Mercury TowSport Inboards User Manual

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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.

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 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.

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

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

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WARRANTY

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WARRANTY

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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. . . . . . . . .

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).

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

• 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. 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

70515 70516

70519

70521

70522

70517

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

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

71339

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

GETTING TO KNOW YOUR POWER PACKAGE

77971

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

77906

77602

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

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

CAUTION

75542

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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90-864197020 MARCH 2002 Page 21

GETTING TO KNOW YOUR POWER PACKAGE

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Page 22 90-864197020 MARCH 2002

Table of Contents

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. . . . . .

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

ON THE WATER

• Watch for signs of weather change and avoid foul weather and rough-sea

boating.

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

• Passenger boarding. Stop the engine whenever passengers are boarding,

unloading or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

• Use personal flotation devices. Federal Law requires that there be a U. S. Coast Guard approved, wearable-type life jacket (personal flotation device), correctly sized and readily accessible for every person on board, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

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

• Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat’s operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.

• Ensure that everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

• Never be under the influence of alcohol or drugs while boating (it is the law).

They impair your judgment and greatly reduce your ability to react quickly.

90-864197020 MARCH 2002 Page 25

ON THE WATER

• Know your boating area and avoid hazardous locations.

• Be alert. The operator of the boat is responsible by law to “maintain a proper lookout

by sight and hearing.” The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when operating the boat above idle or planing transition speed. Watch out for others, the water and your wake.

• Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 25 MPH (40 km/h) will overtake a fallen skier who was 61 m (200 ft) in front of you in 5 seconds.

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

• Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if (1) there is loss of life or probable loss of life, (2) there is personal injury requiring medical treatment beyond first aid, (3) there is damage to boats or other property where the damage value exceeds $500.00 or (4) there is complete loss of the boat. Seek further assistance from local law enforcement.

0023

Be Alert To Carbon Monoxide Poisoning

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

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

WARNING

Avoid prolonged exposure to carbon monoxide. Carbon monoxide poisoning can lead to unconsciousness, brain damage or death. Ensure that the boat, while at rest or underway, is well ventilated.

Page 26 90-864197020 MARCH 2002

0024

GOOD VENTILATION

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

1. Example of desired air flow through the boat.

0025

POOR VENTILATION

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

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

2. Examples of poor ventilation while a boat is stationary:

ON THE WATER

Courtesy of ABYC

a-Operating the engine when the boat is moored in a confined space. b-Mooring close to another boat with its engine operating.

3. Examples of poor ventilation while a boat is moving:

a-Operating the boat with the trim angle of the bow too high. b-Operating the boat with no forward hatches open (station wagon effect).

Courtesy of ABYC

90-864197020 MARCH 2002 Page 27

ON THE WATER

0026

Basic Boat Operation

0027

Launching And Boat Operation Care

To avoid possible ingestion of water that can damage engine components:

• Do NOT turn the ignition key off when the engine is above idle speed. w When launching your boat from a steep ramp, enter the water slowly.

• Do NOT use the lanyard stop switch to shut off the engine above idle speed.

• When coming off plane, if a large following wave may roll over the boat’s

transom, apply a short, light burst of throttle to minimize the wave action against the stern of the boat.

• Do NOT come off plane quickly, shift into reverse and shut off engine.

0028

OPERATION CHART

CAUTION

BEFORE STARTING

Open engine hatch.

Turn battery switch to ON. position

Operate bilge blowers.

Open fuel shutoff valve.

Open seacock.

Close the drain system.

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

Listen for Audio Warning Alarm to sound when the ignition switch is in the ON position.

Operation Chart

AFTER STARTING

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

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

Check shift and throttle control operation.

Check steering operation.

WHILE UNDERWAY

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

Listen for the audio alarm.

AFTER STOPPING

Turn ignition key to OFF position.

Turn battery switch to OFF position.

Close fuel shut off valve.

Close seacock. Flush cooling

system if in saltwater.

Drain bilge.

Page 28 90-864197020 MARCH 2002

0029

Starting And Stopping The Engine

NOTE: Only perform those functions applicable to your power package.

1. Check all items listed in Operation Cart.

2. Place the remote control handle in NEUTRAL.

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

Explosive gasoline fumes collect in the engine compartment. Avoid injury or property damage, operate the bilge blower for at least five minutes prior to starting the engine. If the boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine.

3. Position throttle setting as follows:

a. COLD AND WARM ENGINE - Leave in the NEUTRAL/IDLE speed position.

ON THE WATER

CAUTION

WARNING

b. FLOODED ENGINE - Turn ignition switch to the ON position. Push the THROTTLE

ONLY button and place the throttle lever at 50% position. Attempt to start engine. As soon as engine starts, return the throttle to the IDLE position.

IMPORTANT: Do not operate starter motor continuously for more than 30 seconds.

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

to ON position.

5. If engine is cold, operate engine for 1 or 2 minutes at fast IDLE (1000-1500 rpm) or until

engine temperature reaches 140-160 degrees F (60-71 degrees C).

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

7. To shift into gear, move control handle with a firm, quick motion forward to shift to FOR-

WARD gear, or backward to shift to REVERSE. After shifting drive unit, advance throttle to desired setting.

8. Move the remote control handle to NEUTRAL/IDLE and allow the engine to slow to IDLE

speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at IDLE speed for 3 to 5 minutes.

9. Turn ignition key to the OFF position.

0030

Freezing Temperature Operation

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

0031

Drain Plug and Bilge Pump

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

90-864197020 MARCH 2002 Page 29

ON THE WATER

0032

Protecting People In The Water

While You Are Cruising

It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed.

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 (coasting) in NEUTRAL/IDLE, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.

While Boat Is Stationary

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 gear case or any solid device rigidly attached to a moving boat or gear case.

WARNING

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

0033

High-Speed And High-Performance Boat Operation

If your boat is considered a high-speed or high-performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to Hi-Performance Boat Operation booklet (90-849250--1) from your dealer, distributor or Mercury Marine.

Page 30 90-864197020 MARCH 2002

0034

Wave And Wake Jumping

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 a boat hand hold.

