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350 Magnum EFI Tournament Ski - Brunswick Marine in EMEA

1. glia na PA Sap A aS 59 Quicksilver Instrumentation ili xe Rew Eee aS ewe TE Bed 59 Starting And Charging System Harness od ra P BAGS 60 Ede Syslem Harness week hed ee Pele db ee I sre hana RE beens 61 Warranty Intormatiom 5 5224 Sak eins eure 62 Owner Warranty Registration er n te ODD anne x core id aw ae are REN ao Oei 62 International Owner Registration etek stash eft AS Ua idu sell 62 Warranty PeliGIBS iS 63 MerCruiser Limited Warranty Gasoline Endlles se aede Pana ite recap afe oni e ea og Dorint ida ww atin pew qi Sepe wena 63 MerCruiser International Warranty Gasoline 64 3 Year Limited Warranty Against Gorrosiom Eae do c E avide se ieee c De 65 Warranty Coverage ina cro MU ER EIOS DIOE eor ote mae 66 Warranty Does Not Apply To NET TERT CREDIS ITI M 66 Traristerable Warranty nem D ert Pes Det ve tSp et Hd esae Gand ache Du BA Dad dene d 67 Direct Sale BY OWNER e este ect rm E RR ERR ER ae te Setar ene Su e Eu eee 67 Gi Guard Product Protection Plan 5 ae Poe eec to reta es eb ECHO S ED Ore ately eei bd rare 68 United States and Canada Only osuere t ima RA cec S etai Ux ape UA ecd ee 68 Owner Service Assist
2. alee eo x ae 41 Seawater Pump Impeller REPRE PEAK Rer bland wa edd ay av wig aha aye 41 Drive RE ATI SER gee eyed ek Aves dE LEEREN ERE 43 Flame Arrestor And Crankcase Ment HOSBS 4 5 esed bs yel ee Ge EB V DOM da Se ee dew nrbe ee eee us ne ee 45 Sight Tube Inspection Aah Vu SUN suse Lid 45 Water Separating Fuel Filter rl ut d ac mack beads tet ge anak we Re tee cd 45 Engine Alignment ee eee ede ERs eke a eee RR 47 Miscellaneous Maintenance i4 va te Mad aru Ae coe itte ase ao x Hacer S Ie ne us Ado ed 48 Battery iira M 48 Bolton OP Boats uon bid EON PAER esate EA hee Neale 48 Antifouling Paints a e E ee 48 Inspection And Maintenance aren ee sa ie e ciate 48 Gold Weather or Extended Storage pp 51 Power Package Layup wakes BER eee be 51 Draining HORS uti cene at ear ale da toe iren cni seduto E E 53 Battery Winter Storage vane iw eed RR RE E IARE EUER 54 Power Package Recommissioning BES Qe ino RA CERES 54 Bises MOL Shane eRe tne vie hE ee SRY Bate 55 WaiteFFlow Diagram e eda cca te ea a ta sima usu ete Lec toa tes n ee a ata eee 58 Wiring
3. 3 There are three fuses located in the fuel injection system electrical box These fuses control various EFI circuits A Fuel Pump Fuse 15 Amp Injector Fuse 10 Amp C EOM Battery Fuse 15 Amp 4 20 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 19 CC166 73866 20 CC167 Remote Controls Panel Mounted 1 Neutral Lock Bar Prevents accidental shift and throttle engagement Neutral lock bar must be pulled Up to move the control handle out of neutral 2 Throttle Only Button Allows engine throttle advancement without shifting the engine This is done by disen gaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Lanyard Stop Switch Turns ignition whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at the front of this manual for safety warning on the use of this switch 4 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the ten sion on the control handle This will help prevent Creep of the remote control handle Tu
4. Replace Check and add correct grade and viscosity oil Check entire engine for leaks Check and remove required amount of oil Check for cause of excessive oil improper filling bad fuel pump etc Change oil and oil filter being sure to use correct grade and viscosity oil Determine cause for dilution excessive idling faulty fuel pump etc Straighten hose or replace if damaged Maintain fluid level Inspect shift linkages and shift lever positioning Straighten hoses or replace if damaged Turn off non essential accessories Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connections Repair or re place damaged wiring Replace and or adjust Test battery Lubricate Check all linkages If any are loose or missing SEE YOUR DEALER IMMEDIATELY Remove obstruction Straighten cable or have your dealer replace cable if damaged beyond repair 57 CC163 Water Flow Diagram OVERBOARD SEAWATER 72 S SEAWATER PICKUP PUMP EXHAUST ELBOW THERMOSTAT 12 HOUSING EXHAUST MANIFOLD ENGINE CIRCULATING PUMP 73854 58 CC117 Wiring Diagrams Quicksilver Instrumentation NOTE Refer to gauge manufacturer s instructions for specific connections NOTE 1 Connect Wires Together with Screw and Hex Nut Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connecti
5. 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 Complete Engine Exhaust System Inspect externally for damage and deterioration check all hose clamps for adequate tightness 13 CC93 Operation CRUISELOG 6 CC8 Instrumentation The following is a brief explanation of instrumentation typically found on some boats The owner operator should be familiar with all instruments and their functions on the boat 3 Speedometer indicates boat speed Tachometer indicates engine RPM Oil Pressure Gauge indicates engine oil pressure Battery Meter indicates battery voltage Water Temperature Gauge indicates engine operating temperature Fuel Gauge indicates fuel tank volume Hour Meter records engine running time 10 Bilge Blower Switch must be operated for five minutes to ventilate bilge 11 Ignition Switch allows operator to start and stop engine COON OO 15 CC180 2 70518 16 CC336 Audio Warning Warning buzzer will sound if 1 Cooling system water temperature rises too high 2 Engine oil pressure gets too low 3 Transmission temperature is too high ACAUTION Avoid engine damage Do not operate engine once the buzze
6. unloading or are near the back stern of the boat Just shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal Law requires that there be U S Coast Guard approved wearable type life jacket personal flotation device correctly sized and readily accessible for every person on board plus a throwable cushion or ring We strongly advise that everyone wear a life jacket at all times while in the boat e Prepare other boat operators Instruct at least one person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate When in doubt contact your dealer or the boats manufacturer Know your boat s oper ating and loading limitations e Make sure everyone in the boat is properly seated Don t allow anyone to sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat anywhere that sudden unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat e Never be under the influence of alcohol or drugs while boating it is the law They impair your judgment and greatly reduce yo
7. 17 Electrical System Overload Protection pp 19 Remote Controls Panel Mounted pp 21 Starting Shmigsandstoepplrd ssai ows eA ege aa ean dod ea e a ed 22 Operation Ghart suas doo qua dut eeu es alee sy eae eae Ns a te alan 23 LEE 24 Fuel Recommendations ew ute aon ee ee 24 Seacock Size Hecorimengdaligli sso Mee hae 26 Sea Strainer Recommendation vw ae AE Eakins 26 26 Engine SpecifICatlOllS 225528 S m Ea T edes EA Ny b del o Ae db 27 SOCIO IOS dee ace RD Et e ME E ne cs RR eta RAUS 28 MOM Em 28 er M 30 EFI System Maintenance Precautions ee esa niu Y Da PUR ER PURA AR 31 Maintenance Products 2 0 2 4 054 eo Rr A ERE REA SIRE RR TE EGRE ERG RA EE 31 Maintenance Sohbdules 229 Beg eek IA E Ao 32 CHECKING Fluid LeyelS uc pro etc ee EC roe D n eo eR eque BAT edge Bo sain pts 35 COPIER enu EN eco E Raus Mc cate a eae NR Mena RR 37 LRG AON oin e Urna da GO d cien tice UC uie ert ies ena 39 Flushing Cooling System oce rre ree eret RERO Ra ee A D e e e e
8. AN IMPLIED WARRANTY LASTS OR THE EX CLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU V 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 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 incorporated herein by reference Mercury Marine products are built using the most advanced corrosion protection process available This manufac turing system complemented 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 provided 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 connections nearby boats submerged metal or improper application of cop per 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 ba
9. 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 Purchaser 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 expenses 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 workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obligation 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 IM PLIED WARRANTIES ARE LIMITED TO THELIFE OF THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE E
10. by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard Water entering the engine via the carburetor or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commu tator because of excess cranking Valve or valve seat grinding required because of wear Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material blocking inlets or power package being mounted too high Use of fuels and lubricants which are not suitable for use with or on the product Our limited warranty does not apply to any damage to our products 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 under warranty if they otherwise meet the terms of the limited warranty for that product 66 Transferable Warranty The product warranty is transfer
