Mercury V-6, V-8 User Manual

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Gasoline Engines - Alpha Models

1998, Mercury Marine 90860168985 1098

CB751

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)

SERIAL NUMBERS

The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your MerCruiser power package. When contacting your Authorized 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.

1998, Mercury Marine

The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide, and Thruster.

CA469

71352

ABC12345Z123

-19 48-12345

71345

2,7

74677

1,2

COLOR CODE

MERCRUISER

Division of Mercury Marine

Stillwater, OK, U.S.A.

SPECIFICATIONS

MODEL MCM 4.3LX/4.3LXH GEN +.

DISPLACEMENT 262 CID. . . . . . . . .

IGNITION TIMING 10 BTDC. . . . . . .

CYL. FIRING ORDER 1-6-5-4-3-2. . .

SPARK PLUGS AC-MR43LTS. . . . .

ENGINE ROTATION LH. . . . . . . . . . .

MAX W.O.T. RPM 4400-4800. . . . . .

IDLE RPM IN NEUTRAL 650. . . . . . .

PLUG GAP .045’. . . . . . . . . . . . . . . . .

For Fuel and Oilrequirements refer to Operations & Maintenance Manual

SERIAL NUMBERS

71718

74849

TABLE OF CONTENTS

Page

Welcome! 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Message 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Read This Manual Thoroughly 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lanyard Stop Switch 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Emissions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Be Alert To Carbon Monoxide Poisoning 9. . . . . . . . . . . . . . . . . .

Safe Boating Suggestions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

While You Are Cruising 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Boat Is Stationary 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed And High-Performance Boat Operation 15. . . . . .

Conditions Affecting Operation 16. . . . . . . . . . . . . . . . . . . . . . . . .

Weight Distribution 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cavitation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Selection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How Elevation And Climate Affect Performance 19. . . . . . . . . .

Important Information 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation And Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Freezing Temperature Operation 21. . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Impact Protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Plug and Bilge Pump 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emissions Information (Europe Only) 22. . . . . . . . . . . . . . . . . . . .

Attention Required After Submersion 22. . . . . . . . . . . . . . . . . . . .

Trailering Boat 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Launching And Boat Operation Care 23. . . . . . . . . . . . . . . . . . . .

Stolen Power Package 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Service Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do-It-Yourself Maintenance Suggestions 25. . . . . . . . . . . . . . . . .

Multiple EFI Engine Battery Precautions 26. . . . . . . . . . . . . . . . .

Diagnosing EFI Problems (If Equipped) 27. . . . . . . . . . . . . . . . . .

Water Separating Fuel Filter 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

20-Hour Break-In Period 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Break-In Period 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End of First Season Checkup 29. . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrumentation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Audio Warning System 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Overload Protection 35. . . . . . . . . . . . . . . . . . .

Remote Controls (Panel Mounted) 39. . . . . . . . . . . . . . . . . . . . . .

Remote Controls (Console Mounted) 41. . . . . . . . . . . . . . . . . . . .

Remote Controls (Two Lever) 43. . . . . . . . . . . . . . . . . . . . . . . . . .

Page

Power Trim 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting, Shifting And Stopping 52. . . . . . . . . . . . . . . . . . . . . . . . .

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

Specifications 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Oil 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications (4 Cyl. Models) 59. . . . . . . . . . . . . . . . . . .

Engine Specifications (V-6 Models) 60. . . . . . . . . . . . . . . . . . . . . .

Engine Specifications (V-8 Models) 61. . . . . . . . . . . . . . . . . . . . . .

Maintenance 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Aids 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Chart 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Fluid Levels 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump Sight Tube Inspection 3.0L Models 73. . . . . . . . . . .

Propeller 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Cooling System 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-Belts (3.0L Model) 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serpentine Drive Belt (All Other Models) 83. . . . . . . . . . . . . . . . .

Corrosion And Corrosion Protection 85. . . . . . . . . . . . . . . . . . . . .

Emissions (Europe Only) 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Miscellaneous Maintenance 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottom Of Boat 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection And Maintenance 95. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Or Extended Storage 96. . . . . . . . . . . . . . . . . . . . . .

Power Package Lay Up 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Winter Storage 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do-It-Yourself Maintenance 96. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Package Recommissioning 97. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Information 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Owner Warranty Registration 105. . . . . . . . . . . . . . . . . . . . . . . . .

International Owner Registration 106. . . . . . . . . . . . . . . . . . . . . .

Warranty Policies 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MerCruiser Limited Warranty - Gasoline Engines 107. . . . . . .

MerCruiser International Warranty - Gasoline Engines 109. . .

3 Year Limited Warranty Against Corrosion Failure 112. . . . . .

(Applicable In The United States,

Canada And Australia) 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Coverage 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transferable Warranty 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Q-Guard Product Protection Plan 118. . . . . . . . . . . . . . . . . . . . . .

Owner Service Assistance 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Service Literature 122. . . . . . . . . . . . . . . . . . . . . . . . . .

English Language 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Languages 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordering Literature 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CA753

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 MerCruiser products. We sincerely hope your boating will be pleasant!

Consumer Affairs Department

CA741

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 dis- claimers and limitations of damages, and other related information. Please review this important information.

CA754

IMPORTANT: This manual contains basic Operation, Maintenance and Warranty information for your MerCruiser power package. If you desire to perform some of the maintenance items on your own, you should obtain a copy of the “Maintenance Procedures” Manual for your particular power package. Information for obtaining this manual is located at the back of this manual.

CA755

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

, may be used to alert the installer/user to special

instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them

carefully.

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

WARNING

WARNING-Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION

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.

CA619

General Information

Lanyard Stop Switch

The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed on the dashboard or side adjacent to the operator’s position.

The lanyard is a cord usually between 4 and 5 feet (1220 and 1524 mm) in length when stretched out with an element on one end made to be inserted into the switch and a snap (2) on the other end for attaching to the operator. The lanyard is coiled to make its at-rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects. It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator’s position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator’s wrist or le g, or tie a knot in the lanyard.

IMPORTANT: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator’s position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator’s position. Accidental ejections and falls overboard are more likely to occur in certain types of boats such as low sided sport boats o r bass boats, and high-performance boats. Accidental ejections and falls overboard are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or

gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating at planing speeds in shallow or obstacle-infested waters, releasing your grip on a steering wheel that is pulling in one direction, drinking alcohol or consuming drugs, or daring, high-speed boat maneuvers.

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

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

WARNING

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

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:

1 Occupants could be thrown forward due to unexpected loss of

forward motion - a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller.

2 Loss of power and directional control in heavy seas, strong

current or high winds.

3 Loss of control when docking.

WARNING

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

CA641

CA620

Exhaust Emissions

Be Alert To Carbon Monoxide Poisoning

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

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

WARNING

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

GOOD VENTILATION

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

1 Example of desired air flow through the boat.

CA642

Courtesy of ABYC

CA643

POOR VENTILATION

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

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

2 Examples of poor ventilation while boat is stationary:

A Running the engine when the boat is moored in a confined space. B Mooring close to another boat that has its engine running.