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

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

ON THE WATER

WARNING

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

90-864197020 MARCH 2002 Page 31

ON THE WATER

0035

Impact With Underwater Hazards

Reduce speed and proceed with caution whenever you’re driving a boat in shallow water or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom.

IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of 24 to 40 km/h (15 to 25 MPH).

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

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

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

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

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

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

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

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

WARNING

Avoid serious injury or death from loss of boat control. Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts. Have the power package thoroughly inspected and any necessary repairs made.

Page 32 90-864197020 MARCH 2002

0036

Conditions Affecting Operation

Weight Distribution (Passengers And Gear) Inside The Boat

Shifting weight to rear (stern):

• Generally increases speed and engine rpm

• Causes bow to bounce in choppy water

• Increases danger of following wave splashing into the boat when coming off plane

• At extremes, can cause the boat to porpoise

Shifting weight to front (bow):

• Improves ease of planing

• Improves rough water ride

• At extremes, can cause the boat to veer back and forth (bow steer)

0037

Bottom Of Boat

ON THE WATER

0038

Cavitation

To maintain maximum speed, the boat bottom should be:

• Clean, free of barnacles and marine growth

• Free of distortion; nearly flat where it contacts the water

• Straight and smooth, fore and aft

Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the water inlets and cause the engine to overheat.

Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or a 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 the propeller. Common causes of cavitation are:

• Weeds or other debris snagged on the propeller

• Bent propeller blade

• Raised burrs or sharp edges on the propeller

90-864197020 MARCH 2002 Page 33

ON THE WATER

0039

Elevation And Climate

Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by:

• Higher elevations

• Higher temperatures

• Low barometric pressures

• High humidity

For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum rpm range with a normal boat load during your normal boating weather conditions.

In most cases, performance can be regained by changing to a lower pitch propeller.

0040

Propeller Selection

IMPORTANT: The engines covered in this manual are equipped with an rpm rev-limiter that is set to an upper (or limited) rpm amount. 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 drop into the recommended operating rpm range normal engine operation resumes.

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. Refer to Everything You Need To Know About Propellers (90-8614492).

Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating rpm range with a normal load.

If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch.

• Warmer weather and greater humidity cause a loss of rpm.

• Operating in a higher elevation causes a loss of rpm.

• Operating with a dirty boat bottom causes a loss of rpm.

• Operating with increased load (additional passengers, pulling skiers) causes a loss

of rpm.

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle when using the lower pitch propeller, but not pulling skiers.

Page 34 90-864197020 MARCH 2002

0042

Getting Started

0041

20-Hour Break-In Period

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

• Do NOToperate below 1500 rpm for extended periods of time for the first 10 hours.

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

• Do NOT operate at one speed consistently for extended periods.

• Do NOT exceed 3/4 throttle during the first 10 hours. During the next 10 hours,

occasional operation at full throttle is permissible (5 minutes at a time maximum).

• Avoid full throttle acceleration from IDLE speed.

• Do NOT operate at full throttle until the engine reaches normal operating

temperature.

ON THE WATER

• Frequently check engine oil level. Add oil as needed. It is normal for oil consumption

to be high during the break-in period.

0043

After Break-In Period

To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered;

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

WOT rpm range (Refer to Specifications And Maintenance) when at full throttle with a normal boat load.

• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged

operation at WOT rpm.

• Change the oil and oil filter. Refer to Specifications And Maintenance.

0044

End of First Season Checkup

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

90-864197020 MARCH 2002 Page 35

ON THE WATER

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Page 36 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

Table of Contents

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. . . . . . . . . . . . .

90-864197020 MARCH 2002 Page 37

SPECIFICATIONS AND MAINTENANCE

0045

Specifications

Fuel Recommendations

IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.

FUEL RATINGS

Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications:

USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline [92 (R+M)/2 Octane] is also acceptable. DO NOT use leaded gasoline.

Outside USA and Canada - having a posted pump Octane Rating of 90 RON minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.

0046

USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)

This type of gasoline is required in certain areas of the USA. The two types of oxygenates used in these fuels is Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol.

These Reformulated Gasolines are acceptable for use in your Mercury MerCruiser engine.

Page 38 90-864197020 MARCH 2002

0047

GASOLINES CONTAINING ALCOHOL

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

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

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

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

SPECIFICATIONS AND MAINTENANCE

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.

Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol-free gasoline 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.

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

90-864197020 MARCH 2002 Page 39

SPECIFICATIONS AND MAINTENANCE

0048

Engine Oil

To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil. This oil is a special blend of 25-weight and 40-weight oils for marine engines. If not available, a good grade, straight weight, detergent automotive oil of correct viscosity, with an API classification of SJ, CF-2, CH-4 may be used.

In those areas where Quicksilver 4-Cycle 25W-40 Marine Engine Oil or a recommended straight weight oil are not available, a multi-viscosity 20W-40 or, a less preferable choice, 20W-50, with API service ratings of SJ, CF-2, CH-4 may be used.

IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Quicksilver 25W-40 or a good quality 20W-40 or 20W-50), synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended.

The chart below is a guide to engine oil selection.

Quicksilver 4-Cycle 25W-40 Marine Engine Oil

SAE 40W

SAE 20W

SAE 30W

32° F 0

° C

AIR TEMPERATURE

50 10

° F ° C

75796

Page 40 90-864197020 MARCH 2002

0049

Engine Specifications

0050

SPECIFICATIONS AND MAINTENANCE

Models

Propshaft Horsepower Propshaft Kilowatts

350 MAG

MPI Tow

Sports

315 300 300 315 320

350

MAG

MPI

235 224 224 234 238

350

MAG

MPI

Horizon

MX 6.2

MPI

MX 6.2

MPI

Horizon

Displacement 350 cid (5.7 liter) 377 cid (6.2 liter) Specified WOT rpm

Range Idle rpm in NEUTRAL

Minimum Oil Pressure @ 2000 rpm

Minimum Oil Pressure @

Idle

4600-5000 4400-4800 4600-5000

600

124 kPa (18 psi)

41 kPa (6 psi)

Thermostat 71 degrees C (160 degrees F) Timing @ Idle

0 degrees Firing Order 1-8-4-3-6-5-7-2 Electrical System 12-Volt Negative (–) Ground Alternator Rating - Hot

Operating Amps Alternator Rating - Cold

Operating Amps Recommended Battery

Rating (Minimum)

550 cca / 825 mca / 150 Ah

65 amp

72 amp

Spark Plug Type AC Platinum (AC 41-932) Spark Plug Gap 0.060 in.