11. does not sell to unauthorized dealers or retail customers When inquiring on parts and accessories the dealer requires the motor model and serial number s to order the correct parts 68 Resolving a Problem Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser Any problems with ser vice 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 misunderstanding 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 dealership s owner STEP TWO IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN CONTACT YOUR NEAREST MERCRUISER 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 e Propeller pitch and or part number Normal use and approximate gross load Please bear in mind that Service Centers resolve all problems through the dealership using the dealer s facili ties equi
12. fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks if they existed Marine engines are expected to operate at or near full throttle for most of their life They are also expected to oper ate 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 suspected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket uses special materials to resist corrosive action Since marine engines must be capable of running at or near maximum RPM much of the time special valve springs valve lifters pistons bearings camshafts and other heavy duty moving parts are required for long life and peak performance These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance CB166 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 MerCruise
13. lever positioning will not be covered by Velvet Drive Transmission Warranty To obtain service and or parts literature for your Velvet Drive transmission contact Velvet Drive Marine and Industrial Transmissions Theodore Rice Boulevard Industrial Park New Bedford MA 02745 U S A 39 CC268 40 Cc57 Flushing Cooling System When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possi ble injury remove propeller A CAUTION Do not run engine above 1500 RPM when flushing Suction created by seawater pickup pump may collapse flushing hose causing engine to overheat A CAUTION Watch temperature gauge on dash to ensure that engine does not overheat CAUTION If cooling system is to be flushed with boat in the water water inlet valve if so equipped must be closed or water inlet hose must be disconnected and plugged to prevent water from flowing into boat CAUTION If boat is in the water do not open water inlet valve until engine is to be restarted to prevent contaminated water from flowing back into engine To prevent silt and or salt buildup in cooling system flush with freshwater at specified intervals 1 Disconnect water inlet hose Lower hose from aft end of seawater pickup pump 2 Using appropriate connector connect hose between connector and water tap Partially open water tap about 1 2 maximum Place rem
14. not effective until the product is registered at the factory NOTICE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notification under the Federal Boat Safety Act be required International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the dis tributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and address 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 original purchaser and user of the product A copy ofthe Warranty Registration Card designated as the Purchaser s Copy MUST be given to you immedi ately 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 Center will issue you a permanent
15. open throttle WOT and operating RPM range are listed in SPECIFI CATIONS IMPORTANT The engines covered in this manual are equipped with an RPM rev limiter that is set to an upper or limited RPM amount This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM Once the RPM drop into the recom mended operating RPM range normal engine operation resumes Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide open throttle operating RPM range with a normal load Generally there is a 100 RPM difference between 1 inch changes in propeller diameter or pitch If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal wear and or damage 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 causes an RPM loss e Operating with increased load additional passengers pulling skiers etc For better acceleration such as is needed for water skiing use the next lower pitch propeller However do not operate at full throttle when using the lower pitch propeller but not pulling skiers CA12 How E
16. plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty 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 pro cessing refer to the International Warranty Refer to Table of Contents IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary 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 62 Warranty Policies MerCruiser Limited Warranty Gasoline Engines UNITED STATES AND CANADA ONLY Vi Vil We warrant each new production not those made for high performance 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
17. to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT We strongly recommend that all powerboat operators attend one of these courses You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made e Check safety equipment on board Here are suggestions of the types of safety equipment to carry when boat ing 1 Approved fire extinguisher s paddle or oar 2 Signal devices flashlight rockets or flares flag and whistle or horn 3 Spare propeller thrust hubs and an appropriate wrench 4 Tools for necessary minor repairs first aid kit and book 1 2 3 4 5 Anchor and extra anchor line water proof storage containers 6 Manual bilge pump and extra drain plugs compass and map or chart of area 7 Spare operating equipment batteries bulbs fuses etc 8 Transistor radio 9 Drinking water e Know signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you expect to return e Passenger boarding Stop the engine whenever passengers are boarding
18. your boat owner s manual 3 Place control handle in NEUTRAL FLOODED ENGINE Turn ignition switch to ON position Place the throttle lever at 5096 position Attempt to start engine As soon as engine starts return throttle to the idle position 4 Turn ignition key to START Release key when engine starts and allow switch to return to RUN position 5 Check oil pressure gauge immediately after engine starts If oil pressure is not within specified range see SPECIFICATIONS stop engine immediately and determine cause 6 After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnor mally high If it is stop engine immediately and determine cause 7 Be sure charging system is functioning correctly 8 Observe power package for fuel oil water and exhaust leaks 9 To shift unit into gear move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shift to REVERSE After shifting unit advance throttle to desired setting 10 To shift unit out of gear move control shift lever to NEUTRAL and allow engine to drop to IDLE speed If engine has been run at high speed for a long period of time allow engine to cool by running at IDLE speed for 3 to 5 min utes 11 Turn ignition key to OFF 22 CC98 BEFORE STARTING Open engine hatch Check engine oil level Turn battery switch ON if so equipped Operate bilge blowers if so equipped Ope
19. 50 low quality oils or oils which contain solid additives specifically are not recommended Quicksilver 4 Cycle Marine Engine Oil E SAE 30W SG or CD II SAE 20W SG or CD II mE 32 F 50 F o c 10 C 70534 AIR TEMPERATURE 26 CC337 7 PALA Engine Specifications MODEL 350 MAGNUM EFI TOURNAMENT SKI Propshaft Horsepower Propshaft Kilowatts 1 Displacement 350 1 0 5 7 L Engine Type 101 6 mm 88 39 mm 150 psi 1035 kPa i 3 be ub bia 4400 4800 RPM 3 Idle RPM in Fuel Pump Pressure 3 9 psi 21 63 kPa Oil Pressure 2000 RPM 30 70 psi 207 483 kPa 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 Engine Rated with Velvet Drive 1 1 In Line Transmission Power Output with Other Transmissions Will Be Less 3 Engine is equipped with an RPM Rev Limiter This limiter is designed to help prevent damage from engine over speed When the engine reaches preset RPM fuel is momentarily shut off to the fuel injectors Once the RPM drops below preset limit complete fuel delivery resumes 27 CC338 Tune Up Specifications MODEL 350 MAGNUM EFI TOURNAMENT SKI Spark Plug Type AC MR43T Champion RV15YC4 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