3 Examples of poor ventilation while boat is moving:

A Running the boat with the trim angle of the bow too high. B Running the boat with no forward hatches open (station wagon

effect).

CA476

Safe Boating Suggestions

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

• Know and obey all nautical rules and laws of the waterways.

Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2) The Power Squadron, (3) The Red Cross and (4) your state or provincial boating law enforcement agency. Inquiries may be made to the Boating Hotline, 1-800-368-5647 or the Boat U.S. Foundation information number 1-800-336-BOAT.

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

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

Sources of Waterway Information National Marine Manufacturers Association 410 N. Michigan Avenue Chicago, IL 60611 U.S.A.

• Perform safety checks and required maintenance. Follow a

regular schedule and ensure that all repairs are properly made.

• Check safety equipment on board. Here are suggestions of the

types of safety equipment to carry when boating:

1 Approved fire extinguisher(s); paddle or oar. 2 Signal devices: flashlight, rockets or flares, flag and whistle or

horn.

3 Spare propeller, thrust hubs and an appropriate wrench. 4 Tools for necessary minor repairs; first aid kit and book. 5 Anchor and extra anchor line; water-proof storage containers. 6 Manual bilge pump and extra drain plugs; compass and map or

chart of area.

7 Spare operating equipment; batteries, bulbs, fuses, etc. 8 Transistor radio. 9 Drinking water.

• Know signs of weather change and avoid foul weather and

rough-sea boating.

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

return.

• Passenger boarding. Stop the engine whenever passengers are

boarding, unloading or are near the back (stern) of the boat. Just 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 dealer or the boats manufacturer.

• Make sure everyone in the boat is properly seated. Don’t allow

anyone to sit or ride on any part of the boat that was not intended for such use. This includes backs of seats, gunwales, transom, bow, decks, raised fishing seats, 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. See that all passengers have a proper seat and are in it before any boat movement.

• Never be under the influence of alcohol or drugs while

boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly.

• Know your boating area and avoid hazardous locations.

• Be alert. The operator of the boat is responsible by law to

“maintain a proper lookout by sight (and hearing).” The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operators view when operating the boat above idle or planing transition speed. Watch “the other guy,” 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 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front of you.

• 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 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.

CA282

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) and the drive unit is in neutral position, 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

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

WARNING

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

CC828

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 familiarization demonstration ride with your dealer or an operator experienced with your boat. For additional information, obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-849250--1) from your dealer, distributor, or Mercury Marine.

CA7

Conditions Affecting

Operation

Weight Distribution

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

Shifting weight to rear (stern) will:

• Generally increases speed and engine RPM.

• At extremes can cause boat to porpoise.

• Causes bow to bounce in choppy water.

• Increases danger of following wave splashing into boat when

coming off plane.

Shifting weight to front (bow) will:

• Improve ease of planing.

• Improve rough water ride.

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

CA8

Bottom Of Boat

To maintain maximum speed, the following conditions of the boat bottom should be observed.

A. Clean, free of barnacles and marine growth. B. Free of distortion; nearly flat where it contacts the water. C. Straight and smooth, fore and aft. Marine vegetation may accumulate when boat is docked. This

growth must be removed before operation; it may clog water inlets and cause engine to overheat.

CA9

Cavitation

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

A. Weeds or other debris snagged on propeller or gear housing. B. Bent propeller blade or damaged gear housing skeg. C. Raised burrs or sharp edges on propeller or gear housing.

CA10

Ventilation

Ventilation is caused by surface air or exhaust gases which are introduced around the propeller resulting in propeller speedup and a reduction in boat speed. Excessive ventilation is annoying and usually caused by:

A. Drive unit trimmed out too far. B. A missing propeller diffuser ring. C. A damaged propeller or gear housing, which allows exhaust

gases to escape between propeller and gear housing. D. Drive unit installed too high on transom.

CA406

Propeller Selection

IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open-throttle revolutions per minute (RPM). Use an accurate service tachometer to verify engine operating RPM.

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

IMPORTANT: The engines covered in this manual (Except 3.0L) 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 drops into the recommended operating RPM range normal engine operation resumes.

Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide-open-throttle operating RPM range with a normal load. High RPM, caused by an excessive trim angle, should not be used in determining correct propeller selection.

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. Generally, there is a 200-300 RPM change between propeller pitches.

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 an RPM loss.

• Operating in a higher elevation causes an RPM loss.

• Operating with a damaged propeller or dirty boat bottom causes

an RPM loss.

• Operating with increased load (additional passengers, pulling

skiers, etc.).

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

CA12

How Elevation And Climate Affect Performance

Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air. Heat and humidity thin the air. This condition can become particularly annoying when the propeller testing was done on a cool, dry day. Then later; on a hot, sultry day, the boat doesn’t seem to have the same performance.

Although some performance can be regained by dropping to a lower pitch propeller, the basic problem still exists. In some cases, a gear ratio change to more reduction is possible and very beneficial.

Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds, as much as 2 or 3 miles per hour in some cases. Nothing will regain this speed for the boater, but the coming of cool, dry weather.

In pointing out the practical consequences of weather effects, an engine running on a hot, humid, summer day, may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. With the drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended RPM. This will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be somewhat regained by switching to a lower-pitch propeller that allows the engine to again run at recommended RPM.

For boaters to realize optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide-open-throttle with a normal boat load.

Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine.

CA13

Important Information

Operation And Maintenance

OWNER/OPERATOR RESPONSIBILITIES

It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized 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 assure optimum performance and dependability, and will keep your overall operating expenses at a minimum. See your Authorized MerCruiser Dealer for service aids.

CA14

DEALER RESPONSIBILITIES

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

• Make sure that the boat is properly equipped.

• Prior to delivery, make certain that the 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.

• At the time of delivery, the dealer should 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.

CA407

Freezing Temperature Operation

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

CA17

Drive Unit Impact Protection

The Power Trim hydraulic system is designed to provide impact protection for drive unit. If a submerged object is struck while boat is moving forward, the hydraulic system will cushion the kickup of drive unit as it clears the object, reducing damage to unit. After drive unit has cleared object, the hydraulic system allows drive unit to return to original operating position, preventing loss of steering control and engine overspeed.

Use extreme caution when operating in shallow water or where underwater objects are known to be present. Use extreme care to prevent striking submerged object while operating in REVERSE. No impact protection is provided in REVERSE.

If drive unit should strike a submerged object, stop engine as soon as possible and inspect drive unit for damage. If damage is present or suspected, boat should be taken to an Authorized MerCruiser Dealer for thorough inspection and necessary repair. Operating a damaged drive unit could cause additional damage to other parts of drive unit, or could affect control of boat. If continued running is necessary, do so at greatly reduced speeds.

IMPORTANT: Impact protection system cannot be designed to ensure total protection from impact damage under all conditions.