1 Power Rated in Accordance with NMMA (National Marine Manufacturers’ Association) rating procedures.

Measured using an accurate service tachometer, with engine at normal operating temperature.

Idle speed on EFI models is not adjustable.

Oil pressure must be checked with engine at normal operating temperature.

90-864197020 MARCH 2002 Page 41

SPECIFICATIONS AND MAINTENANCE

0051

Fluid Specifications

0052

ENGINE

IMPORT ANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines).

0053

TRANSMISSION

All Models

Capacity

Fluid Type

Liters (U.S. qts)

Crankcase Oil (With Filter)

Seawater Cooling System

5.20 (5-1/2)

20 (21) Propylene Glycol and Purified Water

Quicksilver 4-Cycle 25W-40 Marine

Engine Oil

Mercury Extended Life

Closed Cooling System

19 (20)

Coolant/Antifreeze or Extended Life

Ethylene Glycol 5/100

Antifreeze/Coolant mixed 50/50 with

Purified Water

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

Seawater Cooling System capacity information is for winterization use only.

Model

Capacity

Fluid Type

Liters (U.S. qts)

5000A 2.84 (3) 5000V 3.30 (3-1/2)

71C In-Line 1.66 (1-3/4) 71C Gear Reduction 2.84 (3) 71C Remote V-Drive 1.66 (1-3/4)

Dexron III Automatic Transmission

Fluid or Equivalent

Mobil 424 or

Dexron III Automatic Transmission

Do Not Mix!

72C In-Line 1.66 (1-3/4) 72C Gear Reduction 1.66 (1-3/4) 72C Remote V-Drive 1.66 (1-3/4)

Universal Tractor Hydraulic Oil

Mobil 424 or

Do Not Mix!

72C V-Drive 3.79 (4)

Fluid

630A 4.00 (4-1/2) 630V 4.00 (4-1/2)

Page 42 90-864197020 MARCH 2002

Dexron III Automatic Transmission

Fluid

0054

Owner/Operator Responsibilities

It is the operator’s responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup.

Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

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

0055

Dealer Responsibilities

In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as:

SPECIFICATIONS AND MAINTENANCE

• Ensure that the boat is properly equipped.

• Prior to delivery, make certain that the Mercury MerCruiser power package and other

equipment are in proper operating condition.

• Make all necessary adjustments for maximum efficiency.

• Familiarize the customer with the on-board equipment.

• Explain and demonstrate the operation of the power package and boat.

• Provide you with a copy of a Predelivery Inspection Checklist.

• Your selling dealer should fill out the Warranty Registration Card completely and mail

it to the factory immediately upon sale of the new product.

90-864197020 MARCH 2002 Page 43

SPECIFICATIONS AND MAINTENANCE

0056

Maintenance

Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package.

Fuel vapors can be present in the engine compartment. Avoid injury or power package damage caused by fuel vapors or explosion. Always ventilate the engine compartment prior to servicing the power package.

IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed. Some listings can be done by owner/operator, while others should be performed by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly.

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

WARNING

CAUTION

• Blue-Coolant

• Yellow-Engine Oil

• Orange-Fuel

• Brown-Transmission Fluid

Page 44 90-864197020 MARCH 2002

0057

Do-It-Yourself Maintenance Suggestions

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

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

• Do not attempt any repairs unless you are aware of the Cautions, Warnings and procedures required. Your safety is our concern.

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

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

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

SPECIFICATIONS AND MAINTENANCE

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

Your authorized dealer is there to service your power package. They have qualified factory-trained mechanics.

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

90-864197020 MARCH 2002 Page 45

SPECIFICATIONS AND MAINTENANCE

0058

Inspection

Inspect your power package often, and at regular intervals, to help maintain its top operating performance and correct potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.

Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as necessary.

Check plug leads and electrical leads for damage. Remove and inspect the propeller . If badly nicked, bent or cracked, contact your authorized

Mercury MerCruiser dealer. Repair nicks and corrosion damage on power package exterior finish. Contact your

authorized Mercury MerCruiser dealer.

0059

Inboard Maintenance Chart

Routine Maintenance *

Check the engine oil (interval can be

Each

Day

Start



Each

Day End

Weekly

extended based on experience). If operating in salt, brackish or polluted

waters, flush the cooling system after each



use. Check the transmission fluid.



Check the water inlets for debris or marine growth. Check the water strainer and clean.



Check the coolant level. Check the battery connections and the fluid

level. Ensure that the gauges and the wiring

connections are secure. Clean the gauges.

* Only perform maintenance which applies to your particular power package

If operating in saltwater, interval is reduced to every 25 hours or 30 days whichever occurs first

Every

Two

Months



 or

50 hours

Page 46 90-864197020 MARCH 2002

0060

Inboard Maintenance Chart (continued)

Scheduled Maintenance *

SPECIFICATIONS AND MAINTENANCE

Every

100

Annually

hours or

Annually



Touch-up paint power package and spray with



corrosion guard. Change the engine oil

and the filter. Change the transmission

fluid.



Replace the fuel filters.  Check the steering

system and the remote control for loose, missing or damaged parts.



Lubricate the cables and the linkages.

Retorque the engine mounts.

Check the spark plugs, the wires, and the distributor cap.

Clean the flame arrestor and the engine ventilation hoses. Replace the PCV valve.

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

Inspect the condition and the tension of the belts.

