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Alpha One V8 Models - Brunswick Marine in EMEA

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1. 72 Alpha V8 CA75 Drive Unit and Transom Assembly 6 Lubricate gimbal bearing with 2 4 C Marine Lubricant 7 For propeller shaft lubrication see PROPELLER 8 Lubricate engine coupler splines thru grease fitting on coupler NOTE Later engines are equipped with a sealed engine cou pler and Perm a Lube U joints The sealed coupler and shaft splines can be lubricated without removing the drive unit The Perm a Lube U joints do not require lubrication The engine coupler is lubricated with Quicksilver Engine Coupler Spline Grease Contact your Authorized MerCruiser Dealer for this ser vice A CAUTION Speedometer water hose must be disconnected from drive unit BEFORE re moving drive unit Failure to do this will result in a broken fitting if drive unit is removed Alpha V8 73 CA76 Alpha V8 CA77 PROPELLER Remote Control must be in NEUTRAL and ignition key removed from switch before removing and or installing propeller Place a block of wood between anti ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when re moving propeller nut A CAUTION Periodically check propeller nut for tightness during boating season A mini mum of 55 lbs ft 75 N m torque is required CA78 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
2. Check all electrical con nections and wires espe cially battery cables Clean and tighten faulty connection Test and replace if bad 105 ENGINE WILL NOT START OR IS HARD TO START 106 Possible Cause Improper starting proce dure Empty fuel tank or fuel shutoff valve closed Faulty fuel pump Choke not operating prop erly Engine flooded Faulty ignition system com ponent Clogged fuel filters Stale or contaminated fuel Fuel line or tank vent line kinked or clogged Remedy Read starting procedure Fill tank or open valve Check sight tube for fuel Have Authorized Mer Cruiser Dealer replace pump if fuel is present Check that choke is closed when engine is cold Check that it opens when engine warms up Do not attempt to start en gine for at least 5 minutes Refer to STARTING PRO CEDURES Service ignition system Replace filters If contaminated drain tank Fill with fresh fuel Replace kinked lines or blow out lines with com pressed air to remove ob struction Alpha V8 ENGINE RUNS ROUGH MISSES AND OR BACKFIRES Possible Cause e Choke not operating prop erly Idle speed too low Faulty ignition system com ponent Clogged fuel filters Stale or contaminated fuel Kinked or clogged fuel line or fuel tank vent line Flame arrestor plugged with foreign material Remedy Check that choke is closed when engine is cold Check
3. telephone or rental charges of any type inconvenience or loss of time or income are the owner s responsibility e Use of other than Quicksilver replacement parts when making warranty repairs e Oils lubricants or fluids changed as a matter of normal mainte nance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for war ranty consideration e Participating in or preparing for racing or other competitive activ ity e Engine noise does not necessarily indicate a serious engine prob lem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty e Lower unit and or propeller damage caused by striking a sub merged object is considered a marine hazard e Water entering the engine via the carburetor or exhaust system or submersion Also water in the starter motor e Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commutator because of ex cess cranking Alpha V8 121 e Valve or valve seat grinding required because of wear e Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material block ing inlets or power package being mounted too high e Use of fuels and lubricants which are not suitable for use with or on the product e
4. Install new anodic plate and tighten screw securely Install plug 2 Anodic Plate serves as a sacrificial anode Unscrew both at taching screws and remove Install a new anodic plate and tighten securely 3 Block Is mounted to underside of gimbal housing and serves as a sacrificial anode Remove two bolts to change block 4 MerCathode System if so equipped Electrode assembly re places Anodic block System should be tested to ensure adequate output Test should be made where boat is moored using Quicksilver Refer ence Electrode and Test Meter Contact your Authorized MerCruiser Dealer to arrange for this test 5 Anode Kit if so equipped Mounted to boat transom Acts as a sacrificial anode Replace as required Alpha V8 87 CA162 88 Alpha V8 CA163 1 Trim Cylinder Anodes are mounted on each trim cylinder To replace the trim cylinder anodes A Remove two screws from each anode B Install new anodes and tighten securely CA164 2 Propeller 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 To re place the propeller anode A Remove propeller B Remove two screws from anode C Install new anode and tighten securely D Reinstall propeller Alpha V8 89 CA168 In addition to the corrosion protection devices the following steps should be taken to inhib
5. Thermostat 160 F 71 C 1 Power Rated in Accordance with NMMA procedure using Marine Engine Rating Code SAE J1228 Technically Identical to ISO 3046 and ICOMIA 28 83 48 Alpha V8 CA266 ENGINE SPECIFICATIONS Displacement 350 C 1 D 5 7 L Maximum RPM 4200 4600 4400 4800 W O T RPM RPM i 650 700 Idle RPM in Forward Gear Idle RPM in Neutral 2 eee 650 RPM Fuel Pump Pressure 3 7 psi 21 48 kPa Our osetia eng 30 55 psi 207 379 kPa RPM Min Oil Pressure Idle 4 psi 28 kPa Thermostat 160 F 71 C 1 Power Rated in Accordance with NMMA procedure using Marine Engine Rating Code SAE J1228 Technically Identical to ISO 3046 and ICOMIA 28 83 2 A special procedure must be followed for adjusting Idle RPM in Forward Gear Consult your Authorized MerCruiser Dealer before adjusting Idle Speed Alpha V8 49 CA268 TUNE UP SPECIFICATIONS AC MR48T or Spark Plug Type Champion RV15YC4 or NGK BR6FS Spark Plug Gap 035 in 9mm Timing Idle RPM 8 BTDC Firing Order 1 8 4 3 6 5 7 2 Electrical System 12 Volt Negative Ground Alternator Rating 55 Amps Recommended Minimum 375 cca 475 mca Battery Rating or 90 Ah AC MR43T or Spark Plug Type Champion RV15YC4 or NGK BR6FS Spark Plug Gap 035 in 9mm Timing Idle RPM 8 BTDC 10 BTDC 1 Firing Order Firing Order 1 18436572 Electrical System 12 Volt Negative Ground Alternator Rating 55 Amps Recommended Minimum 375 cca
6. system with a mixture of antifreeze and tap water mixed to manufac turer s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage Using a new gasket reinstall thermostat and cover Tighten cover bolts securely Alpha V8 99 CA111 71332 EEUU a Alpha V8 CA112 Draining Closed Cooling Coolant Models IMPORTANT Drain seawater section of closed cooling sys tem only ACAUTION 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 tow from the drain holes or removed hoses IMPORTANT Boat must be as level as possible to ensure com plete draining of cooling system CAUTION Seavvater section of cooling system MUST BE COMPLETELY drained for vvin ter storage or immediately after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freeze and or corrosion damage to engine IMPORTANT Closed cooling section must be kept filled year round with recommended coolant If engine will be ex posed to freezing temperatures make sure closed cooling sec tion is filled with an ethylene glycol antifreeze and water Solu tion properly mixed to protect engine to lowest temperature to which it will be exposed IMPORTANT Do not use Propylene Glycol Antifreeze in the closed
7. that it opens when engine warms up Check idle speed and ad just if necessary Service ignition system Replace filters If contaminated drain tank Fill with fresh fuel Replace kinked line or blow out line with compressed air to remove obstruction Clean flame arrestor POOR PERFORMANCE Possible Cause Throttle not fully open Damaged or improper pro peller Excessive bilge water Boat overloaded or load improperly distributed Boat bottom fouled or dam aged Flame arrestor dirty Alpha V8 Remedy Inspect throttle cable and linkages for proper opera tion Replace Drain and check for cause of entry Reduce load or redistribute load more evenly Clean or repair as neces sary Clean flame arrestor 107 EXCESSIVE ENGINE TEMPERATURE Possible Cause Seacock closed Drive belt loose or in poor condition Seawater structed pickups ob Faulty thermostat Coolant level low in closed section If cooling Equipped Heat exchanger cores plugged with foreign mate rial If Equipped Loss of pressure in closed cooling section If Equipped Closed cooling dirty If Equipped section Faulty seawater pickup pump Seawater discharge re stricted or plugged Remedy Open Replace and or adjust belt Remove obstruction Replace Check for cause of low coolant level and repair Fill system with proper coolant solution Clean he
8. DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIM ITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLU SION OR LIMITATION OF INCIDENTAL OR CONSEQUEN TIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLU SION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state or country to country Alpha V8 VI Other details of this warranty are contained in paragraphs IV V and VI of the United States and Canada Product Warranty and paragraphs III IV V and VI of the International Product Warranty contained in this manual which paragraphs are in corporated herein by reference Mercury Marine products are built using the most advanced corro sion protection process available This manufacturing system com plemented by dealer and customer participation in an anti corrosion preventive maintenance program provides protection against repair costs incurred by the effects of marine corrosion Owner s Responsibility Protection against certain types of corrosion damage must be pro vided by using such systems as the Quicksilver MerCathode System and or Galvanic Isolator These certain types of corrosion damage are damage due to stray electrical currents on shore power con nections
9. Electrical ignition and fuel system components on MerCruiser gasoline pow er packages are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize risks of fire or explosion Use of replacement electrical ignition or fuel system components which do not comply to these rules and regulations could result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel systems it is extremely impor tant that all components are properly installed and tightened If not any elec trical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks if they existed Marine engines are expected to operate at or near full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard auto motive engine For example one of the most important and probably the least sus pected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket uses special materials to resist corrosive action Since marine engines must be capable of running at or near maxi mum RPM much of the time special valve springs valve lifters pis
10. POWER PACKAGE LAY UP IMPORTANT This service should be performed by an Autho rized MerCruiser Dealer A CAUTION DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be damaged and subsequent overheating damage to en gine or stern drive unit may result IMPORTANT Before starting engine a water source must be attached to the seawater intake openings in gear housing Fol low all warnings and flushing attachments procedures stated in FLUSHING COOLING SYSTEM 1 Run engine sufficiently to bring it up to normal operating tempera ture Shut off engine and change oil and oil filter 2 Flush cooling system Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation to prevent a potential fire hazard 94 Alpha V8 3 Remove flame arrestor and restart engine While operating en gine at fast idle 1000 1500 RPM fog internal surfaces of engine by squirting approximately 8 ounces 227 g of Quicksilver Storage Seal or if not available SAE 20W motor oil into carburetor bores Stall engine by squirting last 2 ounces 57 g of Storage Seal or oil rapidly into carburetor Turn ignition key to OFF position 4 Fill fuel tank s with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer and Condi tioner to treat gasoline Follow instructions on container 5 lfboatisto be plac
