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1. 77618 INDEX CA859 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 Maintenanc
2. Scheduled Maintenanc 0 Checking Fluid Levels MR Changing E pue ape Recon da do Changing Water Separating Fuel Filter cece cette ees Cleaning Flame Arrestor and Related Components UG NOM TORT ees ees A ean zug M T Inspection And Maintenance pp Cold Weather or Extended Storage Power Package Lay UD iuda tere ee radeon ni taria ag Draining INSTUCUONS usaras Esc or dem pa Roe Sd Flushing Cooling System xax xs aet nat E xr OR acc acd Ra Batt ry Storage tit adden epic Rara b beca E Power Package Recommissioning 9 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks Slow leere Engine RPM Decreases Will Not Rise Above 2000 RPM Engine Will Not Start Or Is Hard To Start dE adr re E ERR se detest bens Engine Runs Rough Misses And Or Backfires pp Poor Performance A Usadas AUS rica SEXO UE Mass a deis de ni Excessive Engine Temperature lt lt iade hod bed dr b edes Cp dti b SUR SAL Rd qubd Low Engine Coolant Temperature sssssesssseseese ee eens Low Engine Oil Pressure faded eds Excessive Transmission Fluid Temper
3. Check spark plugs wires distribu tor cap and ignition timing Check and adjust idle speed Clean flame arrestor flame arrestor ELE 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 Disassemble and inspect seawater pump and replace worn components Clean seawater section of closed cooling system Clean inspect and test pressure cap Replace coolant coolant Pople CoO ee engine to propeller shaft alignment Only perform maintenance which applies to your particular power package Whichever Occurs First 40 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK 41 CH37 42 y Mb oH ojo 77631 INDEX INDEX CC1031 Checking Fluid Levels Mercury MerCruiser recommends that the crankcase oil be checked BEFOR
4. 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 no 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 Avoid Fire or Explosion Fuel injection system is pressurized during operation Use care when remov ing 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 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 sp
5. No individual or entity including Mercury Marine authorized dealers has been given authority by Mercury Marine to make any affirmation representation or warranty regarding the product other than those contained in this limited warranty and if made shall not be enforceable against Mercury Marine DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLU SIONS IDENTIFIED ABOVE AS A RESULT THEY 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 AND COUNTRY TO COUNTRY INDEX CC1049 3 Year Limited Warranty Against Corrosion Worldwide WHAT IS COVERED Mercury Marine warrants that each new Mercury Mariner Mercury Racing Sport Jet Jet Drive tracker by Mercury Marine Outboard MerCruiser Inboard or sterndrive engine Product will not be rendered inoperative as a direct result of corrosion for the period of time described below DURATION OF COVERAGE This limited corrosion warranty provides coverage for three 3 years from either the date the product is first sold or
6. Perform all lubrication and maintenance specified for completion Annually in maintenance schedule except items which were performed at time of engine layup 1 When installing battery in next 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 1 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 63 INDEX 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 CC1033 Engine RPM Decreases Will Not Rise Above 2000 RPM Have an Authorized Mercury MerCruiser Dealer Guardian Mode check trouble codes to determine fault CH Loose or dirt
7. INDEX Horizon Inboard Models eae ot INDEX CH30 Identification Record PLEASE RECORD THE FOLLOWING INFORMATION 1 Engine Model and Horsepower Engine Serial Number 2 Transmission Model Gear Ratio Transmission Serial Number 3 Propeller Number Pitch Diameter 4 Hull Identification Number HIN Purchase Date 5 Boat Manufacturer Boat Model Length 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 2001 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 CH34 2 1 3 oe S mmy N 5 lii sime eig
8. 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 72 INDEX 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 fur 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 sprak Ytterligere informasjon om bruks og vedlikeholdshandbok pa andre spr k 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 cah781 Outros Idiomas Para obter um Manual de Oper
9. 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 shut off engine CH54 8 1L Engine Guardian Strategy IMPORTANT Boat speed could be reduced to idle and may not respond to throttle Engine Guardian Strategy is designed to help reduce the potential for engine damage by reducing engine power when a potential problem is sensed Engine Guardian monitors e Oil Pressure e Coolant Temperature e Sea Pump Pressure e Exhaust Manifold Temperature For example if one exhaust manifold s water cooling passages become partially blocked Engine Guardian Strategy will reduce the power level of the engine to bring the temperature on that manifold back into the normal operating temperature range If the debris passes through and full water flow is restored engine power levels are restored back to normal In other words Engine Guardian Strategy is a looped feedback or smart system CH64 When Engine Guardian Strategy is activated the Audio Warning System alarm will beep In Guardian Mode the alarm will sound in the following patterns e 2 beeps per minute e Constant beep e Continous beeping Refer to the Engine Guardian Strategy troubleshooting 33 INDEX CH57 Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Observe all gauges to Observe all gauges to check condition of monitor
10. help extend the life of your Mercury MerCruiser power package the following recommendations should be considered e 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 CA875 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 operated 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 INDEX CC830 Operation CC831 4 3 70516 CRUISELOG 6 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 OMAN OO BW 26 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
11. more impurities Use only recommended engine oil refer to Specifications 1 With engine at normal operating temperature remove drain plug from oil drain hose or remove dipstick NOTE If engine is factory equipped with Quick Drain Oil Hose pull tether through bilge drain before removing drain plug from oil drain hose 2 Drain crankcase oil using quick drain oil hose NOTE drain plug is not accessible because of boat construction oil may be removed through dipstick tube using a Quicksilver Crankcase Oil Pump See Quicksilver Accessory Guide 3 Drain crankcase oil using Quicksilver Crankcase Oil Pump A Insert hose end of crankcase oil pump onto an appropriate container and using handle pump until crankcase is empty Remove pump B 4 After oil has drained completely reinstall drain plug or dipstick and tighten securely 5 Remove and discard oil filter and its sealing ring 6 Coat sealing ring on new filter with engine oil and install Tighten filter securely following filter manufacturer s instructions DO NOT overtighten 7 Remove oil filler cap Add recommended engine oil to bring level up to but not over FULL or OK RANGE mark on dipstick Refer to Specifications 8 Start engine and check for leaks IMPORTANT Always use dipstick to determine exactly how much oil is required 45 INDEX CC1011 46 INDEX CC1003 Changing Water Separating Fuel Filter
12. 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 56 INDEX CH62 350 MAG MPI Only 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs port and starboard from bottom of exhaust manifolds 3 Remove drain plug from fuel cooler if equipped 4 Remove end caps C sealing washers B and gaskets A from the heat exchanger IMPORTANT Use compressed air to blow any remaining water from the tubes in the heat exchanger 5 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 6 Loosen hose clamps and remove both hoses from seawater pickup pump 7 Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump DO NOT allow engine to start 8 After seawater section of cooling system has been drained completely reconnect all hoses reinstall heat ex changer end caps with new gaskets and reinstall drain plugs 57 INDEX CC1017 EL 2 V Red o HT SON AT A ES d UR yo Ll L y X 5 INDEX CH63 8 1 S Horizon Only CC1024 SINGLE POINT DRAIN SYSTEM 1 Freeze damage can occur if operating where temperatures are below 32 F Use Manual Drain System to en
13. 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 likelinood of lanyard entanglement with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s 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 pl
14. 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 WOT 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 INDEX CA863 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 dea
15. the date on which the product is first put into service whichever occurs first The repair and replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its origi nal expiration date Unexpired warranty coverage can be transferred to subsequent noncommercial use pur chaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Ma rine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process is completed an documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Opera tion and Maintenance Manual and must be timely performed including without limitation the replacement of sac anodes use of specified lubricants and touch up nicks and scratches in order to maintain warranty cover age Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a corroded p
16. 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 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 Turn ignition key to OFF 32 INDEX 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
17. with foreign material water hose in direction opposite normal water flow 66 INDEX CC1046 Low Engine Coolant Temperature Possible Cause Remedy Faulty Thermostat Replace CC1047 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 Engine oil cooler hose kinked causing excessive oil Oil Cooler restricted Straighten hose or replace if temperature and thinning of the oil damaged 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 Excessive oil in crankcase causing it to become aerated CC524 Excessive Transmission Fluid Temperature or Slipping Transmission Low fluid level Maintain fluid level Transmission shift lever not positioned properly T naa causing clutches to slip and overheat fluid Inspect shift linkages and shift lever positioning Fluid cooler hoses kinked Straighten hoses or replace if damaged 67 INDEX CA450 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 electrical connections or damaged wires especially battery cables Clean and tighten wiring faulty connection
18. E 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 8 1L Models Ensure that dipstick is installed with oil level indication marks facing the rear of the engine flywheel ena 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 Remove 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 CH63 7 Z Hurth Transmissions Stop engine and quickly remove dipstick to check level If f
19. Limited Warranty CA869 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 CA20 Launching And Boat Operation Care During launching from trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhaust system into the cylinders The more weight on the transom the more likely this is to occur Slowing down rapidly or stopping suddenly may cause a following wave to swamp the transom In this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the 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 INDEX CA21 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 CA871 Replacement Service Parts Electrical ignition and fuel system components on Merc
20. MPROPER 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 Warranty To obtain service and or parts literature for your Velvet Drive transmission contact Velvet Drive Marine and Industrial Transmissions 200 Theodore Rice Boulevard Industrial Park New Bedford MA 02745 U S A CC846 To obtain service and or parts literature for your ZF Hurth transmission contact Mercury Marine Publications Department P O Box 1939 Fond du Lac WI 54936 1939 51 INDEX CH43 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 A Idler Pulley B Circulating Pump Pulley C Crankshaft Pulley D Alternator Pulley E Seawater Pump Pulley 52 INDEX CA478 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use Recharg
21. R 1 from your dealer distributor or Mercury Marine CA958 Conditions Affecting Operation Weight Distribution Passengers And Gear Inside The Boat Shifting weight to rear stern e Generally increases speed and engine rpm e At extremes can cause boat to porpoise e Causes bow to bounce in choppy water e Increases danger of waves splashing into boat when coming off plane Shifting weight to front bow e Improves ease of planing e Improves rough water ride e At extremes can cause boat to veer back and forth bow steer 959 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 INDEX 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
22. RT 8 Throttle Only Button Allows engine throttle advancement without shifting the engine This is done by disengaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position and should only be used to assist in starting the engine 30 INDEX CC1036 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 toward the detent to decrease speed Pulling the control handle past the detent will increase reverse speed 1 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
23. ac o e 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 6 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 sprak F r att fa Instruktions och underh llsb cker pa andra spr k kontakta n rmaste Mercury Marine eller Marine Power International servicecenter som kan ge ytterligare information En f rteckning artikelnummer andra sprak medf ljer ditt kraftpaket CAm781 AAAEG YAWMOOES Tia va axoxmoete va Eyyerpidto Agroupytoac xau Xvvwipuonc oe GAAN yXAoo00 EMLROLVOVNOTE TO mAnoveote po Ave0v c K vrpo ZX pfic Mercury Marine y ths Marine Power yia zmpodoptec To LOXVOS 005 CUVODEVETOL EVAV APLOUMV MapayyEAtas GAMES YAWOOES 73 INDEX 961 THIS PAGE IS INTENTIONALLY BLANK 74 INDEX CA906 Ordering Literature Before ordering literature please have the following information about your power package available Model Horsepower Serial Num
24. ain medical aid as soon as possible CA962 Inspection And Maintenance Inspect power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all 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 53 INDEX CC1034 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 Avoid Fire or Explosion Ensure that 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 Fuel injection s
25. amage abuse or improper service corrosion to accessories instruments steer ing systems corrosion to factory installed jet drive unit damage due to marine growth product sold with less than a one year limited Product warranty replacement parts parts purchased by the Customer products used 8 INDEX in a commercial application Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of warranty period even if the product is only occasionally used for such purposes Corrosion damage caused by stray electrical currents on shore power connections nearby boats submerged metal is not covered by this corrosion warranty and should be protected against by the use of a corrosion protec tion system such as the Mercury Precision Parts or Quicksilver MerCathode system and or Galvanic Isolator Corrosion damage caused by improper application of copper base anti fouling paints is also not covered by this limited warranty If anti fouling protection si required Tri Butyl Tin Adipate TBTA base anti fouling paints are recommended on Outboard and MerCruiser boating applications In areas where TBTA base paints are prohib ited by law copper base paints can be used on the hull and transom Do not apply paint to the outboard or Mer Cruiser product In addition care must be taken to avoid an electrical interconnection between the warranted product and the paint Fo
26. aning 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 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 Lo
27. art replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the pur chase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the prod uct for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that ser vice Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercu ry The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic d
28. ature or Slipping Transmission Battery Will Not Come Up On Charge pp Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Owner Service Assistance Local Repair Service cierta EUR IDCM EET Re ere tere aor esas Service AWAY From ROME e bs tebe ta nea Ws beca o a lcs DR Pb Ed Pod hes Parts And Accessories Inquiries pp Resolving A PIOD IBIIT Sed iie Reb Bare REIR E E RAE E RE Satu wirds Mercury Marine Service Offices tae t er Customer Service Literature hae ur ma RE RARE ERR RR ain ri MEC de ld ba E INDEX CA455 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY e Itis important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product e t identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address The dealer also certifies that you are the original purchaser and user of the product e Upon receipt of the Warranty Registration Card at the factory you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be requi
29. 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 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 INDEX CA755 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 a particular service or operation that may be hazardous if perf
30. ber 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 8 Attn Publications Department 920 929 5110 920 929 4894 PO 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 75
31. bligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the prod uct for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that ser vice Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercu ry The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage INDEX WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range see the Operation and Maintenance Manual operation of the product in a man ner inconsistent with the recommended operation dut
32. by the service office EXTRA 4 HELP 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 70 INDEX CA915 Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax correspondence Mail Mercury MerCruiser 3003 N Perkins Rd 405 743 6566 405 743 6570 Stillwater OK 74075 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 9791 5822 61 3 9793 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 4800 Verviers Belgium Mexico Central America South America Caribbean Mercury Marine Latin America amp Caribbean 9010 S W 137th Ave 305 385 9585 305 385 5507 Suite 226 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 71 INDEX CA463 Customer Service Literature English Language English lan
33. creational use customer upon proper re registration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Ma rine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial unless properly re registered may void the warranty at the sole discretion of Mercury Marine Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to obtain warranty coverage Mercury Marine reserves the right to make any warranty coverage contingent on proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the pur chase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an o
34. e 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 cool dry day Then later on a hot sultry day the boat doesn t seem to have the same performance Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists In some cases a gear ratio change to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the 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
35. e and Warranty information for your Mercury MerCruiser power package If you desire to perform some of the maintenance items on your own you should obtain 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 Identification Rectora bene eben bene Serial 5 Babe eked Warranty Information Owner Warranty Registration ox ives thse bee neee Saves e e ERES International Owner Registration Mercury MerCruiser Year Limited Warranty Gasoline Fueled Products Only Year Limited Warranty Against Corrosion Worldwide Read This Manual Thoroughly General Information Lanyard Stop Switch cortinas rara ra Aa Exhaust EMISSIONS esre icme neeru atean eaea a a na e DE Sa Sae Safe Boating Suggestions e m RR Rr RR a RO A CR e CR RR Protecting People In The Water oooooocooocrcnrcan hn High Speed And High Performance Boat Operation Conditions Affecting Operation Weight Distribution Passengers And Gear Inside The Boat Bottom Of Boat ed c oce io RATES PAG Aaa ieu np edu ee ee Propeller Selection How Elevation And Climate Affect P
36. e every 30 to 45 days or when specific gravity drops below battery manufacturer s specifications Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precautions when handling a battery 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 Bat teries 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 bat tery 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 obt
37. ed pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a major brand of leaded gasoline CA878 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 CA879 GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethy 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 c
38. engine condition engine If not normal If not normal stop stop engine engine Listen for audio warning Check for fuel oil water E Turn battery switch OFF Check engine oil level fluid and exhaust leaks oe Guardian if equipped Check coolant level Check shift and throttle Close fuel shutoff valve control operation if equipped Check transmission fluid Check steering Close seacock if operation equipped Turn battery switch ON if Flush cooling system if in equipped saltwater Open air actuated drain Operate bilge blowers if system if boat is out of equipped water or seacock is closed Open fuel shutoff valve if equipped Close air actuated drain system Listen for Audio Warning Alarm to sound when the ignition switch is in the ON position Open engine hatch Turn ignition key OFF 34 INDEX CA964 Specifications Fuel Recommendations Use of improper gasoline can damage your engine seriously Engine damage resulting from use of im proper 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 post
39. eparation to take place In addition 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 API 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 API service ratings of SH CF CF 2 may be used IMPORTANT The use of non detergent oils multi viscosity oils other than Quicksilv
40. er 25W 40 or a good quality 20W 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 Oil 75796 AIR TEMPERATURE 36 INDEX CH58 Engine Specifications Moi S80 Mag MPIHorizon B 1 SHorizon Minimum 4 psi 28 kPa Minimum 15 psi 103 kPa 60 F 0170 NA Alternator Rating Hot Operating Alternator Rating Cold Operating Amps 72 Amps Recommended Battery Rating Min 550 cca 700 mca 120 Ah Min 650 cca 825 mca 180 Ah 1 Power Rated in Accordance with NMMA National Marine Manufacturers Association rating procedures 2 Measured using an accurate service tachometer with engine at normal operating temperature 3 A special procedure must be followed to check or adjust timing Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure 4 Idle speed on models is not adjustable 37 INDEX CH7 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 can be done by owner operator while others s
41. erformance 000 cece ete cece e Important Information Operation And Maintenance Freezing Temperature Operation e n Drain Plug and Bilge PUMP vd dese vd Attention Required After Submersion pp Launching And Boat Operation Care pp Stolen Power Package oer antag das Soa QE a Ra ead Re Replacement Service Parts Do It Yourself Maintenance Suggestions eee Multiple EFI Engine Battery Precautions 00 eee ee III Diagnosing EFI Problems uude ebd add ae 20 Hour Break In After Break Im Period NETT E End of First Season Checkup lucus uinci a aa Audio Warning SySIBII os doe Cure Electrical System Overload Protection pp Remote Controls serey ane Fuel Recommendations 2 ee Rr Seacock Size Recommendation ccc eee RR nes Sea Strainer Recommendations Crankcase Engine Specifications REP oi ta Maintenance Maintenance Aids OP cor Fluid Capacities PITE Routine Maintenance usina rai
42. ese 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 equipment 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 OA 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 e Use personal flotation devices Federal Law requires that there be a U S Coast Guard appr
43. g People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the drive unit is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat Is Stationary Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case INDEX CC55 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
44. g circuit breaker 1 A circuit breaker provides protection for engine wiring harness and instrumentation power lead Reset by pushing RESET button IN NOTE In an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or disconnect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 2 90 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 350 MAG MPI A Fuel Pump Fuse 15 Amp B Injector Fuse 10 Amp Battery Fuse 15 Amp 8 1S Horizon e Fuse AB is the Fuel Pump Fuse 20 Amp e Fuse CD is the PCM 555 Power Fuse 20 Amp e Fuse EF is the Injector Fuse 20 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 INDEX CA933 Remote Controls CC999 CC998 Remote Control Features Your boat may be equipped with a Mercury Precision or Quicksilver remote control All controls may not have all features shown If boat is equipped with a remote control othe
45. guage publications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest 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 781 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 781 Andre sprog Kontakt det naermeste Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual pa 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 u 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 motorinstallatie geleverd 781 Muut kielet Saadaksesi K ytt
46. hould be performed by an Authorized Mercury MerCruiser Dealer Before attempting maintenance or repair procedures not covered in this manual it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly NOTE Maintenance points are color coded for ease of identification e Blue Coolant e Yellow Engine Oil e Orange Fuel Brown Transmission Fluid Maintenance Aids 1 Transmission Dexron 1 Automatic Transmission Fluid 2 Oil Quicksilver 4 Cycle Marine Engine Oil Refer to Specifications for alternatives and oil recommendations for varying ambient temperatures 3 Closed Cooling System Coolant Extended Life 5 100 Ethylene Glycol Antifreeze Coolant 4 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard CH59 Fluid Capacities Engine NOTICE Measurements U S Quarts Liters All capacities are approximate fluid measures Crankcase Oil With Filter 1 5 5 5 25 9 8 5 Seawater Cooling System 2 15 14 1 Closed Cooling System 20 19 19 18 1 Always use dipstick to determine exact quantity of oil or fluid required 2 Seawater Cooling System capacity information is for winterization use only IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines 38 INDEX Transmission NOTICE Measurements U S Quarts Liters All capacities are approx
47. ill 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 sealing 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 47 INDEX CH40 70573 48 INDEX CH61 Cleaning Flame Arrestor and Related Components Avoid gasoline fire or explosion Gasoline is extremely flammable and highly explosive under certain conditions Be careful when cleaning flame arrestor and crankcase ventilation hoses ensure that igni tion is OFF DO NOT smoke or allow sources of spark or open flame in area when cleaning flame arres tor and crankcase ventilation hoses 1 Remove cover 2 Remove flame arrestor and related components 3 Clean flame arrestor in solvent Dry with compressed air or allow to air dry completely Avoid gasoline fire or explosion Gasoline is extremely flammable and highly explosive under certain conditions NEVER use gasoline as a cleaning solvent 4 350 MAG MPI Clean crankcase ventilation hoses in solvent Dry with compressed air or allow to air dry comple
48. imate fluid measures Make and Model Fluid Type Velvet Drive Mobil 424 or 71C In Line 1 1 2 1 33 Dexron 1 Automatic Transmission Fluid 72 Series V Drive 3 2 75 Do Not Mix 5000A ede eb Dexron 1 Automatic Transmission Fluid 5000V 3 1 2 3 3 4 1 2 4 0 4 1 2 4 0 6 5 5 ZF Hurth Dexron Automatic Transmission Fluid 1 Fluid should be circulated and then rechecked Add additional fluid as necessary CC1041 Gas Inboard Routine Maintenance Each Each Every Day Day Weekly Two Start Months Check crankcase oil interval can be extended based on experi If operating in salt brackish or polluted waters flush cooling system de after each use Check water pickups for debris or marine growth Check water strainer and clean Check coolant level Check battery connections and fluid level see Only perform maintenance which applies to your particular power package 39 INDEX Gas Inboard Continued Scheduled Maintenance Every Every Every Every 200 300 Every Ever 500 1000 hours hours EYETY hours hours Per or3 03 or5 or5 Annuall N y dde E yeaS eds d s idi Touch up paint power package and spray with corrosion guard Change crankcase oil and filter Replace fuel filter s Check steering system and remote control for loose missing or su damaged parts Lubricate cables and linkages Retoraue engine mounts PA
49. ired 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 22 INDEX 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 e 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 mechanic 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 e f 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 e 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 e Also if you partially disassemble an engine or drive assembly and are unable to repair
50. 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 CC886 75423 INDEX CH49 Flushing Cooling System 350 MAG MPI Only NOTE Flushing is needed only for saltwater applications Flushing is recommended after each outing for best results Do NOT start engine at any point in this procedure If boat is in the water starting engine during this procedure will pull in seawater If boat is out of the water starting engine may damage the seawater pump IMPORTANT Do not use this method on boats equipped with waterlift exhaust collectors or mufflers Remove blue drain plug from the 90 elbows located on the bottom of both exhaust manifolds Remove blue cap from flush socket Attach quick connect to a water hose Turn on the water hose ao amp OD Snap the quick connect and the water hose into the flush socket on the engine IMPORTANT Run bilge pump during flushing to pump flushing water overboard 6 Flush engine for 10 minutes 7 Disconnect the quick connect and water hose from the flush socket on the engine by pressing the release button on the flush socket 8 Reinstall both drain plugs into the 90 elbows located on the bottom of both exhaust manifolds 9 Reconnect the quick connect and hose into the flush socket on the engine and let flushing water run for a maximum of 15
51. 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 WOT 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 engine 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 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 e Operating with increased load additional passengers pulling skiers causes 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 INDEX CA960 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine Sinc
52. 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 e 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 e 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 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 INDEX CC1004 NOTE All references to EFI models apply to EFI and MPI engines CC1037 NOTE All references to ECM apply to all engine control modules CA782 8 Multiple 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 C
53. le 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 Change oil and oil filter Refer to changing crankcase oil 5 Flush cooling system Refer to Flushing Cooling System 6 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 Prepare fuel system for extended storage as follows 54 INDEX A Allow engine to cool down B 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 D Reinstall water separating fuel filter m Disconnect harness connections from fuel pump and fuel boost pump F Start and operate engine at idle speed until the water separating fuel filter and fuel injection system are empty and engine stops G Remove and discard water separating fuel filter H Install a new water separating fuel filter Reconnect harness connections at both fuel pumps 8 Clean flame arrestor Refer to Cleaning Flame Arrestor and Related Components 9 Lubricate all items listed in Lubrication section 10 Drain seawater section of cooling
54. ler 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 At the time of delivery the dealer should provide you with a copy of a Predelivery Inspection Checklist e Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product 20 INDEX CA865 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 CA867 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
55. luid is below top full line add specified fluid through dipstick hole Do not overfill Reinstall dipstick securely CC1042 CHECKING ENGINE COOLANT Avoid serious injury from burns Do not remove coolant cap when engine is hot Coolant may dis charge violently IMPORTANT Check engine coolant BEFORE starting engine 8 Check coolant level in coolant reservoir Add specified coolant as required 9 f coolant is low inspect gasket in cap for damage and replace if necessary 10 Inspect coolant recovery system for leaks 43 INDEX T S OL s M INDEX CH60 Changing Fluids Refer to Maintenance for change interval Crankcase oil should be changed before placing boat in storage Changing Crankcase Oil and Filter 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 IMPORTANT Change crankcase oil when engine is warm from operation Warm oil flows more freely carrying away
56. ntly 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 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 INDEX 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 th
57. o 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 INDEX CC1048 Warranty Policies Mercury MerCruiser One Year Limited Warranty Gasoline Fueled Products Only WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for either one 1 year from the date the product is first sold to a recre ational use retail purchaser or the date on which the product is first put into service whichever occurs first Com mercial users of these products receive warranty coverage of either one 1 year from the date of first retail sale or the accumulation of 500 hours of operation whichever occurs first Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its origi nal expiration date Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent re
58. ontaining alcohol may cause increased 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 fire and explosion hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel sys tem 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 deteriora tion requires replacement before further engine operation 35 INDEX 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 s
59. ontrol 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 power packages require each 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
60. ormed 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 common 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 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 Op eration Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used INDEX 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
61. ous locations e Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above idle or planing transition speed Watch the other guy the water and your wake e Never drive your boat directly behind a water skier in case the skier falls As an example your boat traveling at 25 miles per hour 40 km hr in 5 seconds will overtake a fallen skier who was 200 feet in front of you e Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water e Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement CA282 Protectin
62. oved wearable type life jacket personal flotation device correctly sized and readily accessible for every person on board plus a throwable cushion or ring We strongly advise that everyone wear a life jacket at all times while in the boat e Prepare other boat operators Instruct at least one person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate 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 INDEX 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 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 e Know your boating area and avoid hazard
63. r MerCruiser product an unpainted gap of at least 1 5 inches should be left around the transom assembly DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLU SIONS IDENTIFIED ABOVE AS A RESULT THEY 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 AND COUNTRY TO COUNTRY INDEX 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 P O Box 1939 Fond du Lac WI 54936 1939 e Anew Owner Warranty Registration Card will
64. r than shown consult your dealer for a description and or demonstration of the control 1 Single Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear Continue pushing forward to increase speed Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear Continue pushing back to decrease speed A Dual Control Handles Shift and throttle are controlled by separate handles with throttle control at IDLE push shift control forward for FORWARD or pull back for REVERSE Then push the throttle control forward to increase speed 2 Neutral Release Lever Prevents accidental shift and throttle engagement Neutral lock button must be pushed IN to move the control handle out of NEUTRAL 3 Trim Tilt Button if Equipped Refer to Power Trim Operation 4 Lanyard Stop Switch Turns ignition OFF whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to the Lanyard Stop Switch Safety Explanation and Warning in the General Information Section 5 Lanyard Refer to the Lanyard Stop Switch Safety Explanation and Warning in the General Information Section 6 Throttle Friction Adjustment Console controls require cover removal for adjustment 7 Ignition Key Switch OFF ON STA
65. rCruiser Dealer Ignition System fault Service ignition system Clogged fuel filter Replace filter 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 Have EFI System checked by an Authorized ae Mercury MerCruiser Dealer Low on fuel Fill tank Engine timing off Check timing 65 INDEX CH47 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 Boat overloaded or load improperly distributed Reduce load or redistribute load more evenly Have EFI System checked by an Authorized Se Mercury MefCruiser Dealer C1028 Excessive Engine Temperature Water Inlet valve closed If Equipped 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 Exchanaer material ger Loss of pressure in closed cooling system a for 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
66. red Warranty claims will not be accepted without presentation of this card e 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 e f your plastic card is not received within 30 days from date of new product sale please contact your selling dealer e The product warranty is not effective until the product is registered at the factory e NOTICE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notification under the Federal Boat Safety Act be required INDEX International Owner Registration OUTSIDE THE UNITED STATES AND CANADA e tis 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 e The Warranty Registration Card identifies your name and address product model and serial number s date of sale type of use and the selling di
67. s 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 68 INDEX CA903 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 to the Yellow Pages of the telephone directory If for any reason you cannot obtain service con
68. s battery CC1038 Diagnosing EFI Problems 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 this information in the ECM s memory This data can then be read later by a service technician using a special diagnostic tool 24 INDEX CA413 20 Hour Break In Period IMPORTANT The first 20 hours of operation is the engine break in period Correct break in is essential to obtain minimum oil consumption and maximum engine performance During this break in period the following rules must be observed Do not operate below 1500 rpm for extended periods of time for first 10 hours Shift into gear as soon as possible after starting and advance throttle above 1500 rpm if conditions permit safe operation e Do not operate at one speed consistently for extended periods e 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
69. same as the single engine control handle 3 Trim Button If Equipped Refer to Power Trim Operation 31 INDEX CC995 Starting Shifting And Stopping Before starting engine operate bilge blower for at least five minutes to remove any explosive fumes from engine compartment If boat is not equipped with a bilge blower open engine hatch and leave open while starting engine 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 Observe the following e Do not start engine without water being supplied to seawater pickup pump to prevent pump or en gine damage e Do not operate starter motor continuously for more than 30 seconds 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
70. 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 control in NEUTRAL idle speed position and start engine Operate engine at idle speed in NEUTRAL for about 10 minutes or until discharge water is clear 4 Stop engine Shut off water remove flushing connector from pump inlet and reconnect water inlet hose Tighten hose clamp securely 62 INDEX 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 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 A Inspect serpentine drive belt condition and tension Refer to Serpentine Drive Belt
71. seconds This amount of flushing water is used to fill exhaust manifolds and flush the exhaust elbows Do not let water run more than 15 seconds or too much flushing water will collect in the muffler 10 Disconnect the quick connect and water hose from the flush socket on the engine 11 Attach to next engine if equipped and repeat procedure 12 Turn off water 13 Remove quick connect from the water hose 14 Replace blue cap into the flush socket on the engine 61 INDEX CC1014 CH48 Flushing Cooling System 8 1 S Horizon Only 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 not 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
72. ss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking N 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 INDEX CA766 Exhaust Emissions CA641 Courtesy of ABYC CA767 Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards sterndrives 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 mon oxide 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 13 INDEX CA643 POOR VENTILATION 3B Courtesy of ABYC Under certain running and or wind conditions permane
73. stributor s dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product A copy 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 e n some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you e 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 t
74. sure 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 Pull lever on air pump up vertical to lock pump on actuator fitting Pump air into the system until both green indicators extend and water drains from both sides of the engine o0 5 o 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 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
75. system Refer to Draining Instructions 11 Test coolant to ensure that it will withstand the lowest temperature expected during storage 12 Service 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 II or wipe down with Quicksilver Storage Seal or SAE 20W engine oil 55 INDEX C1023 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 immediately after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freeze and or corrosion damage to engine Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty If engine will be exposed to freezing temperatures ensure closed cooling section is filled with an ethylene glycol antifreeze and water solution properly mixed to protect engine to lowest temperature to which it will be exposed IMPORTANT Closed cooling section must be kept filled year round with recommended coolant IMPORTANT Do
76. tact 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 number s to order the correct parts 69 INDEX 904 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 Mer Cruiser 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 your dealership to resolve all problems The following information will be needed
77. tely 350 MAG MPI Inspect crankcase ventilation hoses for cracks or deterioration and replace if necessary Reinstall flame arrestor and related components in reverse order Tighten flame arrestor fastener securely 0 Reinstall cover 49 CH42 8 P AAA 657 v 7 3 li O es wll a ISS ilk 2 2 IIE RX 1 AA A 50 INDEX INDEX CC990 Lubrication CA73 Throttle Cable 1 Lubricate pivot points with SAE 30W motor oil CH33 A 350 Mag MPI Models B 8 1S Horizon Models 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 I
78. time Bilge Blower Switch Operates bilge blower If equipped See Starting Shifting and Stopping Ignition Switch allows operator to start and stop engine INDEX CC1050 Audio Warning System 2 70518 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 4 Engine Guardian Strategy Activated Refer to 8 1L Engine Guardian Strategy 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 work ing correctly Avoid 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 INDEX CC882 28 INDEX CH56 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 resettin
79. ury 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 leaks if they existed Marine engines are expected to operate at or near full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard 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 requ
80. y cycle section of the Operation and Maintenance Manual neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part which damages the Mercury product and was not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation and Maintenance Manual alteration or removal of parts water entering the engine through the fuel intake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or other competitive activity or operating with a rac ing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal and or replacement of boat parti tions or material caused by boat design for access to the product are not covered by this warranty
81. y electrical connections or damaged wiring Engine Guardian Strategy Sensor Malfunction 2 beeps per minute Disconnected short or corroded circuit 2 beeps per minute Engine coolant temperature overheat condition constant beep B Have an Authorized Mercury MerCruiser Dealer Engine oil pressure low constant beep check trouble codes to determine fault Maximum RPM exceeded constant beep Seawater pressure low constant beep Exhuast manifold overheat condition constant beep 64 INDEX CC1043 Engine Will Not Start Or 15 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 Engine needed Refer to Starting Procedures 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 Fuel line or tank vent line kinked or clogged compressed air to remove obstruction Have EFI System checked by an Authorized Fault Mercury MerCruiser Dealer Faulty wire connections Check wire connections Lanyard Stop Switch activated Check Lanyard Stop Switch CH25 Engine Runs Rough Misses And Or Backfires EFI Models Have EFI system checked by an SPEEA 100 Authorized Mercury Me
82. ystem is pressurized during operation Use care when remov ing 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 tank 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 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 amount of Gasoline Stabilizer to the portab

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