INDEX 2001, Mercury Marine Gasoline Engines - Alpha / Bravo Models 90-860168003 201
INDEX CA940 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 Transmission Model (Inboard) Gear Ratio Transmission Serial Number Propeller Number Pitch Diameter 3. 4. 5. Hull Identification Number (HIN) Purchase Date 6. Boat Manufacturer Boat Model Length 7.
INDEX CA910 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 . . . . . . . . . . . . . . . . . .
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INDEX CA859 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.
INDEX TABLE OF CONTENTS Page Warranty Information Owner Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . International Owner Registration . . . . . . . . . . . . . . . . . . . . . . Mercury MerCruiser Limited Warranty . . . . . . . . . . . . . . . . . 3 Year Limited Warranty Against Corrosion Failure . . . . . . Transferable Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Product Protection Plan . . . . . . . . . . . . . . . . . . . . . .
INDEX Page Operation Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Overload Protection . . . . . . . . . . . . . . . . . Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting, Shifting And Stopping . . . . . . . . . . . . . . . . . . .
INDEX CA455 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. • It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.
INDEX International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.
INDEX CC1048 Warranty Policies Mercury MerCruiser One Year Limited Warranty (Gasoline Fueled Products Only) WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for either one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
INDEX CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
INDEX HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
INDEX Expenses related to haul-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.
INDEX CC1049 3 Year Limited Warranty Against Corrosion (Worldwide) WHAT IS COVERED Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M2 Jet Drive, tracker by Mercury Marine Outboard, MerCruiser Inboard or sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
INDEX CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed an documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
INDEX HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
INDEX CA459 Transferable Warranty The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. Direct Sale By Owner • The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership.
INDEX CA862 Mercury Product Protection Plan United States And Canada Only (Certain performance products, triple engine installations, and commercial applications are excluded) The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty. The optional Mercury Product Protection Plan is the only Factory Plan available for your engine.
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INDEX 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.
INDEX 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.
INDEX CC942 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.
INDEX 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 or bass boats, and high-performance boats.
INDEX CA619 2 1 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.
INDEX CA766 Exhaust Emissions CA641 Courtesy of ABYC 1 CA767 Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
INDEX CA642 2A 2B 3A 3B 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.
INDEX CD543 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water. The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to violently veer in a new direction.
INDEX CD544 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed.
INDEX Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles. After striking a submerged object, stop engine as soon as possible and inspect the sterndrive unit for any broken or loose parts.
INDEX CB795 Operating With Low Water Inlets In Shallow Water A 76363 75827 CAUTION Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be sucked into the water inlets restricting or shutting off the water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets (A) while maneuvering in shallow water. Also, avoid beaching the boat with the engine(s) running.
INDEX CA866 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.
INDEX 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.
INDEX 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.
INDEX • 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.
INDEX • 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.
INDEX 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.
INDEX 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.
INDEX CA958 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): • 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): • Improves ease of planing. • Improves rough water ride. • At extremes, can cause boat to veer back and forth (bow steer).
INDEX 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: • Weeds or other debris snagged on propeller or gear housing. • Bent propeller blade or damaged gear housing skeg.
INDEX CB822 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 propellers. Refer to Specifications for engine WOT and operating rpm range.
INDEX If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage. After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch. • Warmer weather and greater humidity cause a loss of rpm.
INDEX CA960 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine. Since air 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.
INDEX 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 WOT 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 detonation. This, of course, enhances overall reliability and durability of the engine.
INDEX CA863 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 Mercury MerCruiser Dealer for a periodic checkup.
INDEX CA864 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 Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. • Familiarize the customer with the on-board equipment.
INDEX CA865 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 Mercury MerCruiser Limited Warranty. CA867 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.
INDEX CA868 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.
INDEX CA870 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 Mercury MerCruiser Dealer.
INDEX 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.
INDEX 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.
INDEX • 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.
INDEX CC1004 NOTE: All references to EFI models apply to EFI and MPI engines. CA782 Multiple EFI Engine Battery Precautions Situation Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charging current.
INDEX 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.
INDEX 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.
INDEX CA874 After Break-In Period To help extend the life of your Mercury 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.
INDEX CA26 1 70514 10 70523 9 70522 8 70521 54 2 70515 3 4 7 70520 70516 70517 5 70518 6 70519
INDEX 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 3 4 5 Tachometer: Indicates engine rpm.