CA408

Drain Plug and Bilge Pump

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

CA621

Emissions Information (Europe Only)

Your engine may be equipped with special design features and special tuning to minimize the emission output from the engine. If so, it is very important that you strictly adhere to the following:

• Recommended maintenance schedules particularly 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 MerCruiser replacement parts to ensure compliance with emission regulations.

IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine. Refer to “Emissions Testing” procedure found later in this manual.

CA409

Attention Required After Submersion

• Before recovery, contact an Authorized MerCruiser Dealer.

• After recovery, immediate service by an Authorized MerCruiser

Dealer is required to prevent serious damage to power package.

CA19

Trailering Boat

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

If adequate road clearance is a problem, place drive unit in full trailer position and support with an optional trailer kit which is available from your Authorized MerCruiser Dealer.

CA20

Launching And Boat Operation Care

CAUTION

During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat may enter the water rapidly and at a steep angle. This may force water through the exhaust system into the cylinders. The more weight on the transom, the more likely this is to occur.

Slowing down rapidly or stopping suddenly may cause a following wave to “swamp” the transom. In this instance, water may enter the cylinders through the exhaust system.

When backing up rapidly, the same situation may occur as stated in the preceding paragraph.

In any of these situations, water entering the engine could cause severe damage to internal parts. Refer to “Attention Required After Submersion.”

CA21

Stolen Power Package

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

CA22

Replacement Service Parts

WARNING

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

Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.

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

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

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

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

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

CA410

Do-It-Yourself Maintenance Suggestions

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

• Present-day marine equipment, such as your 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.

• Do not attempt any repairs which are not covered in this manual

unless you are aware of the precautions (“Cautions” and “Warnings”) and procedures required. Your safety is of our concern.

• If you attempt to service the product yourself, we suggest you

order the Maintenance Procedures Manual for that model. This manual outlines the correct procedures to follow. Do not attempt repairs if you do not understand the procedures.

• There are special tools and equipment that are required to

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

• Also, if you partially disassemble an engine or drive assembly and

are unable to repair it, the dealer’s mechanic must reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem.

• Do not telephone the dealer, service office or the factory to

attempt for them to diagnose a problem or 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.

CA742

Multiple EFI Engine Battery Precautions

Situation Alternators: Alternators are designed to charge the battery that sup-

plies 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.

Recommendations Batteries: Boats with multi-engine EFI power packages require

each engine be connected to 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 running off 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.

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

CA623

Diagnosing EFI Problems (If Equipped)

NOTE: All references to EFI models apply to EFI and MPI engines.

Your Authorized 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.

CA624

Water Separating Fuel Filter

CAUTION

The electric fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together. Do not install additional fuel filters and/or water separating fuel filters between fuel tank and engine.

The installation of additional filters may cause:

• Fuel Vapor Locking

• Difficult Warm-Starting

• Piston Detonation Due to Lean Fuel Mixture

• Poor Driveability

CA413

20-Hour Break-In Period

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

• Do not operate below 1500 RPM for extended periods of time for

first 10 hours. Shift into gear as soon as possible after starting and advance 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 first 10 hours. During 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 engine reaches normal

operating temperature.

• Frequently check crankcase oil level. Add oil if needed. It is

normal for oil consumption to be high during break-in period.

CA211

After Break-In Period

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

• Use a propeller that allows the engine to operate at or near the top

of the maximum RPM range (See “Specifications” section) when at full throttle with a normal boat load.

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

from prolonged operation at maximum (full throttle) RPM.

CA414

End of First Season Checkup

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

CA26

70514

70515

70516

70523

70517

70522

70518

70521

70520

70519

CA470

Operation

Instrumentation

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

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 Power Trim Gauge: Indicates drive unit angle (trim up/out and

down/in).

8 Hour Meter: Records engine running time. 9 Bilge Blower Switch: Operates bilge blower (If so equipped - See

“Starting, Shifting and Stopping” procedure).

10Ignition Switch: Allows operator to start and stop engine.

CB218

705161

71987

70518

CA625

Audio Warning System

Your MerCruiser power package may be equipped with an Audio Warning System.

The audio warning system horn will sound if one of the following occur:

1 Engine Oil Pressure Too Low 2 Engine Temperature Too Hot 3 Drive Oil Level Too Low

NOTE: To test the system:

Turn the ignition switch to the ON position without cranking the engine. The horn will sound if the system is working correctly.

CAUTION

Avoid engine damage. Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION. The Audio Warning System will not protect the engine from damage. It i s designed to warn the operator that a problem has occurred.

When the horn sounds with the engine running, stop engine immediately. Investigate cause and correct it, if possible. If cause cannot be determined, consult your Authorized MerCruiser Dealer.

CA756

74898

74907

2,3

76037

CA698

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 fuse or resetting circuit breaker.

1 On the following models, a circuit breaker provides protection for

engine wiring harness and instrumentation power lead. Reset by pushing RESET button IN.

A 4.3LH and 5.7L Models B 4.3L EFI, 5.0L EFI, 5.7L EFI and 350 Mag MPI Models

2 On 3.0L, 4.3L and 5.0L Models: A 55 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 On EFI Models: 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.

NOTE: In an emergency, when engine must be operated and cause for high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to engine and instrumentation wiring. Reset circuit breaker or replace fuse as appropriate for your model. If circuit remains open, electrical overload has not been eliminated. Further checks must be made on electrical system.

4 On EFI Models: Three fuses are located on the port side of the

engine. These fuses control various EFI circuits.

A Fuel Pump Fuse - 15 Amp B ECM / Injector Fuse - 10 Amp C ECM / Battery Fuse - 15 Amp

CA697

70528

70527

70526

70525

CA696

5 4.3L EFI Models: Three fuses are located in a single block in the

fuel injection system electrical box. These fuses control various EFI circuits.

A Fuel Pump Fuse - 15 Amp B ECM / Injector Fuse - 10 Amp C ECM / Battery Fuse - 15 Amp

6 A 20 amp fuse may be located in ignition switch “I” terminal lead

to protect electrical system. Check for blown fuse if key is turned to START and nothing happens (and circuit breaker, if equipped, is not tripped).

CA482

7 The Power Trim System is protected from overload by 110 amp

fuse and a 20 amp in-line fuse on Power Trim pump.

8 Quicksilver Three-Button Power Trim Control Panel is further

protected by a 20 amp in-line fuse.

9 The Quicksilver MerCathode System has a 20 amp in-line fuse is

in the wire which connects to positive (+) terminal on controller. If fuse is blown, system will not operate and a loss of corrosion protection will result.

CB181

CB182

Remote Controls (Panel Mounted)

Your boat may be equipped with one of many Quicksilver  remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control.

1 Neutral Lock Bar - Prevents accidental shift and throttle

engagement. Neutral lock bar must be pulled “Up” 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 Power Trim Switch - See “Power Trim” for detailed power trim

operating procedures.

4 Trailer Switch - Used to raise drive unit for trailering, launching,

breaching or shallow water operation. See “Power Trim” for detailed trailer switch operation.