Every

200

hours

or 3

years



Every

300

hours

or 3

years





Every

years

Every

years

Per

OEM

* Only perform maintenance which applies to your particular power package  Whichever occurs first

90-864197020 MARCH 2002 Page 47

SPECIFICATIONS AND MAINTENANCE

Inboard Maintenance Chart (continued)

Scheduled Maintenance *

Check the cooling system and the exhaust system hose clamps for tightness. Inspect both systems for damage or leaks.

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

Clean the seawater section of the closed cooling system. Clean, inspect and test the pressure cap.

Replace the coolant.

Annually

Every

100

hours or

Annually



Every

200

hours

or 3

years



Every

300

hours

or 3

years





Every

years



Every

years



Per

OEM

Check the engine-to-propeller shaft alignment.

* Only perform maintenance which applies to your particular power package

 Whichever occurs first  Interval will be reduced if not using extended life coolant



Page 48 90-864197020 MARCH 2002

0166

Maintenance Record

SPECIFICATIONS AND MAINTENANCE

Date

Hour Meter

Reading

Serviced By

Maintenance Per-

formed

90-864197020 MARCH 2002 Page 49

SPECIFICATIONS AND MAINTENANCE

0062

Engine Oil

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 defined by local authorities.

0063

Checking

1. Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water.

CAUTION

a-Dipstick Tubes

2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube.

3. Remove the dipstick and observe the oil level. Oil level must be between FULL or OK RANGE and ADD. Fill as necessary with specified fluid.

All Models

Engine Oil (With Filter)

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

77808

Capacity

Fluid Type

78027

Liters (U.S. qts)

5.25 (5-1/2) 4-Cycle 25W-40 Marine Engine Oil

Page 50 90-864197020 MARCH 2002

0064

Filling

SPECIFICATIONS AND MAINTENANCE

IMPORTANT: Do not overfill the engine with oil.

1. Remove oil fill cap.

77842

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

mark on the dipstick. Refer to Specifications.

All Models

Capacity

Liters (U.S. qts)

Engine Oil (With Filter)

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

5.25 (5-1/2) 4-Cycle 25W-40 Marine Engine Oil

3. Replace the fill cap.

Fluid Type

90-864197020 MARCH 2002 Page 51

SPECIFICATIONS AND MAINTENANCE

0065

Changing Oil and Filter

Refer to the Maintenance schedule for the change interval. engine oil should be changed before placing the boat in storage.

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

0066

QUICK DRAIN OIL

1. Remove the bilge drain plug.

2. Pull tether through the bilge drain.

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

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

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

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

7. Proceed to ALL MODELS.

0067

ENGINE OIL PUMP

1. Remove the dipstick.

2. Install the oil pump onto the dipstick tube.

70571

a-Typical Oil Pump b-Dipstick Tube c-Oil Drain Hose

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

4. Remove the pump.

5. Install the dipstick.

6. Proceed to ALL MODELS.

Page 52 90-864197020 MARCH 2002

0068

ALL MODELS

SPECIFICATIONS AND MAINTENANCE

1. Remove and discard oil filter.

77808

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

3. Tighten oil filter securely (following filter manufacturer’s instructions). Do NOT

overtighten.

4. Remove oil fill cap.

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

5. Add recommended engine oil to bring level up to, but not over, FULL or OK RANGE mark

on dipstick.

All Models

Capacity

Fluid Type

Liters (U.S. qts)

Crankcase Oil (With Filter)

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

5.25 (5-1/2) 4-Cycle 25W-40 Marine Engine Oil

6. Start engine and check for leaks.

90-864197020 MARCH 2002 Page 53

SPECIFICATIONS AND MAINTENANCE

0069

Transmission Fluid

CHECKING WHILE ENGINE IS WARM

IMPORT ANT: Engine must be operate at 1500 rpm for 2 minutes immediately prior to checking level.

1. Velvet Drive Transmissions T-handle counterclockwise, to remove dipstick. Fluid level should be up to full mark. If low, add specified fluid through dipstick tube on transmissions.

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

3. Walter V-Drive Transmissions is below top (full) line, add specified fluid through breather elbow. Do not overfill. Reinstall dipstick with cap fully seated.

CHECKING WHILE ENGINE IS COLD

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

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

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

2. Remove the dipstick, wipe clean and reinsert.

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

4. Reinstall the dipstick, tighten the T-handle securely. Do NOT overtighten.

0070

CHANGING

- Stop engine and quickly check fluid level by turning

- Stop engine and remove dipstick to check level. If fluid is below

- Stop engine and remove dipstick to check level. If fluid

Contact your authorized Mercury MerCruiser dealer.

Page 54 90-864197020 MARCH 2002

0078

Lubrication

0079

Throttle Cable

SPECIFICATIONS AND MAINTENANCE

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

78033

a-Pivot Points b-Guide Contact Surfaces

Description

Engine Oil

0196

Transmission Linkage - Typical

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

Typical In-Line Transmission

a-Detent Ball Locations

Where Used Part Number

Pivot points, guide contact

surfaces

Obtain Locally

71457

Description

Engine Oil Detent ball and holes Obtain Locally

90-864197020 MARCH 2002 Page 55

Where Used Part Number

SPECIFICATIONS AND MAINTENANCE

0071

Engine Coolant - Closed Cooled Models Only

Checking

CAUTION

Allow the engine to cool down before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.

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

77955

a-Heat Exchanger With Cap

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

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

3. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.

Page 56 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

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

5. Add the specified fluid as necessary.

72520

0072

Filling

0073

Changing

Description

Where Used Part Number

Mercury Extended Life Coolant/Antifreeze or Extended Life Ethylene Glycol 5/100

Closed Cooling System 92-877770K1 Antifreeze/Coolant mixed 50/50 with Purified Water

1. Remove the fill cap from the coolant recovery bottle.

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

Description

Where Used Part Number

Mercury Extended Life Coolant/ Antifreeze or Extended Life Ethylene Glycol 5/100 Antifreeze/

Closed Cooling System 92-877770K1 Coolant mixed 50/50 with Purified Water

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

Contact your authorized Mercury MerCruiser dealer.

90-864197020 MARCH 2002 Page 57

SPECIFICATIONS AND MAINTENANCE

0074

Flame Arrestor and Related Components

Cleaning

1. Remove the engine cover.

2. Remove the crankcase ventilation hose from the fitting on the side of the flame arrestor housing.

3. Remove the flame arrestor.

78480

a-Engine Cover Knob b-Engine Cover c-Nuts, Flame Arrestor d-Cover Mount Bracket e-Flame Arrestor

f-Crankcase Ventilation Hose

4. Clean the flame arrestor in water or steam. Dry with compressed air or allow to air dry completely.

5. Clean the crankcase ventilation hoses. Dry with compressed air or allow to air dry completely.

6. Inspect the crankcase ventilation hoses for cracks or deterioration and replace if necessary.

77946

Page 58 90-864197020 MARCH 2002

7. Install flame arrestor and crankcase ventilation hoses.

8. Install the flame arrestor bracket and tighten the nuts.

Description Nm lb-in. lb-ft

Flame Arrestor Bracket Nuts 12 9

9. Install the engine cover.

0167

Positive Crankcase Ventilation Valve (PCV)

CHANGING

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

1. Remove PCV valve from port valve cover.

SPECIFICATIONS AND MAINTENANCE

a-PCV Valve b-Hose

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

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

4. Ensure valve is tightly seated in valve cover.

71925

90-864197020 MARCH 2002 Page 59

SPECIFICATIONS AND MAINTENANCE

0075

Water Separating Fuel Filter

Changing

Avoid Fire or Explosion: The fuel injection system is pressurized during operation. Use care when removing the water separating fuel filter. Fuel could s pr ay on t he ho t engine causing fire or explosion. Allow the engine to cool down before attempting to remove the water separating fuel filter in the following procedure. Also, hold a clean shop towel over the water separating fuel filter when removing it, to help avoid fuel spraying on the engine.

Be careful when changing the water separating fuel filter. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure the ignition key is OFF. Do not smoke or allow spark or open flame in the area when changing the fuel filter. Wipe up any spilled fuel immediately.

Ensure that no fuel leaks exist before closing the engine hatch.

WARNING

1. Allow the engine to cool down.

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

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

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

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

Description

Engine Oil Filter sealing ring Obtain Locally

Where Used Part Number

Page 60 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

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

70573

77933

a-Fuel Filter Base b-Sealing Ring c-Fuel Filter

6. Supply cooling water to the engine.

7. Start engine. Check the filter connection for gasoline leaks. If leaks exist, recheck filter

installation. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer.

90-864197020 MARCH 2002 Page 61

SPECIFICATIONS AND MAINTENANCE

0168

In-line Fuel Filter

Changing

Be careful when changing the fuel filter. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure that the ignition key is OFF. Do not smoke or allow spark or open flame in the area when changing the fuel filter. Wipe up any spilled fuel immediately.

1. Verify the presence of an anti-siphon valve. If no anti-siphon valve is present, plug fuel line from the fuel tank.

2. Remove the existing in-line fuel filter.

3. Select appropriate size connector for the fuel line and install the connector on the filter.

4. Apply sealant to the male pipe threads on the connectors.

WARNING

Description

Loctite 565 Male threads Obtain locally

5. Torque connectors.

Description

Connectors 19-27 14-20

6. Insert filter into the mounting clip.

Where Used Part Number

Nm lb-in. lb-ft

a-In-line Filter b-Connectors c-Mounting Clip

78289

Page 62 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

7. Install and torque screw and washer through the mounting clip into the stringer.

Description

Nm lb-in. lb-ft

Screw, Mounting Clip 12.2 9

8. Install and torque hose clamps over hose and insert barbs into hose.

a-Fuel Line Stringer Clips b-Fuel Line

Description

Hose Clamps 3.4 -6.8 30-60

Nm lb-in. lb-ft

78289

90-864197020 MARCH 2002 Page 63

SPECIFICATIONS AND MAINTENANCE

0076

Battery

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

Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine. Do not recharge a weak battery in the boat. Remove battery and recharge in a ventilated area away from fuel vapors, sparks or flames.

Batteries contain acid which can cause severe burns. Avoid contact with skin, eyes and clothing. If electrolyte is spilled or splashed on any part of the body, immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible.

Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte.

0077

Multiple EFI Engine Battery Precautions

WARNING

Alternators: Alternators are designed to charge the battery that supplies electrical power

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

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

In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine just appears to have an ignition miss.

Batteries: Boats with multi-engine EFI power packages require each engine be connected to of its own battery. This ensures that the engine’s Electronic Control Module (ECM) has a stable voltage source.

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

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

Generators: The generator’s battery should be considered another engine’s battery.

Page 64 90-864197020 MARCH 2002

0081

Serpentine Drive Belt

Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt.

SPECIFICATIONS AND MAINTENANCE

WARNING

0082

CHECKING

a-Idler Pulley b-Circulating Pump Pulley c-Crankshaft Pulley d-Alternator Pulley e-Seawater Pump Pulley

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

• Excessive wear

• Cracks

NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are NOT acceptable.

• Fraying

• Glazed surfaces

76503

• Proper tension - 6 mm (1/4 in.) deflection, with moderate thumb pressure, on the belt

at the location that has the longest distance between two pulleys.

90-864197020 MARCH 2002 Page 65

75130

SPECIFICATIONS AND MAINTENANCE

0083

REPLACING AND / OR ADJUSTING TENSION

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

NOTE: The upper, left (port) idler pulley is the belt adjustment pulley. NOTE: Belt deflection is to be measured on the belt at the location that has the longest dis-

tance between two (2) pulleys.

1. Loosen the 5/8 in. locking nut on the adjustment stud.

2. Turn the adjustment stud and loosen the belt.

3. Remove the serpentine drive belt.

4. Install the serpentine drive belt onto the pulleys.

5. Put a wrench on the adjustment stud 5/8 in. locking nut.

6. Use a 5/16 in. socket and tighten adjusting the stud to adjust the belt deflection.

7. Using 1 of the 2 methods following, check for correct deflection. a. Push down with moderate thumb pressure on the longest stretch of belt. Proper

deflection is 6 mm (1/4 in.).