11. Speedometer Indicates boat speed 2 Tachometer Indicates engine RPM 3 Oil Pressure Gauge Indicates engine oil pressure 4 Battery Meter Indicates battery voltage 5 Water Temperature Gauge Indicates engine operating tempera ture 6 Fuel Gauge Indicates fuel tank volume 7 Power Trim Gauge Indicates drive unit angle trim up out and down in 8 Hour Meter Records engine running time 9 Bilge Blower Switch Must be operated for five minutes before starting engine to ventilate bilge 10 Ignition Switch Allows operator to start and stop engine Alpha V8 23 CA244 24 Alpha V8 CA248 AUDIO WARNING SYSTEM Your MerCruiser power package may be equipped with an Audio Warning System 1 The audio warning system buzzer will sound if one of the following occur A Insufficient Oil Pressure B Excessive Engine Temperature C Insufficient Drive Lubricant NOTE Toprovide atest of the system the audio warning buzzer will sound when the ignition switch is first turned to the run position prior to cranking the engine Once the engine starts the buzzer should stop 44 CAUTION Avoid engine damage Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occured When the buzzer sounds with the engine running stop engine im mediately Investigate ca
12. THE DEALER S FACILITIES OUR SERVICE CENTERS AND FACTORY DO NOT HAVE FACILITIES TO SERVICE OR RE PAIR YOUR PRODUCT 126 Alpha V8 SERVICE CENTERS UNITED STATES MerCruiser 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6566 Fax 405 743 6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga Ontario L4Y 2C2 Canada Telephone 905 270 4481 Fax 905 270 4510 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 e 32 e 11 Fax 32 87 31 19 65 Alpha V8 127 AUSTRALIA PACIFIC Marine Power International Pry Ltd P B 1420 132 140 Frankston Road Dandenong Victoria 3164 Australia Telephone 61 3 791 5822 Fax 61 3 791 5880 ASIA Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 128 Alpha V8 CUSTOMER SERVICE LITERATURE English language publications are available from Mercur
13. are tight ACAUTION When Installing battery be sure to connect NEGATIVE battery cable to NEGATIVE battery terminal and POSITIVE battery cable to POSITIVE battery terminal If battery cables are reversed electrical system damage will result 2 Install fully charged battery Clean battery cable clamps and ter minals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat terminal connections with a battery terminal anti corrosion agent 4 Perform all checks in OPERATION CHART in the BEFORE STARTING column ACAUTION 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 opera tion 8 Check fuel pump sight tube for evidence of fuel indicating a rup tured fuel pump diaphragm 104 Alpha V8 CB215 TROUBLESHOOTING STARTER MOTOR WILL NOT CRANK ENGINE OR CRANKS SLOW Possible Cause Battery switch turned off Remote control not in neu tral position Open circuit breaker or blown fuse Loose or dirty electrical connections or damaged wiring Bad battery Alpha V8 Remedy Turn switch on Position control lever in neutral Check and reset circuit breaker or replace fuse
14. cooling section of the engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from both exhaust elbows 3 Remove drain plug from heat exchanger 4 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained Alpha V8 101 CA113 102 Alpha V8 CA114 Loosen hose clamps and remove the follovving hoses 5 From seawater pickup pump inlet 6 From power steering fluid cooler 7 Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump DO NOT allow engine to start 8 Make sure gear housing water drain holes and speedometer pitot hole are open and unobstructed After seawater section of cooling system has been drained com pletely coat threads of drain plugs with Quicksilver Perfect Seal and reinstall Reconnect hoses and tighten all hose clamps securely After draining perform all checks inspections lubrication and fluid changes outlined in MAINTENANCE CHART under AT LEAST ONCE A YEAR Store boat with drive unit in full down position Alpha V8 103 BATTERY WINTER STORAGE Follow battery manufacturer s instructions for storage POWER PACKAGE RECOMMISSIONING 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
15. counterclockwise to remove nut 3 Slide tab washer spline washer continuity washer propeller and thrust hub off propeller shaft CA79 Repair Some damaged propellers can be repaired See your dealer Alpha V8 75 Alpha V8 CA81 I 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 5 Slide thrust hub into propeller hub with stepped side toward pro peller hub 6 Align splines and place propeller and thrust hub on propeller shaft 7 Place continuity washer spline washer and tab washer onto shaft 8 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 Bend tabs back down into spline washer Check propeller at least after 20 hours of operation Do not operate with loose propeller Alpha V8 77 CA195 gt 2 70565 70564 78 Alpha V8 FLUSHING COOLING SYSTEM When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possible injury remove propeller CAUTION Do not ru
16. for alkalinity Heat Exchanger Clean seawater section Carburetor Inspect and adjust Drive Unit Bellows and Clamps Inspect Closed Cooling Coolant 58 Alpha V8 CA175 Alpha V8 THIS PAGE IS BLANR CA53 60 Alpha V8 CHECKING FLUID LEVELS Checking Crankcase Oil Stop engine Allow approximately five minutes for oil to drain into oil pan Boat must be at rest in water 1 Remove dipstick Wipe clean and reinstall fully into dipstick tube 2 Remove dipstick and observe oil level Oil level must be between FULL and ADD If oil level is below ADD 3 Remove oil filler cap Add specified oil to bring level up to but not over FULL mark on dipstick IMPORTANT Do not overfill crankcase oil CA55 Checking Power Steering Pump Fluid Stop engine and position drive unit Straight back 4 Remove FILLCAP DIPSTICK and observe level Add specified fluid if required Reinstall FILLCAP DIPSTICK IMPORTANT If fluid is not visible in pump contact your Autho rized MerCruiser Dealer CA56 Checking Engine Coolant Closed Cooled Models Only Do not remove coolant cap when engine is hot Coolant may discharge violent ly 5 Check coolant level in coolant recovery bottle Add specified cool ant as required 6 Periodically remove cap from coolant reservoir to ensure that coolant recovery system is functioning properly Coolant level must be at top of reservoir filler neck If coolant is low inspect gasket in c
17. if you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a prob lem It may be a very simple adjustment to correct the problem e Do not telephone the dealer service office or the factory to at tempt for them to diagnose a problem or request the repair proce dure It is difficult for them to diagnose a problem over the tele phone A doctor can t and vvon t diagnose your illness by telephone he must examine you personally just as a mechanic must examine your power package e Your Authorized Dealer is there to service your power package He has qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on your power package Have him winterize it in the fall and service it before the boating season This will reduce the possibility of any problems occurring during your boating season when you want trouble free boating pleasure Alpha V8 19 CA24 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 mini mum oil consumption and maximum engine performance Dur ing 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 in
18. 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 14 Alpha V8 Use extreme caution when operating in shallow water or where un derwater objects are known to be present Use extreme care to pre vent striking submerged object while operating in REVERSE No im pact protection is provided in REVERSE If drive unit should strike a submerged object stop engine as soon as possible and inspect drive unit for damage If damage is present or suspected boat should be taken to an Authorized MerCruiser Dealer for thorough inspection and necessary repair Operating a damaged drive unit could cause additional damage to other parts of drive unit or could affect control of boat If continued running is nec essary do so at greatly reduced speeds IMPORTANT Impact protection system cannot be designed to ensure total protection from impact damage under all condi tions ATTENTION REQUIRED AFTER SUBMERSION e Before recovery contact a MerCruiser Dealer e After recovery immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to power package CA19 TRAILERING BOAT Boat can be trailered with drive unit in up or down position Ade quate road clearanc
19. maintenance The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strong ly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power pack age and all related accessories before the boat is used LANYARD STOP SWITCH WARNING The following advantages and disadvantages of a Lanyard Stop Switch should be considered before electing to use or not to use such a switch ADVANTAGES The purpose of a Lanyard Stop Switch is to stop the engine when the operator leaves the control station either accidentally by falling into the boat or by falling or being ejected overboard This is most likely in certain types of boats such as low sided bass boats and high performance boats It is also likely as a result of poor operating practices such as sitting on the back of the seat at planing speeds standing at planing speeds operating at high speeds in shallow or obstacle in fested waters drinking and driving or daring high speed boat maneuvers DISADVANTAGES Inadvertent activation of the switch is also a possibility This could cause any or all of the following poten tially hazardous situations e Loss of balance and falling forward of unstable boat passengers a particular concern in bow rider type boats Loss of power and directional control in heavy seas str
20. mecha nism from the control handle The throttle only button can be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control han dle cover must be removed to adjust This will help prevent Creep of the remote control handle Turn screw Clockwise to increase ten sion and Counterclockwise to decrease tension Adjust to tension desired 4 Power Trim Switch See Power Trim section for detailed power trim operating procedures 5 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 6 Power Trim Adjustment Switch s Used on Three Button Trim Control Only See Power Trim section for detailed power trim operating procedures Alpha V8 31 CB185 Alpha V8 REMOTE CONTROLS TWO LEVER 1 Shift Lever shifts unit into gear with full lever movement Move lever forward to shift to FORWARD gear Move lever backward to shift to REVERSE gear Lever in full vertical position shifts to NEU TRAL ACAUTION Never shift unit into or out of gear unless throttle lever is a idle RPM 2 Throttle Lever allows engine RPM to be increased or decreased 3 FRICTION Screw adjusts control
21. observed Check with authorities in regard to local and other governmental boating regulations and restrictions In addition here are suggestions of safety equipment to carry when boating e Approved life jackets for each person on board e Approved throwable personal flotation device e Approved fire extinguisher s paddle or oar e Signal devices flashlight rockets or flares flag and whistle or horn e Spare propeller e Tools for necessary minor repairs first aid kit and book e Anchor and extra anchor line waterproof storage containers e Manual bilge pump and extra drain plugs compass and map or chart of area e Spare operating equipment batteries bulbs fuses etc e Transistor radio and drinking water 8 Alpha V8 CA7 CONDITIONS AFFECTING OPERATION WEIGHT DISTRIBUTION Positioning of weight passengers and gear inside the boat has the following effects Shifting weight to rear stern will e Generally increases speed and engine RPM e At extremes can cause boat to porpoise e Causes bow to bounce in choppy water e Increases danger of following wave splashing into boat when coming off plane Shifting weight to front bow will e Improve ease of planing e Improve rough water ride e At extremes can cause boat to veer back and forth bow steer CA8 BOTTOM OF BOAT To maintain maximum speed the following conditions of the boat bot tom should be observed A Clean free of barn
