NEUTRAL.
To increase tension, turn screw clockwise; to decrease, turn screw counterclockwise.
Do not thread screw all the way out.
Page 16 90-864197020 MARCH 2002
0017
CONSOLE MOUNTED
1
GETTING TO KNOW YOUR POWER PACKAGE
3
3
2
2
1
77971
1. Throttle Only Button - Allows engine throttle advancement without shifting the engine.
This is done by disengaging the shift mechanism from the control handle. The throttle
only button can be depressed only when the remote control handle is in the NEUTRAL
position, and should only be used to assist in starting the engine.
2. Control Handle Tension Adjustment Screw - This screw can be adjusted to increase
or decrease the tension on the control handle (cover must be removed to adjust). This
will help prevent slipping of the remote control handle. Turn screw clockwise to increase
tension and counterclockwise to decrease tension. Adjust to tension desired.
3. Control Handles - Operation of the the shift and throttle are controlled by the movement
of the control handle. Push the control handle forward from NEUTRAL with a quick firm
motion to the first detent for FORWARD gear and continue pushing forward to increase
speed. Pull the control handle back from NEUTRAL with a quick firm motion to the first
detent for REVERSE gear and continue pushing back to increase speed.
90-864197020 MARCH 2002 Page 17
GETTING TO KNOW YOUR POWER PACKAGE
0018
Electrical System Overload Protection
If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause
must be found and corrected before replacing the fuse or resetting the circuit breaker.
NOTE: In an emergency, when the engine must be operated and the cause for the high
current draw cannot be located and corrected, turn OFF or disconnect all accessories
connected to the engine and instrumentation wiring. Reset the circuit breaker . If the breaker
remains open, the electrical overload has not been eliminated. Further checks must be
made on the electrical system. Contact your authorized Mercury MerCruiser dealer.
0019
1
4
77906
3
77602
2
5
74907
70525
1. A red circuit breaker provides protection for engine wiring harness and the instrumentation power lead. Reset by pushing the “RESET” button IN.
2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed
to protect the engine wiring harness if an electrical overload occurs.
3. Three fuses are located on the port side of the engine. These fuses control various EFI
circuits.
4. The main power and fuel pump relays are located next to the fuses and control voltage
to the engine with the ignition key in the ON position.
5. A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical
system. Check for blown fuse if the ignition key is turned to the START position and nothing happens (and circuit breaker is not tripped).
Page 18 90-864197020 MARCH 2002
0020
Audio Warning System
Your Mercury MerCruiser power package may be equipped with an Audio Warning System.
The Audio Warning System will not protect the engine from damage. It is designed to warn
the operator that a problem has occurred.
GETTING TO KNOW YOUR POWER PACKAGE
70516
1
The audio warning system will sound with a continuous horn if one of the following occurs:
1. Engine Oil Pressure Too Low
2. Engine Temperature Too Hot
The audio warning system will sound with an intermittent horn if the following occurs:
3. Transmission Fluid Temperature Too Hot
Operation of the engine after the audio warning system alarm has sounded could
result in damage to the power package. Do not operate engine once the alarm has
sounded EXCEPT TO AVOID A HAZARDOUS SITUATION.
If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if
possible. If cause cannot be determined, consult your authorized Mercury MerCruiser
dealer.
0128
TESTING THE AUDIO WARNING SYSTEM
1. Turn the ignition switch to the ON position without cranking the engine.
2. Listen for the alarm to sound indicating that the system is functioning correctly.
70518
2
CAUTION
75542
3
90-864197020 MARCH 2002 Page 19
GETTING TO KNOW YOUR POWER PACKAGE
0021
Engine Guardian Strategy
IMPORTANT: Boat speed could be reduced to idle and may not respond to the
throttle.
Engine Guardian Strategy is designed to help reduce the potential for engine damage by
reducing engine power when a potential problem is sensed by the ECM. Engine Guardian
monitors:
• Oil Pressure
• Coolant Temperature
• Seawater Pressure
• Engine Overspeed
Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if
any sensor on the power package fails.
For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will
reduce the available power level of the engine to help prevent damage from decreased
water flow to the engine. If the debris passes through and full water flow is restored, engine
power levels are restored to normal.
To avoid a possible recurrence of the problem you should contact an authorized Mercury
MerCruiser dealer. The ECM stores the fault and with this information the technician will be
able to more rapidly diagnose problems.
Page 20 90-864197020 MARCH 2002
GETTING TO KNOW YOUR POWER PACKAGE
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Page 22 90-864197020 MARCH 2002
Table of Contents
ON THE WATER
ON THE WATER
Safe Boating Suggestions 24. . . . . . . . . . . .
Be Alert To Carbon Monoxide
Poisoning 26. . . . . . . . . . . . . . . . . . . . . . . .
Basic Boat Operation 28. . . . . . . . . . . . . . . .
Launching And Boat Operation Care 28
Starting And Stopping The Engine 29. .
Freezing Temperature Operation 29. . .
Drain Plug and Bilge Pump 29. . . . . . . .
Protecting People In The Water 30. . . . . . .
While You Are Cruising 30. . . . . . . . . . . .
While Boat Is Stationary 30. . . . . . . . . . .
High-Speed And High-Performance
Boat Operation 30. . . . . . . . . . . . . . . . . . . . . .
Wave And Wake Jumping 31. . . . . . . . . . . .
Impact With Underwater Hazards 32. . . . .
Conditions Affecting Operation 33. . . . . . . .
Weight Distribution (Passengers
And Gear) Inside The Boat 33. . . . . . . .
Bottom Of Boat 33. . . . . . . . . . . . . . . . . . .
Cavitation 33. . . . . . . . . . . . . . . . . . . . . . .
Elevation And Climate 34. . . . . . . . . . . . .
Propeller Selection 34. . . . . . . . . . . . . . . .
Getting Started 35. . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 35. . . . . . . . . . .
After Break-In Period 35. . . . . . . . . . . . . .
End of First Season Checkup 35. . . . . .
3
90-864197020 MARCH 2002 Page 23
ON THE WATER
0022
Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local and all other
governmental boating regulations and restrictions and also consider the following
suggestions.
• Know and obey all nautical rules and laws of the waterways.
Mercury MerCruiser strongly recommends that all powerboat operators complete a boating
safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The
Power Squadron, The Red Cross and your state or provincial boating law enforcement
agency. Inquiries may be made to the Boating Hotline at 1-800-368-5647 or the Boat U.S.
Foundation at 1-800-336-BOAT.
Y ou should also review the NMMA Sources of W aterway 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.
• Perform safety checks and required maintenance. Follow a regular schedule and
ensure that all repairs are properly made.
• Check safety equipment on board. Here are some suggestions of the types of
safety equipment to carry when boating:
Approved fire extinguishers Paddle or oar
Signal devices: flashlight, rockets or
flares, flag and whistle or horn
Spare propeller, thrust hubs and an
appropriate wrench
Tools necessary for minor repairs First aid kit and instructions
Anchor and extra anchor line Water-proof storage containers
Manual bilge pump and extra drain
plugs
Spare operating equipment, batteries,
bulbs and fuses
Drinking water Compass and map or chart of the area
Transistor radio
Page 24 90-864197020 MARCH 2002
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