Page 66 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

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

ranges for new and used belts.

77573

77574

a-Kent Moore Tension Gauge b-Serpentine Belt

8. While holding the adjustment stud at the correct belt tension, tighten the 5/8 in. locking

nut.

77827

a-5/8 in. Locking Nut b-5/16 in Adjusting Stud

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

90-864197020 MARCH 2002 Page 67

SPECIFICATIONS AND MAINTENANCE

0084

Cold Weather Or Extended Storage

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

CAUTION

Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing is NOT covered by the Mercury MerCruiser Limited Warranty.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer’s recommendations.

0085

Preparing Your Power Package For Storage

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

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

NOTE: If desired, a portable fuel tank can be used to perform the remainder of the power package lay up procedures. Be sure to add an appropriate amount of Gasoline Stabilizer to the portable tank.

3. Flush the cooling system.

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

5. Change the oil and oil filter.

Page 68 90-864197020 MARCH 2002

0086

FUEL SYSTEM

SPECIFICATIONS AND MAINTENANCE

WARNING

The fuel injection system is pressurized. Avoid serious injury from an explosion. Use care when removing water separating fuel filter. Allow engine to cool down before removing the water separating fuel filter. Also, hold a clean shop towel over the water separating fuel filter when removing it, to help avoid fuel spraying on the engine.

WARNING

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

a. 19 liter (5 U.S. gal) regular unleaded 87 octane (90 RON) gasoline b. 1.89 liter (2 U.S. qts.) Premium Plus 2-Cycle TC-W3 Outboard Oil c. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel

System Treatment and Stabilizer Concentrate.

Description

Mercury Fuel System Treatment and Stabilizer

Mercury Fuel System Treatment and Stabilizer Concentrate

Premium Plus 2-Cycle TC-W3 Outboard Oil

Where Used Part Number

Fuel System 92-802875A1

Fuel System 92-802876A1

Fuel System 92-802824A1

2. Allow the engine to cool down.

IMPORTANT: Immediately wipe up any fuel spills or sprays.

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

equipped with a fuel shut-off valve.

4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting.

90-864197020 MARCH 2002 Page 69

SPECIFICATIONS AND MAINTENANCE

IMPORTANT: Supply cooling water to the engine.

5. Start and operate the engine at 1300 rpm for 5 minutes.

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

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

7. Remove and discard the water separating fuel filter.

8. Install a new filter.

0087

BATTERY

Follow the battery manufacturer’s instructions for storage.

0088

Draining Instructions

Ensure that boat is out of the water or seacock is closed and bilge pump is operating before beginning procedure. Excess water in bilge can damage engine or cause boat to sink.

CAUTION

Do not operate engine with drain system open. Excess water in bilge can damage engine or cause boat to sink.

IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.

Your power package is equipped with a drain system. Refer to Identification on the following page to determine which instructions apply to your power package.

The power package should be drained before flushing or prior to extended or cold weather storage.

IMPORTANT: The engine must not be operating at any point during this procedure.

Page 70 90-864197020 MARCH 2002

0179

Identification

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

SPECIFICATIONS AND MAINTENANCE

Closed Cooled Models Seawater Cooled Models

a-Blue Drain Plug Location b-Blue Air Pump c-Air Manifold d-Green Indicators

0180

3 POINT MANUAL DRAIN SYSTEM

77955

a-Blue Drain Plug

77917

77908

90-864197020 MARCH 2002 Page 71

SPECIFICATIONS AND MAINTENANCE

0182

Boat In Water

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

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

1. Close the seacock.

2. Remove the blue air pump from the engine.

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

4. Install air pump on the fitting in the air manifold.

77638

a-Green Indicators

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

6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.

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

77955

Closed Cooled Models Seawater Cooled Models

a-Blue Drain Plug Location b-Blue Air Pump c-Air Manifold d-Green Indicators

Page 72 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

8. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain

System instructions.

77839

77844

a-Port Side Drain Location b-Starboard Side Drain Location

9. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the

green indicators extended.

10. Crank engine over slightly with starter motor to purge any water trapped in seawater

pump. DO NOT allow engine to start.

11. Reinstall the blue drain plug in the thermostat housing.

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

13. Mercury MerCruiser recommends leaving the drain system open while transporting the

boat or while performing other maintenance. This helps ensure that all water is drained.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer’s recommendations.

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

no longer extended.

a-Green Indicators

15. Open the seacock prior to operating the engine.

90-864197020 MARCH 2002 Page 73

77638

SPECIFICATIONS AND MAINTENANCE

0183

3 POINT MANUAL DRAIN SYSTEM

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails.

1. Close the seacock.

2. Remove the blue drain plug from the distribution housing (lower front, port side).

a-Blue Drain Plug

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

77917

a-Blue Drain Plug Location

77949

Page 74 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

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

77908

5. Verify that water is draining from each opening.

6. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends

leaving the drain system open while transporting the boat or while performing other maintenance.

7. Crank engine over slightly with starter motor to purge any water trapped in seawater

pickup pump. Do NOT allow engine to start.

8. Prior to launching boat or starting the engine, close the drain system by installing the

4 blue drain plugs.

9. Open the seacock prior to operating the engine.

90-864197020 MARCH 2002 Page 75

SPECIFICATIONS AND MAINTENANCE

0184

Boat Out Of The Water

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

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

1. Remove the blue air pump from the engine.

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

3. Install air pump on the fitting in the air manifold.

a-Green Indicators

77638

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

5. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.

77955

Closed Cooled Models Seawater Cooled Models

a-Blue Drain Plug Location b-Blue Air Pump c-Air Manifold d-Green Indicators

Page 76 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

6. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain

System.

77839

77844

a-Port Side Drain Location b-Starboard Side Drain Location

7. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the

green indicators extended.

8. Crank engine over slightly with starter motor to purge any water trapped in seawater

pump. DO NOT allow engine to start.

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

10. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or

while performing other maintenance to ensure that all water is drained.