5 Lanyard Stop Switch - Turns ignition “Off” whenever the

operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. See “Lanyard Stop Switch” at the front of this manual for safety warning on the use of this switch.

6 Control Handle Tension Adjustment Screw - This screw can be

adjusted to “Increase” or “Decrease” the tension on the control handle. This will help prevent “Creep” of the remote control handle. Turn screw “Clockwise” to increase tension and “Counterclockwise” to decrease tension. Adjust to tension desired.

7 Control Handle - Operation of the shift and throttle are controlled

by the movement of the control handle. “Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward” gear. Continue pushing forward to increase speed. Pull the control handle back from “Neutral” with a quick firm motion to the first detent for “Reverse” gear. Continue pushing back to increase speed.

CB183

CB184

Remote Controls (Console Mounted)

1 Control Handle(s) - Operation of the shift and throttle are

controlled by the movement of the control handle. “Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward” gear. Continue pushing forward to increase speed. Pull the control handle back from “Neutral” with a quick firm motion to the first detent for “Reverse” gear . Continue pushing back to increase speed.

2 Throttle Only Button - Allows engine throttle advancement

3 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 “Creep” of the remote control handle. Turn screw “Clockwise” to increase tension and “Counterclockwise” to decrease tension. Adjust to tension desired.

4 Power Trim Switch - See “Power Trim” section for detailed power

trim operating procedures.

5 Trailer Switch - Used to raise drive unit for trailering, launching,

breaching or shallow water operation. See “Power Trim” for detailed trailer switch operation.

6 Power Trim Adjustment Switches (Used on Three Button

Trim Control Only) - See “Power Trim” section for detailed power

trim operating procedures.

CB185

70537

71339

CB186

Remote Controls (Two Lever)

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.

CAUTION

Never shift unit into or out of gear unless throttle lever is at idle RPM.

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.

IMPORTANT: Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control.

71338

3 TO 5

DEGREES

CA34

CA418

Power Trim

Power Trim allows the operator to adjust the drive angle, while underway, to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system “Trailering” feature allows the operator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 RPM engine speed), shallow water operation.

CAUTION

Never trim the drive unit UP/OUT using TRAILER switch while boat is underway at engine speeds above 1200 RPM. Use extreme caution when operating with drive unit raised. Severe damage to the drive unit may result if unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 RPM.

1 In most cases, best overall performance is obtained with the drive

unit adjusted so the boat bottom will run at a 3° to 5° angle to the water.

Trimming Drive Unit UP/OUT Can:

• Generally increase top speed.

• Increase clearance over submerged objects or a shallow bottom.

• Cause boat to accelerate and plane off slower.

• In excess, cause boat “porpoising” (bouncing) or propeller

ventilation.

• Cause engine overheating if trimmed UP/OUT to a point where

any cooling water intake holes are above the water line.

Trimming Drive Unit DOWN/IN Can:

• Help the boat accelerate and plane off quicker.

• Generally improve the ride in choppy water.

• In most cases, reduce boat speed.

• If in excess, lower the bow of some boats to a point at which they

begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted, or if a significant wave is encountered.

CB187

73976

73977

CB188

POWER TRIM OPERATION - PANEL MOUNT REMOTE CONTROL

IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed.

1 Trailer Position: Press button until drive unit reaches desired

height.

2 Trim Up/Out: Press UP on Trim switch until drive unit reaches

desired trim position.

3 Lower Drive Unit: Press DOWN on Trim switch until drive unit

reaches desired position.

CB189

POWER TRIM OPERATION - CONSOLE MOUNT REMOTE CONTROL (SINGLE ENGINE VERSION)

4 Trailer Position: Press button until drive unit reaches desired

height.

5 Trim Up/Out: Press UP on Trim switch until drive unit reaches

desired trim position.

6 Lower Drive Unit: Press DOWN on Trim switch until drive unit

reaches desired position.

CB190

73978

73979

CA627

POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS)

CAUTION

When lowering or raising sterndrives equipped with a dual engine tie bar kit, the sterndrives must be raised or lowered evenly to prevent the tie bar from becoming twisted. Failure to raise or lower sterndrives evenly may result in tie bar or sterndrive damage.

1 Trailer Button (Both Versions) - Press button until drive unit

reaches desired height for trailering drive units.

2 Two Button Trim Control (Dual Buttons in Handle) - used to

control both drive units from the handle. Press UP on button(s) to trim drive unit UP/OUT. Press down on button(s) to trim drive unit DOWN/IN.

A Forward Trim Button - Used to trim the port drive unit. B Rear Trim Button - Used to trim the starboard drive unit.

3 Three Button Trim Control (Trim Adjustment Switches) - With

a single integral trim button in the handle to control two drive units simultaneously, these two switches control the fine tune adjustment of each drive unit. Using these Fine Tune Switches, set each drive unit to the desired trim angle. Then use the single trim switch in the handle to control the trim of both drive units simultaneously.

4 Three Button Trim Control (Single Trim Switch in Handle) -

used to trim both drives simultaneously after drives have been fine-tuned as described above.

CB192

70540

CB193

POWER TRIM OPERATION - THREE BUTTON TRIM PANEL (USED ON MODELS WITH TWO-LEVER CONTROL)

IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button(s) and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed.

1 Trailer Position: Simultaneously press the UP button (top) along

with the UP/OUT button (center) until drive unit reaches desired trailer position.

2 Trim Drive Unit UP/OUT: Press center UP/OUT button until drive

unit reaches desired trim position.

3 Trim Drive Unit IN/DOWN: Press IN button until drive unit reaches

desired trim position.

CA757

Starting, Shifting And Stopping

WARNING

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

IMPORTANT: Observe the following:

• Do not start engine without water being supplied to seawater

pickup pump (to prevent pump or engine damage).

• Do not operate starter motor continuously for more than 30

seconds.

• On Carbureted Engines: When engine starts, quickly reduce

throttle setting to avoid exceeding 1500 RPM.

• Never shift drive unit unless engine is at Idle RPM.

Perform the following as appropriate:

1 Check all items listed in OPERATION CHART. 2 Perform any other necessary checks, as indicated by your dealer,

or specified in your boat owner’s manual.

3 Place drive unit in full down/in position. 4 Place control handle in NEUTRAL. 5 Refer to A or B as appropriate for your model.

A Carbureted Engine

- Push THROTTLE ONL Y button and position throttle setting as follows: COLD ENGINE - Move control/throttle lever to full throttle, then return to about 1/4 throttle. In extreme cold it may be necessary to pump lever more than once. WARM ENGINE - Move control/throttle lever to 1/4 throttle position. FLOODED ENGINE - Move control/throttle lever to full throttle. Be prepared to decrease engine speed to 1000-1500 RPM as soon as engine starts.

B EFI Engine - Position throttle setting as follows:

COLD ENGINE - Leave in neutral/idle speed position. WARM ENGINE - Leave in neutral/idle speed position. FLOODED ENGINE - Turn ignition switch to 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 throttle to the idle position.