20. Ground Alternator 65 Amps Minimum Recommended Battery Rating 550 cca 700 mca or 120 Ah 1 Timing must be set using a special procedure as outlined in the appropriate Service manual Timing cannot be properly set using the conventional method CC339 M Capacities MODEL 350 MAGNUM EFI TOURNAMENT SKI Crankcase Oil Approx 5 U S Qts Capacity w New Filter b 1 4L Seawater Cooling System 15 Qts 14 2L Transmission Velvet Drive 1 1 2 Qts 1 9L Always use dipstick to determine exact quantity of oil required 2Seawater Cooling System capacity information is for winterization use only 28 THIS PAGE IS INTENTIONALLY BLANK CC263 Maintenance GASOLINE 30 CC103 Maintenance EFI System Maintenance Precautions Avoid Injury or Electrical System Damage Always disconnect battery cables from battery before working around electrical system components See IMPORTANT statement following ACAUTION Avoid damage to the E F l electrical system components Refer to the following precautions when working on or around the E F I electrical harness or when adding other electrical accessories DO tap accessories into engine harness DO NOT puncture wires for testing Probing DO NOT reverse battery leads e DO NOT splice wires into harness DO NOT attempt diagnostics without proper approved Service Tools CC316 Maintenance Products Always disconnect battery cables f
21. IS INTENTIONALLY BLANK Cold Weather or Extended Storage Power Package Layup IMPORTANT This service should be performed by an Authorized MerCruiser Dealer ACAUTION DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be dam aged and subsequent overheating damage to engine or stern drive unit may result IMPORTANT Before starting engine a water source must be attached to the seawater pump Follow all warnings and flushing attachment procedures stated in FLUSHING COOLING SYSTEM 1 Run engine sufficiently to bring it up to normal operating temperature Shut off engine and change oil and oil filter 2 Flush cooling system CC349 Avoid Fire or Explosion Be sure engine compartment is well ventilated and no gasoline vapors are pres ent during the following operation Avoid Fire or Explosion Fuel injection system is pressurized during operation Use care when removing plug from vapor separator tank Fuel could spray on hot engine causing fire or explosion Allow engine to cool down before attempting to remove the vapor separator tank plug in the following procedure Also hold a clean shop towel over the plug when removing it to help avoid fuel spraying on the engine Prepare fuel system for extended storage as follows Allow engine to cool down Remove plug from top of vapor separator tank Add approximately 1 fluid ounce 30 ml of Quicksilver 2 Cycle Outboard
22. IU 8 How Elevation and Climate Affect Performance od scat vM Bacal 9 important Information x 2 oce pega ie teresa NR aap BAS Sec pA EPOR R s E S BURN 10 Operation And Maintenance isse c gp ERE EREGE ee eed 10 Launching And Boat Operation Care uds sitem hi tinc os xD os eee a P aie E s RR Eee Raa 10 Freezing Temperature Operation pp 11 Attention Required After Submersion pp 11 Stolen Power Paekdu6 etr e tu e ed PP de d feet ise Eee EG E ate eae Be 11 Replacement Service Parts ROCK TERT RAL ee ae CRUEL OC 11 Do It Yourself Maintenance Suggestions pp 12 Diagnosing EFI Problems ure e e eR Rem ERUDO GERI ERE Nds m baad oe bed 12 20 Hour Break In Period rccte MU E AM MM AM EAE 13 After Break In CRO a cos ers tpe ica eco Melty dete ated Denn aa decus OAs ege Mo tate des Nap uo Gast dU 13 Checkup s use ierit e ERU S MORI cate a eae cars M 13 Operation vue a ue a ore rot ed edic iate a Lap d auper t date Red t DCN E 14 STURM IMAL ON eruere testet ee rta ox a wire ox x SR E o NEG Des wA ER Moe ORC E A RR 15 Audio Warning seres Gy Rire etos Dp Sepa dedi duet qued Pup ete at o Dee
23. 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 4822 Verviers Belgium Telephone 0 87 32 32 11 Fax 32 87 31 19 65 70 AUSTRALIA PACIFIC Marine Power International Pty 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 Customer Service Literature English language publications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Marine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s 71 CC342 General Maintenance Parts Engine Parts 27 47510 27 58045 72 CC178 Literature Order Form Mo
24. OPERATION amp MAINTENANCE MANUAL 350 Magnum EFI Tournament Ski 1995 Brunswick Corporation 90 806586960 595 CC264 IDENTIFICATION RECORD PLEASE RECORD THE FOLLOWING INFORMATION Engine Model Horsepower 2 Engine Serial Number 3 Transmission Models Transmission Serial Number Propeller Number Pitch Diameter 5 Hull Identification Number HIN Purchase Date 6 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 NOTE The numbers seen on illustrations are reference for numbered items above CC355 Table of Contents Page Welcome MEM 3 Head This Manual Thoroughly eroe EE CREE et Ex Rute pete ep T E E ed 3 Eanyarg cuts a Sect hak eee quce sae usse ede ce M dL 4 Boating 5 Protecting People In The Water c hcc e Rp c RA ROSA Ul en RS Pl eed ge ee a 6 High Speed And High Performance Boat Operation ox stie A ERE RENT E REREN ATER ERAT eens 6 9 starsat os i e ria e erst os Mie ae ang indu ee ale es redet 7 Bottom Ot BOAR 2 cic este rece st p coge Da Put heb Sonne ded ete 7
25. Oil to fuel in the vapor separator tank Reinstall the plug in top of vapor separator tank Shut off the fuel supply to the engine s fuel pump Start and run engine at idle speed until the vapor separator tank and fuel injection system are empty and engine stops Fill fuel tank s with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gaso line Stabilizer for Marine Engines to treat gasoline Follow instructions on container 5 If boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Vapor separator tank on engine must be run dry at idle RPM Fuel tanks should be drained completely and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to FUEL REQUIREMENTS for additional information 6 Close fuel shut off valve if so equipped mmoou pm A CC185 52 CC186 Draining Instructions DRAINING SEAWATER RAW WATER COOLED MODELS 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 flow from the drain holes or removed hoses ACAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in
26. RTER MOTOR GROUND S STUD NEUTRAL START SAFETY SWITCH 71 73370 60 CC262 E F l System Harness 1 Vapor Separator Tank VST BLK BLACK 2 Throttle Body BLU BLUE 2 c LA BRN BROWN Coi 5 Knock Sensor KS Module GRN GREEN 6 Data Link Connector DLC GRY GRAY 7 Manifold Absolute Pressure MAP Sensor ORN ORANGE 8 Knock Sensor PNK PINK 9 Idle Air Control IAC PUR PURPLE 10 Throttle Position TP Sensor 11 Engine Coolant Temperature Sensor ECT x in 12 Electronic Control Module ECM 13 Fuel Pump Relay WHT WHITE 14 Ignition System Relay YEL YELLOW 15 Fuel Pump 15 Amp Fuse LT LIGHT 16 ECM Iginition Feed Knock Sensor Injectors 10 Amp Fuse DK DARK 17 ECM Battery Feed DLC 15 Amp Fuse 18 Harness Connector To Starting Charging Harness 19 Harness Connector To Lanyard Stop Switch Optional 20 Harness Connector For Dual Engine Data Link Cable 21 Positive Power Wire To Engine Circuit Breaker gt Sw NY 1HM NHD5XQ NYO 18 V lt CNY 73A 18 19 NYO NHO 73717 lI L HM NOTE All BLACK wires with a ground symbol are interconnected within the E F I system harness NOTE Component position and orientation shown above is arranged for visual clarity and ease of circuit identification 61 CA272 Warranty Information Owner Wa
27. XCLUSION 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 63 MerCruiser International Warranty Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA Vi Vil 64 We warrant each new production not those made for high performance 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 workmanship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal opera tion or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Oper ation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or prepar ing for racing or other competitive activity or operating with a racing type lower unit or 5 Alteration or removal of parts or 6 Water entering engine cylinder s through exhaust system or carburetor s Rea
28. able 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 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 distributor in your country or the Marine Power International Service Center closest to you for the transferable warranty procedure that would apply to you 67 Q Guard Product Protection Plan United States and Canada Only Certain performance products triple engine installations and commercial applications are excluded The Mercury Marine Q Guard Product Protection Plan provides coverage 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 y
29. ante n sconti tox costa x se kehrt ied US Scu ab d par pg ue a DA dius 68 Local Repair Service is p Re Ra E eae Bea x ERE EQ ue WR eT EE 68 Service Away From HOME c cue ern poc Oe CR e ERO ERROR UR T urea M es ole te oe RACES 68 Parts and Accessories Inquiries re Remo e Re e RR REUS ER AU Eder etre s 68 Resolving a Problem esee mtis tuo de eiui o ge eu Rae ae aede aded tud eM f ace lade eras 69 singe ug MC DC 70 Customer Service Literature cocer rw RO ROW ERR ORA e OUR E OUR CR e GO RODA ACE RR 71 General Maintenance Parts canens utres alae Don ae bla RAUS acta IMG uL EU tig we A DA 72 Engine Pals netted note Miwa nate BEG Webs Mea ES dette RAP S Ee fede dee beh 72 Literature Onder TEC S Nem PNE ER DIC oe xa ios E eo we ae BA reda 73 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 1995 Brunswick Corporation The following are registered trademarks of Brunswick Corporation Autoblend Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mercu