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

indicators are no longer extended.

a-Green Indicators

90-864197020 MARCH 2002 Page 77

77638

SPECIFICATIONS AND MAINTENANCE

0185

3 POINT MANUAL DRAIN SYSTEM

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails.

1. Remove three blue drain plugs: One from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side).

0187

All Models

77917

77908

a-Blue Drain Plug

2. Verify that water is draining from each opening.

3. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the plu g s o u t w h i l e transporting the boat or while performing other maintenance to ensure that all water is drained.

4. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. DO NOT allow engine to start.

5. Prior to launching boat or starting the engine, close the drain system by re-installing the three blue drain plugs.

1. For additional assurance against freezing and corrosion, fill the cooling system with a mixture of propylene glycol antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage.

a. Remove thermostat housing or hose and fill with propylene glycol coolant until block

and head are full. If thermostat housing was removed, reinstall and tighten cover bolts securely.

Page 78 90-864197020 MARCH 2002

0098

Flushing The Power Package

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at the water inlet during engine operation.

If flushing with the boat in the water, seawater can flow into the engine causing engine damage. Water inlet must be closed when flushing the engine.

If boat is in the water, do not open water inlet valve until engine is to be restarted to prevent contaminated water from flowing back into engine.

Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure the engine is operating in the normal ranges

0099

Inboards

SPECIFICATIONS AND MAINTENANCE

CAUTION

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

1. Close the water inlet valve or remove the water inlet hose and plug the inlet.

2. Drain the seawater from the engine.

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

4. Open the water source completely.

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

CAUTION

Do not let water flow for more than 15 seconds with engine not operating or too much flushing water will collect in the muffler causing engine damage.

90-864197020 MARCH 2002 Page 79

SPECIFICATIONS AND MAINTENANCE

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

a-Quick Connect Fitting

7. Start the engine within 15 seconds.

8. Operate the engine between 600 rpm and 800 rpm. Do NOT exceed 800 rpm.

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

10. Flush the engine for 10 minutes or until discharge water is clear.

75423

11. Shut off the engine.

CAUTION

Do not let water run more than 15 seconds with engine not operating or too much flushing water will collect in the muffler.

12. Within 15 seconds, disconnect the quick connect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket.

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

14. Turn off the water source.

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

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

17. Open the water inlet valve.

Page 80 90-864197020 MARCH 2002

0100

Tow Sports

SPECIFICATIONS AND MAINTENANCE

1. If flushing the engine with the boat in the water, close the water inlet valve or remove

and plug the water inlet hose. a. Models with Walter V-Drive Transmissions: Disconnect water inlet hose from the

transmission fitting. Using appropriate connector, connect water hose to water source. Proceed to Step 3.

75191

b. All other models: Using appropriate connector, connect the flushing hose from the

water to the water inlet hose (upper hose) of the seawater pickup pump. Proceed to Step 3.

77908

WARNING

Contact with moving drive components and the propeller can cause personal injury or death. To avoid possible injury , remove the propeller and ensure that no people or animals are in the propeller area while flushing.

90-864197020 MARCH 2002 Page 81

SPECIFICATIONS AND MAINTENANCE

2. If flushing the engine with the boat out of the water, remove the propeller. Refer to boat manufacturers’ instructions.

a. Models with Walter V-Drive Transmissions: Disconnect water inlet hose from

transmission fitting. Using appropriate connector, connect the flushing hose. Proceed to Step 3.

b. All other models: Using appropriate connector, connect the flushing hose from the

water to the water inlet hose (upper hose) of the seawater pickup pump. Proceed to Step 3.

75191

77908

3. Open the water source.

4. Place remote control in NEUTRAL, idle speed position, and start engine. Operate engine at idle speed, in NEUTRAL, for about 10 minutes or until discharge water is clear.

5. Stop the engine.

6. Remove the flushing connector from the water inlet.

7. Reconnect the water inlet hose.

8. Tighten hose clamp securely.

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

10. Turn off the water source.

11. Open the water inlet or remove the plug from the water inlet fitting and reinstall the water inlet hose.

12. Replace the propeller if removed. Refer to the boat manufacturers’ instructions.

Page 82 90-864197020 MARCH 2002

0101

Power Package Recommissioning

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

CAUTION

When installing the battery, be sure to connect the NEGATIVE (–) battery cable to the NEGATIVE (–) battery terminal and the POSITIVE (+) battery cable to the POSITIVE (+) battery terminal. If the battery cables are reversed, electrical system damage will result.

2. Install a fully-charged battery. Clean the battery cable clamps and terminals and

reconnect cables (see CAUTION listed above). Tighten each cable clamp securely when connecting.

3. Coat the terminal connections with a battery terminal anti-corrosion agent.

4. Perform all the checks in the BEFORE STARTING column of the Operations Chart.

CAUTION

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.

SPECIFICATIONS AND MAINTENANCE

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

functioning correctly.

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

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

90-864197020 MARCH 2002 Page 83

SPECIFICATIONS AND MAINTENANCE

0163

Emissions (Europe Only)

The following information applies only to engines with a special emissions kit installed. If the kit has been installed, your engine complies with SAV1 Regulations.

0164

Emissions Testing

Your engine is equipped with special design features and special tuning to minimize the emission output from the engine. You should follow:

• Recommended maintenance schedules particularly as to the ignition system.

• Proper engine tuning procedures to ensure these features remain in good operating

order.

• Proper steps to maintain the engine within specifications.

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

0165

Installing Test Probes

IMPORT ANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine. The test probes should be installed as follows:

1. Remove plugs from the top of both exhaust elbows.

75319

a-Exhaust Elbow Plug

Page 84 90-864197020 MARCH 2002

SPECIFICATIONS AND MAINTENANCE

2. Apply sealant to the adapter fitting threads that go into the exhaust elbow.

3. Install fittings into elbows. Tighten fittings securely.

a-Adapter Fitting b-Elbow Side c-Probe

71926

Description

Where Used Part Number

A Pipe Sealant with Teflon Adapter fitting threads 92-809822

4. Insert exhaust probes into fittings and tighten securely.

75324

a-Test Probes Installed

The testing agency will connect their adapters and test equipment to the probes to conduct the test. Once the test is complete, they should remove the test probes and fittings, apply Quicksilver Perfect Seal to the threads of both plugs and reinstall them into elbows.

