Mercury V-6, V-8 User Manual
Gasoline Engines - Alpha Models
1998, Mercury Marine 90860168985 1098
0
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.
1
CA469
71352
ABC12345Z123
-19 48-12345
71345
4
5
1
2
2,7
7
2
1
44
5
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
2
71718
74849
2
2
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. . . . . . . . . . . . . . . . . . . . . . . . . .
3
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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.
5
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.
6
CA619
General Information
2
1
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
7
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.
8
CA641
1
9
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.
10
CA642
3A
3B
Courtesy of ABYC
2A
2B
11
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).
12
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.
13
• 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.
14
• 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.
15
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.
16
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.
17
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.”
18
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.
19
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.
20
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.
21
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.
22
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.
23
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.
24
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.
25
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.
26
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.
27
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
28
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.
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