Applicable Requirement Standards Applied Owner’s manual (A.2.5) ISO 10240 Handling characteristics (A.4) ISO 8665 Inboard Engine (A.5.1.1) ISO 15584; ISO 7840; ISO 10133 Fuel System (A.5.2) ISO 7840; ISO 8469 Electrical System (A.5.3) ISO 10133; ISO 8846 General Steering System (A.5.4.1) Applicable portions of: ABYC P‑21; EN ISO 10592 Exhaust emission requirements (B.2) ISO 8178‑1 Owner’s manual (B.
Engine Type: Sterndrive Fuel Type: Gasoline Combustion Cycle: 4 Stroke Engine Family Name: 600SCi Starting Serial Number: 0M955821 Electromagnetic Compatibility Directive 89/336/EC Generic emission standard BS EN 61000‑6‑3 Generic immunity standard BS EN 61000‑6‑1 Vehicles, boats and internal combustion engine driven devices ‑ Radio disturbance characteristics SAE J551; CISPR 12 Electrostatic discharge testing BS EN 61000‑4‑2; BS EN 61000‑4‑3 This declaration is issued under the sole responsibility
The Operation, Maintenance & 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. Again, thank you for purchasing one of our Mercury Marine products.
! WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. Safety Alerts and Notices Throughout this publication, dangers, warnings, cautions, and notices0., accompanied by the international HAZARD symbol ! , are used to alert the technician to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.
IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. Copyright and Trademark Information Mercury Marine, Fond du Lac, Wisconsin U.S.A. Litho in U.S.A.
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TABLE OF CONTENTS Warranty Information Warranty Registration United States And Canada......................1 Transfer Of Warranty...................................................................1 Mercury Racing Division One Year Limited Warranty.................2 Products Sold to Government Agencies......................................6 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products.......................................................................................
TABLE OF CONTENTS Operation Instrumentation..........................................................................30 Warning System........................................................................30 Electrical System Overload Protection......................................33 Remote Controls (Console Mounted Zero Effort)......................37 Power Trim................................................................................38 Starting, Shifting and Stopping...............................
TABLE OF CONTENTS Fuel Filters.................................................................................93 Corrosion and Corrosion Protection..........................................95 Battery.......................................................................................98 Bottom of Boat...........................................................................99 Inspection and Maintenance....................................................100 Attention Required After Submersion.............
TABLE OF CONTENTS Service Assistance..................................................................118 Mercury Mercruiser Service Offices.........................................119 Ordering Literature United States and Canada....................................................... 121 Outside The United States and Canada..................................121 Maintenance Log Maintenance Log.....................................................................
WARRANTY INFORMATION Warranty Registration United States And Canada Outside United States and Canada ‑ Check with your local distributor. 1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information. Mercury Marine Attn.
WARRANTY INFORMATION To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty registration department. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O.
WARRANTY INFORMATION 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.
WARRANTY INFORMATION 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.
WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident, s
WARRANTY INFORMATION No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
WARRANTY INFORMATION Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty.
WARRANTY INFORMATION 5. Labor performed by other than an authorized dealer may be covered only under following circumstances: When performed on emergency basis (providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility). 6. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 7.
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the power package. Be sure at least one additional person on board is instructed in the basics of starting and operating the power package, and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION High‑Speed and High‑Performance Boat Operation If your power package is to be used on 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/ power package combination.
GENERAL INFORMATION ! 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. ! WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.
GENERAL INFORMATION Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds. 21604 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 (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate.
GENERAL INFORMATION 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.
GENERAL INFORMATION While Boat is Moving a b 5449 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). GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 5448 Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating.
GENERAL INFORMATION 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 veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat. ! WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible.
GENERAL INFORMATION Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which 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 to control the boat speed.
GENERAL INFORMATION ! WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts.
GENERAL INFORMATION • Manual bilge pump and extra drain plugs; compass and map or chart of area. • Spare operating equipment; batteries, bulbs, fuses, etc. • Transistor radio and 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. 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.
GENERAL INFORMATION Never be under the influence of alcohol or drugs while boating (it is the law). Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly. Know your boating area and avoid hazardous locations. Prepare other boat operators. Instruct at least one other person on board in the basics of starting and operating the power package, and boat handling, in case the driver becomes disabled or falls overboard. Passenger boarding.
GENERAL INFORMATION 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 Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines.
SPECIFICATIONS Power Package Identification ENGINE IDENTIFICATION Model: Displacement: Max WOT RPM: Spark Plugs: Spark Plug Gap: Spark Timing: Fuel Octane: Engine Oil: Engine Coolant: **see owner's manual HP600 SCi 502 C.I.D. 4800 - 5200 NGK BPR6ES 0.
SPECIFICATIONS DRIVE UNIT AND TRANSOM ASSEMBLY IDENTIFICATION b a 16933 a - Drive unit identification tag location (bottom side) b - Transom assembly identification tag location (inside through transom plate) SERIAL NUMBERS RECORD Engine Model/Horsepower: ________________________ Engine Serial Number1. : ________________________ Transom Assembly Serial Number: ________________________ Sterndrive Serial Number & Gear Ratio2.
SPECIFICATIONS 2. The gear ratio is stamped on the the bolt located next to the serial number label. 3. The running rotation is stamped on the back of the strut. General Engine Specifications (HP600) Horsepower 600 HP (447 kW) Displacement 8.2 L (502 c.i.) Cylinder arrangement V‑8 Bore 114 mm (4.47 in.) Stroke 102 mm (4.00 in.) Compression ratio 7.5:1 Supercharger 3.