90-864197020 MARCH 2002 Page 85

SPECIFICATIONS AND MAINTENANCE

THIS PAGE IS INTENTIONALLY BLANK

Page 86 90-864197020 MARCH 2002

Table of Contents

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. . . . .

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. . . . . . . .

90-864197020 MARCH 2002 Page 87

TROUBLESHOOTING

0102

Diagnosing EFI Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM’s memory. This code can then be read later by a service technician using a special diagnostic tool.

0103

Troubleshooting Charts

Starter Motor Will Not Crank Engine, Or Cranks Slow

Possible Cause Remedy

Battery switch turned off. Turn switch on. Remote control not in neutral position. Position control lever in neutral.

Open circuit breaker or blown fuse.

Loose or dirty electrical connections or damaged wiring.

Bad battery. Test and replace if bad.

0104

Engine Will Not Start, Or Is Hard To Start

Possible Cause Remedy

Lanyard stop switch activated Check lanyard stop switch. Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shutoff valve

closed. Engine flooded.

Faulty ignition system component. Service ignition system. Clogged fuel filter. Replace filter. Stale or contaminated fuel. Drain tank. Fill with fresh fuel. Fuel line or tank vent line kinked or

clogged. EFI system fault.

Faulty wire connections. Check wire connections.

Check and reset circuit breaker or replace fuse.

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

Fill tank or open valve. Do not attempt to start engine for at least

5 minutes. Refer to Basic Boat Operation.

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

Have EFI System checked by an authorized Mercury MerCruiser dealer.

Page 88 90-864197020 MARCH 2002

0105

Engine Runs Rough, Misses And/Or Backfires

Possible Cause Remedy

Clogged fuel filter. Replace filter.

TROUBLESHOOTING

Stale or contaminated fuel. Kinked or clogged fuel line or fuel tank

vent line. Flame Arrestor dirty. Clean Flame Arrestor.

Faulty ignition system component. Service ignition system. Idle speed too low. EFI System fault. Have EFI System checked by an

0106

Poor Performance

Throttle not fully open. Damaged or improper propeller. Replace propeller.

Excessive bilge water. Drain and check for cause of entry. Boat overloaded or load improperly

distributed.

If contaminated, drain tank. Fill with fresh fuel.

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

Have EFI system checked by an authorized Mercury MerCruiser dealer.

authorized Mercury MerCruiser dealer.

Possible Cause Remedy

Inspect throttle cable and linkages for proper operation.

Reduce load or redistribute load more evenly.

Flame arrestor dirty. Clean flame arrestor. Boat bottom fouled or damaged. Clean or repair as necessary.

Ignition problem.

See Engine Runs Rough, Misses or Backfires.

Engine overheating. See Excessive Engine Temperature. EFI system fault.

Have EFI System checked by an authorized Mercury MerCruiser dealer.

90-864197020 MARCH 2002 Page 89

TROUBLESHOOTING

0107

Excessive Engine Temperature

Possible Cause Remedy

Water inlet or seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups obstructed. Remove obstruction. Faulty thermostat. Replace.

Coolant level low in closed cooling section.

Heat Exchanger Cores plugged with foreign material

Loss of pressure in closed cooling section. Faulty seawater pickup pump. Repair.

Seawater discharge restricted or plugged. Clean exhaust elbows.

0108

Insufficient Engine Temperature

Possible Cause Remedy

Faulty thermostat. Replace.

0109

Low Engine Oil Pressure

Possible Cause Remedy

Insufficient oil in crankcase. Check and add oil. Excessive oil in crankcase (causing it to

become aerated).

Diluted or improper viscosity oil.

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

Clean Heat Exchanger. Check for leaks. Clean, inspect and test

pressure cap.

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

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

Page 90 90-864197020 MARCH 2002

TROUBLESHOOTING

0110

Excessive Transmission Fluid Temperature or Slipping Transmission

Possible Cause Remedy

Low fluid level. Fill. Transmission shift lever not positioned

properly (causing clutches to slip and overheat fluid).

Inspect shift linkages and shift lever positioning.

Fluid cooler hoses kinked. Straighten hoses or replace, if damaged.

0111

Battery Will Not Come Up On Charge

Possible Cause Remedy

Excessive current draw from battery. Turn off non-essential accessories. Alternator drive belt loose or in poor

Replace and/or adjust.

condition. Unacceptable battery condition. Test battery.

Check all associated electrical

Loose or dirty electrical connections or damaged wiring.

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

0112

Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual Sounds

Possible Cause Remedy

Insufficient lubrication on shift and throttle linkage fasteners.

Lubricate. Obstruction in shift or throttle linkages. Remove obstruction. Loose or missing shift and throttle

linkages.

Check all throttle linkages. If any are loose

or missing, see authorized Mercury

MerCruiser dealer immediately.

Straighten cable or have authorized Shift or throttle cable kinked.

Mercury MerCruiser dealer replace cable if

damaged beyond repair.

90-864197020 MARCH 2002 Page 91

TROUBLESHOOTING

THIS PAGE IS INTENTIONALLY BLANK

Page 92 90-864197020 MARCH 2002

CUSTOMER ASSISTANCE INFORMATION

Table of Contents

CUSTOMER ASSIST ANCE INFORMA TION

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. . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . .

90-864197020 MARCH 2002 Page 93

CUSTOMER ASSIST ANCE INFORMA TION

0113

Owner Service Assistance

Local Repair Service

Always return your Mercury MerCruiser powered boat to your authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur. He knows your engine best.

* Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser

0114

Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Regional Service Center. Outside the United States and Canada, contact the nearest Marine Power International Service Center.

0115

Stolen Power Package

 sterndrives and inboards.

If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

0116

Attention Required After Submersion

1. Before recovery, contact an authorized Mercury MerCruiser dealer.

2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to prevent serious damage to power package.

Page 94 90-864197020 MARCH 2002

Mercury TowSport Inboards User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual