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Gasoline Engine - 8.1L Inboard Models

1. CC989 Changing Fluids Refer to Maintenance for change interval Crankcase oil should be changed before placing boat in storage Changing Crankcase Oil and Filter IMPORTANT Change crankcase oil when engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended engine oil refer to Specifications 1 With engine at normal operating temperature remove dipstick Install Quicksilver Crankcase Oil Pump onto dipstick tube 2 Insert hose end of crankcase oil pump into an appropriate container and using handle pump until crankcase is empty Remove crankcase oil pump NOTE Alternately the crankcase oil may be drained using the oil pan drain plug and a suitable container placed under the engine Tighten the oil pan drain plug securely upon installation 3 Remove and discard old oil filter and old sealing ring 4 Coat sealing ring on new oil filter with new engine oil Install new oil filter Tighten oil filter securely Hand tighten only do not use a filter wrench DO NOT overtighten 5 Remove oil filler cap Add recommended engine oil to bring level up to but not over FULL OK RANGE mark on dipstick Refer to Specifications IMPORTANT Always use dipstick to determine exactly how much oil is required ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restricted by law Do
2. RESUME A Maintenance 36 Maintenance 42 223 eri oem Sl ot re eode e b b e ap Dr tale e b d 36 lluid Capacllles ceo na toa oe a ia ea rd 36 Maintenance Chart CHA 37 Checking Fluid Levels a A Ad d b AA 41 ENANOS seh atten it US ES 43 Changing Water Separating Fuel Filter 45 Cleaning Flame 5 dd As 47 Ro O Bid p SUE cd e aene 49 Serpentine Drive Belt E anak dead 50 Batey M ETUR RH EN 51 Inspection And Maintenance Peer e E E 51 Cold Weather or Extended Storage 52 Power Package bay Up id cere ER REESE EE dE beu WE ER ES RS 52 Draining e ey OC ete i ue acd 55 Flushing Cooling System uo coo A Ren Se a tese sales m a eae 58 Battery Winter Storage ae qu totum s 59 Power Package Recommissioning 4 3 64 200i kl eR eee RR Rm Re a AER 59 Troubleshooting 61 Owner Service Assistance 64 455 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that
3. 77618 859 Welcome You have selected one of the finest marine power packages available It incorporates numerous design features to assure operating ease and durability With proper care and maintenance you will thoroughly enjoy using this product for many boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation Maintenance and Warranty Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Mercury MerCruiser products We sincerely hope your boating will be pleasant Consumer Affairs Department CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Sections of this manual The warranty statement contains a description of what is covered what is not covered the duration of coverage how to best obtain warranty coverage important disclaimers and limitations of damages and other related information Please review this important information CC961 IMPORTANT This manual contains basic Operation Maintenance and Warranty information for your Mercury MerCruiser power package If you desire to perform some of the maintenance items on your own you should o
4. 463 Customer Service Literature English Language English language publications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Mercury Marine or Marine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s CA781 Other Languages To obtain an Operation and Maintenance and Warranty Manual in another language contact the nearest Mercury Marine or Marine Power International Service Center for information A list of part numbers for other languages is provided with your power package caa781 Andre sprog Kontakt det naermeste Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual et andet sprog En liste med reservedelsnumre for andre sprog leveres sammen med din power pakke cab781 Andere talen Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hierover Een lijst met onderdeelnummers voor andere talen wordt bij uw mo
5. 2000 Merry Maie Gasoline Engine 8 1L Inboard Models CA940 Identification Record PLEASE RECORD THE FOLLOWING INFORMATION 1 Engine Model and Horsepower Engine Serial Number 2 Transom Assembly Serial Number Sterndrive Gear Ratio Sterndrive Unit Serial Number 3 Transmission Model Inboard Gear Ratio Transmission Serial Number 4 Propeller Number Pitch Diameter 5 Hull Identification Number HIN Purchase Date 6 Boat Manufacturer Boat Model Length T Exhaust Gas Emissions Certificate Number Europe Only SERIAL NUMBERS The serial numbers are the manufacturer s keys to numerous engineering details which apply to your Mercury MerCruiser power package When contacting your Authorized Mercury MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2000 Mercury Marine The following are registered trademarks of Brunswick Corporation AutoBlend Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mercury Marine Quicksilver RideGuide Thruster and MMPP CC1005 1 7
6. Bottom Of Boat To maintain maximum speed the boat bottom should be e Clean free of barnacles and marine growth e Free of distortion nearly flat where it contacts the water e 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 CC1027 Propeller Selection IMPORTANT Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute rpm Use an accurate service tachometer to verify engine operating rpm It is the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller Refer to Specifications for engine WOT and operating rpm range 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 recommended operating rpm range normal engine operation resumes Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide open throttle operating rpm range with a normal load If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible en
7. CC1017 CC1024 SINGLE POINT DRAIN SYSTEM Freeze damage can occur if operating where temperatures are below 32 F Use Manual Drain System to ensure heat exchanger is completely drained NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Remove air pump from engine Ensure that lever on top of pump is flush with the handle horizontal Install air pump on the actuator fitting 2 3 4 Pull lever on air pump up vertical to lock pump on actuator fitting 5 Pump air into the system until both green indicators extend and water drains from both sides of the engine 6 Most water will drain from the engine in 3 4 minutes however some will remain trapped in the heat exchanger In order to prevent freeze damage leave system pressurized while transporting boat or during other maintenance items to allow the remaining water to drain IMPORTANT Before launching boat pull up on manual release valve A Verify that green indicators are no longer extended Manual release valve may not close completely Ensure valve is completely seated MANUAL DRAIN SYSTEM NOTE If air actuated drain system fails use the blue drain plugs to drain engine NOTE It may be necessary to lift bend or lower hoses to allow water to drain completely when hoses are disconnected 7 Remove blue drain plugs from front and rear of cool fuel cell and from the seawater pump
8. cah781 Outros Idiomas Para obter um Manual de e Manutenc o em outro idioma contate o Centro de Servico Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informacdes Uma lista de n meros de refer ncia para outros idiomas fornecida com o seu pacote de propuls o caj781 Otros idiomas Para obtener un Manual de operaci n y mantenimiento en otro idioma p ngase en contacto con el centro de servicio m s cercano de Mercury Marine o Marine Power International para recibir informaci n Con su conjunto motriz se entrega una lista de los n meros de pieza para los otros idiomas cak781 Andra spr k F r att fa Instruktions och underh llsb cker andra sprak kontakta narmaste Mercury Marine eller Marine Power International servicecenter som kan ge ytterligare information En f rteckning artikelnummer spr k medf ljer ditt kraftpaket CAm781 AAAEG yAo00 G Tia va axroxmoete va Aertovpylas Zuvimpnons oe GAA yAoo00Q ENLXAOLVOV NOTE TO mAnoveotepo Mercury Marine ths Marine Power yia 2 To voyvoc OVVOSEVETAL d c YAWOOES CA906 Ordering Literature Before ordering literature please have the following information about your power package a
9. 8 Remove end caps sealing washers and gaskets from heat exchangers 9 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 10 Remove both hoses from seawater pump 11 Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump DO NOT ALLOW ENGINE TO START 57 CC1014 CC991 Flushing Cooling System When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possible injury remove propeller Do not run engine above 1500 rpm when flushing Suction created by seawater pickup pump may col lapse flushing hose causing engine to overheat Watch temperature gauge on dash to ensure that engine does overheat If cooling system is to be flushed with boat in the water water inlet valve if equipped must be closed or water inlet hose must be disconnected and plugged to prevent water from flowing into boat If boat is in the water do not open water inlet valve until engine is to be restarted to prevent contami nated water from flowing back into engine NOTE To prevent silt and or salt buildup in cooling system flush with freshwater at specified intervals 1 Disconnect water inlet hose upper hose from aft end of seawater pickup pump Using appropriate connector connect hose between connector and water tap 2 Partially open water tap about 1 2 maximum 3 Place remote co
10. Avoid Fire or Explosion Fuel injection system is pressurized during operation Use care when removing water separating fuel filter Fuel could spray on hot engine causing fire or explosion Allow engine to cool down before attempting to remove the water separating fuel filter in the following procedure Also hold a clean shop towel over the water separating fuel filter when removing it to help avoid fuel spraying on the engine DO NOT operate engine without water flowing through seawater pickup pump as pump impeller may be damaged and subsequent overheating damage to engine may result IMPORTANT Before starting engine a water source must be attached to the seawater pickup pump Follow all warnings and flushing attachments procedures stated in Flushing Cooling System 1 Fill fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat gasoline Follow instructions on container 2 If boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Fuel tanks should be drained as low as possible and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to Fuel Recommendations for additional information NOTE If desired a portable fuel tank can be used to perform the remainder of the power package layup procedures Be sure to add an appropriate amou
11. not spill oil or oil waste into the environment when using or servicing your boat Contain and dispose of oil or oil waste as defined by local authorities 43 CC1011 CC1003 Changing Water Separating Fuel Filter Be careful when changing water separating fuel filter Gasoline is extremely flammable and highly explosive under certain conditions Be sure ignition key is OFF Do not smoke or allow spark or open flame in area when changing fuel filter Wipe up any spilled fuel immediately Make sure fuel leaks exist before closing engine hatch The electric fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together Do not install additional fuel filters and or water separating fuel filters between fuel tank and engine The installation of additional fuel filters and or water separating fuel filters may cause e Fuel Vapor Locking e Difficult Warm Starting e Piston Detonation Due to Lean Fuel Mixture e Poor Driveability 1 Remove water separating fuel filter and sealing ring from mounting bracket Discard filter and sealing ring ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restricted by law Do not spill oil or oil waste into the environment when using or servicing your boat Contain and dispose of oil or oil waste as defined by local authorities 2 Coat seal
12. of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the 5 Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty Refer to Table of Contents IMPORTANT Registration lists must be maintained by the 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 factory copy to the Marine Power International Service Center for your area 860 Warranty Policies Mercury MerCruiser Limited Warranty Gasoline Engines UNITED STATES AND CANADA ONLY VI We warrant each new production not those made for high performance purposes Mercury MerCruiser Sterndrive 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 customer purchases or obtains predelivery service from a Dealer authorized by us to distribute Mercury MerCruiser Product in the country in which the sale or predelivery servi
13. 4 Participating in or preparing 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 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 Mercury Mer Cruiser dealer authorized to service the Product If purchaser cannot deliver Product to such autho rized dealer he may give notice in writing to the Marine Power Service Center or distributor The Marine Power Service Center or distributor shall then arrange for the inspection and repair provided such ser vice 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 pur chaser for inspection or repair must be shipped with transportation charges prepaid Purchaser must provide proof of purchase and s
14. Marine Engine Oil Refer to Specifications for alternatives and oil recommendations for varying ambient temperatures 3 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard 4 Closed Cooling System Coolant Extended Life Ethylene Glycol 5 100 Antifreeze Coolant mixed 50 50 with purified water If this is not available use a 50 50 mixture of ethylene glycol antifreeze and tap water Areas where temperatures generally do not go below 32 F 0 C rust inhibitor and tap water is acceptable CC997 Fluid Capacities ENGINE NOTICE Unit Of Measurement U S Quarts Liters All capacities are approximate fluid measures IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines 496 cid 8 1 1 CL AULAM O 9 8 5 Seawater Cooling System 19 18 Closed Cooling System 20 19 1 Always use dipstick to determine exact quantity of oil or fluid required Seawater Cooling System capacity information is for winterization use only TRANSMISSION NOTICE Unit Of Measurement U S Quarts Liters capacities are approximate fluid measures NOTE Always use dipstick to determine exact quantity of fluid required Make and Model Fluid Type Velvet Drive Dexron Automatic Transmission Fluid ZF Hurth 4 1 4 4 0 3 1 4 3 0 5 3 4 5 5 Dexron Automatic Transmission Fluid
15. United States And Canada Only Certain performance products triple engine installations and commercial applications are excluded The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Mercury Product Protection Plan is the only Factory Plan available for your engine Two three or four year term plans can be purchased up to 12 months after the original engine registration date See your participating Mercury MerCruiser dealer for complete program details CC890 Read This Manual Thoroughly IF YOU DON T UNDERSTAND ANY PORTION CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES NOTICE Throughout this publication and on your power package WARNINGS and CAUTIONS accompanied by the International Hazard Symbol may be used to alert the installer user to special instructions concerning particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special instructions while performing the service plus sense operation are major accident prevention measures WARNING Hazards or unsafe practices which could result in severe personal injury or death CAUTION Hazards or unsafe practices which could
16. 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 861 3 Year Limited Warranty Against Corrosion Failure Applicable In The United States Canada And Australia I We warrant parts and assemblies of each 1988 and newer production Mercury 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 precautionary steps which are specified in Owner s Manuals have been taken 1 Specified maintenance procedures such as replacement of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below ll 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 Dri
17. 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 Avoid serious injury from gasoline fire or explosion 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 Hydrogen gases that escape from the battery during charging are explosive When charging batteries be sure battery compartment or area where batteries are located is well vented Battery electrolyte is a corrosive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible CA962 Inspection A
18. capacities refer to your boat capacity plate Know your boat s operating and loading limitations Know if your boat will float if full of water When in doubt contact your dealer or the boats manufacturer 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 See that all passengers have a proper seat and are in it before any boat movement e Never be under the influence of alcohol or drugs while boating it is the law They impair your judgment and greatly reduce your ability to react quickly 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 Bo