30. d by using up length in the way the lanyard and clip are attached to the operator such as wrapping the lanyard around the operator s wrist or leg or by tying a simple knot in the lanyard Read the Safety Warning on this page and the following page before electing to install use or not to use such a switch The following advantages and disadvantages of a lanyard stop switch should be considered before elect ing to use or not to use such a switch ADVANTAGES The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch This would occur if the operator falls or moves within the boat a sufficient distance from the operator s position This type of accident is most likely in certain types of boats such as low sided 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 releasing your grip on a steering wheel that is pulling in one direction 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 potentially hazardous situations 1 Loss of balance and falling forward of unstable boat passengers a
31. del 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 Total Price Official Use Only Parts Manual Drive Only C 90 4 95 Mm mem BE oo do eo Manual Grand Total 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 73 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 METHOD OF PAYMENT NO CASH OR C O D Personal Check Chshiers Check Mondy Order pa E E 3 is Card Number Visa MasterCard L L Signature Telephone Number 74 Month Year Expiration Date Date
32. e Boat Operation booklet Part Number 90 86168 3 from your dealer distributor or Mercury Marine CA7 Conditions Affecting Operation Weight Distribution Positioning of weight passengers and gear inside the boat has the following effects Shifting weight to rear stern will e Generally increases speed and engine RPM 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 Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom should be observed e Clean free of barnacles and marine growth e Free of distortion nearly flat where it contacts the water 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 CC328 Propeller Selection IMPORTANT Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute RPM Use an accurate service tachometer to verify engine operating RPM Itis the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller s Specified engine wide
33. eceding paragraph In any of these situations water entering the engine could cause severe damage to internal parts Refer to Atten tion Required After Submersion 10 15 Freezing Temperature Operation IMPORTANT It boatis operated during periods of freezing temperature precautions must be taken to pre vent freezing damage to power package Refer to COLD WEATHER or EXTENDED STORAGE for draining instructions CA18 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 CA21 Stolen Power Package If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Motor information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors CA22 Replacement Service Parts Electrical ignition and fuel system components on MerCruiser gasoline power packages are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize risks of fire or explo sion 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
34. ectrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER OPERATOR TASK INTERVAL Seawater Strainer Check and clean Before Use and Whenever Insufficient Seawater Flow is Suspected If Operating Temperature Water Pickups Check for marine growth or debris Exceeds Normal Range Engine Crankcase Oil Check level Transmission Fluid Check level Closed Cooling System Coolant Check level Weekly Battery Check level and inspect for damage Fuel Pump Sight Tube Check for no fuel present Drive Belts inspect condition and check tensions Every 100 Hours of Use or 120 Days Whichever Occurs First Once a Year Power Package Exterior Surfaces spray with Saltwater use Every 50 hours of operation or Quicksilver Corrosion Guard 60 days Whichever Occurs First Freshwater use Every 100 hours of operation or 120 days Whichever Occurs First Power Package Exterior Surfaces clean and paint Cooling System flush seawater section Saltwater Use After Each Use 32 CB310 Maintenance Chart Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL 20 Hour Checkup NOTE 1 At First 20 Hours of Operation i Whenever Insufficient Seawater Flow is Sus Sea
35. ery cable clamps and terminals and reconnect cables see CAUTION listed above Secure each cable clamp when connecting e Coat terminal connections with a battery terminal anti corrosion agent e Perform all checks in OPERATION CHART in the BEFORE STARTING column CAUTION Refer to precautions listed under FLUSHING COOLING SYSTEM before starting engine e Start engine and closely observe instrumentation to make sure that all systems are functioning correctly e Carefully inspect engine for fuel oil fluid water and exhaust leaks e Check steering system shift and throttle control for proper operation e Check fuel system sight tube for evidence of fuel If fuel is present contact your Authorized MerCruiser Dealer for repairs 54 CC121 Troubleshooting Trouble Possible Cause Starter motor e Battery switch turned off if so won t crank en equipped e Turn switch on gine or cranks it very slowly Engine won t start or is hard to start Remote control not in neutral position Open circuit breaker or blown fuse Loose or dirty electrical connec tions or damaged wiring Bad battery Improper starting procedure Empty fuel tank or fuel shut off valve closed if so equipped Faulty fuel pump Engine flooded Faulty ignition system com ponent Clogged fuel filters Contaminated fuel Fuel line or tank vent line kinked or clogged EFI System Fault Position control lever properly L
36. ever MUST BE EXACTLY in neutral Check and reset circuit breaker or replace fuse Check all associated electrical connections and wires especially battery cables Referto wiring diagram following Clean and tighten faulty connection Repair or replace wiring Test and replace if bad Review starting procedure under Operation Instructions Fill tank or open valve Check sight tube for fuel Have your dealer re place pump if fuel is present Do not attempt to start engine for at least 5 min utes then follow the procedure for starting a flooded engine found in the Operation sec tion of this manual Service ignition system Replace filters Inspect fuel for water or other contaminants If contaminated drain tank and flush with fresh fuel Replace kinked lines or blow out lines with compressed air to remove obstruction Have EFI System checked by an Authorized MerCruiser Dealer 55 Trouble Engine runs rough misses and or backfires Poor performance Excessive engine temperature 56 Possible Cause Faulty fuel pump Idle speed too low if engine is rough at idle Faulty ignition system component Clogged fuel filters Contaminated fuel Kinked or clogged fuel line or fuel tank vent line Flame arrestor plugged with foreign material System Fault Throttle not fully open Damaged or improper propeller Excessive bilge water Boat overloaded or load improp erly distr
37. g charging are explosive When charging batteries be sure battery compartment or area where batteries are located is well vented Battery electrolyte is a corro sive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body im mediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible CC71 Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom 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 CC72 Antifouling Paints In some areas it may be advisable to paint bottom to help prevent marine growth See your dealer for recommen dations for your boat CA105 Inspection And Maintenance Inspect power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessi ble engine parts Check for loose damaged or missing parts hoses and clamps tighten or replace as required Check plug leads and electrical leads for damage Remove and inspect propeller If badly nicked bent or cracked see your dealer Repair nicks and corrosion damage on power package exterior finish Use Quicksilver spray paints see your Au thorized MerCruiser Dealer 48 THIS PAGE
38. her assistance from local law enforcement CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the drive unit is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat Is Stationary Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CA283 High Speed And High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat For additional information obtain a copy of our Hi Performanc
39. ibuted Boat bottom fouled or damaged Flame arrestor dirty Engine overheating Ignition or System fault Water inlet valve closed if so equipped Alternator drive belt loose broken or in poor condition Seawater pickup pump drive belt loose broken or in poor condition Water pickup obstructed Kinked collapsed or broken hose Faulty thermostat Transmission fluid cooler and or engine oil cooler plugged with foreign material Remedy Check sight tube Have your dealer replace pump if fuel is present Check idle speed and adjust if necessary Service ignition system Replace filters Inspect fuel for water or other contaminants If contaminated drain tank and flush Fill with fresh fuel Replace line if kinked Blow out line with compressed air to remove obstruction Clean flame arrestor Have EFI System checked by an Authorized MerCruiser Dealer Inspect cable and linkages for binding ob struction or loose fasteners Replace Drain and check for cause of entry Reduce load or redistribute load more evenly Clean or repair as necessary Clean flame arrestor See Excessive engine temperature Refer to Engine runs rough misses and or backfires Open valve COMPLETELY Replace and or adjust belt Replace and or adjust belt Remove obstruction Straighten or replace hose Replace Disconnect hoses from coolers and flush out with a water hose in direction opposi
40. ilable purchaser must provide a copy of the origi nal of Sale Sales Contract for the Product to be serviced Warranty claims will not be accepted until adequate 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 obligation 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 IM PLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME COUNTRIES DO NOT AL LOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITA TION 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 of Brunswick Corporation Fond du Lac Wisconsin 54935 U S A 3 Year Limited Warranty Against Corrosion Failure Applicable in the United States Canada and Australia We warrant parts and assemb
41. l components Quicksilver Gasoline Stabilizer for Marine Engines 92 817529A12 is highly recommended for addition during storage periods See Cold Weather or Extended Storage later in this manual 25 CC218 Seacock Size Recommendation Seacock used must have an internal cross sectional area equal to or greater than hose to prevent restricting wa terflow Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue A 1 1 4 in 82mm brass ball or gate valve is suggested CC16 Sea Strainer Recommendation Strainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling engine A minimum of 30 gallons per minute 114 litres per minute flow rate is required CC18 Crankcase Oil To help obtain optimum engine performance and to provide maximum 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 classification of SG CD Il 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 available a multi viscosity 20W 40 SG CD II or a second but less preferable choice 20W 50 SG CD 1 may be used IMPORTANT The use of non detergent oils multiviscosity oils other than 20W 40 or 20W
42. ld weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s rec ommendations 8 For additional assurance against freezing and rust remove thermostat cover and thermostat Fill engine seawa ter cooling system with a mixture of antifreeze and tap water mixed to manufacturer 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 Perform all checks inspections lubrication and fluid changes outlined in MAINTENANCE CHART under AT LEAST ONCE A YEAR 53 CA115 Battery Winter Storage Follow battery manufacturer s instructions for storage CC165 Power Package Recommissioning To prevent possible injury or damage to equipment do not install battery until all maintenance has been performed on engine e Check that all cooling system hoses are connected properly and hose clamps are tight A CAUTION When installing battery be sure to connect POSITIVE battery cable to POSITIVE battery terminal FIRST and NEGATIVE battery cable to NEGATIVE battery terminal LAST If battery cables are re versed or connection order is reversed electrical system damage will result e Install fully charged battery Clean batt
43. levation and Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine Since air containing oxygen gets thinner as elevation increases the engine begins to starve for air Humidity barometric pressure and tempera ture do have a noticeable effect on the density of air Heat and humidity thin the air This condition can become particularly annoying when the propeller testing was done cool dry day Then later on a hot sultry day the boat doesn t seem to have the same performance Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists In some cases a gear ratio change to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the en gine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less than its recommended RPM This will result in further loss of h
44. lies of each 1988 and newer production MerCruiser Product sold with a one year limited Product warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inoperative as a direct result of corrosion provided the following simple precaution ary 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 completed standard Product warranty registration card and shall remain effective for a period of three years from the date of purchase lll This warranty does not cover 1 electrical system corrosion 2 corrosion resulting from damage abuse or improper service 3 corrosion to accessories instruments steering systems 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 application IV ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IM PLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUN TRIES DO NOT ALLOW LIMITATIONS ON HOW LONG
45. ls CHECKING CRANKCASE OIL 1 Stop engine Allow approximately five minutes for oil to drain into oil pan Boat must be at rest in water 2 Remove dipstick Wipe clean and reinstall fully into dipstick tube 3 Remove dipstick and observe oil level Oil level must be between FULL and ADD If oil level is below ADD 4 Remove oil filler cap Add specified oil to bring level up to but not over FULL mark on dipstick IMPORTANT Do not overfill crankcase oil CC346 CHECKING TRANSMISSION FLUID IMPORTANT Engine must be run at 1500 RPM for 2 minutes immediately prior to checking level 5 Velvet Drive Transmissions Stop engine and quickly check fluid level by turning T handle counterclockwise to remove dipstick Fluid level should be up to full mark If low add specified fluid through dipstick tube on Borg Warner transmissions 35 CC267 im 36 152 Changing Fluids See MAINTENANCE CHART for lubricant change frequency Lubricant should be changed before placing boat in storage Transmission fluid should be changed at specified intervals 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 oil drain hose that is connected near the engine thermo stat housi
46. major brand of leaded gasoline CA291 USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol also These Reformulated Gasolines are acceptable for use in your MerCruiser engine CA277 GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank 24 The fuel system components on your MerCruiser engine will withstand up to 10 alcohol content in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specif ic recommendations on the boats fuel system components fuel tanks fuel lines and fittings Be aware that gaso lines containing alcohol may cause increased e Corrosion of metal parts e Deterioration of rubber or plastic
47. n fuel shutoff valve if so equipped Open seacock if so equipped Perform all other checks specified by your dealer and or boat builder Operation Chart AFTER STARTING Observe all gauges to check condition of engine If not normal stop engine Check for fuel oil water fluid and exhaust leaks etc Check shift and throttle control operation Check steering operation WHILE UNDERWAY Observe all gauges to monitor engine condition If not normal stop engine AFTER STOPPING Turn ignition key OFF Turn battery switch OFF if so equipped Close fuel valve if so equipped Close seacock if so equipped Flush cooling system if in a saltwater area 23 CA261 Specifications Fuel Recommendations IMPORTANT Use of improper gasoline can damage your engine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and damage caused thereby will not be covered under the limited warranty FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows USA and Canada having a posted pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable DO NOT use leaded gasoline Outside USA and Canada having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a