22. specific boating requirements Consult your Authorized MerCruiser Dealer for recommendations HOW ELEVATION AND CLIMATE AFFECT PER FORMANCE Elevation has avery noticeable effect on the wide open throttle pow er of an engine Since air containing oxygen gets thinner as eleva tion increases the engine begins to starve for air Humidity baromet ric pressure and temperature do have a noticeable effect on the density of air Heat and humidity thin the air This condition can be come particularly annoying when the propeller testing was done on acool dry day Then later ona hot sultry day the boat doesn t seem to have the same performance Alpha V8 11 Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists In some cases a gear ratio change to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the engine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an en gine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propel ler will in
23. 475 mca Battery Rating or 90 Ah 1 A special procedure must be followed to check or adjust Timing Consult your Authorized MerCruiser Dealer before attempting this procedure 50 Alpha V8 CA133 CAPACITIES Crankcase Oil Approx 5 Approx 5 5 Capacity U S Quarts U S Quarts w New Filter 1 4 7 L 5 2 L Drive Unit Oil Approximately 39 2 fl oz Capacity 1 1160ml Drive Unit Oil Capacity Approximately 64 fl oz w Reservoir 1892ml Seawater Cooling System 2 15 U S Quarts 14 1 L Closed Cooling System 20 U S Quarts 19 3 L 1 Always use dipstick to determine exact quantity of oil required 2 Seawater Cooling System capacity information is for winterization use only Crankcase Oil Capacity Approx 5 5 U S Quarts 5 2 L w New Filter 1 Drive Unit Oil Approximately 39 2 fl oz Capacity 1 1160ml Drive Unit Oil Capacity w Reservoir Seawater Cooling System 2 15 U S Quarts 14 1L Closed Cooling System 20 U S Quarts 19 3L 1 Always use dipstick to determine exact quantity of oil required 2 Seawater Cooling System capacity information is for winterization use only Approximately 64 fl oz 1892ml Alpha V8 51 CA47 MAINTENANCE A WARNING Always disconnect battery cables from battery before working around electri cal system components to prevent injury to yourself or damage to electrical system IMPORTANT Refer to MAINTENANCE CHART for complete listing of all scheduled maintena
24. 955A12 15 92 817529A12 16 92 17885A12 17 92 815869A12 Alpha V8 14957 807252 2 27 33179 2 27 53045 1 55 805269 1 131 DRIVE PARTS Fat IL Vent Screw O ring 12 19183 132 Alpha V8 C0172 LITERATURE ORDER FORM Model Horsepower Serial Number Year Service Manual shows the complete assembly and disassembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Part Number Qty Total Official Use Only Price Service Manual 30 00 Drive El Service Manual 30 00 Remote Control Ll Service Manual Engine El Parts Manual 4 95 Engine Only Ll Parts Manual Drive Only Ll Operation and Main Ll Sub Total Ship Hand tenance Manual must be collected from customers in all states except AK AZ DE HI ID IA ME MI MT NV NH NY OR VT WV WY Orders Totaling up to 20 00 add 3 00 20 01 50 00 add 4 00 50 01 up Free Alpha V8 133 Please Return with Payment to Mercury Marine Attn Publications Dept P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print or Type This is your Shipping Label Name Address City State Zip Method of Payment No Cash or C O D Personal Check _ Cashiers Check Money Order Vi
25. Alpha V8 123 Q GUARD PRODUCT PROTECTION PLAN UNITED STATES and CANADA ONLY Certain performance products triple engine installations and com mercial applications are excluded The Mercury Marine Q Guard Product Protection Plan provides cov erage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q Guard Product Protection Plan is the only Factory Plan available for your engine Two three or four year term plans can be purchased up to 180 days after the original engine purchase date See your participating MerCruiser dealer for complete program de tails OWNER SERVICE ASSISTANCE LOCAL REPAIR SERVICE Always return your MerCruiser powered boat to your local Autho rized Dealer should the need for service arise Only he has the facto ry trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mer cury Marine specifically for MerCruiser stern drives and inboards SERVICE AWAY FROM HOME If you are away from your local dealer and the need arises for service contact the nearest Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the U
26. LIED WARRANTIES ARE LIM ITED TO THE LIFE OF THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state Alpha V8 115 MERCRUISER INTERNATIONAL WARRANTY GASOLINE ENGINES OUTSIDE THE UNITED STATES AND CANADA 116 We warrant each new production not those made for high per formance purposes MerCruiser Stern Drive Power Package Inboard Engine and accessories attached thereto hereafter referred to as Product to be free from defects in material and workmanship but only when the consumer sale is made in the country to which distribution is authorized by us This warranty shall remain in effect for a period of one 1 year from date of purchase Since this warranty applies to defects in material and workman ship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of mainte nance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other competitive activity or operating with a racin
27. ND CANADA ONLY e Itis important that your selling dealer fills out the Warranty Regis tration Card completely and mails it to the factory immediately upon sale of the new product e It identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address The dealer also certifies that you are the original purchaser and user of the product e Upon receipt of the Warranty Registration Card at the factory you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be required War ranty claims will not be accepted without presentation of this card e Atemporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service dur ing this period present the temporary registration card to the deal er He will attach it to your warranty claim form e Because of your selling dealer s continuing personal interest in your satisfaction the product should be returned to him for war ranty service e If your plastic card is not received within 30 days from date of new product sale please contact your selling dealer e The product warranty is not effecti
28. OPERATION amp MAINTENANCE MANUAL Alpha One V8 Models 1994 Brunswick Corporation 90 821051951 1294 CA1 IDENTIFICATION RECORD Please Record the Following Information Engine Model and Horsepower 2 Engine Serial Number 3 Transom Assembly Serial Number 4 Stern Drive Unit Serial Number and Gear Ratio 5 Propeller Number 6 Propeller Pitch 7 Hull Identification Number HIN Purchase Date 8 Boat Manufacturer Boat Model Length SERIAL NUMBERS The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 1993 Brunswick Corporation The following are registered trademarks of Brunswick Corporation Auto blend Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mercury Marine Quicksilver Ride Guide and Thruster CA2 MERCURY MARINE A BRUNSWICK COMPANY FOND OU LAC WI U S A WCW STLITRE ENGINE ROTATION 280 CID MAX WOT RPM DI
29. Our limited warranty does not apply to any damage to our prod ucts caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered un der warranty if they otherwise meet the terms of the limited war ranty for that product 122 Alpha V8 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 e The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 e Anew Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file e There is no charge for this service Outside the United States and Canada please contact the dis tributor in your country or the Marine Power International Ser vice Center closest to you for the transferable warranty proce dure that would apply to you
30. R SERVICE CENTER Provide the following important information e Your name address and telephone number e The model and serial number s e Your dealer s name and location e Date of purchase e Present hours of operation e Details of problem or complaint e Boat make and size Alpha V8 125 e Propeller pitch and or part number e Normal use and approximate gross load Please bear in mind that Service Centers resolve all problems through the dealership using the dealer s facilities equipment and personnel This is the reason we request you use the preceding steps in sequence when you have a problem or complaint Our expe rience has shown that this is the most expedient and successful pro cedure to follow to ensure satisfaction to our customers FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RE SOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT United States MERCRUISER 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 Canada Contact Nearest Regional Service Center Other Countries Contact the Nearest Marine Power International Service Center The customer service representatives will review all the facts in volved If they feel some further action can be taken they will advise the Service Center They will contact your dealer to bring the problem to a satisfactory conclusion ALL SERVICE WORK IS DONE BY THE AUTHORIZED DEALER USING
31. SPLACEMENT RATED HORSEPOWER IGNITION TIMING CYL FIRING ORDER SPARK PLUGS AC MRAIT For tual and all requirements refer to Operation 8 Maintenance Merual ABC12345Z123 19 48 12345 Alpha V8 1 CA273 TABLE OF CONTENTS Welcome carita tas tok ek iaia arta Ga Read This Manual Thoroughly eee eee Lanyard Stop Switch a i a EE et EE ade ae eta Boating Safety And Seamanship e Water Wisdom Conditions Affecting Operation Weight Distribution zel ia vee press i ep Roa es Bottom OMBOS etc gated aie la ini A per ea ae duane gen sneak aco oe Ventilation o Propeller Selection yi ea hace on ees a ae tere i How Elevation And Climate Affect Performance Important Information ssns carne oe darda tab mea pues Operation And Maintenance Freezing Temperature Operation Drive Unit Impact Protection Attention Required After Submersion Trailering Boats ssi ente Era Soa Launching And Boat Operation Care Stolen Power Package Replacement Service Parts Do it yourself Maintenance Suggestions 20 hour Break in Period After Break in Period 20 hour Checkup eta ts bots rea oer ies Soe Operation siculo oe ee Wael ee ee ee PA In
32. acles and marine growth B Free of distortion nearly flat where it contacts the water C Straight and smooth fore and aft Marine vegetation may accumulate when boat is docked This growth must be removed before operation it may clog water inlets and cause engine to overheat Alpha V8 9 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 hous ing or propeller Common causes of cavitation are A Weeds or other debris snagged on propeller or gear housing B Bent propeller blade or damaged gear housing skeg C Raised burrs or sharp edges on propeller or gear housing CA10 VENTILATION Ventilation is caused by surface air or exhaust gases which are intro duced around the propeller resulting in propeller speedup and a re duction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ring C A damaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing D Drive unit installed too high on transom CA250 PROPELLER SELECTION Select a propeller that will allow the power package to operate at or near the top of the recommender full throttle RPM range with a nor mal lo
33. ad Maximum engine speed RPM for propeller selection ex ists when boat speed is maximum and trim is minimum for the speed High RPM caused by an excessive trim angle should not be used in determining correct propeller Normally there is a 300 to 500 RPM change between propeller pitches Full throttle RPM range is listed in SPECIFICATIONS If full throttle operation is below the recommended range shown in SPECIFICATIONS the propeller must be changed to prevent loss of performance and possible engine damage 10 Alpha V8 IMPORTANT The 350 Magnum engine is equipped with an RPM rev limiter that is set at 4900 RPM This limiter is designed to help prevent damage from engine over speed When the engine reaches 4900 RPM ignition spark is turned off Once the RPM drops below 4600 complete ignition spark resumes After initial propeller installation the following common problems may require that the propeller be changed to a lower pitch e Warmer weather and greater humidity cause an RPM loss e Operating in a higher elevation causes an RPM loss e Operating with a damaged propeller or dirty boat bottom or gear housing causes an RPM loss e Operating with an increased load additional passengers pulling skiers etc For better acceleration such as is needed for water skiing use next lower pitch propeller however do not operate at full throttle when us ing ski propeller but not pulling skiers Propellers are available for
34. and or drive unit to overheat CAUTION Watch temperature gauge on dash to ensure that engine does not overheat To prevent silt and or salt buildup in cooling system flush with fresh water at specified intervals If flushing cooling system with boat in water raise drive unit to TRAIL ER position install flushing attachment and lower drive unit to full down in position IMPORTANT Water must be supplied to both the drive unit and engine during flushing procedure This ensures that drive unit does not overheat while flushing engine 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 Disconnect water inlet hose from aft end of seawater pickup pump Using appropriate connector connect another hose between connector and water tap 4 With drive unit in normal operating position start water flow to both flush devices Place remote control in NEUTRAL idle speed position and start en gine Operate engine at idle speed in NEUTRAL for about 10 min utes or until discharge water is clear Stop engine Shut off water re move flushing connector from pump inlet and reconnect water inlet hose Tighten hose clamp securely Alpha V8 81 CA246 82 Alpha V8 CA218 CLEANING SEAWATER SECTION OF HEAT EXCHANGER CLOSED COOLING COOLANT MODELS ONLY Seawater section of heat exchanger sh
35. ap for damage and replace if necessary To have cap tested contact your Authorized MerCruiser Dealer Inspect coolant recovery system for leaks Alpha V8 61 CA57 62 Alpha V8 CB40 Checking Drive Unit Oil 1 Check gear lube monitor oil level keep oil level at or near Fill line Check for water at bottom of monitor and or if oil appears a milk tan contact your Authorized MerCruiser Dealer immediately both conditions indicate a water leak somewhere in the drive unit See Filling Reservoir IMPORTANT If more than 2 fl oz 59ml of Quicksilver High Performance Gear Lube is required to fill monitor a seal may be leaking Damage to drive unit may occur due to lack of lubrica tion Contact your Authorized MerCruiser Dealer for service CB41 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 and discarded from filler neck B Fill cap is vented frequently check that vent is open and unre stricted Alpha V8 63 CA62 64 Alpha V8 CA63 CHANGING FLUIDS See MAINTENANCE CHART for lubricant change frequency Lubri cant should be changed before placing boat in storage Power T
36. aser s Copy of the Warranty Registration Card or the plastic Warranty Registra tion Card to the dealer authorized to service the Product If ei ther of these items is not available purchaser must provide a copy of the original Bill of Sale Sales Contract for the Product to be serviced Warranty claims will not be accepted until ade quate proof of purchase is presented by purchaser and date of purchase has been substantiated Our obligation under this Warranty shall be limited to repairing a defective part or AT OUR OPTION refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obli gation to modify any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIM ITED TO THE LIFE OF THIS WARRANTY SOME COUN TRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMI TATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other legal rights which vary from country to country MARINE POWER INTERNATIONAL Division o
37. at exchanger Check for leaks Clean in spect and test pressure cap Clean Repair Clean exhaust elbows INSUFFICIENT ENGINE TEMPERATURE Possible Cause Faulty Thermostat Remedy Replace Alpha V8 LOW ENGINE OIL PRESSURE Possible Cause Insufficient oil in crank case Excessive oil in crankcase causing it to become aerated Diluted or improper viscosity oil Possible Cause Excessive current draw from battery Loose or dirty electrical connections or damaged wiring Alternator drive belt loose or in poor condition Unacceptable condition battery Alpha V8 Remedy Check and add oil Check and remove re quired amount of oil Check for cause of excessive oil improper filling bad fuel pump etc Change oil and oil filter us ing correct grade and vis cosity oil Determine cause for dilution excessive id ling faulty fuel pump etc BATTERY WILL NOT COME UP ON CHARGE Remedy Turn off non essential ac cessories Check all associated elec trical connections and wires especially battery cables Clean and tighten faulty connections Repair or replace damaged wiring Replace and or adjust Test battery 109 REMOTE CONTROL OPERATES HARD BINDS HAS EXCESSIVE FREE PLAY OR MAKES UNUSUAL SOUNDS Possible Cause Insufficient lubrication on shift and throttle linkage fasteners Loose or missing shift and throttle linkage fa
38. ator Drive Belt Inspect drive belt for excessive wear or damage 2 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 18mm 3 Power Steering Pump Drive Belt Inspect drive belt for excessive wear or damage 4 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 5 Seawater Pickup Pump Drive Belt Inspect drive belt for exces sive wear or damage 6 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm Alpha V8 85 CA204 Alpha V8 86 CORROSION AND CORROSION PROTECTION Whenever two or more dissimilar metals like those found on the stern drive are submerged in a conductive solution such as saltwa ter polluted water or water with a high mineral content a chemical reaction takes place causing electrical current to flow between met als The electrical current flow causes the metal that is most chemi cally active or anodic to erode This is known as galvanic corrosion and if not controlled it will in time cause the need for replacement of power package components exposed to water IMPORTANT Replace sacrificial anodes if eroded 50 or more 1 Universal Anodic Plate serves as a sacrificial anode Remove plug from drive shaft housing to access attaching screw and insert 1 2 inch socket Unthread attaching screw and remove univer sal anodic plate Do not remove screw
39. brication points especially steering system shift and throttle linkages should be kept well lubricated 6 Flush cooling system periodically preferably after each use Alpha V8 91 MISCELLANEOUS MAINTENANCE BATTERY Alllead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufactur er s specifications Refer to specific instructions and warnings accompanying your bat tery If this information is not available observe the following precau tions when handling a battery Do not use jumper cables and a booster battery to start engine Do not re charge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames Batteries contain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries also produce hydrogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended when han dling batteries or filling with electrolyte Hydrogen gases that escape from the battery during charging are explosive When charging batteries be sure battery compartment or area where batterie
40. cally offered by the following national state and provincial organizations e Coast Guard Auxiliary e Power Squadrons e Red Cross e State or provincial agencies charged with water safety enforce ment In the United States To help locate the course nearest you contact Boat U S Founda tion s toll free national boating safety education hot line at 1 800 336 BOAT You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local naviga tion and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A We strongly recommend that all power boat operators attend one of these courses Alpha V8 7 CA6 WATER WISDOM e Do not overload Know your boat s operating and loading limita tions e Check safety equipment on board e Know your boating area and avoid hazardous locations e Know signs of weather change and avoid foul weather and rough sea boating e Tell someone where you are going and when you expect to return e Know boating s Rules of the Road signals and navigation e Be on the alert Watch the other guy the water and your wake e Do not drink alcoholic beverages and drive a boat Some state laws apply to boats as well as motor vehicles In order to safely enjoy the waterways there are a few precautions that should be
41. ch distribution is authorized by us This warranty shall become effective only upon our receipt of a completed Warranty Registration Card which shall identify the Product so registered by serial number This warranty shall remain in effect for a period of one 1 year from date of pur chase Since this warranty applies to defects in material and workman ship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of mainte nance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 5 Alteration or removal of parts or 6 Water en tering engine cylinder s through the exhaust system or carbure tor s Reasonable access must be provided to the product for warran ty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other conse quential damages or 2 Removal and or replacement of boat partitions or material because of boat design for necessary ac cess to the Product Alpha V8 V Vi Vil VIII Claim shall be made under this vvarranty by delivering the Prod uct for ins
42. ck for loose or damaged wiring Cooling System Hoses and Clamps Inspect for damage and deteriora tion Check clamps for tightness Continuity Circuit Check components for loose connections bro ken or frayed wires Shift and Throttle Cable and Linkage Lubricate and inspect for loose damaged or missing parts Saltwater use Every 300 Hours of Operation or Once Yearly Whichever Occurs First Freshwater use Every 300 Hours of Operation or Once Every Two Years Whichever Occurs First Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichev er Occurs First NOTE 2 Refer to Lubrication for engine coupler lubrication and or related information Alpha V8 57 CA243 Only perform maintenance which applies to your particular power package Scheduled Maintenance to be Performed by Dealer TASK INTERVAL Engine Exhaust System Saltwater use Every 50 Hours of Inspect externally for Operation or 60 Days Whichever damage deterioration Occurs First and restrictions Check Freshwater use Every 100 Hours clamps for tightness of Operation or 120 Days Whichev er Occurs First Ignition System Check timing and adjust if needed Fuel filters Replace Steering Head and Remote Control Inspect and lubricate Quicksilver MerCathode System Test output Once a Year Closed Cooling Coolant Test
43. crew and sealing washer Allow oil to drain completely IMPORTANT It any water drained from OIL FILL DRAIN hole or it oil appears milky brown drive unit is leaking and should be checked immediately by your Authorized MerCruiser Dealer Lower drive unit so anti ventilation plate is level Fill drive unit through OIL FILL DRAIN hole with Specified Gear Lube until an air free stream of lubricant flows from OIL VENT hole Remove tube from OIL FILL DRAIN hole Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 3 Fill gear lube monitor with Specified Gear Lube When oil starts to run out the OIL VENT hole reinstall sealing washer and OIL VENT screw Tighten securely Continue to fill monitor to FILL mark on monitor Lubricate O ring on monitor neck with stern drive oil to ensure ease of installation and removal of cap Install monitor cap do not overtighten Alpha V8 67 CA144 68 Alpha V8 C WATER SEPARATING FUEL FILTER IF SO EQUIPPED Be careful when changing water separating fuel filter Gasoline is extremely flammable and highly explosive under certain conditions Be sure ignition key is OFF Do not smoke or allow spark or open flame in area when changing fuel filter Wipe up any spilled fuel immediately 4 Remove water separating fuel filter by turning counterclockwise and sealing ring s from mounting bracket and discard Coat sealing rings on new filter with motor oil Thread fil
44. duce throttle setting to avoid exceeding 1500 RPM Never shift drive unit unless engine is at Idle RPM Perform the following as appropriate Check all items listed in OPERATION CHART Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual Place drive unit in full down in position Place control handle in NEUTRAL Position throttle setting as follows COLD ENGINE Move control throttle lever to full throttle then return to about 1 4 throttle In ex treme cold it may be necessary to pump lever more than once WARM ENGINE Move control throttle lever to 1 4 throttle position 42 Alpha V8 FLOODED ENGINE Move control throttle lever to full throttle Be prepared to decrease engine speed to 1000 1500 RPM as soon as engine starts F A Turn ignition key to START Release key when engine starts and allow switch to return to RUN position Move control throttle lever back to decrease engine RPM to 1000 1500 RPM if necessary Check oil pressure gauge immediately after engine starts If oil pressure is not within specified range see SPECIFICATIONS stop engine immediately and determine cause If engine is cold run engine for 1 or 2 minutes at fast idle 1000 1500 RPM After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnormally high If itis stop engine immediately and determine cause Be sure charging system is functionin