19. close to another boat that has its engine running 3 Examples of poor ventilation while boat is moving A Running the boat with the trim angle of the bow too high B Running the boat with no forward hatches open station wagon effect CA476 Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions 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 Squadron 3 The Red Cross and 4 your state or provincial boating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT We strongly recommend that all powerboat operators attend one of these courses You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A e Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made Check safety equipment on board Here are suggestions of the types of safety equipm
20. damaged wiring Clogged fuel filters Replace filters Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Replace kinked lines or blow out lines with Fuel line or tank vent line kinked or clogged compressed air to remove obstruction Have EFI System checked by an Authorized Mercury MerCruiser Dealer Faulty wire connections Check wire connections CB771 Engine Runs Rough Misses And Or Backfires Have EFI system checked by an Authorized mie speed MerCruiser Dealer Faulty ignition system component Service ignition system Clogged fuel filters Replace filters Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Replace kinked lines or blow out lines with Kinked or clogged fuel line or fuel tank vent line compressed air to remove obstruction Flame Arrestor plugged with foreign material Clean Flame Arrestor EFI System fault Have EFI System checked CA952 Poor Performance Inspect throttle cable and linkages for proper Damaged or improper propeller Replace propeller Excessive bilge water Drain and check for cause of entry 61 C1028 Excessive Engine Temperature Check for cause of low coolant level and repair Fill Coolant level low in closed cooling system system with proper coolant solution Heat Exchanger Cores plugged with foreign Clean Heat Exchanger material 1 Loss of pressure in closed cooling system 20 for
21. e Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product 865 Freezing Temperature Operation IMPORTANT If boat is operated during periods of freezing temperature precautions must be taken to prevent freezing damage to power package Damage caused by freezing IS NOT covered by Mercury MerCruiser Limited Warranty 867 Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normally equipped with a drain plug and or a bilge pump It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package Components on your engine will be damaged if submerged Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty 869 Attention Required After Submersion e Before recovery contact an Authorized Mercury MerCruiser Dealer e After recovery immediate service by an Authorized Mercury MerCruiser Dealer is required to prevent serious damage to power package 21 CA20 Launching And Boat Operation Care 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 m
22. engine damage Do not operate engine once the alarm has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred When the alarm sounds with the engine running stop engine immediately Investigate cause and correct it if possible If cause cannot be determined consult your Authorized Mercury MerCruiser Dealer 27 CC1006 CC1002 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 pushing RESET button IN NOTE 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 2 A90 Amp fuse is located on the starter solenoid This fuse is designed to protect the engine wiring harness if an electrical overload occurs 3 Three fuses are located on the port side of the engine These fuses control various EFI circuits Fuel Pump Fuse 15 Amp B Injector Fuse 10
23. full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations 1 Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation The boat operator should never leave the operator s station without first disconnecting the stop switch lanyard from the operator CC670 Courtesy of AB
24. leaks Clean inspect and test pressure Kinked collapsed or broken hose Straighten or replace hose Transmission fluid cooler and or engine oil cooler Disconnect hoses from coolers and flush out with a plugged with foreign material water hose in direction opposite normal water flow 448 Insufficient Engine Temperature CC1029 Low Engine Pressure Insufficient oil in crankcase Check and add oil Check and remove required amount of oil Check for cause of excessive oil improper filling bad fuel pump Excessive oil in crankcase causing it to become aerated Engine oil cooler hose kinked causing excessive oil Straighten hose or replace if damaged temperature and thinning of the oil j 1 Change oil and oil filter using correct grade and Diluted or improper viscosity oil viscosity oil Determine cause for dilution excessive idling faulty fuel pump 524 Excessive Transmission Fluid Temperature or Slipping Transmission Low fluid level Maintain fluid level Transmission shift lever not positioned properly is causing clutches to slip and overheat fluid Inspect shift linkages and shift lever positioning Fluid cooler hoses kinked Straighten hoses or replace if damaged 450 Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Check all associated electrical connections and Loose or dirty electric
25. oil pressure is not within specified range Refer to Specifications stop engine immediately and determine cause 7 If engine is cold operate engine for 1 or 2 minutes at fast idle 1000 1500 rpm 8 After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnormally high If it is stop engine immediately and determine cause 9 Be sure charging system is functioning correctly 10 Observe power package for fuel oil water and exhaust leaks 11 To shift unit into gear move control shift lever with a firm quick motion forward to shift into FORWARD gear or backward to shift into REVERSE gear After shifting unit advance throttle to desired setting 12 To shift unit out of gear move control shift lever to NEUTRAL and allow engine to drop to IDLE speed If engine has been operating at a high speed for a long period of time allow engine to cool by operating at IDLE speed for 3 to 5 minutes 13 ignition key to OFF 31 CC829 To avoid possible ingestion of water that can damage engine components Do not turn the ignition key off when the engine is running above idle speed Do not use the lanyard stop switch to shut off the engine above idle speed When coming off plane if a large following wave may roll over the boat s transom apply a short light burst of throttle to minimize the wave action against the stern of the boat Do not come off plane quickly shift into reverse and shu
26. purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Company We shall then arrange for the inspection and repair provided such service is covered under this warranty 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 sole and exclusive 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 with new or Mercury certified remanufactured 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 Vill WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIE
27. 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 Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring on parts and accessories the dealer requires the motor model and serial 5 to order the correct parts CA904 Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us If you ever have a problem question or concern about your power package contact your dealer or any Authorized Mercury MerCruiser Dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and
28. your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product It identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address 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 be issued a plastic Owner Warranty Registration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be required 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 dealer The product warranty is not effective until the product is registered at the factory NOTICE Registra
29. 0W 40 or 20W 50 synthetic oils low quality oils or oils that contain solid additives are specifically not recommended The chart below is a guide to crankcase oil selection The oil filter should always be changed when changing engine oil Quicksilver 4 Cycle 25W 40 Marine Engine 75796 AIR TEMPERATURE CC996 Engine Specifications E Propshaft HorsePower Power Rated in Accordance with NMMA National Marine Manufacturers Association rating procedures Measured using an accurate service tachometer with engine at normal operating temperature 35 CC1018 Maintenance Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system IMPORTANT Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed Some listings be done by owner operator while others should be performed by an Authorized Mercury MerCruiser Dealer Before attempting maintenance or repair procedures not covered in this manual it is recommended that a Service Manual be purchased and read thoroughly NOTE Maintenance points are color coded for ease of identification See the decal on engine for identification Blue Coolant e Yellow Engine Oil e Orange Fuel e Brown Transmission Fluid Maintenance Aids 1 Transmission Dexron Transmission Fluid 2 Crankcase Oil Quicksilver 4 Cycle