48. ne clamping screw and nut on each side 5 Maximum mount trunnion extension is 3 4 in 20mm 6 Tab Washer After alignment is correct bend tab against flat on adjust nut IMPORTANT Be sure to recheck engine mount fasteners for adequate tightness after completing engine alignment 47 CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufacturer s specifications Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precautions when handling a battery Do not use jumper cables and a booster battery to start engine Do not recharge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames Batteries contain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries also produce hydrogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte Hy drogen gases that escape from the battery durin
49. ng Remove fitting from end of hose Lower hose into appropriate container and allow oil to drain When oil has drained completely reinstall fitting in end of hose and and secure hose to engine using the attached clip 2 Turn oil filler 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 37 CC153 38 CC51 Lubrication THROTTLE CABLE 1 Lubricate pivot points with specified motor oil CC319 SHIFT CABLE 2 Lubricate pivot points with specified motor oil 3 Lubricate poppet ball and holes in lever with specified motor oil IMPORTANT Poppet Ball MUST BE centered in detent hole for each F N R position 4 Shift lever must be over this letter when propelling boat FORWARD IMPORTANT Remote control shift cable and linkages must position transmission shift lever so that it is fully in the forward and reverse gear detent positions with the lever over the letter F on transmission case when propelling boat forward IMPROPER POSITIONING OF SHIFT LEVER MAY CAUSE TRANSMIS SION TO FAIL Damage caused to transmission as a result of improper shift
50. oblem over the telephone A doctor can t and won t diagnose your illness by telephone he must examine you personally just as a mechanic must examine your power package 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 winter ize 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 CB129 Diagnosing EFI Problems Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on the Electronic Fuel Injection EFI System The Electronic Control Module ECM on this engine has the ability to detect some prob lems with the system when they occur and store a Trouble Code in the ECM s memory This code can then be read later by a service technician using a special diagnostic tool 12 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 minimum oil consumption and maximum engine performance During this break in period the following rules must be observed Do not operate below 1500 RPM for extended periods of time for first 10 hours Shift into gear as soon as possi ble after starting and advance throttle above 1500 RPM if condition
51. on NOTE 2 Power for a Fused Accessory Panel May Be Taken from This Connection Load Must Not Exceed 40 Amps Panel Ground Wire Must Be Connected to Instrument Terminal That Has an 8 Gauge BLACK Ground Harness Wire Connected to it NOTE 3 Taped back BROWN WHITE wire may be used for an accessory LOAD MUST NOT EXCEED 5 AMPS BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK AUDIO WARNING BUZZER Oi Pressure To Engine Harness 73371 59 CC253 Starting And Charging System Harness BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK WIRING HARNESS TRANS FLUID TEMPERATURE SWITCH GRY 2 PUR 5 TAN BLU 4 REO PUR 6 BLK 1 YEL RED 7 LIT BLU 8 TAN 3 BRN WHT 10 OIL PRESSURE SWITCH A Charging and Starting Circuit B Audio Warning Power Reduction Circuit C Instrumentation Senders 1 Harness Connector To EFI System Harness 2 Positive Power Wire System Harness 3 Auxiliary Tachometer Lead PRESSURE i SENDER lt 3 WATER TEMPERATURE o SENDER STARTER SLAVE SOLENOID 9 LA CIRCUIT Bee BREAKER STA
52. on are major accident prevention measures WARNING Hazards or unsafe practices which could result in severe personal injury or death A 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 main tenance CA280 Lanyard Stop Switch ANNNAAAAAN 1 Some boats come equipped with alanyard stop switch Alanyard stop switch can also be installed as an acces sory The purpose of this switch is to turn off the engine ignition whenever the operator when attached to the lan yard moves far enough away from the operator s position to activate the switch 74608 2 The lanyard is a cord usually between 4 and 5 feet 1220 and 1524 mm in length when stretched out with an element on one end made to be inserted into the switch and a metal snap on the other end for attaching to the operator It is coiled to make its at rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s posi tion If for any reason it is desired to have a shorter functional lanyard this may be accomplishe
53. orsepower at the propeller with another de crease in boat speed This secondary loss however can be somewhat regained by switching to a lower pitch pro peller 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 en gine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation This of course enhances overall reliability and durability of the engine CA13 Important Information Operation And Maintenance OWNER OPERATOR RESPONSIBILITIES Itis the operator s responsibility to perform all safety checks to ensure that all lubrication and maintenance instruc tions are complied with for safe operation and to return the unit to an Authorized MerCruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the responsibility of the owner operator and as such are not considered defects in workmanship or material within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your power package will assure optimum performance and dependability and Will kee
54. ote control in NEUTRAL idle speed position and start engine Operate engine at idle speed in NEUTRAL for about 10 minutes or until discharge water is clear Stop engine Shut off water remove flushing connector from pump inlet and reconnect water inlet hose Tighten hose clamp securely CC58 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer 3 Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected if operating temperature exceeds normal range 41 CC269 Maintenance continued 42 CC62 Drive Belts Avoid injury caused by hands or clothing being caught between belts and pulleys Make sure engine is shut off and ignition key is removed before inspecting belts All drive belts must be periodically inspected for condition and tension Perform the following inspections of alternator drive belt and seawater pickup pump drive belt If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 2 Seawater Pump Drive Belt Inspect drive belt for excessive wear or damage Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 43 CC348 44 CC157 Flame Arrestor And Crankca
55. our 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 details Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local Authorized Dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mercury 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 United States and Canada contact the nearest Marine Power International Service Center Parts and Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories 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 purchase genuine Quicksilver parts and accessories from the factory Mer cury Marine
56. p your overall operating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation such as 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 At the 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 immediate ly upon sale of the new product CA20 Launching And Boat Operation Care A CAUTION During launching from a trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhaust system into the cylinders The more weight on the transom the more likely this is to occur Slowing down rapidly or stopping suddenly may cause a following wave to swamp the transom In this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the pr
57. particular concern in bow rider type boats 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking While activation of the lanyard stop switch will result in immediate power shut down a boat can continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power As we cannot possibly know of and advise the boating public of all conceivable boat motor types and or poor operating practices the final decision of whether to use a lanyard stop switch rests with you the own er driver We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine and boat in an emergency 281 Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions e Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squad ron 3 The Red Cross and 4 your state or provincial boating law enforcement agency Inquiries may be made
58. parts e Fuel permeation through rubber fuel lines e Starting and operating difficulties FIRE AND EXPLOSION HAZARD Fuel leakage from any part of fuel system can be a fire and explosion hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines fittings fuel filters and carburetors fuel injection components should be in spected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration re quires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required IMPORTANT When operating a MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of storage common to boats create unique problems In cars alcohol blend fuels normally are consumed before they can absorb enough moisture to cause trouble but boats often sit idle long enough for phase separation to take place In addi tion internal corrosion may take place during storage if alcohol has washed protective oil films from inter na