SPECIFICATIONS Engine Operating Limitations (HP600) Maximum wide open throttle (W.O.T.
SPECIFICATIONS ! CAUTION Use of improper fuel can seriously damage your engine. Engine damage resulting from use of improper fuel is considered misuse of the engine and damage caused thereby will not be covered under the Mercury Racing limited warranty. OCTANE REQUIREMENTS (U.S./CANADA) FUEL TYPE MINIMUM POSTED OCTANE Premium Unleaded (R+M) ÷ 2 = 91 or RON = 98* NOTE: *Research Octane Number OCTANE REQUIREMENTS (OUTSIDE THE U.S./CANADA) FUEL TYPE MINIMUM POSTED OCTANE Premium Unleaded1.
SPECIFICATIONS Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand.
SPECIFICATIONS Oil Recommendations ENGINE CRANKCASE OIL Preferred Oils API Classification Kendall GT‑1 Motor Oil 20W‑50 SJ, CF‑2, CH‑4 Oil Filter Should Always Be Changed With Oil SUPERCHARGER GEARCASE OIL Preferred Oils API Classification Castrol Syntec Synthetic Motor Oil 5W‑50 SL, SJ, CF IMPORTANT OIL PRACTICES Do Not Use • Straight weight oils • Non‑detergent oils • Oils containing solid additives • Multi‑viscosity oils other than the ones recommended • Low quality oils Do Not Mix •
SPECIFICATIONS Capacities Unit Capacity Fluid Type Crankcase Oil Capacity with New 8 L (8.5 U.S. qts) Filter1. Kendall Motor Oil 20W‑50 Supercharger Gearcase 177 ml ( 6 U.S. oz) Castrol Syntec Synthetic Motor Oil 5W‑50 Closed Cooling System Approximately 15 L (16 U.S. qts) Dex‑Cool Extended Life Anitfreeze/ Coolant (50‑50 mix) VI Drive Dry Sump 4 L (4.25 U.S. qts) Unit Oil Capacity Torco MTF Gear Oil Transom Input Shaft Bearing Housing (Driveline model) Torco MTF Gear Oil 0.47 L (0.5 U.S.
SPECIFICATIONS Engine Break‑in IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 5 Hr. Break‑in Procedure • Allow engine to warm‑up for 30‑ 60 seconds. • Do not exceed 3/4 throttle. • Avoid full throttle acceleration from idle speed. • Always vary throttle setting. • Run engine the majority of time between 3000 ‑ 4500 RPM. • Frequently check engine oil level.
OPERATION Instrumentation It is important to monitor critical engine and boat functions while the boat is in operation. The SmartCraft boat information system uses gauges and/or a System View monitor screen to display the information.
OPERATION ENGINE GUARDIAN SYSTEM The Engine Guardian system monitors sensors on the engine for any early indications of problems. If a sensor indicates a fault, the system responds to the problem by emitting a continuous or intermittent horn and, depending on the type of fault, may reduce engine power to provide engine protection. If the boat is equipped with System View, a message will be given on the display screen in conjuction with the horn. Refer to the System View manual for details.
OPERATION Possible Cause Horn Monitor Display Guardian Activated and Engine Power Reduced PCM Error Steady Horn Yes Forced Idle Battery charging high or low Steady Horn Yes Yes Low Seawater Pressure Steady Horn Yes Yes Low Oil Pressure Steady Horn Yes Yes Engine Overspeed Steady Horn Yes No Charge Temperature Overheat Steady Horn Yes Yes MAP Sensor Error Steady Horn Yes No Oil Temperature High Steady Horn Yes No Coil Pack Failure 5 Beeps‑3 Sec.
OPERATION Possible Cause Horn Fuel Pressure Sensor 3 Beeps‑1.5 Sec. Failure Long Monitor Display Guardian Activated and Engine Power Reduced Yes No Block Pressure Sensor Failure 3 Beeps‑1.5 Sec. Long Yes No Charge Temperature Sensor Failure 3 Beeps‑1.5 Sec. Long Yes No Coolant Temperature Sensor 3 Beeps‑1.5 Sec. Long Yes No Throttle Position Sensor 3 Beeps‑1.5 Sec. Long Yes Yes Low Battery Voltage 2 Beeps‑1 Sec. Long Yes No Low Drive Lube1. 2 Beeps‑1 Sec.
OPERATION A circuit breaker protects the engine wiring harness and instrumentation power lead. Reset by pushing the reset button. a 7764 a - Reset button In an emergency, if you cannot locate and correct the cause of the high current draw, and you must operate the engine, perform the following: 1. Turn off or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker. 2. If the breaker remains open, electrical overload is still present.
OPERATION 4. The power trim pump is internally protected from thermal overload. If it overheats, it will shut off, allowing itself to cool and then reset. However, it is recommended that the power trim system be installed with additional overload protection. Therefore, the power trim may be protected from overload by a 90 amp fuse in the power supply to the pump and a 20 amp in‑line fuse to the switch power. 5. A 90 amp fuse is located on the starter.
OPERATION 6. Eight fuses are located at the upper rear of the engine in two fuse holders (four fuses in each holder).