30. 1 Fluid should be circulated and then rechecked Add additional fluid as necessary CH46 Gas Inboard Routine Maintenance Each Each Every Day Day Weekly Two Start End Months Check crankcase oil interval can be extended based on experi em ence If operating in salt brackish or polluted waters flush cooling system II each use water pickups for debris or marine growth Check water strainer and clean Check coolant level Only perform maintenance which applies to your particular power package 37 Gas Inboard Continued Scheduled Maintenance Every Every Every Every 200 300 500 1000 hours hours Every Every hours hours or3 or3 or5 5 years years hours or ally years years years years Touch up paint power package and spray with corrosion guard Change crankcase oil and filter Change transmission fluid Check steering system and remote control for loose missing or damaged parts Lubricate cables and linkages Retorque engine mounts Er Check spark plugs wires distribu tor cap and ignition timing Check and adjust idle speed Clean flame arrestor flame arrestor electrical system for loose damaged or corroded fasteners Inspect condition and tension of belts Check cooling system and exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disasse
31. 863 Important Information Operation And Maintenance OWNER OPERATOR RESPONSIBILITIES It is the operator s responsibility to perform all safety checks to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized Mercury MerCruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the responsibility of the owner operator and as such are not considered defects in workmanship or material within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your power package will assure optimum performance and dependability and will keep your overall operating expenses at a minimum See your Authorized Mercury MerCruiser Dealer for service aids CA864 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 Mercury MerCruiser power package and other equipment are in proper operating condition e Make all necessary adjustments for maximum efficiency e Familiarize the customer with the on board equipment e Explain and demonstrate the operation of the power package and boat e Atthe time of delivery the dealer should provide you with a copy of a Predelivery Inspection Checklist
32. Amp C Battery Fuse 15 Amp 4 20 amp fuse may be located in ignition switch I terminal lead to protect electrical system Check for blown fuse if key is turned to START and nothing happens and circuit breaker is not tripped 29 CA933 Remote Controls CC1008 Kiekhaefer Remote Control Features Consult your dealer for a description and or demonstration of other remote controls 1 Shift Control Handle Push the control handle forward from NEUTRAL with a quick firm motion for FORWARD gear Pull the control handle back from NEUTRAL with a quick firm motion for REVERSE gear On Dual Engine Applications Both shift control handles should be moved simultaneously into the same gear A Dual Engine Shift Control Handles Dual engine applications have separate control handles for each engine The operation of the dual engine control handles is the same as the single engine control handle 2 Throttle Control Handle Push the control handle forward to increase speed Pull the control handle back to increase speed On Dual Engine Applications Always operate dual engines at similar rpm A Dual Engine Throttle Control Handles Dual engine applications have separate control handles for each engine The operation of the dual engine control handles is the same as the single engine control handle 3 Trim Button If Equipped Refer to Power Trim Operation CC995 Starting Shifting And Stopping Before s
33. S ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state Mercury MerCruiser International Warranty Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA VI We warrant each new production not those made for high performance purposes Mercury MerCruiser Sterndrive 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 customer pur chases or obtains predelivery service from a Dealer authorized by us to distribute Mercury MerCruiser Product in the country in which the sale or predelivery service occurred 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 ab normal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product
34. YC CA620 Exhaust Emissions Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards stern drives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea Avoid the combination of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes 1 Example of desired air flow through the boat CA643 POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 2 Examples of poor ventilation while boat is stationary A Running the engine when the boat is moored in a confined space B Mooring
35. aks if they existed Marine engines are expected to operate at or near full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard automotive engine For example one of the most important and probably the least suspected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket uses special materials to resist corrosive action Since marine engines must be capable of running at or near maximum rpm much of the time special valve springs valve lifters pistons bearings camshafts and other heavy duty moving parts are required for long life and peak performance These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance CA872 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 Mercury MerCruiser power package are highly technical pieces of machinery Electronic ignition and special fuel delivery systems provide greater fuel economies but also are more complex for the untrained m
36. al connections or damaged wires especially battery cables Clean and tighten wiring faulty connections Repair or replace damaged wiring Alternator drive belt loose or in poor condition Replace and or adjust Unacceptable battery condition Test battery CA901 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Insufficient lubrication on shift and throttle linkage Lubricate fasteners Check all throttle linkages If any are loose or Loose or missing shift and throttle linkages missing see Authorized Mercury MerCruiser Dealer immediately Obstruction in shift or throttle linkages Remove obstruction Straighten cable or have dealer replace cable if Shift or throttle cable kinked damaged beyond repair 63 903 Owner Service Assistance Local Repair Service Always return your Mercury MerCruiser powered boat to your local Authorized Dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser sterndrives 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
37. anship 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 adjusting 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 service or freezing temperatures Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reasonable access must be provided to the product for warranty service Customer must deliver product to an Authorized Dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an Authorized Dealer may be covered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work performed at this facility All i
38. at 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 CC828 High Speed And High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat For additional information obtain a copy of our Hi Performance Boat Operation booklet Part Number 90 849250 1 from your dealer distributor or Mercury Marine 958 Conditions Affecting Operation Weight Distribution Passengers And Gear Inside Boat Shifting weight to rear stern e Generally increases speed and engine rpm e Atextremes 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 e Improves ease of planing e Improves rough water ride e Atextremes can cause boat to veer back and forth bow steer 959
39. ated continuously year round operation you should contact your dealer at the end of the first 100 hours of operation or once yearly whichever occurs first 25 Operation CRUISELOG amp CC810 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 1 ODO BW DNDN 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 quantity of fuel in tank Hour Meter records engine running time Bilge Blower Switch Operates bilge blower If equipped See Starting Shifting and Stopping Ignition Switch allows operator to start and stop engine CC680 2 70518 CC1030 Audio Warning System Your MerCruiser power package may be equipped with an Audio Warning System The audio warning system alarm will sound if one of the following occur 1 Engine Oil Pressure Too Low 2 Engine Temperature Too Hot 3 Transmission Fluid Temperature Too Hot NOTE To test the system Turn the ignition switch to the ON position without cranking the engine The alarm will sound if the system is working correctly Avoid