59. pment and personnel This is the reason we request you use the preceding steps in sequence when you have a problem or complaint Our experience has shown that this is the most expedient and successful proce dure to follow to ensure satisfaction to our customers FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RESOLVED 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 involved 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 THE DEALER S FACILITIES OUR SERVICE CENTERS AND FACTORY DO NOT HAVE FACILITIES TO SERVICE OR REPAIR YOUR PRODUCT 69 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
60. r has sounded EXCEPT TO AVOID A HAZ ARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred When the buzzer sounds with the engine running stop engine immediately Investigate cause and correct it if pos sible If cause cannot be determined consult your Authorized MerCruiser Dealer IMPORTANT Warning buzzer will sound for 2 seconds when ignition key is turned to RUN position and engine is not started This allows the operator to test the warning buzzer prior to starting the engine 17 CC254 CC255 Electrical System Overload Protection If an electrical overload occurs a fuse will blow or the circuit breaker will trip open The cause must be found and corrected before replacing fuse or resetting circuit breaker 1 Acircuit breaker provides protection for engine wiring harness and instrumentation power lead Reset by push ing RESET button IN 2 A90 Amp fuse is located on the large post of the starter solenoid This fuse is designed to protect the engine wiring harness if an electrical overload occurs In an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or disconnect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system
61. r power package are highly technical pieces of machin ery Electronic ignition and electronic fuel injection systems provide greater fuel economies but also are more complex for the untrained mechanic Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions Cau tions and Warnings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you order the service manual for that model The ser vice manual outlines 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 perform some repairs Do not attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you Also if you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or request the repair procedure It is difficult for them to diagnose a pr
62. rn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 5 Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from Neutral with a quick firm motion to the first detent for Forward gear Continue pushing forward to increase speed Pull the control handle back from Neutral with a quick firm motion to the first detent for Reverse gear Continue pushing back to increase speed CAUTION DO NOT shift the control handle into Reverse when the engine is not running Forcing the shift mecha nism into Reverse when the engine is not running could damage the remote control mechanism 21 CC 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 e 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 e Never shift unit unless engine is at Idle RPM Perform the following as appropriate 1 Check all items listed in OPERATION CHART 2 Perform any other necessary checks as indicated by your dealer or specified in
63. rom battery before working around electrical system components to prevent injury to yourself or damage to electrical system IMPORTANT Referto MAINTENANCE CHART for complete listing of all scheduled maintenance to be per formed Some listings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempting maintenance or repair procedures not covered in this manual it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly ACAUTION Avoid damage to transmission The transmission on your MerCruiser product is filled with Dexron Ill trans mission fluid at the factory Do not mix other transmission fluids with Dexron transmission fluid 1 Velvet Drive Transmission Dexron III Transmission Fluid or 10 wt tractor hydraulic fluid meeting the C 3 TO 2 specification Preferably Mobil 424 Chevron or Citgo 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Crankcase Oil Quicksilver 4 Cycle Marine Engine Oil Refer to SPECIFICATIONS for alternatives and oil rec ommendations for varying ambient temperatures 5 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard 6 Gasoline Stabilizer Quicksilver Gasoline Stabilizer for Marine Engines CC285 Maintenance Schedules Always disconnect battery cables from battery BEFORE working around el
64. rranty Registration UNITED STATES AND CANADA ONLY Itis important that your selling dealer fills out the Warranty Registration Card completely and mails it to the facto ry immediately upon sale of the new product It identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address The dealer also certifies that you are the original purchaser and user of the product Upon receipt of the Warranty Registration Card at the factory you will issued a plastic Owner Warranty Regis tration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be required Warranty claims will not be accepted without presentation of this card A temporary 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 during this period present the temporary registration card to the dealer He will attach it to your warranty claim form Because of your selling dealer s continuing personal interest in your satisfaction the product should be returned to him for warranty service If your plastic card is not received within 30 days from date of new product sale please contact your selling deal er The product warranty is
65. ry Marine Quicksilver Ride Guide and Thruster Printed in U S A CA165 Welcome You have selected one of the finest marine power packages available It incorporates numerous design features to assure operating ease and durability With proper care and maintenance you will thoroughly enjoy using this product for many boating seasons To en sure maximum performance and carefree use we ask that 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 AC TUAL STARTING AND OPERATING PROCEDURES NOTICE Throughout this publication and on your power package WARNINGS and CAUTIONS accompanied by the Inter national Hazard Symbol 4 may be used to alert the installer user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special in structions while performing the service plus common sense operati
66. s permit safe operation Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during first 10 hours During next 10 hours occasional operation at full throttle is per missible 5 minutes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operating temperature Frequently check crankcase oil level Add oil if needed Itis normal 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 following recommendations should be considered Use propeller that allows the engine to operate at or near the top of the maximum RPM range See Specifica tions 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 CC194 20 Hour Checkup After first 20 hours of operation an Authorized MerCruiser Dealer should be contacted for the following mainte nance The boat owner is responsible for any charges Change crankcase oil and filter Check all fluid levels Cooling System Inspect all hoses for damage and deterioration check all hose clamps for adequate tightness
67. se Vent Hoses Be careful when servicing flame arrestor and crankcase ventilation hose gasoline is extremely flammable and highly explosive under certain conditions Be sure that ignition key is OFF DO NOT smoke or allow sources fo spark or open flame in area when servicing flame arrestor and crankcase ventilation hose 1 Remove nut sealing washer and cover 2 Then remove vent hoses and flame arrestor Clean Flame arrestor and vent hoses in solvent and dry Install all parts and tighten nut securely CC158 Sight Tube Inspection 3 The engine is equipped with fuel system sight tubes which provide a visual indication of a problem in the fuel delivery system There is one coming from the mechanical fuel pump and one coming from the vapor seperator tank Both of the tubes are joined together and drain into the intake manifold If there is fuel visible in the sight tube have your engine repaired by an Authorized MerCruiser Dealer immediately A Fuel Pump Sight Tube See Illustration B Vapor Seperator Tank Sight Tube See Illustration CC159 Water Separating Fuel Filter Be careful when changing water separating fuel filter Gasoline is extremely flammable and highly explo sive 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 Make sure no fuel leaks exist before closing engine hatch 4 Remove water separating f
68. se 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 transom assembly In addition care must be taken to avoid an electrical interconnection between the MerCruiser Product and the paint Corrosion 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 65 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 Installation 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 distribution is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have Warranty Does Not Apply To The Following Minor adjustments and tune ups including checking cleaning or adjus
69. 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 purchase Since this warranty applies to defects in material and workmanship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal opera tion or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Oper ation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or prepar ing for racing or other competitive activity or operating with a racing type lower unit 5 Alteration or removal of parts or 6 Water entering engine cylinder s through the exhaust system or carburetor s Reasonable access must be provided to the product for warranty 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 replacement 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 Product for inspection to a MerCruiser dealer autho rized to service the Purchaser s product If purchaser cannot deliver Product to such
70. sonable access must be provided to the Product for warranty 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 replacement 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 Product for inspection to a MerCruiser dealer autho rized to service the Product If purchaser cannot deliver Product to such authorized 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 Pur chaser 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 expenses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transporta tion charges prepaid Purchaser must provide proof of purchase and substantiate date of purchase by presenting the Purchas er s Copy of the Warranty Registration Card or the plastic Warranty Registration Card to the dealer autho rized to service the Product If either of these items is not ava
71. te normal water flow continued next page Trouble Excessive engine temperature continued Insufficient engine temperature Low engine oil pressure Excessive trans mission fluid temperature or slipping trans mission Battery will not come up on charge Remote control operates hard binds has exces sive free play or makes unusual sounds Possible Cause Coolant level low in fresh water section Heat exchanger cores plugged with foreign material Loss of pressure in fresh water section Faulty thermostat Insufficient oil in crank case Excessive oil in crankcase causing it to become aerated Diluted or improper viscosity oil Engine oil cooler hose kinked causing excessive oil temper ature and thinning of the oil Low fluid level Transmission shift lever not posi tioned properly causing clutches to slip and overheat fluid Fluid cooler hoses kinked Excessive current draw from bat tery Loose or dirty electrical connec tions or damaged wiring Alternator drive belt loose or in poor condition Unacceptable battery condition Insufficient lubrication on shift and throttle linkages Loose or missing shift and throttle linkage fasteners Obstruction in shift or throttle linkages Shift or throttle cable kinked Check for cause of low coolant level and repair Fill system with proper coolant solution Clean Check for leaks Clean test and inspect pres sure cap
72. ting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection with normal services Damage caused by neglect lack of maintenance accident abnormal operation or improper installation or ser vice 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 Reason able access must be provided to the product for warranty service Customer must deliver product to an Autho rized Dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by otherthan an Authorized Dealer may be covered 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 per formed at this facility All incidental and or consequential damages storage charges telephone or rental charges of any type incon venience or loss of time or income are the owner s responsibility Use of other than Quicksilver replacement parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused
73. trapped water causing freeze and or corrosion damage to engine Ensure engine is as level as possible to ensure complete draining of cooling system Remove drain plugs from cylinder block as follows Port Side from cylinder block Starboard Side from Y fitting Do not disturb 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 tight ened to a Critical specification at the factory 3 Remove drain plug from transmission cooler 4 Remove the drain plugs from bottom of exhaust manifolds port and stbd 5 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained gt NOTE may be necessary to lift or bend hoses to allow water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow engine to start Loosen hose clamps and disconnect the following hoses 6 From engine circulating pump 7 From seawater pickup pump both hoses After cooling system has drained completely coat drain plug threads with Quicksilver Perfect Seal and reinstall drain plugs Reconnect hoses and tighten all hose clamps securely IMPORTANT MerCruiser recommends that propylene glycol antifreeze nontoxic and biodegradable which makes it friendly to lakes and rivers be used in seawater section of the cooling system for co
74. uel filter by turning counterclockwise and sealing ring from mounting bracket and discard Coat sealing rings on new filter with motor oil Thread filter 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 immediately and contact your Authorized MerCruiser Dealer 45 CC69 TYPICAL FRONT MOUNT TYPICAL REAR MOUNT 46 CC70 Engine Alignment Engine alignment should be checked by your Authorized MerCruiser Dealer at specified intervals IMPORTANT Engine alignment must be checked with boat in the water fuel tanks filled and with a normal load on board 1 Engine must be aligned so that transmission and propeller shaft coupling centerlines are aligned and coupling faces are parallel within 003 in 07mm After alignment is correct coupler attaching screws and nuts must be torqued to 50 Ib ft 68 N m 2 Locking Nut After alignment is correct tighten securely 3 Adjusting Nut Turning nut clockwise lowers engine IMPORTANT Both front mounts or rear mounts adjusting nuts must be turned equally to keep engine level from side to side 4 Clamping Screw s and Nut s Loosen to allow sideways movement of engine After alignment is correct tight en securely NOTE Some rear mounts have two clamping screws and nuts on each side others have only o
75. ur ability to react quickly e Know your boating area and avoid hazardous locations e Bealert The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should blockthe operators view when operating the boat above idle or planing transition speed Watch the other guy the water and your wake e Never drive your boat directly behind a water skier in case the skier falls As an example your boat travel ing at 25 miles per hour 40 km hr in 5 seconds will overtake a fallen skier who was 200 feet in front of you e Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water e Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek furt
76. water Pickup Pump Disassemble pected If Operating Temperature Exceeds Nor and Inspect mal Range Transmission Fluid Chan After first 20 hours then every 100 rANSIMISSION EUI ange hours of operation thereafter Crankcase Oil and Oil Filter change Ignition System clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose clean and inspect _ Every 100 Hours of Operation or ee uae Once Yearly Whichever Occurs Replace Positive Crankcase Ventilation Valve zi In Line Fuel Filter Mounted on port side of Plenum Electrical system Check for loose or damaged wiring Cooling system hoses and clamps Inspect for damage and deterioration Check clamps for tightness Saltwater use Every 50 hours of operation or 60 days Whichever Occurs First Engine Exhaust System Inspect externally for Freshwater use Every 100 hours of operation damage deterioration and restrictions Check or 120 days Whichever Occurs First clamps for tightness Shift and Throttle Cable and Linkage Lubri cate and inspect for loose damaged or miss ing parts Ignition System check timing adjust if needed Fuel Filter replace Once a Year Steering Head and Remote Control Inspect and lubricate Throttle Body Inspect NOTE 1 Fora list of 20 Hour Checkup maintenance items to be performed see IMPORTANT INFORMATION section of this manual 33 CC265 73694 34 CC37 Checking Fluid Leve

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