6 Turn ignition key to START. Release key when engine starts and

allow switch to return to RUN position.

7 Carbureted Engines - Move control/throttle lever back to

decrease engine RPM to 1000-1500 RPM if necessary.

8 Check oil pressure gauge immediately after engine starts. If oil

pressure is not within specified range (see SPECIFICATIONS), stop engine immediately and determine cause.

9 If engine is cold, run engine for 1 or 2 minutes at fast idle

(1000-1500 RPM).

10After engine has warmed up, check water temperature gauge to

ensure that engine temperature is not abnormally high. If it is, stop engine immediately and determine cause.

11Be sure charging system is functioning correctly. 12Observe power package for fuel, oil, water and exhaust leaks. 13To shift drive unit, return control/throttle lever to NEUTRAL. Move

control/shift lever with a firm, quick motion forward to shift to FORWARD gear, or backward to shift to REVERSE. After shifting drive unit, advance throttle to desired setting.

14Move control/shift lever to NEUTRAL and allow engine to drop to

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

15 Turn ignition key to OFF.

CC829

CAUTION

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

• Do not turn the ignition key off when the engine is running

above idle speed.

• 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.

CB575

IMPORTANT: Avoid stopping engine if the drive unit is in gear. If engine does stop with drive unit in gear, refer to the following procedure:

1 Push and pull repeatedly on remote control handle until handle re-

turns to the neutral detent position. This may take several tries if the power package was operating above idle RPM when the engine stopped.

2 After handle returns to the neutral detent position, resume normal

starting procedures.

CA41

Operation Chart

BEFORE STARTING

AFTER STARTING

WHILE UNDERWAY

AFTER STOPPING

Open engine hatch.

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

Turn ignition key to OFF.

Turn battery switch ON, if so equipped.

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

Turn battery switch OFF, if so equipped.

Operate bilge blowers, if so equipped.

Check shift and throttle control operation.

Close fuel valve.

Open fuel shutoff valve.

Check steering operation.

Close seacock, if so equipped.

Open seacock, if so equipped.

Flush cooling system if in saltwater.

Place drive unit if full DOWN/IN position.

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

CA261

Specifications

Fuel Recommendations

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

FUEL RATINGS

MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows:

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.

CA291

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” also.

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

CA618

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 ef fects 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 MerCruiser engine will withstand up t o 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.

WARNING

FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of 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 including fuel tanks, whether plastic metal or fiberglass, fuel lines, fittings, fuel filters and carburetors/fuel injection 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 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.

CA420

FUEL SYSTEM ADDITIVES (V6 MODELS)

To maximize the life of valves and valve seats on your MerCruiser engine, use Quicksilver Valve Lubricant (92-826259A12) regularly.

CA693

Crankcase 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 SH, CF/CF-2, 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, as a second but less preferable choice, 20W-50, with API service ratings of SH, CF/CF-2 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 crankcase oil selection. The oil filter should always be changed when changing engine oil.

75796

Quicksilver 4-Cycle 25W-40 Marine Engine Oil

SAE 20W

SAE 30W

SAE 40W

32° F 0

° C

° F

° C

AIR TEMPERATURE

CA759

Engine Specifications

(4 Cyl. Models)

Models 3.0L

Propshaft Horsepower (SAV1 Rating)

135

(1142)

Propshaft Kilowatts (SAV1 Rating)

101

(852) Displacement 181 cid (3.0L) Maximum RPM @ W.O.T.

4400-4800 RPM

Idle RPM in NEUTRAL

700 RPM Oil Pressure @ 2000 RPM 30-60 psi (207-414 kPa) Min. Oil Pressure @ Idle 4 psi (28 kPa) Thermostat 140° F (62° C)

160° F (71° C)

Timing @ Idle RPM

1° ATDC

2° ATDC

Firing Order 1-3-4-2 Electrical System 12-Volt Negative (–) Ground Alternator Rating 55 Amps Recommended Battery

Rating

Minimum 375 cca/475 mca/90 Ah

Power Rated in Accordance with NMMA (National Marine Manufacturers’ Associa-

tion) rating procedures.

Measured using an accurate service tachometer with engine at normal operating

temperature.

A special procedure must be followed to check or adjust timing. Consult your Au-

thorized MerCruiser Dealer before attempting this procedure.

140°thermostat housing (T iming: 1° ATDC) and 160° thermostat housing (Timing:

° ATDC)

CA760

Engine Specifications

(V-6 Models)

Models 4.3L 4.3LH 4.3L EFI

Propshaft Horsepower (SAV1 Rating)

190

205

(1902)

210

(1882)

Propshaft Kilowatts (SAV1 Rating)

142

153

(142

)

157

(1402) Displacement 262 cid (4.3L) Maximum RPM @ W.O.T.

4400-4800 RPM

Idle RPM in NEUTRAL 650 RPM

600 RPM

Oil Pressure @ 2000 RPM 30-70 psi (207-483 kPa) Min. Oil Pressure @ Idle 4 psi (28 kPa) Thermostat 160° F (71° C) Timing @ Idle RPM

10 ° BTDC 8° BTDC Firing Order 1-6-5-4-3-2 Electrical System 12-Volt Negative (–) Ground Alternator Rating 55 Amps 65 Amps Recommended Battery

Rating

Min 375 cca/ 475 mca/90 Ah

Min 550 cca/ 700 mca/120 Ah

Power Rated in Accordance with NMMA (National Marine Manufacturers’ Associa-

tion) rating procedures.

Power Rated in Accordance with BSO/SAV rating procedures. This rating proce-

dure is used to certify that the engine complies with “Stage 1” Bodensee and Swiss Regulations. Horsepower differences shown result from differences in test RPM, allowable test tolerances, and/or installation of special kit components.

Measured using an accurate service tachometer with engine at normal operating

temperature.

A special procedure must be followed to check or adjust timing. Consult your Au-

thorized MerCruiser Dealer before attempting this procedure.

A special procedure must be followed to adjust idle RPM. Consult your Authorized

MerCruiser Dealer before attempting this procedure.

Idle speed on EFI models is not adjustable.

CA761

Engine Specifications

(V-8 Models)

Models 5.0L 5.0L EFI

Propshaft Horsepower 220

240

Propshaft Kilowatts 164

179

Displacement 305 CID (5.0L) Maximum RPM @ W.O.T.

4400-4800 RPM

Idle RPM in NEUTRAL

650 RPM

600 RPM

Oil Pressure @ 2000 RPM 30-60 psi (207-414 kPa) Min. Oil Pressure @ Idle 4 psi (28 kPa) Thermostat 160° F (71° C) Timing @ Idle RPM

10° BTDC 8° BTDC Firing Order 1-8-4-3-6-5-7-2 Electrical System 12-Volt Negative (–) Ground Alternator Rating 55 Amps 65 Amps Recommended Battery

Rating

Minimum

375 cca/475

mca/90 Ah

Minimum

550 cca/700

mca/120 Ah

Power Rated in Accordance with NMMA (National Marine Manufacturers’ Associa-

tion) rating procedures.