OPERATION Fuse Holder ‑ C26 Fuse Holder ‑ C27 (1) ‑ 15 amp ‑ RED to RED/BLU constant (5) ‑ 20 amp ‑ RED/BLK to RED/PNK power coil (2) ‑ 5 amp ‑ PPL to PPL/WHT accessories (6) ‑ 20 amp ‑ RED/GRN to RED/ WHT fuel injection (3) ‑ 15 amp ‑ RED/GRN to RED/ORN hour meter (7) ‑ 25 amp ‑ RED/BLK to RED/PNK fuel pump (4) ‑ 15 amp ‑ RED to RED/PPL key switch/CAN power (8) ‑ 20 amp ‑ RED/GRN to RED/BLU driver power Remote Controls (Console Mounted Zero Effort) 1.
OPERATION 2. Control shifting by moving the shorter control lever(s). This control shifts the unit into gear with full lever movement. Move the lever forward to engage the forward gear. Move lever backward to engage reverse gear. Place the lever in the center position to shift to neutral. Shifting should occur only with the engine at idle speed. Always move to the desired gear position with a quick, firm motion.
OPERATION ! CAUTION Avoid excessive wear on the U‑joint/input shaft. The VI drive does not have a trim limit switch. Depressing the trim or trailer buttons allows the drive to be tilted to its full extension without stopping at a preset trim limit. The drive's position should be monitored with the trim gauge(s) so that the drive is not trimmed excessively. In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3° to 5° angle to the water.
OPERATION • In excess, cause boat porpoising (bouncing) or propeller ventilation. 7419 Trimming Drive Unit Down/In Can: 7420 • • • • Help the boat accelerate and plane off quicker. Generally improve the ride in choppy water. In most cases, reduce boat speed. If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction, called bow steering or over steering.
OPERATION ! CAUTION Avoid twisting or binding dual engine tie bars. Damage to the tie bar and sterndrives could occur. Always raise or lower the sterndrive units evenly. NOTE: The word "trim" is usually considered the first 20° up/out movement from vertical position. 1 2 7868 a - Trailering and trimming up/out position - Press (top) up/out portion of switch until drive unit reaches desired trim/trailering position.
OPERATION Starting, Shifting and Stopping ! WARNING Avoid fire or explosion. Before starting the engine, operate the bilge blower for at least five minutes to remove any explosive fumes from the engine compartment. If the boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine. NEW ENGINES OR ENGINES COMING OUT OF STORAGE See Power Package Recommissioning.
OPERATION FLOODED ENGINE Move control/throttle lever to half throttle. Be prepared to decrease engine speed to 1000 ‑ 1500 RPM as soon as engine starts. STARTING PROCEDURE 1. Turn the key switch to "START." Release the key when the engine starts and allow the switch to return to the "RUN" position. 2. Check the oil pressure gauge immediately after the engine starts. If oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause. 3.
OPERATION Check steering operation. 3. While Underway Observe all gauges to monitor engine condition. 4. After Stopping Shift to neutral. Turn ignition key "OFF." Turn battery switch "OFF," if equipped. Close fuel valve. Close seacock. Flush cooling system if in saltwater area. Freezing Temperature Operation IMPORTANT: If boat is operated in freezing temperatures, ensure that closed coolant is rated for the temperature range in which it is to be used.
OPERATION In any of the situations described in the preceding caution, water entering the engine could cause severe damage to internal parts. Refer to Attention Required After Submersion in the General Information section of this manual.
CONDITIONS AFFECTING OPERATION Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) may: • • • • Increase speed and engine RPM. Cause the boat to porpoise. Cause the bow to bounce in choppy water. Increase the danger of a following wave splashing into the boat when coming off plane. Shifting weight to front (bow) may: • • • Improve ease of planing. Improve rough water ride.
CONDITIONS AFFECTING OPERATION Ventilation Ventilation occurs when surface air or exhaust gases surround the propeller, causing propeller speed‑up (slippage) and a decrease in boat speed. Excessive ventilation is annoying and usually caused by: • A drive unit trimmed out too far. • A damaged propeller or gear housing, allowing exhaust gases to escape between propeller and gear housing. • A drive unit installed too high on the transom.
CONDITIONS AFFECTING OPERATION • • • Operating in a higher elevation. Operating with a damaged propeller or dirty boat bottom. Operating with increased load (additional passengers, pulling skiers, etc.). Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems. • Above sea level elevations • High temperature. • Low barometric pressure. • High humidity.
MAINTENANCE Servicing High Horsepower Engines All high performance engines require frequent maintenance and inspection schedules due to the extreme duty cycles and related stress these products endure. Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastrophic engine failure and increased owner expense.
MAINTENANCE • • Explaining and demonstrating the operation of the power package and boat. Providing the customer with a copy of a Pre-delivery Inspection Checklist prior to delivery. Replacement Service Parts ! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with U.S. Coast Guard rules to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these rules.
MAINTENANCE • Present‑day marine equipment, such as your Mercury Marine power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but are more complex for the untrained mechanic. • Do not attempt any repairs that 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.
MAINTENANCE IMPORTANT: Refer to the Maintenance Charts (on following pages) for a complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner/operator, while others should be performed by an authorized Mercury Marine dealer. Before attempting maintenance or repair procedures not covered in this manual, Mercury Marine recommends purchasing a Mercury Marine Service Manual. Maintenance Charts NOTE: The following maintenance charts should be used as a guideline.
MAINTENANCE Interval Task Saltwater use: Every 50 hours of Power Package Exterior Surfaces ‑ operation or 60 days, whichever occurs Spray with rust preventive first Perform all 25 hour maintenance items Engine Oil and Filter ‑ Change Serpentine and Supercharger Belts ‑ Inspect condition and check tension Cooling System Hoses and Clamps ‑ Inspect for damage and deterioration.
MAINTENANCE Interval Task Perform all 25 hour and 50 hour maintenance items Supercharger ‑ Change oil Power Package Exterior Surfaces ‑ Clean and paint Engine Cylinder Compression ‑ Check Engine and Power Steering Oil Coolers ‑ Clean the seawater sections Positive Crankcase Ventilation (PCV) Every 100 hours of operation or once a Valve ‑ Replace year, whichever occurs first Flame Arrestor and Crankcase Ventilation Hose ‑ Inspect, clean or replace Engine Alignment ‑ Check Exhaust ‑ Check for signs of water
MAINTENANCE DRY SUMP SIX DRIVE MAINTENANCE SCHEDULE Interval Task Drive, Transom, and Propeller ‑ Inspect. Lower Gear Housing Oil ‑ Check level. Check prior to use and every 3 hours Power Trim Pump Oil ‑ Check level and of operation. for any water contamination. Replace if necessary. Anodes ‑ Inspect for erosion. Initial break‑in at 25 hours. Drive ‑ Change Oil and filter Tie‑bar Mounting Bracket Nuts ‑ Inspect and tighten to specifications as needed. Propeller Shaft ‑ Lubricate.
MAINTENANCE Interval Task Peform 25, 50, and 100 Hour Maintenance Items. Every 200 hours of operation or once Engine Alignment ‑ Check. a year, whichever occurs first. Propeller Shaft Bearing ‑ Inspect by measuring shaft deflection. Every 200 hours of operation1.
MAINTENANCE NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum (approximately 1/4 turn). Then turn the filter back clockwise until the oil filter seal makes light contact with the housing (approximately an 1/8 turn) to prevent unwanted oil leakage. Let the oil drain back into the system for 15 minutes prior to complete removal of the filter. a 10449 a - Crankcase oil filter 1. With the engine at normal operating temperature, remove the dipstick. 2.
MAINTENANCE 3. Insert the hose end of the crankcase oil pump into an appropriate container and pump out the oil until the crankcase is empty. a b 10460 a - Crankcase oil pump b - Crankcase oil pump hose 4. Remove the crankcase oil pump. 5. Place a container below the oil filter. 6. Remove the oil filter from the adaptor and discard the old oil filter and old sealing ring. 7. Coat the sealing ring on the new filter with new motor oil and install the new sealing ring and filter.
MAINTENANCE 8. Tighten the filter securely by hand. Do not overtighten. 25262 a a - Oil filter sealing ring 9. Remove the oil filler cap (port or starboard). 10. Add enough oil to bring the oil level into the "OK RANGE" on the dipstick; approximately 8 L (8.5 qts.). IMPORTANT: Engine crankcase capacity is 8 L (8.5 qts.). However, due to possible incomplete oil pump out, always use the dipstick to confirm proper oil level and prevent overfilling.
MAINTENANCE Tube Ref No. Description Kendall GT-1 SAE 20W50 Where Used Part No. Engine crankcase Obtain Locally 11. Start the engine and check for proper oil pressure. Allow the engine to idle for one minute and verify that no oil is leaking. 12. Shut off the engine. 13. Wait a few minutes for the engine oil to return to the crankcase and then check the oil level. If the oil level is low, add enough oil to bring it within the "OK RANGE" on the dipstick. Do not overfill.
MAINTENANCE 1. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up. 2. Open the water tap to supply enough flow to the sea pump so that suction created by the sea pump, does not collapse the supply hose. 3. Place the remote control in neutral position and start the engine. Operate the engine at idle speed, in neutral, until the engine reaches normal operating temperature. 4. Stop the engine and shut off the water.
MAINTENANCE 5. Remove the bilge plug. The oil drain hose is tethered to the plug. b c a d e 6150 a - Bilge drain plug b - Tether c - Oil drain plug d - Bilge drain flange e - Oil drain hose 6. Pull the oil drain hose through the bilge drain flange. 7. Place an appropriate container directly under the oil drain hose. 8. Using two wrenches, separate the oil drain hose plug from the oil drain hose and allow crankcase oil to drain until empty. 9. Place a container below the oil filter. 10.
MAINTENANCE 11. Coat the sealing ring on the new filter with new motor oil. Install the sealing ring and filter. Tighten the filter securely by hand. Do not overtighten. 25262 a a - Oil filter sealing ring 12. Using two wrenches, connect the oil drain hose plug to the oil drain hose and place it back into the boat. 13. Tighten the bilge drain plug. 14. Remove the oil filler cap (port or starboard). Add oil to bring the oil level into the "OK RANGE" on the dipstick; approximately 8 L (8.5 qts.).
MAINTENANCE IMPORTANT: Engine crankcase capacity is 8 L (8.5 qts.).However, always use the dipstick to confirm proper oil level. a 10152 a - Crankcase oil filler cap Tube Ref No. Description Kendall GT-1 SAE 20W50 Where Used Part No. Engine crankcase Obtain Locally 15. Turn on the water supply hose to the water pick‑up. 16. Start the engine and check for proper oil pressure. Allow the engine to idle for one minute and verify that no oil is leaking. 17.
MAINTENANCE 1. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up. 2. Open the water tap to supply enough flow to the sea pump so that suction created by the sea pump, does not collapse the supply hose. 3. Place the remote control in neutral position and start the engine. Operate the engine at idle speed, in neutral, until the engine reaches normal operating temperature. 4. Stop the engine and shut off the water. 5.
MAINTENANCE 11. Install the fill plug and torque to specifications. c b a 10567 a - Drain plug b - Sight‑glass c - Fill plug Description Nm Fill and drain plugs, supercharger gearcase 13.5 Tube Ref No. lb. in. lb. ft. 10 Description Where Used Part No. Castrol Syntec 5W-50 Synthetic Oil Supercharger gearcase Obtain Locally CHANGING ENGINE COOLANT Contact your authorized Mercury Marine dealer. CHANGING TRANSMISSION OIL 1. Place a suitable container (minimum 2.8 liter [3 qt.
MAINTENANCE 3. Remove the check valve assembly from the lower fitting and drain the transmission fluid. 4. Re‑install the check valve assembly and the upper and lower oil lines. 5. Fill the transmission through the dipstick tube with approximately 1.9 liters (2 qt.) of Type F or FA transmission fluid. 6. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up. 7.
MAINTENANCE 9. Stop the engine, shut off the water and check the transmission oil level with the dipstick. If additional oil is required, add it through the dipstick tube to bring the level up to the "FULL" mark. a b FULL c 6790 a - Dipstick b - "FULL" mark c - Dipstick tube Tube Ref No. Description Type F or FA Transmission Fluid Where Used Part No. Transmission Obtain Locally CHANGING DRIVE UNIT GEAR LUBE IMPORTANT: Use only Torco MTF Gear Oil in drive unit. 1.
MAINTENANCE 3. Fill the drive unit, through the fill/drain hole, with Torco MTF Gear Oil until an air‑free stream of lubricant flows from gear oil level hole of gear housing. a b 150 7429 a - Top vent screw b - Fill/drain screw Tube Ref. No. Description Where Used Part No. Torco MTF Gear Oil Drive unit 92‑849684‑1 4. Install vent screw and washer and remove tube from fill/drain hole. Quickly install sealing washer and fill/drain screw. Tighten securely. 5. Check oil level after first test trial.
MAINTENANCE CHANGING TRANSOM INPUT SHAFT BEARING HOUSING GEAR LUBE (DRIVE-LINE MODELS) 1. Remove 3 pipe plugs from the transom input shaft bearing housing. Allow gear lube to drain completely. a b 12868 c a - Top pipe plug (Fill) b - Middle pipe plug (Check level) c - Bottom pipe plug (Drain) Tube Ref No. Description Torco MTF Gear Oil Where Used Part No. Input shaft housing Obtain Locally 2. Re‑install bottom pipe plug. 3.
MAINTENANCE IMPORTANT: Re‑check the transom input shaft bearing housing gear lube level after the first use. The gear lube should be to the middle plug level. Gear lube level will rise and fall during drive unit operation due to gear lube expansion; check level when drive unit is cool and engine is shut down. Checking Fluid Levels CHECKING CRANKCASE OIL IMPORTANT: Check the engine crankcase oil at the intervals specified in the Maintenance Chart.
MAINTENANCE IMPORTANT: Do not overfill the crankcase with oil. b a OK E NG RA D AD 9987 a - Oil level dipstick b - Crankcase oil filler cap Tube Ref No. Description Kendall GT-1 SAE 20W50 Where Used Part No. Engine crankcase Obtain Locally CHECKING SUPERCHARGER GEARCASE OIL IMPORTANT: The oil level covers approximately half of the sight‑glass located in the front cover of the supercharger. If the oil level increases, decreases, or changes in color, expect a problem within the supercharger.
MAINTENANCE 3. Visually inspect the level and quality of the oil in the sight‑glass gage. The oil should be covering approximately half of the sight‑glass. a 7356 a - Sight‑glass CHECKING POWER STEERING PUMP FLUID IMPORTANT: If fluid is not visible in the reservoir, contact your authorized Mercury Marine dealer. 1. Stop the engine and turn the drive unit straight ahead. 2. Remove the fill cap/dipstick and observe the level. Ensure that the oil level is between the lower and upper marks.
MAINTENANCE 3. Add power steering fluid to bring the oil level up to the full mark on the cap/dipstick if required. a b c 21834 a - Reservoir cap b - Add fluid mark Tube Ref No. 114 Description Power Trim and Steering Fluid c - Full fluid mark Where Used Part No. Power steering pump 92-858074K0 1 4. Re‑install the cap/dipstick.
MAINTENANCE NOTE: Vapor or condensation can occur in the tube and is acceptable. a 16981 a - Fuel pump sight tube (routed from pump, past the intake manifold, and into the throttle body) CHECKING SEAWATER/FUEL PUMP OIL IMPORTANT: Change the oil at specified intervals. Refer to the Maintenance Chart for specific requirements. Use only High Performance Gear Lube in the pump. 1. Remove the fill screw and check the oil level.
MAINTENANCE 2. Ensure that the oil is level with the bottom of the fill hole. A low oil level indicates an internal problem, contact your authorized Mercury Marine dealer for appropriate service. Do not operate engine if this oil level is low. a 87 10073 a - Oil level screw Tube Ref No. 87 Description High Performance Gear Lubricant Where Used Part No. Seawater/fuel pump 92-802854A1 CHECKING ENGINE COOLANT ! WARNING Avoid personal injury and burns from hot engine coolant.
MAINTENANCE 1. Check the coolant level in the coolant reservoir when the engine is cold. Ensure that the coolant level is at the "COLD FULL" line on the front of the reservoir or to the top of the raised bosses on the back of the reservoir. Add specified coolant by turning the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.
MAINTENANCE CHECKING POWER TRIM PUMP FLUID IMPORTANT: Check oil level with the sterndrive unit in the full down position. Use only Mercury Quicksilver Power Trim and Steering Fluid, SAE 10W‑30, or 10W‑40 engine oil in power trim system. 1. Place the sterndrive unit in the full down/in position. 2. Wipe the fill/vent screw with a clean lint‑free cloth. 3. Re‑insert it back into the pump, but do not thread into the pump. 4. Remove the fill/vent screw and note the oil level.
MAINTENANCE 7. Reinstall the fill/vent screw by turning it all the way in, then loosen one and a half turns. ! CAUTION Fill/Vent screw must be backed out one and a half (1‑1/2) turns (after bottoming out) to vent pump reservoir. Failure to loosen the screw could damage the pump. CHECKING TRANSOM INPUT SHAFT BEARING HOUSING (DRIVE-LINE MODELS ONLY) 1. Remove the level indication (middle) pipe plug from the input shaft housing. Ensure that the gear lube level lies at the bottom of the hole.
MAINTENANCE 3. Install the pipe plugs into the input shaft housing and tighten securely. CHECKING DRIVE UNIT GEAR LUBE ! WARNING Avoid damage to the sterndrive assembly. Do not overfill the Dry Sump Six (VI) Drive. IMPORTANT: Fill the dry sump drive with TORCO MTF Gear Oil. NOTE: The Dry Sump Six Drive is filled with Torco MTF Gear Oil at the factory. Check the drive unit gear oil level before and after the first sea trial. 1. Remove the upper vent plug from the gearcase.
MAINTENANCE CHECKING TRANSMISSION FLUID LEVEL IMPORTANT: Place the boat on a trailer or in a sling with the engine level during the first fluid level check. Add fluid until the dipstick reads "FULL," then put the boat in the water and re‑check the fluid level. Mark the dipstick at the new fluid level and use this mark when checking the fluid with the boat in the water.
MAINTENANCE Tube Ref No. Description Type F or FA Transmission Fluid Where Used Part No. Transmission Obtain Locally 3. Do not use the transmission expansion bottle as a fluid reservoir. The bottle is only to be used for fluid expansion and overflow. a 7434 a - Transmission expansion bottle Lubrication Points Lubricate the following grease fittings with Optimal PD‑2: • Engine driveshaft universal joints and slip yoke (driveline models only). • Transmission shift lever ‑ Lubricate poppet ball.
MAINTENANCE Tube Ref. No. Description Where Used Optimal Longtime PD2 Engine drive shaft and Extreme Pressure transmission shift lever Grease Tube Ref No. Description Where Used MerCruiser 4-cycle 25W40 Engine Oil 79 Part No. 92‑848767 Part No. Shift cable and throttle 92-802837A1 linkage Lubricate pivot points with SAE 25W40 motor oil: • Shift cable. • Throttle linkage and cable ‑ Lubricate cable and swivels. 79 a 79 a 10305 a - Lubrication points Tube Ref No.
MAINTENANCE Propellers ! WARNING Avoid serious injury or death. Place the remote control in neutral and remove the ignition key from the switch before removing and/ or installing the propeller. Place a block of wood between the anti‑ventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating when removing the propeller nut. ! CAUTION Avoid propeller/sterndrive damage or injury. Periodically check propeller nut for tightness during boating season.
MAINTENANCE 3. Slide washer, continuity washer, and propeller off propeller shaft. NOTE: Some damaged propellers can be repaired. See your dealer. INSTALLATION 1. Apply a liberal coat of Optimal Longtime PD2 Extreme Pressure Grease to propeller shaft. 2. Align splines and install propeller, washer and propeller nut. 94 d a b c a - Propshaft b - Cleaver propeller Tube Ref. No. 5915 c - Flat washer d - Propeller nut Description Where Used Part No.
MAINTENANCE Flushing Cooling System ! WARNING Avoid possible death or serious injury. Always remove the propeller before flushing the cooling system. ! CAUTION Avoid engine damage from overheating. If the engine is operated above 1500 RPM during flushing, suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat. To prevent silt and salt build‑up in the cooling system, flush with freshwater. 1.
MAINTENANCE 1. Inspect seawater pump impeller if insufficient seawater flow occurs or if operating temperature exceeds normal range. a 8022 a - Seawater pump Cleaning the Seawater (Raw Water) Section of the Engine Oil, Power Steering, Fuel, and Transmission Coolers ! CAUTION Avoid seawater entry into the boat.
MAINTENANCE 3. Flush the passages with fresh water. 4. Inspect the gaskets for deterioration and replace if necessary. 5. Install the gaskets and end plates. Tighten the screws securely. POWER STEERING COOLER NOTE: The power steering cooler is located on the lower port side of the engine. 1. Loosen the water hose clamps and remove the hoses to inspect and clean the cooler.
MAINTENANCE 2. If the fuel hoses need to be removed from the cooler, have this service done by an authorized Mercury Marine dealer. a a 10262 a - Hose clamps to the fuel cooler 3. Re‑install the cooler and tighten the hose clamps securely. 4. Start the engine and inspect the cooling system for leaks. TRANSMISSION COOLER NOTE: The transmission cooler is located on the lower rear port side of the engine, next to the flywheel. 1.
MAINTENANCE 4. Drain the water from the cooler and hoses completely. 5. Install the hoses and clamps. Tighten the screws securely. Serpentine and Supercharger Drive Belts SERPENTINE DRIVE BELT ROUTING AND TENSION ! WARNING Avoid possible serious injury. Make sure that the engine is turned off and the ignition key is removed before inspecting belts. IMPORTANT: The drive belt must be routed as shown or damage may result. 1. Install the belt tension gauge onto the belt.
MAINTENANCE Description N lb. New Belt 489 110 Used Belt 400 90 2. Loosen the 5/8 in. locking nut on the adjusting screw. Leave the wrench on the adjustment nut. 3. Use a 5/16 in. socket and tighten the adjusting screw until the belt tension conforms to the correct setting on the gauge. 4. Hold the adjustment stud and tighten the 5/8 in locking nut. b a c 10287 a - Belt tensioner pulley b - Adjustment locking nut c - Adjustment screw 5. Remove the belt tension gauge from the belt. 6.
MAINTENANCE SUPERCHARGER DRIVE BELT ROUTING AND TENSION a b c d e 10289 a - Supercharger pulley b - Self adjusting belt tensioner c - Idler pulley d - Supercharger belt e - Crankshaft pulley The supercharger belt uses a self tensioner and does not require tension adjustment.
MAINTENANCE INSPECTING BELTS NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable. a b c 6164 a - Fraying b - Transverse cracks c - Longitudinal cracks The belt will have to be replaced for the following conditions: • Excessive wear • Cracks as explained previously • Fraying • Glazed surfaces Fuel Filters ! WARNING Avoid serious injury or death from a gasoline fire or explosion.
MAINTENANCE 1. Remove the water separating fuel filter (by turning counter‑clockwise) and the sealing ring from the water separating/fuel pressure regulator housing and discard. a b c 9973 a - Water separating/fuel pressure regulator housing b - Sealing ring c - Water separating fuel filter 2. Coat the sealing ring on the new filter with clean motor oil. IMPORTANT: Do not use a filter wrench when installing the water separating fuel filter. 3.
MAINTENANCE 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.
MAINTENANCE IMPORTANT: If a boat is equipped with stainless steel after planes, a large anode should be installed on each to handle the increased galvanic corrosion potential. Replace sacrificial anodes if eroded 50% or more. Mercury Marine recommends using anodes sold through Mercury Precision Parts only. Some other manufacturers of aluminum anodes use alloys that are insufficiently pure to adequately protect critical drive components for the duration of the anodes' expected life.
MAINTENANCE a. If anti‑fouling protection is required for boat hull or boat transom, copper or tin base paints can be used unless otherwise prohibited by law. b. If using copper or tin based anti‑fouling paints, avoid any electrical interconnection between the Mercury Marine Product, anodic blocks, and the paint by allowing a minimum of 40 mm (1.5 in.) unpainted area on the transom of the boat around these items.
MAINTENANCE 2. Painting Drive Unit or Transom Assembly • Paint the drive unit and transom assembly with a good quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct electrical current. Do not paint drain holes, anodes, or items specified by the boat manufacturer. 3.
MAINTENANCE ! WARNING Observe the following when jump starting, charging or handling a battery: • Do not use jumper cables and a booster battery to start engine. • When charging batteries, ensure battery compartment or area where batteries are located, is well‑vented. • Do not recharge a weak battery in the boat. • Remove battery and recharge in a ventilated area away from fuel vapors, sparks or flames. • Hydrogen gases that escape from the battery during charging are explosive.
MAINTENANCE Inspection and Maintenance Inspect the 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. 1. Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as required. 2. Check plug leads and electrical leads for damage. 3. Remove and inspect the propeller.
COLD WEATHER OR EXTENDED STORAGE Power Package Lay‑up In addition to the procedures listed in the Maintenance Chart of this manual, the following procedures should also be done when ever the power package will not be used for any extended period of time. The boat should be taken out of the water to complete the tasks. Consult your authorized Mercury Marine dealer. NOTE: It is recommended that the power package lay‑up be performed by an authorized Mercury Marine dealer.
COLD WEATHER OR EXTENDED STORAGE • 150 ml (5 fl oz) Fuel System Treatment and Stabilizer or 30 ml (1 fl oz) Fuel System Treatment and Stabilizer Concentrate. 5. Close the fuel shut off valve if equipped. 6. Disconnect the boat's fuel line from the mechanical fuel pump inlet. 7. Connect the remote outboard fuel tank supply line to the mechanical fuel pump inlet. a b c d 13030 a - Mechanical fuel pump b - Fuel inlet c - Primer bulb (optional) d - 23 L (6 U.S. gal) remote outboard fuel tank 8.
COLD WEATHER OR EXTENDED STORAGE 9. Start the engine. If the engine has trouble starting and the remote tank is equipped with a primer bulb, squeeze the primer bulb until firm and attempt starting again. 10. Once the engine starts, run the engine at idle for a short warm‑up period and then increase to 1300 RPM for a minimum of five minutes. IMPORTANT: Do not run the engine's fuel system dry of the fogging mixture in the 23 liter (6 U.S. gal) remote outboard fuel tank. 11.
COLD WEATHER OR EXTENDED STORAGE 19. Make sure the drainage passage near the anode in the anti‑cavitation plate is open and unobstructed. a 12893 a - Anti‑cavitation plate anode drain hole 20. The drive unit should be stored in the full down position. NOTICE The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position. 21.
COLD WEATHER OR EXTENDED STORAGE NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine. IMPORTANT: In the following draining procedure, the seawater inlet hose will be removed from the engine. If the boat is in the water during the following procedure, close the seawater inlet valve to avoid water entering the boat.
COLD WEATHER OR EXTENDED STORAGE a c d b e 16941 f 106
COLD WEATHER OR EXTENDED STORAGE a - Exhaust header balance rail plastic wing‑nut plugs (2, Starboard side) b - Fuel cooler plastic wing‑nut plug c - Sea water inlet hose ‑ remove from sea pump to drain d - Exhaust header distribution rail plastic wing‑nut plugs (2, Port side, one plug is hidden) e - Transmission cooler ‑ remove hose to drain f - Power steering cooler plastic wing‑nut plug 3. Use a stiff piece of wire to clean out any seawater debris from the drain holes.
COLD WEATHER OR EXTENDED STORAGE 4. Place the hose into the container of premixed antifreeze. The antifreeze mixture should be at the correct concentration level to protect the engine to the lowest temperature to which it will be exposed during cold weather or extended storage. a c b d 13180 f a - Seawater inlet valve b - Disconnect the hose at the valve and place into container of antifreeze c - Sea strainer e d - To the seawater pump e - Boat hull f - Seawater pickup 5.
COLD WEATHER OR EXTENDED STORAGE Power Package Recommissioning ! WARNING To prevent possible injury or damage to equipment, do not install the battery until all engine maintenance has been performed. 1. Ensure that all cooling system hoses are connected properly and hose clamps are tight, all removed drain plugs have been installed and are tight. ! CAUTION Reversing the battery cables or connection order will damage the electrical system.
COLD WEATHER OR EXTENDED STORAGE 3. Start the engine. If the engine does not start right away, crank the engine over for a maximum of 10 seconds at a time and stop. 4. Repeat the cranking procedure until the engine starts and runs smoothly. Observe the instrumentation to ensure all systems are functioning. 5. Inspect engine for fuel, oil, fluid, water and exhaust leaks. 6. Check the steering system. 7. Check shifting and throttle control for proper operation.
TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch "OFF". Switch to "ON" position. Remote control not in neutral position. Position control lever to neutral. Open 50 amp circuit breaker or 15 or 90 Check and reset circuit breaker or amp fuse circuit. replace fuse. Master or starter solenoid defective. Replace. Loose or dirty electrical connections or Check all electrical connections and damaged wiring, battery cable wires (especially battery cables).
TROUBLESHOOTING Engine Cranks But Will Not Start Possible Cause Remedy Improper starting procedure Read starting procedure Low battery voltage Charge the battery Empty fuel tank or fuel shut off valve closed Fill tank or open valve Faulty fuel pump, wiring, fuel pump fuse, 50 amp circuit breaker or a fuel pump relay Replace faulty component Faulty ignition system component Service ignition system Lanyard Stop Activated Reset Obstructed fuel filter Replace filters Stale or contaminated fuel
TROUBLESHOOTING Poor Performance Possible Cause Remedy Throttle not fully open. Inspect throttle cable and linkages for proper operation. Damaged or incorrect 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 or restricted. Change or clean flame arrestor. Stale or contaminated fuel.
TROUBLESHOOTING Engine Coolant Temperature Too High Possible Cause Remedy Seacock closed. Open. Serpentine belt loose or in poor condition. Replace or adjust belt. Recirculating pump defective. Replace. Seawater pickups obstructed. Inspect. Faulty thermostat. Replace. Oil cooler cores plugged with foreign material. Clean cooler cores. Heat exchanger restricted. Backflush. Faulty seawater pickup pump. Repair. Seawater discharge restricted or plugged. Clean exhaust elbows.
TROUBLESHOOTING Power Trim Does Not Operate (Motor Doesn't Run) Possible Cause Remedy Open fuse. Replace fuse. Check all associated electrical connections and wires (especially Loose or dirty electrical connections or battery cables). Clean and tighten faulty damaged wiring. connections. Repair or replace damaged wiring. Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery. Turn off non‑essential accessories.
TROUBLESHOOTING Electrical Analog Trim Gauge Malfunction Possible Cause Remedy Check wires between the sender and Gauge indicates off‑scale high with no the trim module. self‑test1. function. Replace defective trim sender. Gauge does not indicate properly but the self test1function works. Index the trim sender, test the trim sender circuit or replace defective trim sender.
TROUBLESHOOTING Seawater Pressure Is Below Specification Possible Cause Remedy Check if seacock is completely open. Check supply hoses for obstruction. Insufficient water supply. Check for external water pick‑up obstruction. Check for sea strainer obstruction. Check condition of sea pump.
OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Service Away From Home If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer.
OWNER SERVICE ASSISTANCE • • • Model and serial number of your outboard The name and address of your dealership Nature of problem Mercury Mercruiser Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone Fax (405) 743‑6566 (405) 743‑6570 Mercury MerCruiser 3003 N.
OWNER SERVICE ASSISTANCE Europe, Middle East, Africa Telephone Fax Marine Power - Europe, Inc. Parc Industriel de Petit-Rechain B-4800 (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Verviers, Belgium Mexico, Central America, South America, Caribbean Telephone Fax (954) 744‑3500 (954) 744‑3535 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 U.S.A.
ORDERING LITERATURE United States and Canada Before ordering literature, please have the following information about your power package available: Engine Model: Horsepower: Serial Number: Model year: 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 Fax Mail Mercury Marine Attn: Publications Department P.O.
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