40. btain a copy of the Service Manual for your particular power package Information for obtaining the Service Manual is located at the back of this manual Table of Contents Warranty Information Owner Warranty erae TE oen International Owner Registr ds eR baute eno ann e o ROLE GER e n Mercury MerCruiser Limited Warranty Gasoline Mercury MerCruiser International Warranty Gasoline Engines 3 Year Limited Warranty Against Corrosion Failure 4 Read This Manual Thoroughly General Information Lanyard Stop SWiteh UN ees Meade ERES Exhaust EMISSIONS esque tei ae wide tiles Rio Gh io Safe Boating Suggestions ed eet as ure Lak NER a EXE E ES Protecting People In The Water 3 suas eaae e al se pa DU ct Re OR Me RN High Speed And High Performance Boat Operation Conditions Affecting Operation Important Information Operation And Maintenance ues NA dos Mus irs a n AL Freezing Temperature Operation eue see eta et Db eese tes ende room NORMA BR a Drain Pl g and Bilge PUMP aa kde UE Rabe e
41. ce occurred This warranty shall become effective only upon our receipt of a completed Warranty Registration Card which shall identify the Product so registered by serial number This warranty shall remain in effect for a period of one 1 year from date of 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 operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubri cants which are not suitable for use with the Product 4 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 5 Alteration or removal of parts or 6 Water 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 Mercury MerCruiser dealer authorized to service the Purchaser s product If
42. ch engine be connected to its own battery This ensures that the engine s Electronic Control Module ECM has a stable voltage source Battery Switches Battery switches should always be positioned so each engine is running off its own battery DO NOT operate engines with switches in BOTH or ALL position In an emergency another engine s battery can be used to start an engine with a dead battery Battery Isolators Isolators can be used to charge an auxiliary battery used for powering accessories in the boat They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose Generators The generator s battery should be considered another engine s battery CA873 Diagnosing EFI Problems If Equipped NOTE All references to EFI models apply to EFI and engines Your Authorized Mercury MerCruiser Dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection EFI Systems The Electronic Control Module ECM on these engines has the ability to detect some problems with the system when they occur and store a Trouble Code in the ECM s memory This code can then be read later by a service technician using a special diagnostic tool 413 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 Duri
43. e and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the engine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less than its recommended rpm This will result in further loss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be somewhat regained by switching to a lower pitch propeller that allows the engine to again run at recommended rpm For boaters to realize optimum engine performance under changing weather conditions it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum rpm range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an rpm range that discourages detonation This of course enhances overall reliability and durability of the engine
44. e due to stray electrical currents on shore power connections nearby boats submerged metal or improper application of copper base anti fouling paint If anti fouling protection is required Tri Butyl Tin Adipate TBTA base anti fouling paints are recommended on Mercury MerCruiser boating applications In areas where Tri Butyl Tin Adipate base paints are prohibited by law copper base paints can be used on the boat hull and transom Do not apply paint to the Mercury MerCruiser drive unit or transom assembly In addition care must be taken to avoid an electrical interconnection between the Mercury 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 corrosion warranty 458 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 workm
45. echanic Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions Cautions and Warnings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you order the service manual for that model The service 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 problem over the telephone Your Authorized Dealer is there to service your power package They have qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on
46. ent to carry when boating Approved fire extinguisher s paddle or oar Signal devices flashlight rockets or flares flag and whistle or horn Spare propeller thrust hubs and an appropriate wrench Tools for necessary minor repairs first aid kit and book Anchor and extra anchor line water proof storage containers Manual bilge pump and extra drain plugs compass and map or chart of area Spare operating equipment batteries bulbs fuses etc Transistor radio Drinking water OAN Know signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you expect to return Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal Law requires that there be a U S Coast Guard approved wearable type life jacket personal flotation device correctly sized and readily accessible for every person on board plus a throwable cushion or ring We strongly advise that everyone wear life jacket at all times while in the boat Prepare other boat operators Instruct at least one person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight
47. g of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a major brand of leaded gasoline 878 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 Mercury MerCruiser engine 879 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 The fuel system components on your Mercury 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 specific recommendations on the boats fuel system components fuel tanks fuel lines and fittings Be aware that gasolines containing alcoho
48. gine damage On the other hand operating an engine above the recommended operating rpm range will cause higher than normal wear and or damage After initial propeller selection the following common problems may require that the propeller be changed to a lower pitch e Warmer weather and greater humidity cause a loss of rpm e Operating in a higher elevation causes a loss of rpm e Operating with a damaged propeller or dirty boat bottom causes a loss of rpm Operating with increased load additional passengers pulling skiers causes a loss of rpm For better acceleration such as is needed for water skiing use the next lower pitch propeller Do not operate at full throttle when using the lower pitch propeller but not pulling skiers 960 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine Since air gets thinner as elevation increases the engine begins to starve for air Humidity barometric pressure and temperature do have a noticeable effect on the density of air Heat and humidity thin the air This condition can become particularly annoying when the propeller testing was done on a cool dry day 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 possibl
49. in seawater section of cooling system Refer to Draining Instructions 11 Test coolant to ensure that it will withstand the lowest temperature expected during storage 12Service batteries 13 Clean outside of engine and repaint any areas required with Quicksilver Primer and Spray Paint After paint has dried spray Quicksilver Corrosion and Rust Preventive Type Il or wipe down with Quicksilver Storage Seal or SAE 20W engine oil 53 CA961 THIS PAGE IS INTENTIONALLY BLANK CC1023 Draining Instructions NOTE If recommended coolant is unavailable any type of ethylene glycol based antifreeze may be used but it will require replacement every two years IMPORTANT Drain seawater section of closed cooling system only IMPORTANT Boat must be as level as possible to ensure complete draining of cooling system Seawater section of cooling system MUST BE COMPLETELY drained for winter storage or immediate ly after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freeze and or corrosion damage to engine Damage caused by freezing IS NOT covered by the Mercury Mercruiser Limited Warranty IMPORTANT Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine Ensure that boat is out of the water or seacock is closed and that bilge pump is operating Excess water in the bilge can damage engine or cause boat to sink 55
50. ing ring on new water separating fuel filter with engine oil Thread water separating fuel filter onto bracket and tighten securely by hand Do not use a filter wrench 3 Start and operate engine Check water separating fuel filter connection for gasoline leaks If leaks exist stop engine immediately and recheck filter installation If leaks continue contact your Authorized Mercury MerCruiser Dealer Avoid Fire or Explosion Fuel injection system is pressurized during operation Use care when removing water separating fuel filter Fuel could spray on hot engine causing fire or explosion Allow engine to cool down before attempting to remove the water separating fuel filter in the following procedure Also hold a clean shop towel over the water separating fuel filter when removing it to help avoid fuel spraying on the engine 45 CB813 9 1 NA RR e gt 9 O 9 1 O 2 WA 70573 CC1021 Cleaning Flame Arrestor Avoid gasoline fire or explosion Gasoline is extremely flammable and highly explosive under certain conditions Be careful when cleaning flame arrestor ensure that ignition is OFF DO NOT smoke or allow sources of spark or open flame in area when cleaning flame arrestor 1 Remove engine cover 2 Remove flame arrestor 3 Clean flame arrestor in solvent Dry with compressed air or allow to air dry completely Avoid gasoline fire or explo
51. is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard IMPORTANT The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator s position Accidental ejections and falls overboard are more likely to occur in certain types of boats such as low sided sport boats or bass boats and high performance boats Accidental ejections and falls overboard are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds standing at planing speeds sitting on elevated fishing boat decks operating at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel that is pulling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a
52. l may cause increased e Corrosion of metal parts e Deterioration of rubber or plastic 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 fire and explosion hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines fittings fuel filters and carburetors fuel injection components should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation 33 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 Mercury 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 additi
53. mble and inspect seawater pump and replace worn components Clean seawater section of closed cooling system Clean inspect and test pressure cap Replace coolant 0 coolant Only perform maintenance which applies to your particular power package Whichever Occurs First CA961 THIS PAGE IS INTENTIONALLY BLANK 39 CC1009 po 77631 CC1031 Checking Fluid Levels Mercury MerCruiser recommends that the crankcase oil be checked BEFORE starting the engine If it is necessary to check the oil level after starting the engine stop engine and allow a minimum of 10 minutes for the oil to drain back into the oil pan CHECKING CRANKCASE OIL IMPORTANT Boat must be at rest in the water to obtain an accurate reading in the following procedure 1 Check oil level before starting engine 2 Remove dipstick Wipe clean NOTE Ensure that dipstick is installed with oil level indication marks facing the rear of the engine flywheel end 3 Reinstall dipstick fully into dipstick tube Wait 60 seconds to allow trapped air to vent 4 Remove dipstick and observe oil level Oil level must be between FULL or OK RANGE and ADD If oil level is below ADD 5 Remo
54. ncidental and or consequential damages storage charges telephone or rental charges of any type inconvenience 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 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 commutator 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 warra
55. nd Maintenance Inspect power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts Check for loose damaged or missing parts hoses and clamps tighten or replace as required Check plug leads and electrical leads for damage Remove and inspect propeller If badly nicked bent or cracked see your Authorized Mercury MerCruiser Dealer Repair nicks and corrosion damage on power package exterior finish Use Quicksilver spray paints see your Authorized Mercury MerCruiser Dealer 51 CC1025 Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT Mercury MerCruiser strongly recommends that this service be performed by an Authorized Mercury MerCruiser Dealer Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation to prevent a potential fire hazard BE CAREFUL while working on fuel system gasoline is extremely flammable and highly explosive under certain conditions Be sure that ignition key is OFF and do not smoke or allow sources of spark and or open flames in the area Avoid Fire or Explosion Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation
56. ng this break in period the following rules must be observed Do not operate below 1500 rpm for extended periods of time for first 10 hours Shift into gear as soon as possible after starting and advance throttle above 1500 rpm if conditions permit safe operation Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during first 10 hours During next 10 hours occasional operation at full throttle is permissible 5 minutes at a time maximum e Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operating temperature e Frequently check crankcase oil level Add oil if needed It is normal for oil consumption to be high during break in period CA874 After Break In Period To help extend the life of your Mercury MerCruiser power package the following recommendations should be considered Use a propeller that allows the engine to operate at or near the top of the maximum rpm range See Specifications section when at full throttle with a normal boat load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at maximum full throttle rpm 875 End of First Season Checkup At the end of the first season of operation an Authorized Mercury MerCruiser Dealer should be contacted to discuss and or perform various scheduled maintenance items If you are in an area where the product is oper
57. nt of Gasoline Stabilizer to the portable tank 3 Operate engine sufficiently to bring it up to normal operating temperature and allow fuel with Quicksilver Gasoline Stabilizer to circulate through fuel system Shut off engine 4 5 6 Change oil and oil filter Refer to Changing Crankcase Oil Flush cooling system Refer to Flushing Cooling System Close the fuel shut off valve if equipped If no fuel shut off valve is present a suitable method must be employed to STOP the flow of fuel from the fuel tank to the engine before proceeding 7 A B C g 8 9 Prepare fuel system for extended storage as follows Allow engine to cool down Remove the water separating fuel filter Refer to Changing Water Separating Fuel Filter Pour out a small amount of fuel into a suitable container then add approximately 2 fluid ounces 60 ml of Quicksilver 2 Cycle Outboard Oil to fuel in the water separating fuel filter Reinstall water separating fuel filter Disconnect harness connections from fuel pump and fuel boost pump Start and operate engine at idle speed until the water separating fuel filter and fuel injection system are empty and engine stops Remove and discard water separating fuel filter Install a new water separating fuel filter Reconnect harness connections at both fuel pumps Clean flame arrestor Refer to Cleaning Flame Arrestor And Related Components Lubricate all items listed in Lubrication section 10 Dra
58. ntrol 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 4 Stop engine Shut off water remove flushing connector from pump inlet and reconnect water inlet hose Tighten hose clamp securely CA115 Battery Winter Storage Follow battery manufacturer s instructions for storage CC1026 Power Package Recommissioning To prevent possible injury or damage to equipment do not install battery until all maintenance has been performed on engine Refer to FLUSHING COOLING SYSTEM before starting engine 1 Verify that all cooling system hoses are connected and tight and all drain plugs are installed and tight IMPORTANT Before launching boat pull up on manual release valve Verify that green indicators are no longer extended 2 Pull up on manual release valve to release pressure from the drain system Manual release valve may not close completely Ensure valve is completely seated 3 Verify that air actuator and water drain system pressure indicators have returned to the closed position and that the manual relief valve is completely closed 4 Inspect serpentine drive belt condition and tension Refer to Serpentine Drive Belt 5 Perform all lubrication and maintenance specified for completion Annually in maintenance schedule except items which were performed at time of engine layup When installing battery in nex