Power Rated in Accordance with BSO/SAV rating procedures. This rating proce-

Measured using an accurate service tachometer with engine at normal operating

temperature.

A special procedure must be followed to check or adjust timing. Consult your Au-

thorized MerCruiser Dealer before attempting this procedure.

A special procedure must be followed to adjust idle RPM. Consult your Authorized

MerCruiser Dealer before attempting this procedure.

Idle speed on EFI models is not adjustable.

CA758

Engine Specifications

(V-8 Models)

Models 5.7L 5.7L

EFI

350 Mag

MPI

Propshaft Horsepower (SAV1 Rating)

250

260

(2332)

300

(2592)

Propshaft Kilowatts (SAV1 Rating)

186

194

(1742)

224

(1932) Displacement 350 cid (5.7L) Maximum RPM @ W.O.T.

4400-4800 RPM 4600-5000

RPM

Idle RPM in NEUTRAL

650 RPM

600 RPM

Oil Pressure @ 2000 RPM 30-60 psi (207-414 kPa) Min. Oil Pressure @ Idle 4 psi (28 kPa) Thermostat 160° F (71°C) Timing @ Idle RPM

10° BTDC 8° BTDC Firing Order 1-8-4-3-6-5-7-2 Electrical System 12-Volt Negative (–) Ground Alternator Rating 55 Amps 65 Amps Recommended Battery

Rating

Minimum

375 cca/475

mca/90 Ah

Minimum 550 cca/

700 mca/120 Ah

Power Rated in Accordance with NMMA (National Marine Manufacturers’ Associa-

tion) rating procedures.

Power Rated in Accordance with BSO/SAV rating procedures. This rating proce-

Measured using an accurate service tachometer with engine at normal operating

temperature.

A special procedure must be followed to check or adjust timing. Consult your Au-

thorized MerCruiser Dealer before attempting this procedure.

A special procedure must be followed to adjust idle RPM. Consult your Authorized

MerCruiser Dealer before attempting this procedure.

Idle speed on EFI models is not adjustable.

CA749

Maintenance

WARNING

Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted.

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 MerCruiser Dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a MerCruiser Maintenance Procedures Manual or Service Manual be purchased and read thoroughly.

NOTE: Maintenance points are color coded for ease of identifica-

tion. See the decal on engine for identification.

Maintenance Aids

1 Power Steering System - Quicksilver Power Trim and Steering

Fluid or Dexron III automatic transmission fluid (ATF).

2 Propeller Shaft - Quicksilver Special Lubricant 101. 3 Sterndrive Unit - Quicksilver High Performance Gear Lube. 4 All Exterior Surfaces - Quicksilver Primer and Spray Paint and

Quicksilver Corrosion Guard.

5 Power Trim System - Quicksilver Power Trim and Steering Fluid,

or SAE 10W-30 motor oil.

6 Crankcase Oil - Quicksilver 4-Cycle Marine Engine Oil (Refer to

SPECIFICATIONS for alternatives and oil recommendations for varying ambient temperatures.)

7 Closed Cooling System Coolant - Extended Life Ethylene Glycol

5/100 Antifreeze/Coolant mixed 50/50 with purified water. If this is not available, use a 50/50 mixture of ethylene glycol antifreeze and tap water. Areas where temperatures generally do not go below 32° F (0° C), rust inhibitor and tap water is acceptable.

CA426

Maintenance Chart

SCHEDULED MAINTENANCE THAT CAN BE PERFORMED

BY OWNER/OPERATOR

NOTE: Only perform maintenance which applies to your particular

power package.

Task Interval

Engine Crankcase Oil - Check level

Closed Cooling Coolant Check level

Power Steering Fluid - Check level

Sterndrive Unit Oil - Check level

Battery - Check level and inspect for damage

Weekly

Fuel Pump Sight Tube (If so Equipped) - Check that no fuel is present

Power Trim Pump Oil - Check level

Anodes - Inspect for erosion Gear Housing Water Pickups -

Check for marine growth or debris

CA427

SCHEDULED MAINTENANCE THAT CAN BE PERFORMED

BY OWNER/OPERATOR

NOTE: Only perform maintenance which applies to your particular

power package.

Task Interval

Drive Belt(s) - Inspect condition and check tension

Every 100 hours of operation or 120 days, whichever occurs first.

Propeller Shaft - Lubricate

Saltwater Use: Every 50 hours of operation or 60 days,

Power Package - Exterior Surfaces - Spray with rust preventative

60 y ,

whichever occurs first. Freshwater Use: Every 100 hours of operation or 120 days, whichever occurs first.

Power Package Exterior Surfaces - Clean and paint

Once a year

Cooling System - Flush seawater section

Saltwater Use: After every use.

CA742

SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED

BY A DEALER

NOTE: Only perform maintenance which applies to your particular

power package.

Task Interval

Seawater Pickup Pump Disassemble and inspect.

Whenever insufficient seawater flow is suspected. (If operating temperature exceeds normal range.)

Crankcase Oil and Filter Change.

Ignition system - Clean and inspect condition.

Flame Arrestor and Crankcase Ventilation Hose - Clean and inspect.

Positive Crankcase Ventilation (PCV) Valve (If Equipped) Change.

End of first boating season and thereafter, every 100

Sterndrive Unit Oil - Change.

hours of o eration or once

yearly, whichever occurs first.

Gimbal Ring Clamping Screws

- Retorque to 55 ft. lb. (74 N·m).

yy,

Rear Engine Mounts - Torque to 35-40 ft. lb. (47-54 N·m).

Gimbal Bearing - Lubricate. Cooling System - Clean and

inspect.

CA429

SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED

BY A DEALER

NOTE: Only perform maintenance which applies to your particular

power package.

Task Interval

Steering System - Lubricate and inspect for loose, damaged or missing parts.

Electrical System - Check for loose or damaged wiring.

Closed Cooling System Pressure Cap - Clean, inspect and test.

Cooling System Hoses and Clamps - Inspect for damage and deterioration. Check clamps for tightness.

End of first boating season and Continuity Circuit - Check components for loose connections, broken or frayed wires.

End of first boating season and

thereafter, every 100 hours of

operation or once yearly,

whichever occurs first.

Shift and Throttle Cable and Linkage - Lubricate and inspect for loose, damaged or missing parts.

Engine Exhaust System Inspect externally for damage, deterioration and restrictions. Check for tightness.

Ignition System - Check timing and adjust as needed.

CA740

SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED

BY A DEALER

NOTE: Only perform maintenance which applies to your particular

power package.

Task Interval

Steering Head and Remote Control - Inspect and lubricate.

End of first boating season and Carburetor (If Equipped) Inspect and adjust.

End of first boating season and

thereafter, every 100 hours of

operation or once yearly, Throttle Body (EFI Models) -

Inspect.

yy,

whichever occurs first.

Fuel Filter - Replace. Quicksilver MerCathode

System - Test output. Closed Cooling Coolant - Test

for alkalinity.

