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350 Magnum MPI Gen + Tournament Ski (Black Scorpion)

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1. 70516 5 70517 70518 010101011 CRUISELOG 6 00 70522 CC8 Instrumentation The following is a brief explanation of instrumentation typically found on some boats The owner operator should be familiar with all instruments and their functions on the boat 1 Speedometer indicates boat speed Tachometer indicates engine RPM Oil Pressure Gauge indicates engine oil pressure Battery Meter indicates battery voltage Water Temperature Gauge indicates engine operating temperature Fuel Gauge indicates fuel tank volume Hour Meter records engine running time OMAN Oo BW N Ignition Switch allows operator to start and stop engine Bilge Blower Switch must be operated for five minutes to ventilate bilge 15 CC180 2 70518 16 CC336 Audio Warning Warning buzzer will sound if 1 Engine oil pressure gets too low 2 Cooling system water temperature rises too high 3 Transmission temperature is too high A CAUTION Avoid engine damage Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZ ARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred When the buzzer sounds with the engine running stop engine immediately Investigate cause and correct it if pos sible If cause cannot be determined consult your Authorized MerCruiser Dealer IMPORTANT W
2. a im N QUU N E Cr L J 74828 74832 44 CC159 Water Separating Fuel Filter Be careful when changing water separating fuel filter Gasoline is extremely flammable and highly explo sive under certain conditions Be sure ignition key is OFF Do not smoke or allow spark or open flame in area when changing fuel filter Wipe up any spilled fuel immediately Make sure no fuel leaks exist before closing engine hatch 1 Remove water separating fuel filter by turning counterclockwise and sealing ring from mounting bracket and discard Coat sealing rings on new filter with motor oil Thread filter clockwise onto bracket and tighten securely by hand Do not use a filter wrench Start and run engine Check filter connection for gasoline leaks If leaks exist recheck filter installation If leaks continue stop engine immediately and contact your Authorized MerCruiser Dealer CC432 In Line Fuel Filter 2 The in line filter is located on starboard side by the water separating fuel filter Replace every year or 100 hours of operation whichever occurs first 45 CC69 TYPICAL FRONT MOUNT TYPICAL REAR MOUNT 46 CC70 Engine Alignment Engine alignment should be checked by your Authorized MerCruiser Dealer at specified intervals IMPORTANT Engine alignment must be checked with boat in the water fuel tanks filled and with a normal load on board 1 Engine must b
3. CC218 Seacock Size Recommendation Seacock used must have an internal cross sectional area equal to or greater than hose to prevent restricting wa terflow Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue A 1 1 4 in 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 litres per minute flow rate is required CC18 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection we strongly recommend the use of Quicksilver 4 Cycle Marine Engine Oil If not available a good grade straight weight detergent automotive oil of correct viscosity with an API classification of SG CD Il may be used The chart below is a guide to crankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not available a multi viscosity 20W 40 SG CD II or as a second but less preferable choice 20W 50 SG CD Il may be used IMPORTANT The use of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oils or oils which contain solid additives specifically are not recommended Quicksilver 4 Cycle Marine Engine Oil ME z m E SAE 20W SG or CD II BERN 32 F 50 F 0 C
4. Fill with fresh fuel Replace line if kinked Blow out line with compressed air to remove obstruction Clean flame arrestor Have EFI System checked by an Authorized MerCruiser Dealer Run tank dry and fill with 91 Octane fuel Inspect cable and linkages for binding ob struction or loose fasteners Replace Drain and check for cause of entry Reduce load or redistribute load more evenly Clean or repair as necessary Clean flame arrestor See Excessive engine temperature Refer to Engine runs rough misses and or backfires Open valve COMPLETELY Replace and or adjust belt Replace and or adjust belt Remove obstruction Straighten or replace hose Replace Disconnect hoses from coolers and flush out with a water hose in direction opposite normal water flow continued next page Trouble Excessive engine temperature continued Insufficient engine temperature Low engine oil pressure Excessive trans mission fluid temperature or slipping trans mission Battery will not come up on charge Remote control operates hard binds has exces sive free play or makes unusual sounds Possible Cause Coolant level low in fresh water section Heat exchanger cores plugged with foreign material Loss of pressure in fresh water section Faulty thermostat Insufficient oil in crank case Excessive oil in crankcase causing itto become aerated Diluted or impr
5. Pump Disassemble pected If Operating Temperature Exceeds Nor and Inspect mal Range Transmission Fluid Chan After first 20 hours then every 100 rANSMISSION UI ange hours of operation thereafter Crankcase Oil and Oil Filter change Ignition System clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose clean and inspect 1 Every 100 Hours of Operation or ne A Once Yearly Whichever Occurs Replace Positive Crankcase Ventilation Valve zi In Line Fuel Filter Mounted on starboard side by water separating fuel filter Electrical system Check for loose or damaged wiring Cooling system hoses and clamps Inspect for damage and deterioration Check clamps for tightness Saltwater use Every 50 hours of operation or 60 days Whichever Occurs First Engine Exhaust System Inspect externally for Freshwater use Every 100 hours of operation damage deterioration and restrictions Check or 120 days Whichever Occurs First clamps for tightness Shift and Throttle Cable and Linkage Lubri cate and inspect for loose damaged or miss ing parts Ignition System check timing adjust if needed Fuel Filter replace Once a Year Steering Head and Remote Control Inspect and lubricate Throttle Body Inspect NOTE 1 For a list of 20 Hour Checkup maintenance items to be performed see IMPORTANT INFORMATION section of this manual 33 CC425 34 CC426 Checkin
6. YOUR CONCERN CONTACT YOUR NEAREST MERCRUISER SERVICE CENTER Provide the following important information e Your name address and telephone number e The model and serial number s Your dealer s name and location Date of purchase e Present hours of operation e Details of problem or complaint e Boat make and size e Propeller pitch and or part number Normal use and approximate gross load Please bear in mind that Service Centers resolve all problems through the dealership using the dealer s facili ties equipment and personnel This is the reason we request you use the preceding steps in sequence when you have a problem or complaint Our experience has shown that this is the most expedient and successful proce dure to follow to ensure satisfaction to our customers FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RESOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT United States MERCRUISER 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 Canada Contact Nearest Regional Service Center Other Countries Contact the Nearest Marine Power International Service Center The customer service representatives will review all the facts involved If they feel some further action can be taken they will advise the Service Center They will contact your dealer to bring the problem to a satisfactory conclusion ALL SERVICE WORK IS DONE BY THE AU
7. 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 e Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate When in doubt contact your dealer or the boats manufacturer Know your boat s oper ating and loading limitations Make sure everyone in the boat is properly seated Don t allow anyone to sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat anywhere that sudden unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat e Never be under the influence of alcohol or drugs while boating it is the law They impair your judgment and greatly reduce your ability to react quickly Know your boating area and avoid hazardous locations e Bealert The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers
8. be given to you immedi ately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim pro cessing refer to the International Warranty Refer to Table of Contents IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the facto ry copy to the Marine Power International S
9. breaker is not tripped 19 CC166 73866 20 CC167 Remote Controls Panel Mounted 1 Neutral Lock Bar Prevents accidental shift and throttle engagement Neutral lock bar must be pulled Up to move the control handle out of neutral 2 Throttle Only Button Allows engine throttle advancement without shifting the engine This is done by disen gaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Lanyard Stop Switch Turns ignition Off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at the front of this manual for safety warning on the use of this switch 4 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the ten sion on the control handle This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 5 Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from Neutral with a quick firm motion to the first detent for Forward gear Continue pushing forward to increase speed Pu
10. cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines fittings fuel filters and carburetors fuel injection components should be in spected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration re quires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required IMPORTANT When operating a MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of storage common to boats create unique problems In cars alcohol blend fuels normally are consumed before they can absorb enough moisture to cause trouble but boats often sit idle long enough for phase separation to take place In addi tion internal corrosion may take place during storage if alcohol has washed protective oil films from inter nal components Quicksilver Gasoline Stabilizer for Marine Engines 92 817529A12 is highly recommended for addition during storage periods See Cold Weather or Extended Storage later in this manual 25
11. ee e kx ex RA XO EROR ACE LADO CR ERR DA S P 71 General Maintenance Parts agite s asm ng SUD pe ENS be E de pla dcus Wa Bhar ond ere BA a 72 Engine Pans uds E kw A AR De WA x m A EP aa ben 72 Literature Order FOM sss den vary a deme Ce wd Ute Niel ur Np iiss BAGS 73 The description and specifications contained herein were in effect atthe 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 Printed in 1996 Brunswick Corporation a e The following are registered trademarks of Brunswick Corporation Auto add blend Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mer cury Marine Quicksilver Ride Guide and Thruster CA165 Welcome You have selected one of the finest marine power packages available It incorporates numerous design features to assure operating ease and durability With proper care and maintenance you will thoroughly enjoy using this product for many boating seasons To en sure maximum performance and carefree use we ask that you thoroughly read this manual The Operation and Maintenance Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the w
12. in this manual CC434 Avoid Fire or Explosion Be sure engine compartment is well ventilated and no gasoline vapors are pres ent during the following operation Avoid Fire or Explosion Fuel injection system is pressurized during operation Use care when removing 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 3 Fill fuel tank s with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gaso line Stabilizer for Marine Engines to treat gasoline Follow instructions on container 4 If boatis to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Fuel tanks should be drained completely and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to FUEL REQUIREMENTS for additional information Prepare fuel system for extended storage as follows Allow engine to cool down Remove the water separating fuel filter Pour out a small amount of fuel into a suitable container then add approximately 2 fluid ounces 60 ml of Quick silver 2 Cycle Outboard Oil to fuel in the water separating fuel filter Install water separating fu
13. is written for the trained mechanic so there may be procedures you don t understand Do not attempt repairs if you do not understand the procedures There are special tools and equipment that are required to perform some repairs Do not attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you Also if you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or request the repair procedure It is difficult for them to diagnose a problem over the telephone A doctor can t and won t diagnose your illness by telephone he must examine you personally just as a mechanic must examine your power package Your Authorized Dealer is there to service your power package He has qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on your power package Have him winter ize it in the fall and service it before the boating season This will reduce the possibility of any problems occurring during your boating season when you want trouble free boat
14. manifolds port and stbd Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained ar 0 NOTE It may be necessary to lift or bend hoses to allow water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow engine to start Loosen hose clamps and disconnect the following hoses 6 From engine circulating pump 7 From seawater pickup pump and fuel cooler After cooling system has drained completely coat drain plug threads with Quicksilver Perfect Seal and reinstall drain plugs Reconnect hoses and tighten all hose clamps securely IMPORTANT MerCruiser recommends that propylene glycol antifreeze nontoxic and biodegradable which makes it friendly to lakes and rivers be used in seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s rec ommendations 8 For additional assurance against freezing and rust remove thermostat cover and thermostat Fill engine seawa ter cooling system with a mixture of antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage Using a new gasket reinstall thermostat and cover Tighten cover b
15. not recharge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames Batteries contain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries also produce hydrogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte Hy drogen gases that escape from the battery during charging are explosive When charging batteries be sure battery compartment or area where batteries are located is well vented Battery electrolyte is a corro sive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body im mediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible cen Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom should be observed e Clean free of barnacles and marine growth e Free of distortion nearly flat where it contacts water Straight and smooth fore and aft 0072 Anti Fouling Paints In some areas it may be advisable to paint bottom to help preve
16. operational instructions for the power package and all related accessories before the boat is used Co CA280 Lanyard Stop Switch SARAN 1 Some boats come equipped with a lanyard stop switch A lanyard stop switch can also be installed as an acces sory The purpose of this switch is to turn off the engine ignition whenever the operator when attached to the lan yard moves far enough away from the operator s position to activate the switch 74608 2 The lanyard is a cord usually between 4 and 5 feet 1220 and 1524 mm in length when stretched out with an element on one end made to be inserted into the switch and a metal snap on the other end for attaching to the operator It is coiled to make its at rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s posi tion If for any reason itis desired to have a shorter functional lanyard this may be accomplished by using up length in the way the lanyard and clip are attached to the operator such as wrapping the lanyard around the operator s wrist or leg or by tying a simple knot in the lanyard Read the Safety Warning on this page and the following page before electing to install use or n
17. provide you with a copy of a Predelivery Inspection Checklist e Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediate ly upon sale of the new product CA20 Launching And Boat Operation Care A CAUTION During launching from a trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhaust system into the cyl inders 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 Atten tion Required After Submersion CA318 Freezing Temperature Operation IMPORTANT Ifboatis operated during periods of freezing temperature precautions must be taken to pre vent freezing damage to power package Refer to COLD WEATHER or EXTENDED STORAGE for draining instructions Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty CA18 Attention Required After Submersion e Before recovery contact a MerCruiser Dealer e After recovery immediate service by an Auth
18. 10 C 70534 AIR TEMPERATURE 26 CC419 8 m 8 Engine Specifications MODEL 350 MAGNUM MPI GEN TOURNAMENT SKI Propshaft Horsepower 1 Propshaft Kilowatts 1 Displacement 350 C I D 5 7 L Engine Type Bore 4 00 in 101 6 mm 88 39 mm 150 psi 1035 kPa Maximum RPM WOT 3 4600 5000 RPM 3 Idle RPM in Electric Fuel Pump Pressure 43 psi 296 7 kPa 30 70 psi Oil Pressure 2000 RPM 207 483 kPa Min Oil Pressure Idle 4 psi 28 kPa Thermostat 160 F 71 C 1 Power Rated in Accordance with NMMA Procedure Using Marine Engine Rating Code SAE J1228 Technically Identical to ISO 3046 and ICOMIA 28 83 2 Engine Rated with Velvet Drive 1 1 In Line Transmission Power Output with Other Transmissions Will Be Less 3 Engine is equipped with an RPM Rev Limiter This limiter is designed to help prevent damage from engine over speed When the engine reaches this preset limit fuel is momentarily shut off to the fuel injectors Once the RPM drops complete fuel delivery resumes 27 CC420 Malz Tune up Specifications MODEL 350 MAGNUM MPI GEN TOURNAMENT SKI Spark Plug Type AC MR43LTS Champion RS9YC NGK BPR6ESS Spark Plug Gap 045 in 1 1 mm Timing Idle RPM 8 BTDC Firing Order 1 8 4 3 6 5 7 2 Electrical System 12 Volt Negative Ground Alternator 65 Amps Recommended Battery Rating Minimum 550 cca 700 mca or 120 Amp Hrs 1 Timing must be set using a special procedure as outlined in the appropr
19. 53 Starting And Charging System Harness BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK WIRING en m m u nn HARNESS TRANS FLUID TEMPERATURE SWITCH GRY 2 PUR 5 TAN BLU 4 RED PUR 6 BLK 1 YEL RED 7 LIT BLU 8 TAN 3 BRN WHT 10 OIL PRESSURE SWITCH Q Qa gt PRESSURE 1 SENDER Ei E 2 o WATER L TEMPERATURE o SENDER A Charging and Starting Circuit B Audio Warning C Instrumentation Senders 1 Harness Connector To EFI System Harness 2 Positive Power Wire To EFI System Harness 3 Auxiliary Tachometer Lead STARTER SLAVE SOLENOID CIRCUIT BREAKER STARTER A MOTOR GROUND Ey 9 STUD NEUTRAL START SAFETY SWITCH 73370 60 CC440 EFI System Harness 1 Electric Fuel Pump 2 Distributor 3 Coil 4 Electronic Spark Control KS Module 5 Data Link Connector DLC 6 Manifold Absolute Pressure MAP Sensor 7 Knock Sensor 8 Idle Air Control IAC 9 Throttle Position TP Sensor 10 Engine Coolant Temperature ECT Sensor 11 Electronic Control Module ECM 12 Fuel Pump Relay 13 Ignition System Relay 14 Fuse 15 Amp Fuel Pump 15 Fuse 15 Amp ECM DLC Battery 16 Fuse 10 Amp ECM Injector Ignition Knock Module 17 Harness Connector To Starting Charging Harness 18 Harness Connector To Lanyar
20. ED WARRANTY LASTS OR THE EXCLUSION OR LIMI TATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLU SIONS MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other legal rights which vary from country to country MARINE POWER INTERNATIONAL Division of Brunswick Corporation Fond du Lac Wisconsin 54935 U S A 3 Year Limited Warranty Against Corrosion Failure Applicable in the United States Canada and Australia I We warrant parts and assemblies of each 1988 and newer production MerCruiser Product sold with a one year limited Product warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inoperative as a direct result of corrosion provided the following simple precaution ary steps which are specified in Owner s Manuals have been taken 1 Specified maintenance procedures such as replacement of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below Il This warranty shall become effective upon receipt of a completed standard Product warranty registration card and shall remain effective for a period of three years from the date of purchase lll This warranty does not cover 1 electrical system corrosion 2 corrosion resulting from damage abuse or improper service 3 corrosion t
21. OPERATION 8 MAINTENANCE MANUAL 350 Magnum MPI Gen Tournament Ski Black Scorpion 1996 Brunswick Corporation 90 807784961 196 CC418 IDENTIFICATION RECORD PLEASE RECORD THE FOLLOWING INFORMATION Engine Model Horsepower 2 Engine Serial Number 3 Transmission Models Transmission Serial Number 4 Propeller Number Pitch Diameter 5 Hull Identification Number HIN Purchase Date 6 Boat Manufacturer Boat Model Length Serial Numbers The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers NOTE The numbers seen on illustrations are reference for numbered items above CC354 Table of Contents Page Welcome MEM 3 Head This Manual Thoroughly a Se peti ep T Ex E 3 Eanyarg 510 SWIICEE SE AC e er duce o ede ce Pai GG a td dL E ae MAU cos dd 4 Sale BOALING Suggestions ereus u a tac p E wo t E meis da erect nds sar pe Ee E d E ta Ede 5 Protecting People In The Water dens a Det et eme PER DIR Sc NUR Rr esses 6 While YOU A A tbe bres ea E ES o EE aie bugie cu De ehe hati 6 While Boat Is Stationary iu er ue E Rem a A RE RR EE RE 6 High Speed And High Performance Boat Operation tantos tah deba eta ui er en Mat Rr e ot iate ec AAA 6 Conditions Aff
22. Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Marine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s 71 CC441 General Maintenance Parts Engine Parts Ignition Coil 806673 Spark Plug Wire Set 816608A68 Thermostat 160 F 807252 2 Thermostat Gaskets 27 47510 27 53045 1 Alternator Belt 57 48120A1 Water Pump Belt 57 13457T Water Separating Filter 35 807172 Quicksilver Motor Oil 92 816096A12 Storage Seal 92 86145A12 Valvtane Plus 92 17955A12 72 CC178 Literature Order Form Model Horsepower Serial Number Year Service Manual shows the complete assembly and disassembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Part Number Total Price Official Use Only Parts Manual Drive Only C 90 4 95 Operation and Maintenance 5 00 Manual Sasae must be collected from customers in all states except x AK AZ DE HI ID lA ME MI MT NV NH NY Ship Hand OR VT WV WY Grand T
23. THORIZED DEALER USING THE DEALER S FACILITIES OUR SERVICE CENTERS AND FACTORY DO NOT HAVE FACILITIES TO SERVICE OR REPAIR YOUR PRODUCT 69 Service Centers UNITED STATES MerCruiser 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6566 Fax 405 743 6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga Ontario L4Y 2C2 Canada Telephone 905 270 4481 Fax 905 270 4510 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 e 11 Fax 32 87 31 19 65 70 AUSTRALIA PACIFIC Marine Power International Pty Ltd P B 1420 132 140 Frankston Road Dandenong Victoria 3164 Australia Telephone 61 3 791 5822 Fax 61 3 791 5880 ASIA Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 Customer Service Literature English language publications are available from Mercury Marine Attn
24. TRAL idle speed position and start engine Operate engine at idle speed in NEUTRAL for about 10 minutes or until discharge water is clear Stop engine Shut off water remove flushing connector from pump inlet and reconnect water inlet hose Tighten hose clamp securely CC58 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer 3 Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected if operating temperature exceeds normal range 41 CC430 Maintenance continued 42 CC62 Drive Belts Avoid injury caused by hands or clothing being caught between belts and pulleys Make sure engine is shut off and ignition key is removed before inspecting belts All drive belts must be periodically inspected for condition and tension Perform the following inspections of alternator drive belt and seawater pickup pump drive belt If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 2 Seawater Pump Drive Belt Inspect drive belt for excessive wear or damage Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 43 CC431 N d e tla O UM
25. afety 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 e Check safety equipment on board Here are suggestions of the types of safety equipment to carry when boat ing 1 Approved fire extinguisher s paddle or oar 2 Signal devices flashlight rockets or flares flag and whistle or horn 3 Spare propeller thrust hubs and an appropriate wrench 4 Tools for necessary minor repairs first aid kit and book 1 2 8 4 5 Anchor and extra anchor line water proof storage containers 6 Manual bilge pump and extra drain plugs compass and map or chart of area 7 Spare operating equipment batteries bulbs fuses etc 8 Transistor radio 9 Drinking water Know signs of weather change and avoid foul weather and rough sea boating e Tell someone where you are going and when you expect to return e 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 approved wearable type life jacket personal flotation device correctly sized
26. arning buzzer will sound for 2 seconds when ignition key is turned to RUN position and engine is not started This allows the operator to test the warning buzzer prior to starting the engine 17 CC435 CC255 Electrical System Overload Protection If an electrical overload occurs a fuse will blow or the circuit breaker will trip open The cause must be found and corrected before replacing fuse or resetting circuit breaker 1 Acircuit breaker provides protection for engine wiring harness and instrumentation power lead Reset by push ing RESET button IN 2 A 90 Amp fuse is located on the large post of the starter solenoid This fuse is designed to protect the engine wiring harness if an electrical overload occurs In an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or disconnect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 3 There are three fuses located in the fuel injection system electrical box These fuses control various EFI circuits A Fuel Pump Fuse 15 Amp B ECM Injector Fuse 10 Amp C ECM Battery Fuse 15 Amp 4 A20 amp fuse may be located in ignition switch I terminal lead to protect electrical system Check for blown fuse if key is turned to START and nothing happens and circuit
27. arranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replacement of boat partitions or material because of boat design for necessary access to the Product Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho rized to service the Purchaser s product If purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Company We shall then arrange for the inspection and repair provided such service is covered under this warranty Purchaser shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid The Warranty Registration Card is the only valid registration identification and must be presented at the time warranty service is required Warranty claims will not be accepted without presentation of the Warranty Registration Card Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to re
28. ater Thank you for purchasing one of our MerCruiser products We sincerely hope your boating will be pleasant CONSUMER AFFAIRS DEPARTMENT CA166 Read This Manual Thoroughly IF YOU DON T UNDERSTAND ANY PORTION CONTACT YOUR DEALER FOR A DEMONSTRATION OF AC TUAL STARTING AND OPERATING PROCEDURES NOTICE Throughout this publication and on your power package WARNINGS and CAUTIONS accompanied by the Inter national Hazard Symbol 44 may be used to alert the installer user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special in structions while performing the service plus common sense operation are major accident prevention measures WARNING Hazards or unsafe practices which could result in severe personal injury or death A CAUTION CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or main tenance The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the
29. ation Check steering operation WHILE UNDERWAY Observe all gauges to monitor engine condition If not normal stop engine AFTER STOPPING Turn ignition key OFF Turn battery switch OFF if so equipped Close fuel valve if so equipped Close seacock if so equipped Flush cooling system ifina saltwater area 23 CC423 Specifications Fuel Recommendations IMPORTANT Use of improper gasoline can damage your engine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and damage caused thereby will not be covered under the limited warranty ACAUTION Failure to use the recommended octane fuel may result in severe engine damage If the recommended oc tane fuel is not available wide open throttle is not recommended FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows USA and Canada having a posted pump Octane Rating of at least 91 R M 2 minimum Premium gasoline above 91 R M 2 Octane is also acceptable DO NOT use leaded gasoline Outside USA and Canada having a posted pump Octane Rating of 98 RON minimum If unleaded gasoline is not available use a major brand of leaded gasoline CA291 USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alc
30. d Stop Switch Optional 19 Positive Power Wire To Engine Circuit Breaker NOTE All BLACK wires with a ground symbol are interconnected within the EFI system harness Q X S 2 2 3 BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK NOTE Component position and orientation shown above is arranged for visual clarity and ease of circuit identification 61 CA272 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY Itis important that your selling dealer fills outthe Warranty Registration Card completely and mails itto the facto ry immediately upon sale of the new product It identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address The dealer also certifies that you are the original purchaser and user of the product Upon receipt of the Warranty Registration Card at the factory you will be issued a plastic Owner Warranty Regis tration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be required Warranty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from
31. d of hose Lower hose into appropriate container and allow oil to drain When oil has drained completely reinstall fitting in end of hose and and secure hose to engine using the attached clip 2 Turn oil filler counterclockwise to left remove and discard old oil filter and old sealing ring Coat sealing ring on new filter with motor oil Install new sealing ring and filter by turning clockwise to right Tighten filter securely Do not overtighten 3 Remove oil filler cap Add correct type oil see SPECIFICATIONS to bring level up to but not over FULL mark on dipstick IMPORTANT Always use dipstick to determine exactly how much oil is required 37 CC428 38 CC51 E Lubrication THROTTLE CABLE 1 Lubricate pivot points with specified motor oil CC403 SHIFT CABLE 2 Lubricate pivot points with SAE 30W motor oil 3 Lubricate detent ball and holes in lever with SAE 30W motor oil ACAUTION IMPROPER POSITIONING OF SHIFT LEVER MAY CAUSE TRANSMISSION FAILURE Remote control shift cable and linkages must move the transmission shift lever completely into the detent position of the selected gear Detent ball MUST BE centered in detent hole for each F N R position on the Velvet Drive Transmissions IMPORTANT Damage caused to the transmission as a result of improper shift lever positioning will not be covered by the MerCruiser Limited Warranty or Velvet Drive Transmission Warranty 4 Shift lever must be over this
32. date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will attach it to your warranty claim form Because of your selling dealer s continuing personal interest in your satisfaction the product should be returned to him for warranty service If your plastic card is not received within 30 days from date of new product sale please contact your selling deal er The product warranty is not effective until the product is registered at the factory NOTICE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notification under the Federal Boat Safety Act be required International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the dis tributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and address product model and serial number s date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product A copy ofthe Warranty Registration Card designated as the Purchaser s Copy MUST
33. e 62 Warranty Policies i oaa r aro nr ee Roue ee ee ge aS 63 MerCruiser Limited Warranty Gasoline 5 aia af oni e pill a ies 63 MerCruiser International Warranty Gasoline ENGINES is ee M CC DE 64 3 Year Limited Warranty Against 00710516 Failure sch tnc ee ac Lu uM Es eA Eu LE E M edu Aral dad 65 Warranty Coverage Destaca ina nme MU ER PEG P DIOS ek oto O S Petre tto te tesis ERE NONE 66 Warranty Does Not Apply To THE OU OWN REC TERT D UE TE 66 Transferable Warranty on oe dct De Ee Gn GOES eio radere ce ed eros ed dis Tales Da Rr ptg 67 Direct Sal By OWNER sic mesa e tort eei A mA Eae s Eats Mi ean ite a dud mr E 67 Guard Product Protection Planer satten ep Door eee eee HU IURE ep PO e EY 68 United States and Canada Only 40 60 eleme y RR xh RA ut ek m m De e ne 68 Owner Service ASSISTANCE noo io e moda teat se ace lf ceto t Seal bob Ser 68 Local Repair Service i cose u eh xs m Ree Kea RERO RE REESE EXAMEN E bas 68 Service Away From HOME us cata noe oe wee Cette e Brag Oe RAO OR a RD crt RC dte e 68 Parts and Accessories Inquiries i e a tr men RR ete Ree x Re man 68 Hesolving a Problemi nr sense ea tero SRE eased aati a treat 69 Service Gemors eC PM ICI 70 Customer Service Literature cube
34. e Schedules Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER OPERATOR TASK INTERVAL Seawater Strainer Check and clean Before Use and Whenever Insufficient Seawater Flow is Suspected If Operating Temperature Water Pickups Check for marine growth or debris Exceeds Normal Range Engine Crankcase Oil Check level Transmission Fluid Check level Battery Check level and inspect for damage Drive Belts inspect condition and check tensions Every 100 Hours of Use or 120 Days Whichever Occurs First Once a Year Saltwater use Every 50 hours of operation or Power Package Exterior Surfaces spray with 60 days Whichever Occurs First Quicksilver Corrosion Guard Freshwater use Every 100 hours of operation or 120 days Whichever Occurs First Power Package Exterior Surfaces clean and paint Cooling System flush seawater section Saltwater Use After Each Use 32 CC443 Maintenance Chart Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL 20 Hour Checkup NOTE 1 At First 20 Hours of Operation Whenever Insufficient Seawater Flow is Sus Seawater Pickup
35. e aligned so that transmission and propeller shaft coupling centerlines are aligned and coupling faces are parallel within 003 in 07 mm After alignment is correct coupler attaching screws and nuts must be torqued to 50 Ib ft 68 N m 2 Locking Nut After alignment is correct tighten securely 3 Adjusting Nut Turning nut clockwise lowers engine IMPORTANT Both front mounts or rear mounts adjusting nuts must be turned equally to keep engine level from side to side 4 Clamping Screw s and Nut s Loosen to allow sideways movement of engine After alignment is correct tight en securely NOTE Some rear mounts have two clamping screws and nuts on each side others have only one clamping screw and nut on each side 5 Maximum mount trunnion extension is 3 4 in 20 mm 6 Tab Washer After alignment is correct bend tab against flat on adjust nut IMPORTANT Be sure to recheck engine mount fasteners for adequate tightness after completing engine alignment 47 THIS PAGE IS INTENTIONALLY BLANK CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufacturer s specifications Refer to specific instructions and warnings accompanying your battery Ifthis information is not available observe the following precautions when handling a battery Do not use jumper cables and a booster battery to start engine Do
36. ecting Operation a eire Oe qae A eae ee 7 Weight Distribution s 2 rt A A a Sce ee toes D adn e A ERE dedos 7 5011011077 Of BOA e ASE ER ML d ie DLE 7 How Elevation and Climate Affect Performance Hr rar a a A deen 8 Important Information a ata p 9 Operation And Maintenance 2530 d octubre ee ied ee en hed Bed aet an prz eS 9 Launching And Boat Operation Care ans aca a RES 9 Freezing Temperature Operation tc A El 10 Attention Required After Submersion eser err see em a ee Re ee ae RR 10 Stolen Power Package Auskenner en eger Be aS 10 Replacement Service Parts 2 sis sus a a REG MR ET kn 10 Do It Yourself Maintenance Suggestions ooocccocccccccccr een 11 Diagnosing EFI Problems a Art a e de e A dee c er dr e aua des e ades 11 20 KlaurBreak IfrPeriod c es seco eun s VERD Rr E Fal npe eg tussis dune Sardi Maa a BAR ae 12 Alter Break In Period 3 a don E oer dec ear sau ie Opi e A TAE ei iaces e d ura 12 2D Hour Gheckup en A A ROW IO OR ES OR een 12 OperatigM aset tome tani tri a Eee a ale elo een Boar altus Qut Dual a 14 Instrumentation asyan a EXERCERE E GE AS Bea ee eae RM REGUM REG RE Re 15 0 VAT o AM E A LE E MU M MR Mu EUM MM Ul 17 Electrical System Overload Protection 2 clTe een engen enge trace ee un ran 19 Remote Controls Panel Mounted suum a ROI RR ER ates Eye Saee Pne
37. el filter Shut off the fuel supply to the engine Start and run engine at idle speed for two minutes Stop engine remove and discard water separating fuel filter and in line fuel filter Install new filters Close fuel shut off valve if so equipped OU lt gt u O TO mM 0 CC462 52 CC438 Draining Instructions DRAINING SEAWATER RAW WATER COOLED MODELS A CAUTION If boat is to remain in water after draining seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses CAUTION 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 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from cylinder block as follows A Port Side from Y fitting Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sensor in the upper hole of the fitting This sensor must not be loosened or removed lt is tightened to a critical specification at the factory Starboard Side from cylinder block Remove hose from transmission cooler Remove the drain plugs from bottom of exhaust
38. ervice Center for your area 62 Warranty Policies MerCruiser Limited Warranty Gasoline Engines UNITED STATES AND CANADA ONLY Vi Vil VIII We warrant each new production not those made for high performance purposes MerCruiser Stern Drive Power Package Inboard Engine and accessories attached thereto hereafter referred to as Product to be free from defects in material and workmanship but only when the consumer sale is made in the country to which distribution is authorized by us This warranty shall become effective only upon our receipt of a completed Warranty Registration Card which shall identify the Product so registered by serial number This warranty shall remain in effect for a period of one 1 year from date of purchase Since this warranty applies to defects in material and workmanship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal opera tion or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Oper ation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or prepar ing for racing or other competitive activity or operating with a racing type lower unit 5 Alteration or removal of parts or 6 Water entering engine cylinder s through the exhaust system or carburetor s Reasonable access must be provided to the product for w
39. g Fluid Levels CHECKING CRANKCASE OIL 1 Stop engine Allow approximately five minutes for oil to drain into oil pan Boat must be at rest in water 2 Remove dipstick Wipe clean and reinstall fully into dipstick tube 3 Remove dipstick and observe oil level Oil level must be between FULL and ADD If oil level is below ADD 4 Remove oil filler cap Add specified oil to bring level up to but not over FULL mark on dipstick IMPORTANT Do not overfill crankcase oil CHECKING TRANSMISSION FLUID IMPORTANT Engine must be run at 1500 RPM for 2 minutes immediately prior to checking level 5 Velvet Drive Transmissions Stop engine and quickly check fluid level by turning T handle counterclockwise to remove dipstick Fluid level should be up to full mark If low add specified fluid through dipstick tube on Velvet Drive transmissions 35 DE i 00152 Changing Fluids See MAINTENANCE CHART for lubricant change frequency Lubricant should be changed before placing boat in storage Transmission fluid should be changed at specified intervals by your Authorized MerCruiser Dealer CHANGING CRANKCASE OIL AND FILTER IMPORTANT Change oil when engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended motor oil see SPECIFICATIONS 1 With engine at normal operating temperature remove oil drain hose that is connected near the engine thermo stat housing Remove fitting from en
40. gauge immediately after engine starts If oil pressure is not within specified range see SPECIFICATIONS stop engine immediately and determine cause 6 After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnor mally high If it is stop engine immediately and determine cause 7 Be sure charging system is functioning correctly 8 Observe power package for fuel oil water and exhaust leaks 9 To shift unit into gear move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shift to REVERSE After shifting unit advance throttle to desired setting 10 To shift unit out of gear move control shift lever to NEUTRAL and allow engine to drop to IDLE speed If engine has been run at high speed for a long period of time allow engine to cool by running at IDLE speed for 3 to 5 min utes 11 Turn ignition key to OFF 22 CC98 BEFORE STARTING Open engine hatch Check engine oil level Turn battery switch ON if so equipped Operate bilge blowers if so equipped Open fuel shutoff valve if so equipped Open seacock if so equipped Perform all other checks specified by your dealer and or boat builder Operation Chart AFTER STARTING Observe all gauges to check condition of engine If not normal stop engine Check for fuel oil water fluid and exhaust leaks etc Check shift and throttle control oper
41. haser shall pay for all related labor and material and any other expenses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transporta tion charges prepaid Purchaser must provide proof of purchase and substantiate date of purchase by presenting the Purchas er s Copy of the Warranty Registration Card or the plastic Warranty Registration Card to the dealer autho rized to service the Product If either of these items is not available purchaser must provide a copy of the origi nal Bill of Sale Sales Contract for the Product to be serviced Warranty claims will not be accepted until adequate proof of purchase is presented by purchaser and date of purchase has been substantiated Our obligation under this Warranty shall be limited to repairing a defective part or AT OUR OPTION refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obligation to modify any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IM PLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLI
42. iate Service manual Timing cannot be properly set using the conventional method 28 CC421 Capacities MODEL 350 MAGNUM MPI GEN TOURNAMENT SKI Crankcase Oil Approx 5 U S Capacity w New Filter Quarts 4 7L Seawater Cooling System 15 Qts 14 2L Transmission Velvet Drive en Weel RINE 2 Qts 1 9L TAlways use dipstick to determine exact quantity of oil required 2Seawater Cooling System capacity information is for winterization use only 29 CC422 Maintenance GASOLINE 30 CC103 Maintenance EFI System Maintenance Precautions Avoid Injury or Electrical System Damage Always disconnect battery cables from battery before working around electrical system components See IMPORTANT statement following A CAUTION Avoid damage to the EFI electrical system components Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories e DO NOT tap accessories into engine harness e DO NOT puncture wires for testing Probing e DO NOT reverse battery leads DO NOT splice wires into harness DO NOT attempt diagnostics without proper approved Service Tools IMPORTANT Referto MAINTENANCE CHART for complete listing of all scheduled maintenance to be per formed Some listings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempting maintenance or repair proced
43. ing pleasure CB129 Diagnosing EFI Problems Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on the Electronic Fuel Injection EFI System The Electronic Control Module ECM on this engine has the ability to detect some prob lems with the system when they occur and store a Trouble Code in the ECM s memory This code can then be read later by a service technician using a special diagnostic tool CA24 20 Hour Break In Period IMPORTANT The first 20 hours of operation is the engine break in period Correct break in is essential to obtain minimum oil consumption and maximum engine performance During this break in period the following rules must be observed Do not operate below 1500 RPM for extended periods of time for first 10 hours Shift into gear as soon as possi ble after starting and advance throttle above 1500 RPM if conditions permit safe operation Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during first 10 hours During next 10 hours occasional operation at full throttle is per missible 5 minutes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operating temperature Frequently check crankcase oil level Add oil if needed Itis normal for oil consumption to be high during break in period After 20 hour break in period drain crankcase oil and replace oi
44. l filter see MAINTENANCE Fill crankcase with correct oil see SPECIFICATIONS CA211 After Break In Period To help extend the life of your MerCruiser power package the following recommendations should be considered Use a propeller that allows the engine to operate at or near the top of the maximum RPM range See Specifica tions section when at full throttle with a normal boat load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at maximum full throttle RPM CC196 20 Hour Checkup After first 20 hours of operation an Authorized MerCruiser Dealer should be contacted for the following mainte nance The boat owner is responsible for any charges Change crankcase oil and filter Check all fluid levels Cooling System Inspect all hoses for damage and deterioration check all hose clamps for adequate tightness Inspect ignition system and timing Check for loose missing or damaged parts Check shift and throttle cable adjustments lubricate and inspect for loose damaged or missing parts Steering System Lubricate and inspect for loose damaged or missing parts Inspect all drive belts Check engine alignment Complete Engine Exhaust System Inspect externally for damage and deterioration check all hose clamps for adequate tightness 12 THIS PAGE IS INTENTIONALLY BLANK CC93 Operation 4 4 US gt 7 2 7 6 E x 1000 0 2 S x 8 RPM
45. letter when propelling boat FORWARD To obtain service and or parts literature for your Velvet Drive transmission contact Velvet Drive Marine and Industrial Transmissions Theodore Rice Boulevard Industrial Park New Bedford MA 02745 U S A 39 CC429 74832 CC436 Flushing Cooling System When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possi ble injury remove propeller A CAUTION Do not run engine above 1500 RPM when flushing Suction created by seawater pickup pump may collapse flushing hose causing engine to overheat A CAUTION Watch temperature gauge on dash to ensure that engine does not overheat A CAUTION If cooling system is to be flushed with boat in the water water inlet valve if so equipped must be closed or water inlet hose must be disconnected and plugged to prevent water from flowing into boat A CAUTION If boat is in the water do not open water inlet valve until engine is to be restarted to prevent contaminated water from flowing back into engine To prevent silt and or salt buildup in cooling system flush with freshwater at specified intervals 1 Disconnect water inlet hose Lower hose from aft end of fuel cooler 2 Using appropriate connector connect hose between connector and water tap Partially open water tap about 1 2 maximum Place remote control in NEU
46. ll the control handle back from Neutral with a quick firm motion to the first detent for Reverse gear Continue pushing back to increase speed A CAUTION DO NOT shift the control handle into Reverse when the engine is not running Forcing the shift mecha nism into Reverse when the engine is not running could damage the remote control mechanism 21 CC Starting Shifting And Stopping Before starting engine operate bilge blower for at least five minutes to remove any explosive fumes from engine compartment If boat is not equipped with a bilge blower open engine hatch and leave open while starting engine IMPORTANT Observe the following e Do not start engine without water being supplied to seawater pickup pump to prevent pump or engine damage Do not operate starter motor continuously for more than 30 seconds e Never shift unit unless engine is at Idle RPM Perform the following as appropriate 1 Check all items listed in OPERATION CHART 2 Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual 3 Place control handle in NEUTRAL FLOODED ENGINE Turn ignition switch to ON position Place the throttle lever at 5096 position Attempt to start engine As soon as engine starts return throttle to the idle position 4 Turn ignition key to START Release key when engine starts and allow switch to return to RUN position 5 Check oil pressure