59. nty 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 CA459 Transferable Warranty The product warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to products used for commercial applications Direct Sale By Owner 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 Box 1939 Fond du Lac WI 54936 1939 e Anew Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file e There is no charge for this service Outside the United States and Canada please contact the distributor in your country or the Marine Power International Service Center closest to you for the transferable warranty procedure that would apply to you CA862 Mercury Product Protection Plan
60. on internal corrosion may take place during storage if alcohol has washed protective oil films from internal components CC540 Seacock Size Recommendation Seacock used must have an internal cross sectional area equal to or greater than hose to prevent restricting waterflow Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue A 1 1 4 in 32 mm 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 liters per minute flow rate is required CA693 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection we strongly recommend the use of Quicksilver 4 Cycle 25W 40 Marine Engine Oil This oil is a special blend of 25 weight and 40 weight oils for marine engines If not available a good grade straight weight detergent automotive oil of correct viscosity with an classification of SH CF CF 2 may be used In those areas where Quicksilver 4 Cycle 25W 40 Marine Engine Oil or a recommended straight weight oil are not available a multi viscosity 20W 40 or as a second but less preferable choice 20W 50 with service ratings of SH CF CF 2 may be used IMPORTANT The use of non detergent oils multi viscosity oils other than Quicksilver 25W 40 or a good quality 2
61. ore likely this is to occur Slowing down rapidly or stopping suddenly may cause a following wave to swamp the transom In this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the preceding paragraph In any of these situations water entering the engine could cause severe damage to internal parts Refer to Attention Required After Submersion 21 Stolen Power Package If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial numbers 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 871 Replacement Service Parts Electrical ignition and fuel system components on Mercury MerCruiser gasoline power packages are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize risks of fire or explosion Use of replacement electrical ignition or fuel system components which do not comply to these rules and regulations could result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system le
62. result in minor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or maintenance The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used CA961 THIS PAGE IS INTENTIONALLY BLANK CC942 General Information CA619 Lanyard Stop Switch 74608 The purpose of a lanyard stop switch 1 is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Some remote control units are equipped with a lanyard stop switch A lanyard stop switch can be installed on the dashboard or side adjacent to the operator s position The lanyard is a cord usually between 4 and 5 ft 1220 and 1524 mm in length when stretched out with an element on one end made to be inserted into the switch and a snap 2 on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects It
63. sion Gasoline is extremely flammable and highly explosive under certain conditions NEVER use gasoline as a cleaning solvent 4 Reinstall flame arrestor 5 Tighten flame arrestor fastener securely 47 CC1013 2 0 m S 21 9 Y ENS see SO CC990 Lubrication CA73 Throttle Cable 1 Lubricate pivot points with SAE 30W motor oil CC1020 Shift Cable 2 Lubricate pivot points with SAE 30W motor oil 3 Lubricate poppet ball and holes in lever with SAE 30W 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 This does not apply to Velvet Drive Down Angle Transmission On this transmission the shift lever will be positioned aft rear for Forward Gear Right Hand Rotation Propeller and will be positioned forward front for Forward Gear Left Hand Rotation Propeller 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 There are no letters F or R on Velvet Drive Down Angle and V Drive Transmissions IMPROPER POSITIONING OF SHIFT LEVER MAY CAUSE TRANSMISSION TO FAIL Damage caused to transmission as a result of improper shift lever positioning will not be covered by Velvet Drive Transmission Warran
64. t off engine CC1022 Operation Chart BEFORE STARTING AFTER STARTING Observe all gauges to check condition of engine If not normal stop engine Open engine hatch Check for fuel oil water fluid and exhaust leaks Check engine oil level Turn battery switch ON if equipped control operation Operate bilge blowers if equipped Check steering operation Open fuel shutoff valve if equipped Close air actuated drain system Check shift and throttle Close seacock if equipped WHILE UNDERWAY AFTER STOPPING Observe all gauges to monitor engine condition If not normal stop engine Turn ignition key OFF Turn battery switch OFF if equipped Close fuel valve if equipped Flush cooling system if in saltwater area Open air actuated drain system CA877 Specifications Fuel Recommendations Use of improper gasoline can damage your engine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and damage caused thereby will not be covered under the limited warranty FUEL RATINGS Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows USA and Canada having a posted pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable DO NOT use leaded gasoline Outside USA and Canada having a posted pump Octane Ratin
65. t step be sure to connect positive battery cable to positive terminal and negative grounded battery cable to negative battery terminal If battery cables are reversed damage to electrical system WILL result 6 Install fully charged battery Clean battery cable clamps and terminals to help retard corrosion Coat terminal connections with a battery terminal anti corrosion agent DO NOT operate engine without cooling water being supplied to seawater pickup pump or water pump impeller will be damaged and subsequent overheating damage to engine may result 7 Start engine and closely observe instrumentation to ensure that all systems are functioning properly 8 Carefully inspect entire engine for fuel oil water and exhaust leaks 9 Check steering system shift and throttle controls for proper operation 59 CA442 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks Slow Check all electrical connections and wires especially battery cables Clean and tighten faulty connection Bad battery Test and replace if bad CH24 Engine Will Not Start Or Is Hard To Start Improper starting procedure Read starting procedure Empty fuel tank or fuel shutoff valve closed Fill tank or open valve Do not attempt to start engine for at least 5 minutes 109084 Refer to Starting Procedures Faulty ignition system component Service ignition system Loose or dirty electrical connections or
66. tarting 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 It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant IMPORTANT Observe the following Do not start engine without water being supplied to seawater pickup pump to prevent pump engine damage Do not operate starter motor continuously for more than 30 seconds e Never shift drive 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 your boat owner s manual 3 Place control handle in NEUTRAL 4 Position throttle setting as follows A COLD ENGINE Leave in NEUTRAL IDLE speed position B WARM ENGINE Leave in NEUTRAL IDLE speed position C FLOODED ENGINE Turn ignition switch to ON position Push the throttle only button and place the throttle lever in the 5096 position Attempt to start engine As soon as engine starts return throttle to the IDLE position 5 Turn ignition key to the START position Release key when engine starts and allow switch to return to the RUN position 6 Check oil pressure gauge immediately after engine starts If
67. tion 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 distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and address product model and serial number s date of sale type of use and the selling distributor s dealers code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product A copy of the Warranty Registration Card designated as the Purchaser s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy
68. torinstallatie geleverd cac781 Muut kielet Saadaksesi Kaytt6 ja huolto ohjekirjoja muilla kielill ota yhteys l himp n Mercury Marine tai Marine Power International huoltokeskukseen josta saat l hempi tietoja Moottorisi mukana seuraa monikielinen varaosanumeroluettelo cad781 Autres langues Pour obtenir un Manuel d utilisation et d entretien dans une autre langue contactez le centre de service apr s vente international Mercury Marine ou Marine Power le plus proche pour toute information Une liste des num ros de pi ces en d autres langues accompagne votre bloc moteur 67 cae781 Andere Sprachen Um eine Betriebs und Wartungsanleitung in einer anderen Sprache zu erhalten wenden Sie sich an das nachste Mercury Marine oder Marine Power International Service Center Eine Liste mit Teilenummern f r Fremdsprachen ist im Lieferumfang Ihres Motors enthalten caf781 Altre lingue Per ottenere il manuale di funzionamento e manutenzione in altra lingua contattate il centro assistenza internazionale Mercury Marine o Marine Power pi vicino In dotazione con il gruppo motore viene fornito l elenco dei codici prodotto dei componenti venduti all estero cag781 Andre spr k Ytterligere informasjon om bruks og vedlikeholdsh ndbok pa andre sprak kan fas ved henvendelse til naermeste internasjonale servicecenter for Mercury Marine eller Marine Power En liste over delenumre for andre spr k f lger med aggregatet
69. ty To obtain service and or parts literature for your Velvet Drive transmission contact Velvet Drive Marine and Industrial Transmissions 200Theodore Rice Boulevard Industrial Park New Bedford MA 02745 U S A CC846 To obtain service and or parts literature for your 2F Hurth transmission contact Mercury Marine Publications Department P O Box 1939 Fond du Lac WI 54936 1939 49 CC1015 Ei mii pM e A PARQUET 22 85 5 aC Oe EN Y a C 77627 CC992 Serpentine Drive Belt 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 Belt must be periodically inspected for condition and tension NOTE Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys 1 Check the tension of the serpentine drive belt If there is more than 1 4 in 6 mm deflection the tension needs adjustment See your Authorized Mercury MerCruiser Dealer to have the tension adjusted or belt replaced Idler Pulley B Circulating Pump Pulley C Crankshaft Pulley D Alternator Pulley E Seawater Pump Pulley CA478 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below
70. u X bea ot eed Sel ota Attention Required ATter SuUDmaersioh uere A RE SE aes Ex Ee Launching And Boat Operation Care ecce rr rec Exe KA eae ee Stolen Power PACKAGE MR Replacement Service Parts i poet PEN po ode tot Pe ipt we Do It Yourself Maintenance Suggestions Multiple EFI Engine Battery Precautions Diagnosing BRI 5 ER der OE Rb e Qa Ud al At de Grana 20 Hou r Break In Period ai Er ELS I v PI amar aede EAR CR RIEN E ete After Break In Period vo ti rere DH eR ERO e acea d Endo First season o s Dd Operation Instrumentation octo Ra Y Ei ede br e eu ce e me Audio Warning Systeme censo cA cx EE ta dd Electrical System Overload Protection iet ed e re Re oo edt E dee Doe M amas ERA E Kp Re d Starting Shifting And Stopping vs pins p OC Me e ea oC c oos Operation ENE T m Specifications Grankcase Oil e equali wan poe uds Engine Specifications
71. ubstantiate date of purchase by presenting the Purchaser s Copy of the Warranty Registration Card or the plastic Warranty Registration Card to the dealer authorized to service the Product If either of these items is not available purchaser must provide a copy of the original Bill of Sale Sales Contract for the Product to be serviced Warranty claims will not be accepted until adequate proof of purchase is presented by purchaser and date of purchase has been substantiated Our sole and exclusive 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 with new or Mercury certified remanufactured 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 WAR RANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU VIII This warranty gives you specific legal rights
72. vailable Model Horsepower Serial Number Year United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Telephone Mercury Marine Attn Publications Department 920 929 5110 920 929 4894 P O Box 1939 Fond du Lac WI 54936 1939 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature Please return with payment to Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print Or Type This Is Your Shipping Label Name Address City State ZIP 69
73. ve Units nor 6 Product used in commercial application ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR 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 Ill 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 manufacturing 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 damag
74. ve oil filler cap Add specified oil to bring level up to but not over FULL or OK RANGE mark on dipstick IMPORTANT DO NOT overfill crankcase oil CHECKING TRANSMISSION FLUID IMPORTANT Engine must be operated at 1500 rpm for 2 minutes immediately prior to checking level IMPORTANT DO NOT screw dipstick in press it firmly in and remove to obtain an accurate reading 6 Velvet Drive Transmissions Stop engine and quickly check fluid level by turning T handle counterclockwise to remove dipstick If fluid is below top full line add specified fluid through dipstick hole Do not overfill Reinstall dipstick securely CC1019 7 Hurth Transmissions Stop engine and quickly remove dipstick to check level If fluid is below top full line add specified fluid through dipstick hole Do not overfill Reinstall dipstick securely CB800 CHECKING ENGINE COOLANT Avoid serious injury from burns Do not remove coolant cap when engine is hot Coolant may discharge violently 8 Check coolant level in coolant reservoir Add specified coolant as required 9 If coolant is low inspect gasket in cap for damage and replace if necessary 10 Inspect coolant recovery system for leaks 41 CC1010 77630 77631
75. your dealership to resolve all problems The following information will be needed by the service office IE e Your name and address e Daytime telephone number e Model and serial numbers for your power package e The name and address of your dealership e Nature of problem Mercury Marine Service Offices are listed on the next page 65 CA915 Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax correspondence Telephone Mail Mercury MerCruiser 3003 N Perkins Rd Stillwater OK 74075 United States 405 743 6566 405 743 6570 Canada Mercury Marine Ltd 2395 Meadowpine Blvd 905 567 MERC 6372 905 567 8515 Mississauga Ontario Canada L5N 7W6 Australia Pacific Mercury Marine Australia 132 140 Frankston Road 61 3 791 5822 61 3 793 5880 Dandenong Victoria 3164 Australia Europe Middle East Africa Marine Power Europe Inc Parc Industriel de Petit Rechain 32 87 32 32 11 32 87 31 19 65 B 4800 Verviers Belgium Mexico Central America South America Caribbean Mercury Marine Latin America amp Caribbean 9010 S W 137th Ave 805 385 9585 305 385 5507 Miami FL 33186 U S A Mercury Marine Japan 283 1 Anshin cho 81 53 426 2500 81 53 423 2510 Hamamatsu Shizuoka 435 0005 Japan Asia Singapore Mercury Marine Singapore 72 Loyang Way 5466160 5467789 Singapore 508762
76. your power package Have them winterize it in the fall and service it before the boating season This will reduce the possibility of any problems occurring during your boating season when you want trouble free boating pleasure 23 CC1004 NOTE All references to EFI models apply to EFI and engines CA782 8 Multiple EFI Engine Battery Precautions Situation Alternators Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on When batteries for two different engines are connected one alternator will supply all of the charging current for both batteries Normally the other engine s alternator will not be required to supply any charging current EFI Electronic Control Module ECM The ECM requires a stable voltage source During multiple engine operation an onboard electrical device may cause a sudden drain of voltage at the engine s battery The voltage may go below the ECM s minimum required voltage Also the alternator on the other engine may now start charging This could cause a voltage spike in the engine s electrical system In either case the ECM could shut off When the voltage returns to the range that the ECM requires the ECM will reset itself The engine will now run normally This ECM shut down usually happens so fast that the engine just appears to have an ignition miss Recommendations Batteries Boats with multi engine EFI power packages require ea

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