Once a Year

Heat Exchanger - Clean seawater section.

Drive Unit Bellows and Clamps - Inspect.

Engine Alignment - Check.

End of first boating season and

thereafter, Engine Coupling Universal Joint

Shaft Splines - Lubricate.

Saltwater Use: Every 300

hours of operation or once

yearly, whichever occurs first.

Universal Joint Cross BearingsInspect.

Freshwater Use: Every 300

hours of operation or once every

two years, whichever occurs

first. Closed Cooling Coolant -

Replace.

Every Five Years

Only if Extended Life 5/100 Ethylene Glycol Antifreeze/Coolant is used. If any non-compatible coolant is added to this coolant, coolant must be changed every 2 years or 400 hours, whichever occurs first. All coolants other than Extended Life 5/100 Ethylene Glycol Antifreeze/Coolant must be changed every 2 years or 400 hours, whichever occurs first.

THIS PAGE IS INTENTIONALLY BLANK

CA175

CA431

70543

74766

70547

70546

74764

71340

75028

CA54

Checking Fluid Levels

CHECKING CRANKCASE OIL

Stop engine. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water.

1 Remove dipstick. Wipe clean and reinstall fully into dipstick tube. 2 Remove dipstick and observe oil level. Oil level must be between

FULL and ADD. If oil level is below ADD:

3 Remove oil filler cap. Add specified oil to bring level up to, but not

over, FULL mark on dipstick.

IMPORTANT: Do not overfill crankcase oil.

CA55

CHECKING POWER STEERING PUMP FLUID

Stop engine and position drive unit straight back.

4 Remove FILLCAP/DIPSTICK and observe level. Add specified

fluid if required. Reinstall FILLCAP/DIPSTICK.

IMPORTANT: If fluid is not visible in pump, contact your Authorized MerCruiser Dealer.

CA477

CHECKING ENGINE COOLANT - CLOSED COOLED MODELS ONLY

WARNING

Avoid serious injury from burns. Do not remove coolant cap when engine is hot. Coolant may discharge violently.

5 Check coolant level in coolant recovery bottle. Add specified

coolant as required.

6 Periodically remove cap from coolant reservoir to ensure that

coolant recovery system is functioning properly. Coolant level must be at top of reservoir filler neck. If coolant is low , inspect gasket in cap for damage and replace if necessary. To have cap tested, contact your Authorized MerCruiser Dealer . Inspect coolant recovery system for leaks.

CA763

70979

70551

71425

75028

CA632

CHECKING DRIVE UNIT OIL

NOTE: Oil level will fluctuate during operation. Oil level should be

checked with cold engine before starting.

1 Check gear lube monitor oil level. Keep oil level at or near FULL

line. If any water is visible at the bottom of monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your Authorized MerCruiser Dealer immediately. Both conditions may indicate a water leak somewhere in the drive unit.

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

CB763

CHECKING POWER TRIM PUMP FLUID

Place drive unit in full down/in position.

2 Remove fill cap from reservoir and observe oil level. Level must

be up to, but not over bottom of filler neck. Add Quicksilver Power Trim and Steering Fluid or SAE 10W-30 motor oil, if required, to bring level to bottom of filler neck. Replace cap.

A Check that “Cap plug” has been removed from filler neck and

discarded.

B Fill cap is vented; frequently check that vent is open and

unrestricted.

CA633

Fuel Pump Sight Tube Inspection

3.0L Models

3 The engine fuel pump is equipped with a sight tube which gives

visible evidence of a ruptured fuel pump diaphragm.

If fuel is visible in tube, fuel pump should be replaced by your Authorized MerCruiser Dealer immediately.

CA473

75492

CA77

Propeller

WARNING

Avoid Injury: Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propeller.

WARNING

Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.

CAUTION

Avoid Injury: Periodically check propeller nut for tightness during boating season. A minimum of 55 lbs. ft. (75 N

⋅m)

torque is required.

CA746

REMOVAL

1 Place wood block between propeller blade and anti-ventilation

plate to prevent rotation. Straighten bent tabs on tab washer.

2 Turn propeller shaft nut counterclockwise to remove nut. 3 Slide tab washer, spline washer, propeller and thrust hub off

propeller shaft.

CA79

REPAIR

Some damaged propellers can be repaired. See your dealer.

CA634

75492

CA635

INSTALLATION

IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable.

4 Apply a liberal coat of one of the following Quicksilver lubricants

to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon.

5 Slide thrust hub onto propeller shaft, with stepped side toward

propeller hub.

6 Install Flo-Torque II Drive Hub into propeller.

NOTE: The drive sleeve is tapered and will slide fully into the propel-

ler as the nut is tightened and properly torqued.

7 Align splines and place propeller on propeller shaft. 8 Install drive sleeve adapter and locking tab washer. 9 Install propeller nut. T ighten nut securely. A minimum of 55 lbs. ft.

(75 N·m) torque is required. Bend three tabs on tab washer down into grooves in spline washer. After first use, bend the three tabs straight, retighten propeller nut to minimum 55 lbs. ft. torque (75 N·m). Bend tabs back down into spline washer . Check propeller at least after 20 hours of operation. Do not operate with loose propeller.

CA202

70565

71353

70564

CA83

Flushing Cooling System

WARNING

When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller.

CAUTION

Do not run engine above 1500 RPM when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine and/or drive unit to overheat.

CAUTION

Watch temperature gauge on dash to ensure that engine does not overheat.

To prevent silt and/or salt buildup in cooling system, flush with freshwater at specified intervals.

CB672

If flushing cooling system with boat in water, raise drive unit to TRAILER position, install flushing attachment and lower drive unit to full DOWN/IN position.

1 Install Quicksilver flushing attachment (or equivalent) over water

intake openings in gear housing.

2 Connect hose between flushing attachment and water tap. 3 With drive unit in normal operating position, partially open water

tap (about 1/2 maximum). 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. Stop engine, shut off water and remove flushing attachment.

CA150

71428

CA438

V-Belts (3.0L Model)

WARNING

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

All drive belts must be periodically inspected for condition and tension.

Perform the following inspections of alternator drive belt and power steering pump drive belt (if so equipped).

If any drive belts need replacement or tension needs adjustment, see your Authorized MerCruiser Dealer.

1 Alternator Drive Belt - Inspect drive belt for excessive wear or

damage. Check belt tension by depressing upper strand of belt at point shown.

Belt should depress 1/2 in. (13mm).

2 Power Steering Pump Drive Belt (If So Equipped) - Inspect drive

belt for excessive wear or damage. Check belt tension by depressing upper strand of belt at point shown.

Belt should depress 1/4 in. (6mm).

CA436

CA636

Serpentine Drive Belt (All Other Models)

WARNING

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

Belt must be periodically inspected for condition and tension.

NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys. Normally this location is between the power steering pump and belt adjustment idler pulley on models without

closed cooling. This location is between the power steering pump and alternator pulleys on models with

closed cooling.

1 Check the tension of the serpentine drive belt. If there is more than

1/4 in. deflection on the drive belt, see your Authorized MerCruiser Dealer to have the tension of the drive belt adjusted.

If any drive belts need replacement or tension needs adjustment, see your Authorized MerCruiser Dealer.

2 Models without closed cooling 3 Models with closed cooling

A Idler Pulley B Circulating Pump Pulley C Crankshaft Pulley D Alternator Pulley E Power Steering Pulley

CA204

71335

70578

70577

70576

70033

235

73919

CA439

Corrosion And Corrosion Protection

Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion and, if not controlled, it will in time cause the need for replacement of power package components exposed to water.

IMPORTANT: Replace sacrificial anodes if eroded 50% or more.

1 Universal Anodic Plate - serves as a sacrificial anode. 2 Anodic Plate - serves as a sacrificial anode. 3 Block - Is mounted to underside of gimbal housing and serves as

a sacrificial anode.

4 MerCathode System (if so equipped) - Electrode assembly

replaces Anodic block. System should be tested to ensure adequate output. Test should be made where boat is moored, using Quicksilver

Reference Electrode and Test Meter. Contact your Authorized MerCruiser Dealer to arrange for this test.

5 Anode Kit (if so equipped) - Mounted to boat transom. Acts as

a sacrificial anode.

CA162

71958

71957

CA440

1 Trim Cylinder Anodes - are mounted on each trim cylinder.

CA646

2 Bearing Carrier Anode - is located in front of the propeller,

between the front side of the propeller and the gear housing. Refer to “Propeller” section in this manual for propeller removal and installation.

CA93

71176

CA168

In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion:

IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty.

1 Painting Boat Hull or Boat T ransom: Anti-fouling paint may be

applied to boat hull and boat transom

but you must observe the

following precautions:

IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

IMPORTANT: If anti-fouling protection is required for boat hull or boat transom, copper or tin base paints, if not prohibited by law, can be used. If using copper or tin based anti-fouling paints, observe the following:

2 Avoid any electrical interconnection between the MerCruiser

Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40mm) UNP AINTED area on transom of the boat around these items.

3 Painting Drive Unit or Transom Assembly: Drive unit and

transom assembly should be painted with a good quality marine paint or an anti-fouling paint that DOES NOT

contain copper, tin, or any other material that could conduct electrical current. Do not paint drain holes, anodes, MerCathode system, and items specified by boat manufacturer.

4 Spray power package components on inside of boat every 2-3

weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion. External power package components may also be sprayed.

5 All lubrication points, especially steering system, shift and throttle

linkages, should be kept well lubricated.

6 Flush cooling system periodically, preferably after each use.

CA97

71925

71918

“SEE CAUTION”

CA474

Emissions

(Europe Only)

CA399

The following information applies only to engines with a special emissions kit installed. If the kit has been installed, your engine complies with “Stage 1” Bodensee and Swiss Regulations.

CA398

Sealed Carburetor Mixture Screws

The carburetor on this engine has seals on the carburetor mixture screws. These seals prevent adjustment of the fuel mixture settings.

CAUTION

Do not remove mixture screw seals and/or attempt to adjust fuel mixture setting. Tampering with the mixture setting on this engine could affect the exhaust emissions level, thus voiding the emissions certification. These seals should only be removed by an authorized dealer or emissions testing agency.

CA99

Changing Positive Crankcase Ventilation Valve (PCV)

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

1 Remove PCV valve from port valve cover . Disconnect it from t h e

hose and discard valve. Install new PCV valve in valve cover and reconnect hose. Ensure valve is tightly seated in valve cover.

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

CA637

75319

75324

71926

CA100

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.

CA638

Installing Test Probes

IMPORTANT: 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 both exhaust elbows. 2 Install exhaust elbow adapter fittings as follows.

A Apply Loctite Pipe Sealant with Teflon to threads that go into

elbow.

B Install fittings into elbows. Tighten fittings securely.

3 Insert exhaust probes (C) into fittings and tighten securely.

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.

CA478

Miscellaneous Maintenance

Battery

All lead acid batteries discharge when not in use. Recharge every 30 to 45 days, or when specific gravity drops below battery manufacturer ’s specifications.

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

WARNING

Avoid serious injury from gasoline 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.

WARNING

Batteries contain acid which can cause severe burns-Avoid contact with skin, eyes and clothing. Batteries also produce hydrogen and oxygen gases when being charged. This explosive gas escapes fill/vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged. Sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury.

Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte. Hydrogen gases that escape from the battery during charging are explosive. When charging batteries, be sure battery compartment or area where batteries are located, is well-vented. Battery electrolyte is a corrosive acid and should be handled with care. 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.

CA104

Bottom Of Boat

To maintain maximum speed, the following conditions of the boat bottom should be observed:

• Clean, free of barnacles and marine growth.

• Free of distortion, nearly flat where it contacts water.

• Straight and smooth, fore and aft.

ANTI-FOULING PAINTS

See Anti-Fouling Paint recommendations and related information on previous pages.

IMPORTANT: Refer to CORROSION AND CORROSION PROTECTION for additional information.

CA105

Inspection And Maintenance

Inspect 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 required.

Check plug leads and electrical leads for damage. Remove and inspect propeller . If badly nicked, bent or cracked, see

your dealer. Repair nicks and corrosion damage on power package exterior

finish. Use Quicksilver spray paints - see your Authorized MerCruiser Dealer.

CA639

Cold Weather Or Extended Storage

Power Package Lay Up

IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer. Damage caused by freezing IS NOT

covered by the

MerCruiser Limited Warranty.

CA115

Battery Winter Storage

Follow battery manufacturer’s instructions for storage.

CA645

Do-It-Yourself Maintenance

If you desire to perform your own maintenance, contact an Authorized MerCruiser Dealer to obtain a “Maintenance Procedures Manual.” Refer to the Do-It-Yourself Maintenance Suggestions at the front of the manual for additional information.

CA116

Power Package Recommissioning

WARNING

To prevent possible injury or damage to equipment, do not install battery until all maintenance has been performed on engine.

1 Check that all cooling system hoses are connected properly and

hose clamps are tight.

CAUTION

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

2 Install fully-charged battery. Clean battery cable clamps and

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

3 Coat terminal connections with a battery terminal anti-corrosion

agent.

4 Perform all checks in OPERATION CHART in the BEFORE

STARTING column.

CAUTION

Refer to FLUSHING COOLING SYSTEM before starting engine.

5 Start engine and closely observe instrumentation to make sure

that all systems are functioning correctly.

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

leaks.

7 Check steering system, shift and throttle control for proper

operation.

8 Check fuel pump sight tube (if so equipped) for evidence of fuel

(indicating a ruptured fuel pump diaphragm).

CA442

Troubleshooting

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.

Check and reset circuit breaker or replace fuse.

Loose or dirty electrical connections or damaged wiring.

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

Bad battery. Test and replace if bad.

Mercury V-6, V-8 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual