Maintenance
Contents
1. Models Without Gear Lube Monitor Models With Gear Lube Monitor Index Page 1B 1 1B 1 1B 1 1B 2 1B 4 1B 4 1B 5 1B 5 1B 5 1B 5 1B 5 1B 6 1B 6 Page Changing Sterndrive Oil 1B 9 Models Without Gear Lube Monitor 1B 9 Units With Gear Lube Monitor 1B 10 General Maintenance 1B 12 Maintaining Power Package Exterior SUN ACES xxeeaac dedu dod 1B 12 Steering Head and Remote Control Maintenance 1B 12 Checking Quicksilver MerCathode System ees 1 12 Maintaining Alloy Trim Tab and Anodic ES 12 Replacing Trim Tab 1B 12 Maintaining Continuity Circuit 1B 13 Replacing Anodic Heads One Each DIGG PEE 1B 13 Checking Optional Quicksilver Anti Corrosion Anode Kit 1B 13 Boat Bottom Care 1B 13 Power Package Layup Out of Season Storage 1B 14 Engine 1B 14 OLerDdrV6 uua vsu y 1B 14 Power Package Recommissioning 1B 15 ONC ARP 1B 15 Sterndrive 1B 15 90 12934 2 1097 Maintenance Schedules Maintenance Intervals Maintenance intervals and the tasks to be performed as shown in this current schedule or as found in a pre viously printed schedules are generally based on an average boating application and envi2. connections broken or frayed wires Shift and Throttle Cable and Linkage Lubricate and inspect for loose damaged or missing parts Engine Exhaust System Inspect externally for damage deterioration and restrictions Check for tightness Ignition System Check timing and adjust as needed Index 1B 2 MAINTENANCE 90 12934 2 1097 Scheduled Maintenance That Be Performed by Dealer Continued NOTE Only perform maintenance which applies to your particular power package Steering Head and Remote Control In lubricate spect and End of first boating season and thereafter every 100 hours of operation or once yearly whichever occurs Carburetor Inspect and adjust first Fuel Filters Replace Quicksilver Mercathode System Test output Closed Cooling Coolant Test for alkalinity Once a Year Heat Exchanger Clean seawater section Drive Unit Bellows and Clamps Inspect Engine Alignment Check End of first boating season and thereafter Saltwater Use Every 300 hours of operation or once yearly whichever occurs first Freshwater Use Every 300 hours of operation or Universal Joint Cross Bearings Inspect once every two years whichever occurs first Closed Cooling Coolant Replace Every Five Years Only if Extended Life 5 100 Ethylene Glycol Antifreeze Coolant is used If any non compatible coolant is added to this coolant coolant must be changed every 2 years or 400 hours whichev
3. the cooling system periodically prefer ably after each use Index 1B 14 MAINTENANCE Power Package Layup Out of Season Storage Engine Refer to appropriate Engine Service Manual Sterndrive 1 Lubricate steering system Refer to SECTION 1 B 2 Lubricate transom gimbal housing assembly swivel shaft and pin hinge pins gimbal bearing and propeller shaft Refer to SECTION 1 B 3 Lubricate sterndrive unit U Joint shaft splines and cross bearings Refer to SECTION 3 A 4 Inspect U Joint bellows for cracks or other signs of deterioration Check bellows clamps for tight ness Refer to SECTION 4 5 Check engine alignment Refer to Engine Service Manual 6 Change sterndrive unit oil CAUTION Water drain holes in sterndrive unit MUST BE open to allow water to drain or trapped water may freeze and cause severe damage to housings 90 12934 2 1097 7 Using a piece of wire check water drain holes in sterndrive unit to ensure that they are open d m JM TL NR 23253 Sterndrive Unit Water Drain Holes a Drive Shaft Housing Water Drain Holes Two Each Side b Gear Housing Water Drain Hole 8 Inspect sterndrive for damage Repair or replace damaged components 9 Clean sterndrive exterior surfaces and repaint any bare metal surfaces with Quicksilver Primer and Spray Paint Refer to SECTION 1 B 10 After paint has dried spray entire sterndrive with Quicksilver Corrosion Guard Re
4. GENERAL INFORMATION Pater Pickups heck tor marine 51 C Every 100 hours of operation or 120 condition and check tension Whichever neeurs first Lubricate saltwater Use Every 50 hours of op days Whichever occurs Tirstz Exterior Surfaces Spray with rust Freshwater Use Every 100 hours o 120 days whichever occurs first Exterior Surfaces Clean and Onee a year Flush Seawater section Saltwater Use After every use MAINTENANCE Index Table of Contents Maintenance Schedules Maintenance Intervals Scheduled Maintenance That Can Be Performed By Owner Operator Scheduled Maintenance That Can Be Performed by Dealer Lubricating Shift Cable Pivot Points Lubricating Propeller Shaft Lubricating Steering System Power Steering Models Manual Steering Models Lubricating Tie Bar Pivot Points Control Valve Mounted on Starboard ransom Lubricating Tie Bar Pivot Points Control Valve Mounted on Port ransom Lubricating Transom Gimbal Housing Assembly Swivel Shaft Swivel Pin Hinge Pins and Gimbal Bearing Checking and Adding Sterndrive Oil Units Without Gear Lube Monitor Models With Gear Lube Monitor Checking Lubricant for Water
5. al for the anodes and MerCathode System if equipped to function most effectively Inspect the following continuity circuit components at intervals specified in Maintenance Chart for loose connections or broken or fraying wires Refer to SECTION 7 REPLACING ANODIC HEADS ONE EACH SIDE CAUTION DO NOT paint new anodic heads as this will ren der them ineffective as galvanic corrosion inhibi tors 1 Remove anodic heads and gaskets not seen by turning counterclockwise with a pair of pliers CAUTION To be effective new anodic heads MUST make good electrical contact with gimbal housing 2 Clean anodic head mounting surfaces 3 Install new heads using new gaskets and tight en securely 22090 a Anodic Heads One Each Side Index 90 12934 2 1097 Checking Optional Quicksilver Anti Corrosion Anode Kit If boat is equipped with Quicksilver Anti Corrosion Anode Kit inspect anode and replace if eroded to less than 50 of its original size Carefully follow installation instructions that accompany new Anode Kit to ensure proper installation Boat Bottom Care To achieve maximum performance and fuel econo my boat bottom MUST BE kept clean Accumulation of marine growth or other foreign matter can greatly reduce boat speed and increase fuel consumption To ensure best performance and efficiency periodi cally clean boat bottom in accordance with manufac turer s recommendations In some area
6. c heads MUST BE replaced if eroded 50 or more To re place trim tab and or anodic heads proceed as fol lows REPLACING TRIM TAB CAUTION DO NOT paint new trim tab as this will render it ineffective as a galvanic corrosion inhibitor 1 Mark position of trim tab fin in relation to gear housing so that new trim tab can be installed in same relative position If power package is equipped with Power Steering trim tab is posi tioned with fin straight back Index 1B 12 MAINTENANCE 2 Remove plug from drive shaft housing to gain ac cess to trim tab attaching screw not shown in photo Use a 3 8 in allen wrench and unthread trim tab attaching screw from trim tab DO NOT attempt to remove trim tab attaching screw CAUTION To be effective new trim tab MUST make good electrical contact with gear housing 4 Scrape trim tab mounting surface on gear hous ing down to bare metal 5 Install trim tab aligning trailing edge with index mark made in Step 1 Tighten screw securely Reinstall plug in drive shaft housing If power package is equipped with manual steer ing adjust trim tab 23253 a Trim Tab b Plug c 3 8 in Allen Wrench 90 12934 2 1097 Maintaining Continuity Circuit Transom assembly sterndrive unit be equipped with a continuity circuit to ensure good electrical continuity between engine transom as sembly and sterndrive components Good continuity is essenti
7. ect cause for leak before unit is placed in operation 1 Maintain oil level to Full mark on reservoir DO NOT OVERFILL 2 Reinstall reservoir cap Make sure cap is tight Cr b SZ 22161 a Oil Reservoir b Cap Index 1B 8 MAINTENANCE Checking Lubricant for Water Periodically inspect lubricant for water to ensure that drive unit seals are not leaking Models Without Gear Lube Monitor 1 Trim drive unit to the full trim UP OUT position Remove fill drain plug to take a sample of lubri cant If water is observed or if lubricant appears discolored drive unit is leaking and must be re sealed 70115 a Fill Drain Plug b Sealing Washer Or O ring 2 Reinstall fill drain plug Torque to 30 50 Ib in 3 4 5 7 N m 90 12934 2 1097 Models With Gear Lube Monitor Check for water at bottom of monitor If oil appears discolored a water leak is indicated somewhere in the drive unit and the drive unit must be resealed CAUTION If more than 2 fl oz 59 mL of Quicksilver Gear Lube is required to fill monitor a seal may be leaking Find and correct cause of leak before unit is placed in operation IMPORTANT If drive unit has set overnight or longer check for water in drive unit as follows 1 Trim drive unit to full UP OUT position 70115 a Oil Fill Drain Plug b Sealing Washer Or O ring 2 Remove fill drain plug to sample lubricant If water runs ou
8. ed for comple tion At Least Once Each Year in Maintenance Chart In Front of This Section except items which were performed at the time of sterndrive lay up 2 Install fully charged battery Clean battery cable clamps and terminals and reconnect cables Be sure to tighten clamps securely Apply a thin coat of petroleum base grease to clamps and termi nals to help retard corrosion 3 After recommissioning and starting engine check steering system and shiftcontrol for proper operation LE MAINTENANCE 1B 15 THIS PAGE IS INTENTIONALLY BLANK Index 1B 16 MAINTENANCE 90 12934 2 1097
9. er occurs first All cool ants other than Extended Life 5 100 Ethylene Glycol Antifreeze Coolant must be changed every 2 years or 400 hours whichever occurs first Engine Coupling Universal Joint Shaft Splines Lubricate Index 90 12934 2 1097 MAINTENANCE 1B 3 Lubricating Shift Cable Pivot Points 1 Lubricate with SAE 20 or SAE 30 Oil Models With Shift Assist Assembly a Lubrication Points Lubricating Propeller Shaft 1 Lubricate with Special Lubricant 101 2 4 C Ma rine Lubricant With Teflon or Perfect Seal listed in order of effectiveness Later Models a Lubrication Point Index 1B 4 MAINTENANCE 90 12934 2 1097 Lubricating Steering System Manual Steering Models Transom end of steering cable MUST BE fully re tracted into cable housing when lubricating cable If cable is lubricated while extended hy draulic lock of cable could occur Power Steering Models 1 Lubricate following points with specified lubri a Steering Cable Grease Fitting 2 4 C Marine Lubricant b Steering Cable End And Exposed Portion Special Lubri cant 101 C Pivot Points SAE 20 Or 30 Engine Oil d Pivot Bolts Special Lubricant 101 e Lubricating Tie Bar Pivot Points Lubricating Tie Bar Pivot Points CONTROL VALVE MOUNTED ON STARBOARD TRANSOM 1 Lubricate pivot points with SAE 20 or SAE 30 oil 22079 a Steering Cable Grease Fitting 2 4 C Marine Lubricant With Teflon See Pre
10. fer to SECTION 1 B CAUTION The gear case exhaust cavity might fill with water and freeze if stored in the UP OUT position Avoid gear case damage by storing the sterndrive unit in the full IN DOWN position CAUTION U Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service Store sterndrive unit in the full trim IN DOWN position Index 90 12934 2 1097 11 If notalready done place sterndrive unit in the full trim IN DOWN position 12 Store battery using the following procedure a Remove battery as soon as possible and re move all grease sulfate and dirt from top sur face b Fill battery with distilled water to level speci fied by manufacturer c Coverterminal bolts well with petroleum base grease d Store battery in a COOL DRY place in a dry carton or box CAUTION A discharged battery can be damaged by freez ing e Remove battery from storage every 45 days Check water level and place on charge fol lowing battery manufacturer s instructions DO NOT fast charge NOTE Larger batteries generally will accept a higher charging rate f When replacing battery in service remove excess grease from terminals leaving small amount on recharge as necessary and rein stall in your equipment Power Package Recommissioning Engine Refer to appropriate Engine Service Manual Sterndrive 1 Perform ALL maintenance specifi
11. fill drive unit through oil vent hole as air will be trapped in drive unit and unit will be damaged from lack of lubricant a Oil Vent Screw CAUTION If more than 2 fl oz 60 ml of oil is required to fill drive unit an oil leak may exist Find and correct cause of leak before unit is placed in operation 4 Ifoil level is low reinstall oil vent screw and seal ing washer Remove oil fill drain screw and insert lubricant pump into oil fill drain hole 5 Remove oil vent screw Fill drive unit through oil fill drain hole with oil until an an air free stream of oil flows out of oil vent hole Index 90 12934 2 1097 6 Without removing lubricant pump from fill drain hole reinstall vent screw and sealing washer Torque to 30 50 Ib in 3 4 5 7 7 Remove lubricant pump and quickly reinstall fill drain screw and sealing washer Torque to 30 50 Ib in 3 4 5 7 N m 8 Recheck oil level after operation of unit 23264 a Oil Vent Screw b Sealing Washer 23266 a Oil Fill Drain Screw b Sealing Washer MAINTENANCE 1B 7 Models With Gear Lube Monitor IMPORTANT DO NOT check oil level with drive unit hotfrom operation as hot expanded oll may provide a false reading at reservoir Allow drive unit to cool prior to checking oil level CAUTION If color of oil appears milky or if continuous low oil level readings in reservoir are noted a leak may exist Find and corr
12. itting then torque hose fitting to 30 50 Ib in 3 4 5 7 12 If necessary add oil to reservoir up to Full mark 23253 a Adapter b Hose Fitting 22161 C Oil Reservoir d Cap 13 Recheck oil level after first use MAINTENANCE 1B 11 General Maintenance Maintaining Power Package Exterior Surfaces Entire Power Package should be sprayed at recom mended intervals with Quicksilver Corrosion and Rust Preventive Type ll Follow instructions on can for proper application At least once each year entire Power Package should be cleaned and external surfaces which have become bare should be repainted with Quicksilver Primer and Spray Paint Steering Head and Remote Control Maintenance Lubricate steering head and remote control with 2 4 C Marine Lubricant Inspect steering head and remote control for ease of operation Checking Quicksilver MerCathode System If boat is equipped with a Quicksilver MerCathode System system should be tested to ensure that it is providing adequate output to protect underwater metal parts on boat Test should be made where boat is moored using Quicksilver Reference Electrode and Test Meter Refer to SECTION 7 Maintaining Alloy Trim Tab and Anodic Heads Sterndrive unit is equipped with a sacrificial alloy trim tab and 2 anodic heads to help protect underwater metal parts from galvanic corrosion Because of their self sacrificing nature trim tab and anodi
13. le or if oil col or appears milky a leak in drive unit is indicated Find and correct cause of leak before placing unit back in operation 2 Remove fill drain screw and remote oil reservoir cap and allow oil to drain completely S 23266 a Oil Fill Drain Screw b Sealing Washer Index 1B 10 MAINTENANCE 3 Remove reservoir from bracket and remove any remaining oil from reservoir lt 22161 Oil Reservoir b Cap c Bracket 4 Remove hose and adapter from vent hole 23253 a Adapter and Seal b Hose 90 12934 2 1097 5 Position sterndrive unit so that anti ventilation plate is level 6 Using lubricant pump fill drive unit through fill drain hole until an air free stream of oil flows out of vent hole 7 Temporarily plug vent hole Remove lubricant pump and quickly reinstall fill drain screw and sealing washer lt lt T ed 23253 a Vent Hole b Fill Drain Screw c Sealing Washer 23266 Index 90 12934 2 9 194 9 Unplug vent hole then install adapter and seal ing washer into vent hole Torque adapter to 30 50 Ib in 3 4 5 7 N m Install reservoir hose and tighten fitting LOOSELY 10 Fill oil reservoir to Fill mark DO NOT OVER FILL Install cap and tighten securely 11 Loosen hose fitting from adapter until an air free stream of oil flows from between adapter and hose f
14. ronment However individual operating habits and personal maintenance preferences can have an impact on the suggested inter vals In consideration of these factors MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed In some cases this may allow for more individual tasks to be performed in a single visit to the serving dealer rather than multiple visits Therefore it is very important that the boat owner and servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits environment and maintenance requirements Scheduled Maintenance That Can Be Performed By Owner Operator NOTE Only perform maintenance which applies to your particular power package Engine Crankcase Oil Check level Closed Cooling Coolant Check level Power Steering Fluid Check level Sterndrive Unit Oil Check level Battery Check level and inspect for damage Fuel Pump Sight Tube If Equipped Check that no fuel is present Power Trim Pump Oil Check level Anodes Inspect for erosion Gear Housing Water Pickups Check for marine growth or debris Drive Belts Inspect condition and check tension mid 109 of operation or 120 days whichever occurs first Propeller Shaft Lubricate Saltwater Use Every 50 hours of operation or 60 days whichever occurs first Power Package Exterior Surfaces Spray with ru
15. s it may be advisable to paint bottom to help prevent marine growth CAUTION DO NOT paint anodes or MerCathode System anode and reference electrode if equipped as this will render them ineffective as a galvanic cor rosion inhibitors IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the limited warranty If anti fouling protection is required for boat hull or boat transom copper or tin base paints if not prohib ited by law can be used If using copper or tin based anti fouling paint avoid any electrical interconnec tion between the MerCruiser product anodic blocks or MerCathode system and the paint Allow a mini mum of 1 5 in 40 mm of UNPAINTED area around these items to ensure that there is no interconnec tion MAINTENANCE 1B 13 Paint the drive unit and transom assembly with good quality marine paint or anti fouling paint that DOES NOT contain copper tin or any other material that could conduct electrical current Do not paint drain holes anodes MerCathode system or items specified by the boat manufacturer Spray power package components inside the boat every 2 3 weeks with Quicksilver Corrosion Guard to protect the finish from dulling and corrosion Exter nal power package components may also be sprayed All lubrication points especially steering system shift and throttle linkages should be kept well lubri cated Flush
16. st Freshwater Use Every 100 hours of operation or preventative 120 days whichever occurs first paint Cooling System Flush seawater section Saltwater Use After every use Index 90 12934 2 1097 MAINTENANCE 1B 1 Scheduled Maintenance That Be Performed by Dealer NOTE Only perform maintenance which applies to your particular power package Whenever insufficient seawater flow is suspected Seawater Pickup Pump Disassemble and inspect If operating temperature exceeds normal range Crankcase Oil and Filter Change Ignition system Clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose Clean and inspect Positive Crankcase Ventilation PCV Valve If Equipped Change Sterndrive Unit Oil Change Gimbal Ring Clamping Screws Retorque to 50 55 ft Ib 67 74 N m Rear Engine Mounts Check torque to 30 40 ft Ib 47 54 N m Gimbal Bearing Lubricate Cooling System Clean and inspect End of first boating season and thereafter every 100 Steering System Lubricate and inspect for loose damaged or missing parts hours of operation or once yearly whichever occurs first Electrical System Check for loose or damaged wiring Closed Cooling System Pressure Cap Clean inspect and test Cooling System Hoses and Clamps Inspect for damage deterioration Check clamps for tightness Continuity Circuit Check components for loose
17. t and or if lubricant appears discolored drive unit is leaking and must be resealed Reinstall fill drain plug Torque to 30 50 Ib in 3 4 5 7 N m Index 90 12934 2 1097 Changing Sterndrive Oil Models Without Gear Lube Monitor CAUTION If any water drains from fill drain hole or if oil is discolored a leak in drive unit may exist Find and correct cause of leak before placing unit back in operation CAUTION DO NOT attempt to fill drive unit thru oil vent hole as air will be trapped in drive unit and unit will be damaged from lack of lubricant 4 Remove fill drain screw and vent plug from drive unit and allow oil to drain completely gn Position drive unit so that anti ventilation plate is level 23253 Oil Vent Screw Sealing Washer O f 6 Using lubricant pump fill drive unit through fill drain hole until oil level is even with bottom edge of vent hole 7 Without removing lubricant pump from fill drain hole reinstall oil vent plug and sealing washer Torque to 30 50 Ib in 3 4 5 7 Nem MAINTENANCE 1B 9 8 Remove lubricant pump and quickly reinstall fill drain screw and sealing washer Torque to 30 50 Ib in 3 4 5 7 N m 9 Recheck oil level after first use Y 23266 a Oil Fill Drain Plug b Sealing Washer Units With Gear Lube Monitor 1 Raise drive unit to the full trim OUT position CAUTION If any water drains from fill drain ho
18. vious Warning b Control Valve Grease Fitting 2 4 C Marine Lubricant With Teflon Steering Cable End Special Lubricant 101 d Pivot Point SAE 20 Or 30 Engine Oil e Pivot Bolts Special Lubricant 101 Starboard Engine Index 90 12934 2 1097 MAINTENANCE 1B 5 ae Lubricating Transom Gimbal Qu Housing Assembly Swivel ZW og Shaft Swivel Pin Hinge Pins A A C Vert J and Gimbal Bearing 1 Lubricate the following points with specified lubri cant Port Engine a Pivot Points Lubricating Tie Bar Pivot Points CONTROL VALVE MOUNTED ON PORT TRANSOM 1 Lubricate pivot points with SAE 20 or SAE 30 oil 22079 a Swivel Shaft Later Models May Not Be Equipped With Fitting 2 4 Marine Lubricant With Teflon Starboard Engine b Hinge Pin One Each Side 2 4 C Marine Lubricant With Teflon Gimbal Bearing U Joint And Gimbal Bearing Grease d Swivel Pin 2 4 C Marine Lubricant With Teflon a Pivot Points O Index 1B 6 MAINTENANCE 90 12934 2 1097 Checking and Adding Sterndrive Oil Units Without Gear Lube Monitor 1 Position sterndrive unit so that anti ventilation plate is level Remove oil vent plug from drive shaft housing Check oil level Oil should be even with bottom edge of oil vent hole If oil is at proper level rein stall vent screw and sealing washer If oil level is low proceed with next steps CAUTION DO NOT attempt to
Download Pdf Manuals
Related Search