INDEX CB218 1 70516 2 70518 3 76230 56
INDEX CA963 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The audio warning system alarm 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 alarm will sound if the system is working correctly. CAUTION Avoid engine damage.
INDEX CB758 3 1A 1B 74898 76037 1C 2 75989 58 74907
INDEX CB775 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 A circuit breaker provides protection for engine wiring harness and instrumentation power lead. Reset by pushing RESET button IN. A Carburetor Models B EFI Models Except 7.4L MPI C 7.
INDEX CB654 55 4 70525 70526 6 70527 60 7 70528
INDEX CA941 4 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 is not tripped). 5 The Power Trim System is protected from overload by 110 amp fuse and a 20 amp in-line fuse on Power Trim pump. 6 Quicksilver Three-Button Power Trim Control Panel is further protected by a 20 amp in-line fuse.
INDEX CA933 Remote Controls CC999 3 3 2 1 1 8 8 4 6 5 7 6 77443 CC998 Remote Control Features Your boat may be equipped with a Mercury Precision or Quicksilver remote control. 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 Single Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
INDEX 2 Neutral Release Lever - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed IN to move the control handle out of NEUTRAL. 3 Trim/Tilt Button(if Equipped) - Refer to Power Trim Operation. 4 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. Refer to the Lanyard Stop Switch safety explanation and Warning in the General Information Section.
INDEX CA768 3-5° 1 2 3 64
INDEX 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.
INDEX • 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. CB804 SINGLE ENGINE TRIM/TRAILER Single engine applications will have a button that can be pressed to trim the drive unit up or down.
INDEX 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. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant.
INDEX 5 Refer to A or B as appropriate for your model. A Carbureted Engine - Push THROTTLE ONLY 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.
INDEX 10 After 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. 11 Be sure charging system is functioning correctly. 12 Observe power package for fuel, oil, water and exhaust leaks. 13 To 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.
INDEX 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 returns 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.
INDEX CA971 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. Observe all gauges to check condition of engine. If not normal, stop engine. Turn ignition key to OFF. Turn battery switch ON, if equipped. Check for fuel, oil, water, fluid and exhaust leaks. Check shift and throttle control operation. Check steering operation. Operate bilge blowers, if equipped.
INDEX CA877 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 Mercury 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.
INDEX CA879 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.
INDEX 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.
INDEX CB789 FUEL SYSTEM ADDITIVES (V6 AND 5.0L/305 CID MODELS) To maximize the life of valves and valve seats on your Mercury MerCruiser engine, use Quicksilver Valve Lubricant (92-826259A12) regularly. CC540 Seacock Size Recommendation Seacock used must have an internal cross-sectional area equal to or greater than hose to prevent restricting waterflow. Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue. A 1-1/4 in.
INDEX 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.
INDEX CA953 Engine Specifications (4 Cyl. Models) Models 3.0L Propshaft Horsepower (SAV1 Rating) 1351 (1142) Propshaft Kilowatts (SAV1 Rating) 1011 (852) Displacement Maximum rpm @ Idle rpm in 181 cid (3.0L) WOT3 NEUTRAL3 4400-4800 rpm 700 rpm Oil Pressure @ 2000 rpm 30-60 psi (207-414 kPa) Min.
INDEX CA954 Engine Specifications (V-6 Models) Models 4.3L 4.3LH 4.3L EFI Propshaft Horsepower (SAV1 Rating) 1901 2051 (1902) 2101 (1882) Propshaft Kilowatts (SAV1 Rating) 1421 1531 (1422) 1571 (1402) Displacement Maximum rpm @ 262 cid (4.3 l) WOT3 Idle rpm in NEUTRAL 4400-4800 rpm 650 rpm5 600 rpm6 Oil Pressure @ 2000 rpm 30-70 psi (207-483 kPa) Min.
INDEX CA955 Engine Specifications (V-8 Models) Models 5.0L 5.0L EFI Propshaft Horsepower 2201 2401 Propshaft Kilowatts 1641 1791 Displacement Maximum rpm @ 305 cid (5.0 l) WOT3 4400-4800 rpm Idle rpm in NEUTRAL3 650 rpm5 Oil Pressure @ 2000 rpm 30-60 psi (207-414 kPa) Min.
INDEX CA950 Engine Specifications (V-8 Models) 5.7L Models 5.7L EFI 350 Mag MPI MX 6.2L MPI Propshaft Horsepower (SAV1 Rating) 2501 2601 3001 (2332) (2592) 3201 Propshaft Kilowatts (SAV1 Rating) 1861 1941 2241 (1742) (1932) 2391 Displacement Maximum rpm @ WOT3 Idle rpm in NEUTRAL3 Oil Pressure @ 2000 rpm 377 cid (6.2l) 350 cid (5.7 l) 4400-4800 46004800-5200 5000 6505 6006 30-60 psi (207-414 kPa) Min.
INDEX CA956 Engine Specifications (V-8 Models) Models 7.4L MPI 454 Mag MPI Propshaft Horsepower (SAV1 Rating) 3101 (2752) 3851 Propshaft Kilowatts (SAV1 Rating) 2311 (2052) 2871 Displacement Maximum rpm @ Idle rpm in 454 cid (7.4 l) WOT3 4200-4600 rpm NEUTRAL3 4600-5000 rpm 600 rpm6 Oil Pressure @ 2000 rpm 30-70 psi (207-483 kPa) Min.
INDEX CA957 Engine Specifications (V-8 Models) Models 502 Mag MPI Propshaft Horsepower 4151 Propshaft Kilowatts 3091 Displacement Maximum rpm @ 502 cid (8.2 l) WOT3 4600-5000 rpm Idle rpm in NEUTRAL3 600 rpm6 Oil Pressure @ 2000 rpm 30-70 psi (207-483 kPa) Min.
INDEX CB811 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 Mercury MerCruiser Dealer.
INDEX 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.
INDEX MCM 305 cid / 5.0L and 350 cid / 5.7L and 377 cid / 6.2L Engine Model Crankcase Oil (With Filter) 1 5.5 (5.25) 2 15 (14.1) Seawater Cooling System Closed Cooling System 20 (19) MCM 454 cid / 7.4L and 502 cid / 8.2L Engine Model Crankcase Oil (With Filter) 1 7 (6.6) 2 20 (19) Seawater Cooling System Closed Cooling System 18 (17) 1 Always use dipstick to determine exact quantity of oil or fluid required. 2 Seawater Cooling System capacity information is for winterization use only.
INDEX CA951 Gas Sterndrive Routine Maintenance * Each Day Start Each Day End Weekly Every Two Months Check crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush cooling system after each use. Check drive unit oil level, trim pump oil level and power steering pump fluid level. Check water pickups for debris or marine growth. Check water strainer and clean. Check coolant level.
INDEX Gas Sterndrive (Continued) Scheduled Maintenance * Every Every Every Every 2 Every 5 100 200 300 Annually Years Years Hours or Hours or Hours or Annually 3 Years 3 Years Touch-up paint power package and spray with corrosion guard. Change crankcase oil and filter. Change drive unit oil and retorque connection of gimbal ring to steering shaft. Replace fuel filter. Check steering system and remote control for loose, missing or damaged parts. Lubricate cables and linkages.
INDEX Gas Sterndrive(Continued) Scheduled Maintenance * (Continued) Every Every Every Every 2 Every 5 100 200 300 Annually Years Years Hours or Hours or Hours or Annually 3 Years 3 Years Clean flame arrestor and crankcase ventilation hoses. Replace PCV valve. Check electrical system for loose, damaged or corroded fasteners. Inspect condition and tension of belts. Check cooling system and exhaust system hose clamps for tightness. Inspect both systems for damage or leaks.
INDEX 2 2 4 76386 74766 76385 CB819 Checking Fluid Levels CHECKING CRANKCASE OIL 1 Stop engine. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water. 2 Remove dipstick. Wipe clean and reinstall fully into dipstick tube. 3 Remove dipstick and observe oil level. Oil level must be between FULL or OK RANGE and ADD. If oil level is below ADD: 4 Remove oil filler cap. Add specified oil to bring level up to, but not over, FULL or OK RANGE mark on dipstick.
INDEX 5 5 70546 77108 CA886 CHECKING POWER STEERING PUMP FLUID Stop engine and position drive unit straight back. 5 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 Mercury MerCruiser Dealer.
INDEX 7 6 71340 70547 CA887 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. 6 Check coolant level in coolant recovery bottle. Add specified coolant as required. 7 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.
INDEX 1 1 75028 75988 CA888 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 Mercury MerCruiser Dealer immediately. Both conditions may indicate a water leak somewhere in the drive unit.
INDEX 2A 70979 71425 3 CA942 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. CA889 Fuel Pump Sight Tube Inspection 3.
INDEX CA857 3 5 70571 7 5 94 74767 74766
INDEX CB820 Changing Fluids Refer to Maintenance for change interval. Crankcase oil should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. Changing Crankcase Oil and Filter IMPORTANT: Change crankcase oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended engine oil (refer to Specifications).
INDEX CB688 50132 1 2 70568 76230 3 96 72522 4 77106
INDEX CA967 Changing Drive Unit Oil 1 2 3 4 Remove gear lube monitor bottle from bracket. Empty contents into suitable container. Install monitor in bracket. Bravo One Models: Remove propeller, place drive unit in full trim limit IN position, remove OIL FILL/DRAIN SCREW and sealing washer, and drain oil. 5 All Other Models: Place drive unit in full trim limit OUT position, remove OIL FILL/DRAIN SCREW and sealing washer, and drain oil. 6 Remove OIL VENT screw and sealing washer.
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INDEX CA968 Changing Water Separating Fuel Filter WARNING Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use care when removing water separating fuel filter. Fuel could spray on hot engine causing fire or explosion. Allow engine to cool down before attempting to remove the water separating fuel filter in the following procedure. Also, hold a clean shop towel over the water separating fuel filter when removing it, to help avoid fuel spraying on the engine.
INDEX CA518 2 1, 5 75034 74812 6 3, 7 70573 100
INDEX 1 Unsnap latch and slide top and bottom cover pieces from around the water separating fuel filter and bracket. NOTE: Top and bottom cover pieces are formed with a groove on each side that slides around the brackets outer edges. 2 Remove water separating fuel filter and sealing ring from mounting bracket and discard. 3 Coat sealing ring on new filter with motor oil. Thread filter onto bracket and tighten securely by hand. Do not use a filter wrench. 4 Start and run engine.
INDEX CA921 75142 72806 76360 102
INDEX CA806 Cleaning Flame Arrestor and Related Components WARNING Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Be careful when cleaning flame arrestor and crankcase ventilation hoses: Be sure that ignition is OFF. DO NOT smoke or allow sources of spark or open flame in area when cleaning flame arrestor and crankcase ventilation hoses. 1 Remove flame arrestor and related components. 2 Clean flame arrestor in solvent.
INDEX CA922 7A 71903 1 71359 2 7B 74941 71901 7C 3 71480 71904 7D 6 71357 104 75454
INDEX CA524 Lubrication Steering System 1 If Steering Cable Has Grease Fittings: Turn steering until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand-operated grease gun. Lubricate at fitting with 2-4-C Marine Lubricant with Teflon. WARNING Do not grease steering cable while extended. Hydraulic lock could occur and cause loss of steering control. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased.
INDEX CA930 1 A 77044 77068 3 71569 4 71346 106 5 71347
INDEX CA938 Drive Unit and Transom Assembly 1 Lubricate gimbal bearing by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun using Quicksilver U-Joint and Gimbal Bearing Grease. A Alpha Models - Lubricate hinge pins by applying a couple of pumps of grease from a typical hand-operated grease gun using Quicksilver 2-4-C Marine Lubricant with Teflon. 2 For propeller shaft lubrication, see PROPELLER.
INDEX CA634 76910 CA816 Propeller Alpha 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.
INDEX 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, drive sleeve, propeller and thrust hub off propeller shaft. CA79 REPAIR Some damaged propellers can be repaired. See your dealer.
INDEX CA634 4 5 6 7 8 9 76910 CA774 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.
INDEX NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued. 7 Align splines and place propeller on propeller shaft. 8 Install drive sleeve and locking tab washer. 9 Install propeller nut. Tighten 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).
INDEX CB422 BRAVO ONE 76910 2 BRAVO TWO 112 70561
INDEX CA817 Propellers Bravo One and Two 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.
INDEX CB423 BRAVO ONE 4 6 5 76910 7 8B 9 8A BRAVO TWO 114 70561
INDEX CA818 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 into propeller hub, with stepped side toward propeller hub. 6 Bravo One: Install Flo-Torque II Drive Hub into propeller.
INDEX CH3 2 4 77107 CH4 Propellers Bravo Three 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.
INDEX CAUTION Avoid Injury: Periodically check propeller nut for tightness during boating season. A minimum of 55 lbs. ft. (75 N⋅m) torque is required. REMOVAL (BRAVO THREE DRIVE) 1 Place wood block between propeller blades and anti-ventilation plate to prevent rotation. 2 Turn aft propeller shaft nut (1-7/16 in. or 37mm) counterclockwise to remove nut. 3 Slide propeller and thrust hub off propeller shaft. 4 Turn front propeller shaft nut (2-3/4 in. or 70mm) counterclockwise to remove nut.
INDEX CB150 1 2 3 4 5 6 7 77107 CA820 INSTALLATION 1 Apply a liberal coat of one of the following Quicksilver lubricants to both propeller shafts: Special Lubricant 101, 2-4-C Marine Lubricant with Teflon, or Anti-Corrosion Grease. 2 Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub (toward end of shaft). 3 Align splines and place propeller on propeller shaft.
INDEX 4 Install propeller nut. Tighten nut securely. A minimum of 100 lbs. ft. (136 N·m) torque is required. Check propeller at least after 20 hours of operation. Do not operate with loose propeller. 5 Slide aft thrust hub onto propeller shaft, with tapered side toward propeller hub (toward end of shaft). 6 Align splines and place propeller on propeller shaft. 7 Install propeller nut. Tighten nut securely. A minimum of 60 lbs. ft. (81 N·m) torque is required.
INDEX CA529 2B 2A 1 71428 3 4 A 50633 3 120 B C 50633
INDEX CA839 Drive Belts WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belts. V-Belts (3.0L Model) CHECKING 1 Inspect the alternator and power steering pump drive belts for the following: • Excessive wear • Fraying • Cracks • Glazed surfaces 2 Check belt tension by depressing belts, with moderate hand pressure, at points shown. A Alternator Belt - Belt should depress 1/2 in. (13 mm).
INDEX D Loosen the alternator as outlined below. Remove and replace the alternator belt. E Replace the spacer block between the bracket assembly and the engine block. Install the two screws using the flat and lock washers removed previously. Torque the two screws to 21 lb. ft. (28 N·m). F Install power steering belt. Adjust tension of both drive belts as outlined in the following. Power Steering Pump Drive Belt 4 Remove drive belt as follows: A Loosen power steering pump attaching bolts and mounting bolts.
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INDEX CA948 B A D F C 76503 B D A F A C 76338 E 1 124 75130
INDEX CA947 Serpentine Drive Belt WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt. The various components are: A Idler Pulley D Alternator Pulley B Circulating Pump Pulley E Seawater Pump Pulley C Crankshaft Pulley F Power Steering Pulley CHECKING 1 Inspect drive belt for proper tension and for the following: • Excessive wear • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable.
INDEX CA928 REPLACING AND / OR ADJUSTING TENSION IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before. 1 Remove drive belt as follows: NOTE: The upper, left (port) idler pulley is the belt adjustment pulley. A Loosen 5/8 in. locking nut on adjustment stud. B Turn adjustment stud and loosen belt. Remove belt. 2 Install drive belt on pulleys and adjust tension as follows: 3 Loosen 5/8 in. locking nut on adjustment stud. Leave wrench on adjustment stud.
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INDEX CA925 1 5 73919 71176 70577 4 3 70576 70578 2 2 128 70575
INDEX CA926 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.
INDEX 6 7 71966 72032 8 72029 CD679 6 Trim Cylinder Anodes - are mounted on each trim cylinder. To replace the trim cylinder anodes: A Remove two screws from anode. B Clean mounting surfaces down to bare metal for proper contact. C Install new anode. Tighten screws securely. CA969 7 Bearing Carrier Anode (Alpha and Bravo One) - is located in front of the propeller, between the front side of the propeller and the gear housing.
INDEX D Install new anode. Tighten screws securely. E Reinstall propeller. See Propeller Installation for proper tightening. 8 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. 9 Gear Housing Anode (Bravo Two and Three) - is located in the splash plate, just above the propellers.
INDEX 2 Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40 mm) UNPAINTED 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.
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INDEX CA97 “SEE CAUTION” 1 134 71918 71925
INDEX CA474 Emissions (Europe Only) CA893 The following information applies only to engines with a special emissions kit installed. If the kit has been installed, your engine complies with SAV1 Regulations. 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.
INDEX CA637 1 75319 2A 2B C 71926 3 75324 136
INDEX CA913 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 igni- tion system. • Proper engine tuning procedures to ensure these features remain in good operating order. • Proper steps to maintain the engine within specifications. Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations.
INDEX 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.
INDEX CA962 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.
INDEX CA896 Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT: Mercury MerCruiser Strongly recommends that this service should be performed by an Authorized Mercury MerCruiser Dealer. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. WARNING Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation to prevent a potential fire hazard. WARNING Fuel and gases from a battery are flammable and/or explosive.
INDEX IMPORTANT: Before starting engine, a water source must be attached to the seawater intake openings in gear housing, and/or seawater pickup pump. Follow all warnings, and flushing attachments procedures stated, in Flushing Cooling System. CAUTION Sterndrive unit should be stored in full DOWN position. Universal Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service.
INDEX CA575 Power Package Lay Up (continued) CARBURETED MODELS 75844 WARNING Avoid Fire or Explosion: Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation. 1 Close the fuel shut-off valve, if so equipped. If no fuel shut off valve is present, a suitable method must be employed to STOP the flow of fuel from the fuel tank to the engine before proceeding. 2 Remove flame arrestor and start engine.
INDEX CA576 Power Package Lay Up (continued) EFI MODELS WITH COOL FUEL SYSTEM WARNING Avoid Fire or Explosion: Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation. WARNING Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use care when removing water separating fuel filter. Fuel could spray on hot engine causing fire or explosion.
INDEX 2C 2B 77108 2 Prepare fuel system for extended storage as follows: A B C D E F G H Allow engine to cool down. Depress latch and remove (slide down) the lower filter cover. Remove the water separating fuel filter. Pour out a small amount of fuel into a suitable container, then add approximately 2 fluid ounces (60 ml) of Quicksilver 2-Cycle Outboard Oil to fuel in the water separating fuel filter. Install water separating fuel filter.
INDEX CA798 Draining CA853 Seawater (Raw-Water) Cooled Models NOTE: This procedure will not work with 3.0L Single Point Drain System. See specific instructions later in this manual. CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses. IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.
INDEX 2C 75432 2B 2D 2A 75081 2 Remove drain plugs from the following locations, if equipped: A B C D E Port and starboard side of cylinder block. Bottom of exhaust manifolds. Starboard side Y-fitting. Fuel cooler. Port seawater pipe. 3 Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained.
INDEX 6 5 4 76038 71216 CA897 NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. 4 Models equipped with circulating pump hose drain plug: Remove drain plug. 5 Models without circulating pump hose drain plug: Loosen hose clamps and disconnect hose from circulating pump. Allow water to drain. 6 Make sure gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed.
INDEX IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer’s recommendations.
INDEX CA898 Closed Cooled (Coolant) Models The following information outlines the procedures for draining the seawater section of the closed cooling systems. IMPORTANT: Drain seawater section of closed cooling system only. CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses.
INDEX CA795 3A 2 75039 5 4 73581 71515 9 7 71170 71216 150
INDEX CA796 IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. 1 Ensure engine is as level as possible to ensure complete draining of cooling system. 2 Remove drain plug(s) from bottom of exhaust manifold(s). 3 Remove drain plug from A or B, depending on model: A Fuel cooler. B Port seawater pipe. 4 3.0L: Remove aft (rear) drain plug from heat exchanger. 5 All Other Models: Remove end caps, sealing washers and gaskets from heat exchangers.
INDEX CA797 2A 2B 76242 3A 3B 4A 76244 7A 152 76243 76244
INDEX CA854 3.0L Single Point Drain CAUTION Ensure bilge pump is operating before beginning procedures. Excess water in bilge can damage engine or cause boat to sink. CAUTION Allow engine to cool down before disconnecting blue drain hoses. Engine water temperature can exceed 160° F ( 71° C). CAUTION Do not operate engine with blue drain hoses disconnected. Hot water can discharge violently. IMPORTANT: Do NOT start or operate engine at any point in this procedure. 1 Turn on bilge pump.
INDEX Clearing Clogged Blue Drain Hoses 7A 76287 BOAT IN WATER CAUTION Allow engine to cool down before disconnecting blue drain hoses. Engine water temperature can exceed 160° F ( 71° C). CAUTION Ensure bilge pump is operating before beginning procedures. Excess water in bilge can damage engine or cause boat to sink. 1 Reconnect the UNCLOGGED blue drain hose to the bracket. 2 Ensure CLOGGED blue drain hose is in correct position below its connection point to the block. 3 Turn on bilge pump.
INDEX 8 Attach the CLOGGED blue drain hose to the male end on the water hose adapter fitting. 9 Fully open the water supply and allow it to run for 1 minute. 10 Turn off the water supply. 11 Disconnect the water hose adapter from the blue drain hose and the water hose. 12 Push down on T-handle to force the blue drain hoses down below their connection points to the block. 13 Check for water draining from the blue drain hose.
INDEX Clearing Clogged Blue Drain Hoses (continued) 2A 72693 Engine Running 1 Attach UNCLOGGED blue drain hose to the bracket, leaving the CLOGGED blue drain hose disconnected. 2 Install flushing attachment over water pickup holes (A) in gear housing as shown. 3 Attach a hose between the flushing attachment and a water supply. 4 Partially open water supply (approximately 1/2 maximum capacity). DO NOT use full water pressure. CAUTION Ensure bilge pump is operating before beginning procedures.
INDEX CAUTION Do not run engine above 1300 rpm. Suction created by seawater pickup pump may collapse water supply hose, causing engine to overheat. WARNING Be certain the area around propeller is clear and no one is standing nearby. To avoid possible injury, remove propeller. CAUTION Watch temperature gauge on dash to ensure that engine does not overheat. 6 Start engine. Allow it to run at idle until the obstruction is cleared from the hose or for approximately 1 minute, whichever occurs first.
INDEX CA799 8 4 76287 3 CA825 Flushing Cooling System CA801 3.0L Single Point Drain If engine is operated in salty or brackish water, flush cooling system (preferably after each use) to reduce corrosion and prevent the accumulation of deposits in the system. Thoroughly flush cooling system prior to storage. IMPORTANT: Do NOT start or operate engine at any point in this procedure. CAUTION Do not operate engine with blue drain hoses disconnected. Hot water can discharge violently.
INDEX 5 Fully open the water supply and allow it to run for 10 minutes. 6 Turn off the water supply. 7 Disconnect the water hose adapter from the blue drain hose and the water hose. 8 Pull T-handle until the quick connect fittings on the blue drain hoses are within reach. 9 Install quick connect fittings on the bracket. Pull on the hoses to ensure they are firmly connected. 10 Push down on handle and move into the slot on the bracket.
INDEX CA824 1 70564 CA800 All Other Models CA827 To prevent silt and/or salt buildup in cooling system, flush with freshwater after each use and prior to storage. 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. If flushing cooling system with boat out of water, remove propeller before proceeding. If propeller is not removed observe the following precaution.
INDEX 1 Install Quicksilver flushing attachment (or equivalent) over water intake openings in gear housing. 2 Connect hose between flushing attachment and water source valve. 3 With drive unit in normal operating position, partially open water source valve (about 1/2 maximum). 4 Place drive in NEUTRAL, idle speed position and start engine. CAUTION Avoid possible engine damage. • Do NOT run engine continuously at idle rpm. • Do NOT run engine above 1500 rpm.
INDEX 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.
INDEX 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).
INDEX 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. Bad battery. 164 Check all electrical connections and wires (especially battery cables). Clean and tighten faulty connection.
INDEX CA972 Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shutoff valve closed. Fill tank or open valve. Faulty fuel pump. Choke not operating properly. 3.0L: Check sight tube for fuel. Have Authorized Mercury MerCruiser Dealer replace pump, if fuel is present. Carburetor Models: Check choke linkages for freedom of movement. Engine flooded. Do not attempt to start engine for at least 5 minutes.
INDEX CA900 Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Idle speed too low. EFI Models: Have EFI system checked by an Authorized Mercury MerCruiser Dealer. Choke not operating properly. Carburetor Models: Check choke linkages for binding or an obstruction. Faulty ignition system component. Service ignition system. Clogged fuel filter. Replace filter. Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.
INDEX CA914 Poor Performance Possible Cause Remedy Throttle not fully open. Inspect throttle cable and linkages for proper operation. Damaged or improper propeller. Replace propeller. Excessive bilge water. Drain and check for cause of entry. Boat overloaded or load improperly distributed. Reduce load or redistribute load more evenly. Boat bottom fouled or damaged. Clean or repair as necessary. Flame Arrestor dirty. Clean Flame Arrestor. Ignition or carburetion problem.
INDEX CA447 Excessive Engine Temperature Possible Cause Remedy Seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups obstructed. Remove obstruction. Faulty thermostat. Replace. Coolant level low in closed cooling section (If Equipped). Check for cause of low coolant level and repair. Fill system with proper coolant solution. Heat Exchanger Cores plugged Clean Heat Exchanger. with foreign material (If Equipped).
INDEX CA448 Insufficient Engine Temperature Possible Cause Faulty Thermostat. Remedy Replace. CA449 Low Engine Oil Pressure Possible Cause Insufficient oil in crankcase. Remedy Check and add oil. Check and remove required Excessive oil in crankcase amount of oil. Check for cause (causing it to become aerated). of excessive oil (improper filling, bad fuel pump, etc.). Change oil and oil filter, using correct grade and viscosity oil. Diluted or improper viscosity Determine cause for dilution oil.
INDEX CA450 Battery Will Not Come Up On Charge Possible Cause Excessive current draw from battery. Loose or dirty electrical connections or damaged wiring. Alternator drive belt loose or in poor condition. Unacceptable battery condition. Remedy Turn off non-essential accessories. Check all associated electrical connections and wires (especially battery cables). Clean and tighten faulty connections. Repair or replace damaged wiring. Replace and/or adjust. Test battery.
INDEX CA902 Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level. Refill system with fluid. Drive belt loose or in poor condition. Replace and/or adjust. Insufficient lubrication on steering components. Lubricate. Loose or missing steering fasteners or parts. Check all parts and fasteners if any are loose or missing, see Authorized Mercury MerCruiser Dealer immediately. Contaminated power steering fluid. Drain and replace.
INDEX CA453 Power Trim Does Not Operate (Motor Doesn’t Run) Possible Cause Remedy Blown fuse. Replace fuse. Loose or dirty electrical connections or damaged wiring. Check all associated electrical connections and wires (especially battery cables). Clean and tighten faulty connection. Repair or replace wiring. CA454 Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive unit binding in gimbal ring.
INDEX CA903 Owner Service Assistance Local Repair Service Always return your Mercury MerCruiser powered boat to your local Authorized Dealer, should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur. He knows your engine best.
INDEX CA904 Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any Authorized Mercury MerCruiser Dealership. If additional assistance is required, take these steps. 1 Talk with the dealership’s sales manager or service manager. If this has already been done, then contact the owner of the dealership.
INDEX CA915 Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. Telephone Fax Mail United States (405) 743-6566 (405) 743-6570 Mercury MerCruiser 3003 N. Perkins Rd. Stillwater, OK 74075 (905) 567-8515 Mercury Marine Ltd. 2395 Meadowpine Blvd.
INDEX CA463 Customer Service Literature English Language English language publications are available from: Mercury Marine Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: 1. List your product, model, year and serial number(s). 2. Check the literature and quantities you want. 3.
INDEX cab781 Andere talen Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient u contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hierover. Een lijst met onderdeelnummers voor andere talen wordt bij uw motorinstallatie geleverd.
INDEX cag781 Andre språk Ytterligere informasjon om bruks– og vedlikeholdshåndbok på andre språk kan fås ved henvendelse til nærmeste internasjonale servicecenter for Mercury Marine eller Marine Power. En liste over delenumre for andre språk følger med aggregatet. cah781 Outros Idiomas Para obter um Manual de Operação e Manutenção em outro idioma, contate o Centro de Serviço Internacional de “Marine Power” (Potência Marinha) ou a Mercury Marine mais próxima para obter informações.
INDEX CA906 Ordering Literature Before ordering literature, please have the following information about your power package available: Model __________ Horsepower__________ Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone (920) 929–5110 Fax (920) 929-4894 Mail Mercury Marine Attn