45. e a Year Clean and paint Cooling System Flush seawater section Saltwater use After Each Use Alpha V8 55 CA242 Only perform maintenance which applies to your particular power package Scheduled Maintenance to be Performed by Dealer TASK INTERVAL 20 Hour Checkup See at First 20 Hours of Operation NOTE 1 Seawater Pickup Pump Whenever Insufficient Seawater Flow Disassemble and is Suspected If Operating Tempera Inspect ture Exceeds Normal Range Crankcase Oil and Filter Change Ignition System Clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose Clean and inspect DIS Dave UNIRE Every 100 Hours of Operation or Once Yearly Whichever Occurs Gimbal Ring Clamping First Screws Retorque to 50 55 lb ft 67 74 N m Rear Engine Mounts Check torque to 35 40 Ib ft 47 54 N m Gimbal Bearing Lubricate Cooling System Clean inspect NOTE 1 See IMPORTANT INFORMATION for a list of 20 Hour Checkup maintenance 56 Alpha V8 CA51 Only perform maintenance which applies to your particular power package Scheduled Maintenance to be Performed by Dealer TASK INTERVAL Engine Alignment Check See Note 2 Engine Coupling Universal Joint Shaft Splines Lubricate See Note 2 Universal Joint Cross Bearings Inspect See Note 2 Steering System Lu bricate and inspect for loose damaged or missing parts Electrical System Che
46. e is required between road and gear housing skeg when trailering with drive unit in down position If adequate road clearance is a problem place drive unit in full trailer position and support with an optional trailer kit which is available from your Authorized MerCruiser Dealer Alpha V8 15 LAUNCHING AND BOAT OPERATION CARE A CAUTION During launching from a trailer ifthe unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhaust system into the cylinders The more weight on the transom the more likely this is to occur Slowing down rapidly or stopping suddenly may cause a following wave to swamp the transom In this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the pre ceding paragraph In any of these situations water entering the engine could cause se vere damage to internal parts Refer to Attention Required After Submersion CA21 STOLEN POWER PACKAGE If your power package is stolen immediately advise the local authori ties 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 16 Alpha V8 CA22 REPLACEMENT SERVICE PARTS
47. ed Severe damage to drive unit may result it unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 RPM CA37 Trimming Drive Unit Down In Will e Help boat accelerate and plane off quicker e Generally improve ride in choppy water e In most cases reduce boat speed Alpha V8 35 CB187 73976 73977 36 Alpha V8 CB188 Power Trim Operation Panel Mount Remote Control IMPORTANT If TRAILER button is held depressed after drive unit reaches end of upward travel an internal circuit breaker will open and pump will stop Should this happen release button and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Press button until drive unit reaches desired height 2 Trim Up Out Press UP on Trim switch until drive unit reaches de sired trim position 3 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position CB189 Power Trim Operation Console Mount Remote Control Single Engine Version 4 Trailer Position Press button until drive unit reaches desired height 5 Trim Up Out Press UP on Trim switch until drive unit reaches de sired trim position 6 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position Alpha V8 37 CB190 Alpha V8 CB191 Povver Trim Operation Dual Engine Console Mount Remote Control Tvvo Button and Three Butt
48. ed in storage with fuel containing alcohol in fuel tanks carburetors must be run dry at idle RPM Fuel tanks should be drained completely and Quicksilver Gasoline Stabilizer and Con ditioner added to any fuel remaining in the tank Also refer to FUEL REQUIREMENTS 6 Close fuel shutoff valve if so equipped ACAUTION Stern drive unit should be stored in full down position Universal Joint bel lows may develop a set if unit is stored in raised position and may fail when unit is returned to service Alpha V8 95 CB232 96 Alpha V8 CA253 DRAINING INSTRUCTIONS Draining Seawater Raw water Cooled Models A CAUTION If boat is to remain in water after draining seawater inlet hose must be re moved and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses A CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for win ter storage or immediately after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freeze and or corrosion damage to engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from cylinder block as follows 5 0L 5 7L Models Port amp Starboard from cylinder block 350 Magnum Model Port Side from cylinder block 350 Magnum Model Starboard Side from Y fittin
49. effect become too large Consequently the engine oper ates at less than its recommended RPM This will resultin further loss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be somewhat regained by switch ing to a lower pitch propeller that allows the engine to again run at recommended RPM For boaters to realize optimum engine performance under changing weather conditions it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating inan RPM range that discourages damaging detonation This of course en hances overall reliability and durability of the engine 12 Alpha V8 IMPORTANT INFORMATION OPERATION AND MAINTENANCE Owner Operator Responsibilities It is the operator s responsibility to perform all safety checks to en sure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized Mer Cruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the respon sibility of the owner operator and as such are not considered defects in workmanship or material within the terms of the warranty Individu al operating habits and usage contribute
50. els Cooling System Inspect all hoses for damage and deterioration check all hose clamps for adequate tightness Check carburetor adjustment Inspect ignition system and timing Check for loose missing or damaged parts Check shift and throttle cable adjustments Lubricate and inspect for loose damaged or missing parts Steering System Lubricate and inspect for loose damaged or missing parts Inspect all drive belts Check engine alignment Include proper lubrication of U joint and splined shaft Complete Engine Exhaust System Inspect externally for damage and deterioration check all hose clamps for adequate tightness Retorque gimbal ring clamping screws to 50 55 Ib ft 67 74 N m Check that both front engine mount locknuts are tightened se curely Then check to ensure that tab washers are bent down over adjusting nuts Check that rear engine mounts are torqued to 35 40 Ib ft 47 54 N m Alpha V8 21 CA26 hin e SS 6 z E a DT S 8 o o o o o CRUISELOG 6 22 Alpha V8 CA27 OPERATION INSTRUMENTATION The following is a brief explanation of instrumentation typically found on some boats The owner operator should be familiar with all instru ments 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 ap pear on your style gauges 1
51. en gine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and damage caused thereby will not be covered under the limited warranty Fuel Ratings MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows USA and Canada having a posted pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable DO NOT use leaded gasoline Outside USA and Canada having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also accept able If unleaded gasoline is not available use a major brand of leaded gasoline CA214 Gasolines Containing Alcohol Gasolines containing alcohol either methyl alcohol methanol or ethyl alcohol ethanol may cause increased e Corrosion of metal parts e Deterioration of elastomer and plastic parts e Fuel permeation through flexible fuel lines e Wear and damage of internal engine parts e Starting and operating difficulties Some of these adverse effects are due to the tendency of gasolines containing alcohol to absorb moisture from the air resulting in a phase of water and alcohol separating from the gasoline in the fuel tank Alpha V8 45 The adverse effects of alcohol are more severe with methyl alcohol methanol and are worse with increasing alcohol content FIRE AND EXPLOSION HAZARD Fuel leakage from any part of fuel system can be a f
52. f Brunswick Corporation Fond du Lac Wisconsin 54935 U S A Alpha V8 117 3 Year Limited Warranty Against Corrosion Failure APPLICABLE IN THE UNITED STATES CANADA AND AUSTRALIA 118 We warrant parts and assemblies of each 1988 and newer pro duction MerCruiser Product sold with a one year limited Prod uct warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inopera tive as a direct result of corrosion provided the following simple precautionary steps which are specified in Owner s Manuals have been taken 1 Specified maintenance procedures such as replacement of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below This warranty shall become effective upon receipt of a com pleted standard Product warranty registration card and shall re main effective for a period of three years from the date of pur chase This warranty does not cover 1 electrical system corrosion 2 corrosion resulting from damage abuse or improper ser vice 3 corrosion to accessories instruments steering sys tems 4 damage due to marine growth 5 Product sold with less than a one year limited Product warranty except for Bravo and TRS Drive Units nor 6 Product used in commercial appli cation ALL INCIDENTAL AND OR CONSEQUENTIAL
53. g Do not dis turb the Y fitting when removing the drain plug There is an ignition control Knock Sensor in the upper hole of the fitting This sensor must not be loosened or removed It is tightened to a critical speci fication at the factory 3 Remove drain plugs from bottom of exhaust manifolds port and stbd 4 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained OU gt Alpha V8 97 CA264 98 Alpha V8 CA110 Loosen hose clamps and remove the following hoses 5 From engine circulating pump 6 From oil power steering fluid cooler 7 Make sure gear housing water drain holes are open Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump Do not allow engine to start After cooling system has been drained completely install petcocks reconnect hoses and tighten all hose clamps securely IMPORTANT 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 ex tended 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 manufactur er s recommendations 8 For additional assurance against freezing and rust remove the thermostat cover and thermostat Fill the engine seawater cooling
54. g type lower unit or 5 Alteration or removal of parts or 6 Water entering engine cylinder s through exhaust system or carbure tor s Reasonable access must be provided to the Product for war ranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replace ment of boat partitions or material because of boat design for necessary access to the Product Claim shall be made under this warranty by delivering the Prod uct for inspection to a MerCruiser dealer authorized to service the Product If purchaser cannot deliver Product to such autho rized dealer he may give notice in writing to the Marine Power Service Center or distributor The Marine Power Service Center or distributor shall then arrange for the inspection and repair provided such service is covered under this warranty Purchas er shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other ex penses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid Alpha V8 V VI VII VIII Purchaser must provide proof of purchase and substantiate date of purchase by presenting the Purch
55. g correctly Observe power package for fuel oil water and exhaust leaks To shift drive unit return control throttle lever to NEUTRAL Move control shift lever with a firm quick motion forward to shift to FOR WARD gear or backward to shiftto REVERSE After shifting drive unit advance throttle to desired setting Move control shift lever to NEUTRAL and allow engine to drop to IDLE speed If engine has been run at high speed for along period of time allow engine to cool by running at IDLE speed for 3 to 5 minutes Turn ignition key to OFF Alpha V8 43 CA41 OPERATION CHART BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Observe all Observe all Turn ignition gauges to key OFF monitor condition of engine engine If not condition normal stop engine Turn battery Check for Turn bat switch ON if sol fuel oil wa tery switch equipped ter fluid and OFF if so exhaust equipped leaks etc Operate Check shift Close fuel bilge and throttle valve blovvers if control op so eration equipped Open fuel Check Close sea shutoff valve steering cock if so operation equipped Open Flush cool seacock if ing system so if in saltwa equipped ter area Place drive unit in full down in position Perform all other checks specified by your dealer and or boat builder 44 Alpha V8 CA263 SPECIFICATIONS FUEL RECOMMENDATIONS IMPORTANT Use of improper gasoline can damage your
56. handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread screw all the way out 4 DETENT Screw controls the effort needed to move control han dle out of NEUTRAL To increase tension turn screw clockwise to decrease turn screw counterclockwise Do not thread screw all the way out IMPORTANT Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control Alpha V8 33 CA34 34 Alpha V8 CA35 POVVER TRIM The Power Trim system allows operator to raise and lower drive unit for trailering beaching launching and shallow water operation Pow er Trim also allows operator to adjust drive unit angle while under way to provide ideal boat angle for varying load and water condi tions 1 Inmostcases best overall performance is obtained with drive unit adjusted so boat will run at a 3 to 5 angle to water CA36 Trimming Drive Unit Up Out Will e Lift bow of boat e Generally increase top speed e Increase clearance over submerged objects e Cause boat to accelerate and plane off slower e In excess cause porpoising and or propeller ventilation e Cause overheating if trimmed up out beyond gimbal ring support flanges CAUTION Never trim drive unit up out using TRAILER switch while boat is underway Use extreme caution when operating with drive unit rais
57. ire and explosion hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particu larly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines fittings fuel filters and carburetors fuel injec tion components should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replace ment before further engine operation Because of possible adverse effects of alcohol in gasoline it is rec ommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alco hol is unknown increased inspection frequency for leaks and abnor malities is required IMPORTANT When operating a MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of storage common to boats create unique problems In cars alcohol blend fuels normally are consumed before they can absorb enough mois ture to cause trouble but boats often sit idle long enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed protective oil films from internal components Quicksilver Fuel System Treatment and Stabilizer 92 78383A12 and Gasoline Stabilizer 92 817529A1 2 is highly recommended for addition during
58. it corrosion IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the lim ited warranty 1 Painting Boat Hull or BoatTransom Antifouling paint may be applied to boat hull and boat transom but you must observe the fol lowing precautions IMPORTANT DO NOT paint anodes or MerCathode System ref erence electrode and anode as this will render them ineffective as galvanic corrosion inhibitors IMPORTANT If anti fouling protection is required for boat hull or boat transom copper or tin base paints if not prohibited by law can be used If using copper or tin based anti fouling paints observe the following 2 Avoid any electrical interconnection between the MerCruiser Product Anodic Blocks or MerCathode System and the paint by allowing a minimum of 1 1 2 in 40mm UNPAINTED area on transom of the boat around these items 3 Painting Drive Unit or Transom Assembly Drive unit and tran som assembly should be painted with a good quality marine paint or an anti fouling paint that DOES NOT contain copper tin or any other material that could conduct electrical current Do not paint drain holes anodes MerCathode system and items specified by boat manufacturer 4 Spray power package components on inside of boat every 2 3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion External power package components may also be sprayed 5 Alllu
59. n engine above 1500 RPM when flushing Suction created by seawa ter pickup pump may collapse flushing hose causing engine and or drive unit to overheat CAUTION Watch temperature gauge on dash to ensure that engine does not overheat To prevent silt and or salt buildup in cooling system flush with fresh water at specified intervals CA84 Seawater Raw Water Cooled Models Ifflushing cooling system with boatin water raise drive unitto TRAIL ER position install flushing attachment and lower drive unit to full down in position 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 With drive unit in normal operating position partially open water tap about 1 2 maximum Place remote control in NEUTRAL idle speed positron and start engine Operate engine at idle speed in NEUTRAL for about 10 minutes or until discharge water is clear Stop engine shut off water and remove flushing attachment Alpha V8 79 CA177 S 2 70565 EMM 70564 80 Alpha V8 CA178 Closed Cooling Coolant Models When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possible injury remove propeller CAUTION Do not run engine above 1500 RPM when flushing Suction created by seawa ter pickup pump may collapse flushing hose causing engine
60. nce to be performed Some list ings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempt ing maintenance or repair procedures not covered in this manu al it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly NOTE Maintenance points are color coded for ease of identifica tion See the decal on engine for identification MAINTENANCE AIDS 1 Power Steering System QuickSilver Power Trim and Steering Fluid or Dexron Il automatic transmission fluid ATF 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Exposed portion of Steering Cable and Propeller Shaft Quicksil ver Special Lubricant 101 5 Stern Drive Unit Quicksilver High Performance Gear Lube 6 All Grease Fittings and Universal Joints Quicksilver 2 4 C Ma rine Lubricant 7 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard 8 Power Trim System Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor oil Continued on next page 52 Alpha V8 9 Crankcase Oil Quicksilver 4 Cycle Marine Engine Oil Refer to SPECIFICATIONS for alternatives and oil recommendations for va rying ambient temperatures 10 Closed Cooling System Coolant 50 50 mixture of ethylene glycol antifreeze must meet GM specification 1825 M and tap water Areas where tempera
61. nearby boats submerged metal or improper application of copper base anti fouling paint If anti fouling protection is required Tri Butyl Tin Adipate TBTA base antifouling paints are recommended on MerCruiser boating applications In areas where Tri Butyl Tin Adipate base paints are prohibited by law copper base paints can be used on the boat hull and transom Do not apply paint to the MerCruiser drive unit or tran som assembly In addition care must be taken to avoid an electrical interconnection between the MerCruiser Product and the paint Cor rosion damage that results from the improper application of copper base paint will not be covered by this limited warranty Transfer of Warranty This Limited Warranty is transferable to subsequent purchasers for the remainder of the unused portion of the 3 year limited warranty Alpha V8 119 Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The table explains some of the types of services that are not covered by warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship In stallation errors accidents normal wear and a variety of other causes that affect the product are not covered Warranty is limited to defects in material or workmanship but only when the consumer sale is made in the country to which distributi
62. nited States and Canada contact the nearest Marine Power International Service Center 124 Alpha V8 PARTS AND ACCESSORIES INQUIRIES All inquiries concerning Quicksilver replacement parts and accesso ries should be directed to your local Authorized Dealer The dealer has the necessary information to order parts and accessories for you should he not have them in stock Only Authorized Dealers can pur chase genuine Quicksilver parts and accessories from the factory Mercury Marine does not sell to unauthorized dealers or retail cus tomers When inquiring on parts and accessories the dealer re quires the motor model and serial number s to order the correct parts RESOLVING A PROBLEM Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser Any problems with service sales warranty or operation of your MerCruiser power package will be resolved by your dealer He also is your primary source of information on your boat power package and trailer Should there be a misunderstand ing or if your problem has not been resolved to your satisfaction please follow these steps STEP ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Misunderstandings or complaints can be quickly resolved by the dealer If you are unable to obtain satisfaction contact the dealer ship s owner STEP TWO IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN CONTACT YOUR NEAREST MERCRUISE
63. on is authorized by us Should you have any questions concerning warranty coverage con tact your authorized dealer They will be pleased to answer any ques tions that you may have WARRANTY DOES NOT APPLY TO THE FOL LOWING e Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connec tion with normal services e Damage caused by neglect lack of maintenance accident ab normal operation or improper installation or service e Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reasonable access must be provided to the prod uct for warranty service Customer must deliver product to an Au thorized Dealer e Additional service work requested by customer other than that necessary to satisfy the warranty obligation 120 Alpha V8 e Labor performed by other than an Authorized Dealer may be cov ered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in 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 e All incidental and or consequential damages storage charges
64. on Versions IMPORTANT If TRAILER button is held depressed after drive unit reaches end of upward travel an internal circuit breaker will open and pump will stop Should this happen release button and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed CAUTION When lowering or raising stern drives equipped with a dual engine tie bar kit in the trailering position stern drives must be lowered evenly to prevent tie bar from becoming twisted Failure to lower stern drives evenly may result in tie bar or stern drive s damage 1 Trailer Button Both Versions Press button until drive unit reach es desired height for trailering drive units 2 Two Button Trim Control Dual Buttons in Handle used to contol both drive units from the handle Press UP on button s to trim drive unit UP OUT Press down on button s to trim drive unit DOWN IN A Forward Trim Button Used to trim the port drive unit B Rear Trim Button Used to trim the starboard drive unit 3 Three Button Trim Control Trim Adjustment Switch s With a single integral trim button in the handle to control two engines simultaneously these two switches control the Fine Tune adjust ment of each engine Using these Fine Tune Switches set each engine to the desired trim angle Then use the single trim switch in the handle to control the trim of both engines simultaneously 4 Three Bu
65. ong cur rent or high winds Loss of control when docking Alpha V8 al As we cannot possibly know of and advise the boating public of all conceivable boat power package types and or poor oper ating practices the final decision of whether or not to use a Lan yard Stop Switch rests with you the owner driver We strongly recommend that other occupants be instructed on prop er starting and operating procedures so they will be prepared should they be required to operate the power package and boat in an emer gency It is difficult for persons standing or floating in the water to move clear if they see a powerboat heading toward them even at slow speed Shift the unit to neutral and shut off engine when your boat is near people in the water Serious Injury is likely if a person in the water is struck by a moving boat gear housing propeller or accessory rigidly attached to your boat or motor The use of accessories not manufactured or sold by Mercury Marine are not recommended for use with your MerCruiser unit If your MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine Be sure to read the Operation and Maintenance Manual for that accessory before oper ation If you haven t been supplied with such a manual contact your dealer or the manufacturer of the accessory to secure the applicable manual o Alpha V8 CAS BOATING SAFETY AND SEAMANSHIP Boating safety and seamanship courses are periodi
66. ould be cleaned at least once a year or whenever decreased cooling efficiency is noticed 1 Remove bolts securing end plates to each end of heat exchanger Remove end plates sealing washers and gaskets Discard sealing washers and gaskets and clean gasket material from end plates and heat exchanger Clean water passages in heat exchanger by inserting a suitable size wire brush into each passage Use compressed air to blow loose par ticles out Apply Quicksilver Perfect Seal to both sides of new end plate gaskets Assemble new gaskets new sealing washers and end plates onto heat exchanger Install bolts and tighten securely Start engine and inspect cooling system for leaks CA88 SEAVVATER PUMP IMPELLER This maintenance should be performed by an Authorized MerCruiser Dealer 2 Seawater Cooled Models 3 Closed Cooling Models Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected if operating temperature exceeds nor mal range Alpha V8 83 CA90 DRIVE BELTS Make sure engine is shut off and ignition key is removed before inspecting belts All drive belts must be periodically inspected for condition and ten sion Perform the following inspections of alternator drive belt power steering pump drive belt if so equipped and seawater pickup pump drive belt closed cooling If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer 1 Altern
67. pection to a MerCruiser dealer authorized to service the Purchaser s product If purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Company We shall then arrange for the inspection and repair provided such service is covered under this warranty Purchas er shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other ex penses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid The Warranty Registration Card is the only valid registration identification and must be presented at the time warranty service is required Warranty claims will not be accepted without presentation of the Warranty Registration Card Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workman ship as covered by this Warranty We reserve the right to im prove the design of any Product without assuming any obliga tion to modify any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMP
68. rim or Power Steering fluids do not require changing Coolant in closed cooling system should be changed at specified in tervals by your Authorized MerCruiser Dealer Changing Crankcase Oil and Filter IMPORTANT Change oil when engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended motor oil see SPECIFICATIONS 1 With engine at normal operating temperature remove dipstick In stall Quicksilver Crankcase Oil Pump onto dipstick tube Insert hose end of crankcase oil pump into an appropriate container and using pump handle pump until crankcase is empty Remove crankcase oil pump 2 Turn oil filter counterclockwise to left remove and discard old oil filter and old sealing ring Coat sealing ring on new filter with motor oil Install new sealing ring and filter by turning clockwise to right Tighten filter securely Do not overtighten 3 Remove oil filler cap Add correct type oil see SPECIFICATIONS to bring level up to but not over FULL mark on dipstick IMPORTANT Always use dipstick to determine exactly how much oil is required Alpha V8 65 Alpha V8 CA67 Changing Drive Unit Oil Models With Gear Lube Monitor if So Equipped IMPORTANT Use only specified gear lubricant in drive unit See SPECIFICATIONS Place drive unit in trim out position Do Not Raise to TRAILER Posi tion 1 Remove OIL FILL DRAIN screw and sealing washer 2 Remove OIL VENT s
69. s are located is well vented Battery electrolyte is a cor rosive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain medi cal aid as soon as possible 92 Alpha V8 CA104 BOTTOM OF BOAT To maintain maximum speed the following conditions of the boat bot tom should be observed e Clean free of barnacles and marine growth e Free of distortion nearly flat where it contacts water e Straight and smooth fore and aft Antifouling Paints See Antifouling Paint recommendations and related information on previous pages IMPORTANT Refer to CORROSION AND CORROSION PRO TECTION for additional information CA105 INSPECTION AND MAINTENANCE Inspect power package often and at regular intervals to help main tain 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 tight en or replace as required Check plug leads and electrical leads for damage Remove and inspect propeller If badly nicked bent or cracked see your dealer Repair nicks and corrosion damage on power package exterior fin ish Use Quicksilver spray paints see your Authorized MerCruiser Dealer Alpha V8 93 CA106 COLD WEATHER OR EXTENDED STORAGE
70. sa MasterCard Month Year AAA a i 7 Card Number Expiration Date a A Signature Date Telephone Number 134 Alpha V8
71. steners Obstruction in shift or throttle linkages Shift or kinked throttle cable Remedy Lubricate Check all linkages If any are loose or missing see Authorized MerCruiser Dealer immediately Remove obstruction Straighten cable or have dealer replace cable if damaged beyond repair STEERING WHEEL TURNS HARD OR JERKY 110 Possible Cause Low power steering pump fluid level Drive belt loose or in poor condition Insufficient lubrication on steering system compo nents Loose or missing steering fasteners or parts Contaminated power steering fluid Remedy Refill system with fluid Replace and or adjust Lubricate Check all parts and fasten ers If any are loose or missing see Authorized MerCruiser Dealer immedi ately Drain and replace Alpha V8 POWER TRIM DOES NOT OPERATE MOTOR DOESN T RUN Possible Cause Remedy Blown fuse e Replace fuse Loose or dirty electrical e Check all associated elec connections or damaged trical connections and wiring wires especially battery cables Clean and tighten faulty connection Repair or replace wiring POWER TRIM DOES NOT OPERATE MOTOR RUNS BUT DRIVE UNIT DOES NOT MOVE Possible Cause Remedy e Trim pump oil level low e Fill pump with oil e Drive unit binding in e Check for obstruction gimbal ring Alpha V8 111 CA262 WARRANTY INFORMATION OWNER WARRANTY REGISTRATION UNITED STATES A
72. storage periods See Cold Weather or Extended Storage later in this manual 46 Alpha V8 CA43 CRANKCASE OIL To help obtain optimum engine performance and to provide maxi mum protection we strongly recommend the use of Quicksilver 4 Cycle Marine Engine Oil If not available a good grade straight weight detergent automotive oil of correct viscosity with an API clas sification of CD or SG may be used The chart below is a guide to crankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not avail able a multiviscosity 20W 40 SG or CD or as a second but less preferable choice 20W 50 SG or CD may be used IMPORTANT The use of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oils or oils which contain solid additives are specifically not recommended Quicksilver 4 Cycle Marine Engine Oil SAE 40W SG or CD SAE 30W SG or CD a Do 32 F 50 F 0 C 10 C 70534 AIR TEMPERATURE Alpha V8 47 CA265 ENGINE SPECIFICATIONS Propshaft Horsepower 190 205 Propshaft Kilowatts 1 152 Displacement 305 C 1 D 5 L Bore 3 74 in 94 99mm Stroke 3 48 in 88 39 mm Compression Pressure 180 psi 1241 kPa Maximum RPM WOT 4200 4600 RPM Idle RPM in 650 700 RPM Fuel Pump Pressure 3 7 psi 21 48 kPa il P 2 a A 2000 30 55 psi 207 379 kPa Min Oil Pressure 4 psi 28 kPa Idle
73. strumentation u e a ea aa Le Audio Warning System eee ee Electrical System Overload Protection Models With Mercathode System Remote Controls dues tae ge it Ri ea eren Power Tia se een a a Starting Shifting And Stopping Operation Chart ue Gre occa esd Helio path Specifications ovni Da an arie Fuel Recommendations ce eee eee ee Grankcase Oila es dda ach Sd a PA ae dee Mae an de ENGINE Suda A ahd ia TRUS UD caste an ies cast trader ceca ty Se cee SG ERC ee ee Capacities sucs as EEES aco net meee ee U g Q o CO CO CO CO JOA 2 Alpha V8 Maintenance coil molts ga Pee desu gal usa Vida mia la 52 Maintenance Aids eee 52 Maintenance Chart eee eee 54 Checking Fluid Levels 61 Changing Fluids Se EE ent ee Maer Sac tag mes 65 Water Separating Fuel Filter If So Equipped 69 Fuel Pump Sight Tube Inspection 69 LUDTICIION iaia dia yeas pare dau RA RR ita is 71 Propeller occ wai cowed adem Say es DE Sak EE ales 75 Flushing Cooling System ee eee 79 Seawater Pump Impeller 83 Drive Belts LL 85 Corrosion And Corrosion Protection 87 Miscellaneous Maintenance eee eee 92 Battery ecards das dels pe elo deriva e tira e 92 Bottom OB y arrob dis PAL 93 Inspec
74. ter clockwise onto bracket and tighten securely by hand Do not use a filter wrench Start and run engine Check filter connection for gasoline leaks If leaks exist recheck filter installation If leaks continue stop engine im mediately and contact your Authorized MerCruiser Dealer Make sure no leaks exist before closing engine hatch CA145 FUEL PUMP SIGHT TUBE INSPECTION 5 The engine fuel pump is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphragm If fuel is visible in tube fuel pump should be replaced by your Authorized MerCruiser Dealer immediately Alpha V8 69 CA70 70 Alpha V8 CA174 LUBRICATION Steering System 1 If Steering Cable Has Grease Fittings VVith cable fully retracted into cable housing lubricate fitting vvith 2 4 C Marine Lubricant 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 2 With steering cable fully extended lubricate exposed part of cable with Special Lubricant 101 3 Lubricate steering system pivot points with SAE 30W motor oil On dual engine boats lubricate all pivot points including tie bar pivot points with SAE 30W motor oil CA72 Shift Cable 4 Lubricate pivot points with SAE 30W motor oil CA73 Throttle Cable 5 Lubricate pivot points with SAE 30W motor oil Alpha V8 71 CA74
75. ter will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registra tion Card from your distributor dealer If you receive a plastic War ranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty Refer to Table of Contents IMPORTANT Registration lists must be maintained by the fac tory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be neces sary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the facto ry copy to the Marine Power International Service Center for your area Alpha V8 113 WARRANTY POLICIES MERCRUISER LIMITED WARRANTY GASOLINE ENGINES UNITED STATES AND CANADA ONLY 114 We warrant each new production not those made for high per formance purposes MerCruiser Stern Drive Power Package Inboard Engine and accessories attached thereto hereafter referred to as Product to be free from defects in material and workmanship but only when the consumer sale is made in the country to whi
76. the front of this manual for safety warning on the use of this switch 6 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control han dle This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 7 Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle for ward from Neutral with a quick firm motion to the first detent for For ward gear Continue pushing forward to increase speed Pull the control handle back from Neutral with a quick firm motion to the first detent for Reverse gear Continue pushing back to increase speed Alpha V8 29 REMOTE CONTROLS CONSOLE MOUNTED 1 Control Handle s Operation of the the shift and throttle are controlled by the movement of the control handle Push the control handle forward from Neutral with a quick firm motion to the first det ent for Forward gear Continue pushing forward to increase speed Pull the control handle back from Neutral with a quick firm motion to the first detent for Reverse gear Continue pushing back to increase speed 2 Throttle Only Button Allows engine throttle advancement with out shifting the engine This is done by disengaging the shift