47. 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 travel ing at 25 miles per hour 40 km hr in 5 seconds will overtake a fallen skier who was 200 feet in front of you 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 Protecting People In The Water While You Are Cruising Itis 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 d
48. medy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obligation to modify any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IM PLIED WARRANTIES ARE LIMITED TO THELIFE OF THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state 63 MerCruiser International Warranty Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA Vi Vil VIII 64 We warrant each new production not those made for high performance purposes MerCruiser Stern Drive Power Package Inboard Engine and accessories attached thereto hereafter referred to as Product to be free from defects in material and workmanship but only when the consumer sale is made in the country to which distribution is authorized by us This warranty shall remain in effect for a period of one 1 year from date of purchase Since this warranty applies to defects in material and workmanship it does not apply to normal worn parts adjustments
49. national Service Center closest to you for the transferable warranty procedure that would apply to you 67 Q Guard Product Protection Plan United States and Canada Only Certain performance products triple engine installations and commercial applications are excluded The Mercury Marine Q Guard Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q Guard Product Protection Plan is the only Factory Plan available for your engine Two three or four year term plans can be purchased up to 180 days after the original engine purchase date See your participating MerCruiser dealer for complete program details Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local Authorized Dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for MerCruiser stern drives and inboards Service Away From Home If you are away from your local dealer and the need arises for service contact the nearest Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot ob
50. ng inlets or power package being mounted too high Use of fuels and lubricants which are not suitable for use with or on the product Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product 66 Transferable Warranty The product warranty is 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 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 A new Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file e There is no charge for this service Outside the United States and Canada please contact the distributor in your country or the Marine Power Inter
51. ngine For example one of the most important and probably the least suspected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket uses special materials to resist corrosive action Since marine engines must be capable of running at or near maximum RPM much of the time special valve springs valve lifters pistons bearings camshafts and other heavy duty moving parts are required for long life and peak performance These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance 10 CB166 Do It Yourself Maintenance Suggestions If you are one of those persons who likes to do it yourself here are some suggestions for you Present day marine equipment such as your MerCruiser power package are highly technical pieces of machin ery Electronic ignition and electronic fuel injection systems provide greater fuel economies but also are more complex for the untrained mechanic Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions Cau tions and Warnings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you order the service manual for that model The ser vice manual outlines the correct procedures to follow It
52. nt marine growth See your dealer for recommen dations for your boat CA105 Inspection And Maintenance Inspect power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessi ble engine parts Check for loose damaged or missing parts hoses and clamps tighten or replace as required Check plug leads and electrical leads for damage Remove and inspect propeller If badly nicked bent or cracked see your dealer Repair nicks and corrosion damage on power package exterior finish Use Quicksilver spray paints see your Au thorized MerCruiser Dealer CC461 Cold Weather or Extended Storage Power Package Layup IMPORTANT This service should be performed by an Authorized MerCruiser Dealer ACAUTION DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be dam aged and subsequent overheating damage to engine or stern drive unit may result IMPORTANT Before starting engine a water source must be attached to the seawater pump Follow all warnings and flushing attachment procedures stated in FLUSHING COOLING SYSTEM 1 Run engine sufficiently to bring it up to normal operating temperature Shut off engine and change oil and oil filter 2 Flush cooling system Refer to Flushing Cooling System procedure as shown earlier
53. o accessories instruments steering systems 4 damage due to marine growih 5 Product sold with less than a one year limited Product warranty except for Bravo and TRS Drive Units nor 6 Product used in commercial application IV ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IM PLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUN TRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EX CLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU V This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state or country to country VI Other details of this warranty are contained in paragraphs IV V and VI of the United States and Canada Product Warranty and paragraphs Ill IV V and VI of the International Product Warranty contained in this manual which paragraphs are incorporated herein by reference Mercury Marine products are built using the most advanced corrosion protection process available This manufac turing system complemented by dealer and customer participation in an anti corrosion preventive maintenance program provides protection against repair costs incurred by the effects of marine corrosion OWNER S RESPONSIBILITY Protection against certain t
54. ohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol also These Reformulated Gasolines are acceptable for use in your MerCruiser engine CA277 GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank 24 The fuel system components on your MerCruiser engine will withstand up to 10 alcohol content in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specif ic recommendations on the boats fuel system components fuel tanks fuel lines and fittings Be aware that gaso lines containing alcohol may cause increased Corrosion of metal parts Deterioration of rubber or plastic parts e Fuel permeation through rubber fuel lines e Starting and operating difficulties FIRE AND EXPLOSION HAZARD Fuel leakage from any part of fuel system can be a fire and explosion hazard which can
55. olts securely Perform all checks inspections lubrication and fluid changes outlined in MAINTENANCE CHART under AT LEAST ONCE A YEAR 53 CA115 Battery Winter Storage Follow battery manufacturer s instructions for storage CC165 Power Package Recommissioning To prevent possible injury or damage to equipment do not install battery until all maintenance has been performed on engine e Check that all cooling system hoses are connected properly and hose clamps are tight A CAUTION When installing battery be sure to connect POSITIVE battery cable to POSITIVE battery terminal FIRST and NEGATIVE battery cable to NEGATIVE battery terminal LAST If battery cables are re versed or connection order is reversed electrical system damage will result e Install fully charged battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Secure each cable clamp when connecting e Coat terminal connections with a battery terminal anti corrosion agent e Perform all checks in OPERATION CHART in the BEFORE STARTING column A CAUTION Refer to precautions listed under FLUSHING COOLING SYSTEM before starting engine e Start engine and closely observe instrumentation to make sure that all systems are functioning correctly e Carefully inspect engine for fuel oil fluid water and exhaust leaks Check steering system shift and throttle control for proper opera