77. tion And Maintenance 93 Cold Weather Or Extended Storage 94 Power Package Lay Up 94 Draining Instructions sleale 97 Battery Winter Storage 104 Power Package Recommissioning 104 Troubleshootng 25 crows Es eee eae ede oe eee 105 Warranty Information 112 Owner Warranty Registration 112 International Owner Registration 113 Warranty Policies ante as LE ook sa de bases st 114 3 Year Limited Warranty Against Corrosion Failure 118 Warranty Coverage u e ue ua a ue au eee ees 120 Transferable Warranty ea eL 123 Q Guard Product Protection Plan 124 Owner Service Assistance 4 124 Service Centers Lu aa veia ea 127 Customer Service Literature 129 General Maintenance Parts 130 Literature Order Form eee eee eens 133 Alpha V8 3 CA165 WELCOME You have selected one of the finest marine power packages available It in corporates numerous design features to assure operating ease and durabil ity 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
78. tion see Corrosion and Corrosion Protection sec tion Alpha V8 27 CB181 28 Alpha V8 REMOTE CONTROLS PANEL MOUNTED Your boat may be equipped with one of many Quicksilver remote controls available All controls feature an integral safety switch that allows starting engine in NEUTRAL only Also all controls may not have all features shown If boat is equipped with a remote control oth er than shown consult your dealer for a description and or demon stration of the control 1 Neutral Lock Bar Prevents accidental shift and throttle engage ment Neutral lock bar must be pulled Up to move the control handle out of neutral 2 Throttle Only Button Allows engine throttle advancement with out shifting the engine This is done by disengaging the shift mecha nism from the control handle The throttle only button can be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Power Trim Switch See Power Trim for detailed power trim operating procedures 4 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 5 Lanyard Stop Switch Turns ignition Off whenever the opera tor when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at
79. to gear as soon as possible after starting and advance throttle above 1500 RPM if conditions permit safe op eration Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during first 10 hours During next 10 hours occasional operation at full throttle is permissible 5 min utes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operat ing temperature Frequently check crankcase oil level Add oil if needed It is nor mal for oil consumption to be high during break in period After 20 hour break in period drain crankcase oil and replace oil filter see MAINTENANCE Fill crankcase with correct oil see SPECIFICATIONS CA211 AFTER BREAK IN PERIOD To help extend the life of your MerCruiser power package the follow ing recommendations should be considered 20 Use a propeller that allows the engine to operate at or nearthe 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 Alpha V8 CA236 20 HOUR CHECKUP After first 20 hours of operation an Authorized MerCruiser Dealer should be contacted for the following maintenance The boat owner is responsible for any charges Change crankcase oil and filter Check all fluid lev
80. to the need for maintenance service Proper maintenance and care of your power package will assure op timum performance and dependability and will keep your overall op erating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 Dealer Responsibilities In general a dealer s responsibilities to the customer include prede livery inspection and preparation such as e Make sure that the boat is properly equipped e Prior to delivery make certain that the MerCruiser power package and other equipment are in proper operating condition e Make all necessary adjustments for maximum efficiency e Familiarize the customer with the on board equipment e Explain and demonstrate the operation of the power package and boat e Atthe time of delivery the dealer should provide you with a copy of a Predelivery Inspection Checklist e Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product Alpha V8 13 FREEZING TEMPERATURE OPERATION IMPORTANT It boat is operated during periods of freezing tem perature precautions must be taken to prevent freezing dam age to power package Refer to COLD WEATHER or EX TENDED STORAGE for draining instructions DRIVE UNIT IMPACT PROTECTION The Power Trim hydraulic system is designed to provide impact pro tection for drive unit If a submerged object is struck while boat
81. tons bearings camshafts and other heavy duty moving parts are re quired for long life and peak performance These are but a few of the many special modifications that are re quired in MerCruiser marine engines to provide long life and depend able performance Alpha V8 17 CA23 DO IT YOURSELF MAINTENANCE SUGGESTIONS If you are one of those persons who likes to do it yourself here are some suggestions for you Present day marine equipment such as your MerCruiser power package are highly technical pieces of machinery Electronic ig nition and special carburetion provide greater fuel economies but also are more complex for the untrained mechanic Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions Cautions and Warn ings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you or der the service manual for that model The service manual out lines the correct procedures to follow It is written for the trained mechanic so there may be procedures you don t understand Do not attempt repairs if you do not understand the procedures There are special tools and equipment that are required to per form 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 Alpha V8 e Also
82. tton Trim Control Single Trim Switch in Handle used to trim both drives simultaneously after drives have been fine tuned as described above Alpha V8 39 CB192 Alpha V8 CB193 Power Trim Operation Three Button Trim Panel Used on Models withTwo Lever Control IMPORTANT If TRAILER button is held depressed after drive unit reaches end of upward travel an internal circuit breaker will open and pump will stop Should this happen release button s and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Simultaneously press the UP button top along with the UP OUT button center until drive unit reaches desired trail er position 2 Trim Drive Unit UP OUT Press center UP OUT button until drive unit reaches desired trim position 3 Trim Drive Unit IN DOWN Press IN button until drive unit reaches desired trim position Alpha V8 41 STARTING SHIFTING AND STOPPING Before starting engine operate bilge blower for at least five minutes to remove any explosive fumes from engine compartment If boat is not equipped with a bilge blower open engine hatch and leave open while starting engine IMPORTANT Observe the following wp 00 Do not start engine without water being supplied to seawater pickup pump to prevent pump or engine damage Do not operate starter motor continuously for more than 30 seconds When engine starts quickly re
83. tures generally do not go below 32 F 0 C rust inhibitor and tap water is acceptable 11 Gasoline Stabilizer Quicksilver Marine Fuel System Treatment and Stabilizer 12Grease Fittings on Drive Shaft Extension Models Quicksilver 2 4 C Marine Lubricant Alpha V8 53 CA134 MAINTENANCE CHART Only perform maintenance which applies to your particular power package Scheduled Maintenance to be Performed by Owner Operator TASK INTERVAL Engine Crankcase Oil Check level Closed Cooling Coolant Check level Power Steering Fluid Check level Stern Drive Unit Oil Check level Battery Check level and inspect for damage Fuel Pump Sight Tube Check that no fuel is present Power Trim Pump Oil Check level Anodes Inspect for erosion Gear Housing Water Pickups Check for ma rine growth or debris 54 Alpha V8 CA49 Only perform maintenance which applies to your particular power package Scheduled Maintenance to be Performed by Owner Operator TASK INTERVAL Drive Belts All Inspect condition and check tension Propeller Shaft Saltwater use Every 50 Hours of Lubricate Operation or 60 Days Whichever Power Package Exte Occurs First rior Freshwater use Every 100 Hours Every 100 Hours of Operation or 120 Days Whichever Occurs First Surfaces Spray with of Operation or 120 Days Whichever rust preventative Occurs First Power Package Exterior Surfaces Onc
84. use and correct it if possible If cause can not be determined consult your Authorized MerCruiser Dealer Alpha V8 25 CA29 Alpha V8 26 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 replac ing 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 an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or discon nect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker will not reset electrical overload has not been eliminated Further checks must be made on electrical sys tem 2 A20 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 3 The Power Trim System is protected from overload by 110 amp fuse and a 20 amp in line fuse on Power Trim pump 4 Quicksilver Three Button Power Trim Control Panel is further pro tected by a 20 amp in line fuse MODELS WITH MERCATHODE SYSTEM 5 A20 amp in line fuse is in wire which connects to positive ter minal on controller If fuse is blown system will not operate For ad ditional informa
85. ve until the product is registered at the factory e NOTICE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notifi cation under the Federal Boat Safety Act be required 112 Alpha V8 INTERNATIONAL OWNER REGISTRATION OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Regis tration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and ad dress product model and serial number s date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the origi nal purchaser and user of the product Acopy of the Warranty Registration Card designated as the Pur chaser s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Cen
86. y 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 Ma rine 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 Enclose full remittance in check or money order NO C O D s Alpha V8 129 CA269 GENERAL MAINTENANCE PARTS ENGINE PARTS e ST sv 3 mon Col 5 6 Spark Plug 84 816761A17 84 816761A17 Wire Set Thermostat 807252 2 807252 2 160 F 7 Thermostat 27 33179 2 27 33179 2 Gaskets 27 53045 1 27 53045 1 8 Alternator Belt 57 49213A1 57 49213A1 9 Power Steering 57 816295T 57 816295T Belt 10 Sea Water 57 49213A1 57 49213A1 Pump Belt 11 Water 55 805269 1 55 805269 1 Separating Filter 12 Quicksilver 92 816096A12 92 816096A12 Motor Oil 13 Storage Seal 92 86145A12 92 86145A12 14 Valvtane Plus 92 17955A12 92 17955A12 15 Fuel Treatment 92 817529A12 92 817529A12 and Stabilizer 16 Fuel System 92 17885A12 92 17885A12 Cleaner 17 Corrosion 92 815869A12 92 815869A12 Guard Spray 130 Alpha V8 ENGINE PARTS 5 7L 1 14957 2 9393 59571 805759A2 392 805570A2 5 84 816761A17 6 807252 2 7 27 33179 2 27 53045 1 8 57 48120A1 9 57 816295T 10 57 74271T 11 55 805269 1 12 92 816096A12 13 92 86145A12 14 92 17
87. you thoroughly read this manual The Operation and Maintenance Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our MerCruiser products We sincerely hope your boating will be pleasant Consumer Affairs Department CA166 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 WARN INGS and CAUTIONS accompanied by the International Hazard Symbol A may be used to alert the installer user to special instruc tions concerning a particular service or operation that may be haz ardous if performed incorrectly or carelessly Observe them care fully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special instructions while per forming the service plus common sense operation are major acci dent prevention measures WARNING Hazards or unsafe practices which could result in severe personal injury or death 4 Alpha V8 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

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