56. oper viscosity oil Engine oil cooler hose kinked causing excessive oil temper ature and thinning of the oil Low fluid level Transmission shift lever not posi tioned properly causing clutches to slip and overheat fluid Fluid cooler hoses kinked Excessive current draw from bat tery Loose or dirty electrical connec tions or damaged wiring Alternator drive belt loose or in poor condition Unacceptable battery condition Insufficient lubrication on shift and throttle linkages Loose or missing shift and throttle linkage fasteners Obstruction in shift or throttle linkages Shift or throttle cable kinked Check for cause of low coolant level and repair Fill system with proper coolant solution Clean Check for leaks Clean test and inspect pres sure cap Replace Check and add correct grade and viscosity oil Check entire engine for leaks Check and remove required amount of oil Check for cause of excessive oil improper filling bad fuel pump etc Change oil and oil filter being sure to use correct grade and viscosity oil Determine cause for dilution excessive idling faulty fuel pump etc Straighten hose or replace if damaged Maintain fluid level Inspect shift linkages and shift lever positioning Straighten hoses or replace if damaged Turn off non essential accessories Check all associated electrical connections and wires especially battery cables Clean and tighten fa
57. orized MerCruiser Dealer is required to prevent serious damage to power package CA21 Stolen Power Package If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Motor information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors CA22 Replacement Service Parts Electrical ignition and fuel system components on MerCruiser gasoline power packages are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize risks of fire or explo sion Use of replacement electrical ignition or fuel system components which do not comply to these rules and regulations could result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks if they existed Marine engines are expected to operate at or near full throttle for most of their life They are also expected to oper ate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those ofthe standard auto motive e
58. ot to use such a switch The following advantages and disadvantages of a lanyard stop switch should be considered before elect ing to use or not to use such a switch ADVANTAGES The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch This would occur if the operator falls or moves within the boat a sufficient distance from the operator s position This type of accident is most likely in certain types of boats such as low sided boats and high performance boats It is also likely as a result of poor operating practices such as sitting on the back of the seat at planing speeds standing at planing speeds operating at high speeds in shallow or obstacle in fested waters releasing your grip on a steering wheel that is pulling in one direction drinking and driving or daring high speed boat maneuvers DISADVANTAGES Inadvertent activation of the switch is also a possibility This could cause any or all of the following potentially hazardous situations 1 Loss of balance and falling forward of unstable boat passengers a particular concern in bow rider type boats 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking While activation of the lanyard stop switch will result in immediate power shut down a boat can continue to coast for
59. otal Orders Totaling up to 20 00 add 3 00 20 01 50 00 add 4 00 50 01 up Free 73 Please Return with Payment to Mercury Marine Attn Publications Dept P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print or Type This is your Shipping Label Name Address City State METHOD OF PAYMENT NO CASH OR C O D Personal Check Cashiers Check Money Order Visa MasterCard A ME Card Number Signature Telephone Number 74 Month Year Expiration Date Date
60. own and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the drive unit is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat Is Stationary Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CA283 High Speed And High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat For additional information obtain a copy of our Hi Performance Boat Operation booklet Part Number 90 86168 3 from your dealer distributor or Mercury Marine CA7 Conditions Affecting Operation Weight Distribution Positioning of weight passengers and gear inside the boat has the following effects Shifting weight to rear ste
61. rating Fuel Filter user re A ee en ee 45 dz dee an en hee aaa Be 45 Engine Allgnment 12 22 ra A a pe eed ea ee ego CAREY Y GO eee E a R3 ERO RE 47 Miscellaneous Maintenance ss ee en re re 49 Battery era sun we ee ne nee ee ch ae ehr een 49 Bolton OP BOA A E N ee AO E ANE 49 BAIRNSDALE 49 Inspection And Maintenance x 42 ad LEI ERA AAA eq ed tou sa ie e c ee 49 Cold Weather or Extended Storage ir 14 x vo pee E dete eher iot rep US SQ Iob E FO BA IINE VIR 51 Power Package Lay p mesos sta RR RR a a Se ES ee a Ea 51 Draining 115110611697 uti cene at ar aa face ee en ie AI n Rey lee 53 Battery Winter Storage cech seams Cs ihe En ERE RU xe Reged e RR RE E IARE EUER 54 Power Package Recommissioning zu eu AA UE ee Qe ino wed RA EAS 54 Troubleshooting MOL A A fr ERR A A RS 55 Wale ElOW 019019111 E TI ETA AAA areca a ata eee 58 Winng Dlagrams rss po napisy glia na DA Sap sth one 59 Quicksilver Instrumentation caviar A a Bed 59 Starting And Charging System Harness eva is ee ae u S ra ARE lea bet 60 EFLSysiem Harness Lube rs A eee rn en ea eed a anal 61 Warranty intormatiom a A A E ERE EAE ee ace ee at era 62 Owner Warranty Registration re ee ae O RN st 62 International Owner Registration a cet tec dete ne ee i
62. required or have no facilities to haul out etc and prior factory approval has been given to have the work per formed at this facility All incidental and or consequential damages storage charges telephone or rental charges of any type incon venience or loss of time or income are the owner s responsibility Use of other than Quicksilver replacement parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard Water entering the engine via the carburetor or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commu tator because of excess cranking Valve or valve seat grinding required because of wear Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material blocki
63. rn will e Generally increases speed and engine RPM At extremes can cause boat to porpoise e Causes bow to bounce in choppy water e Increases danger of following wave splashing into boat when coming off plane Shifting weight to front bow will Improve ease of planing Improve rough water ride e At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom should be observed e Clean free of barnacles and marine growth e Free of distortion nearly flat where it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when boat is docked This growth must be removed before operation it may clog water inlets and cause engine to overheat CA12 How Elevation and Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine Since air containing oxygen gets thinner as elevation increases the engine begins to starve for air Humidity barometric pressure and tempera ture do have a noticeable effect on the density of air Heat and humidity thin the air This condition can become particularly annoying when the propeller testing was done on a cool dry day Then later on a hot sultry day the boat doesn t seem to have the same performance Although some performance can be regained by dropping to a lower pitch propeller the basic problem s
64. s Inspect fuel for water or other contaminants If contaminated drain tank and flush with fresh fuel Replace kinked lines or blow out lines with compressed air to remove obstruction Have EFI System checked by an Authorized MerCruiser Dealer 55 Trouble Engine runs rough misses and or backfires Poor performance Excessive engine temperature Possible Cause Faulty fuel pump Low on fuel level Faulty ignition system component Clogged fuel filters Contaminated fuel Kinked or clogged fuel line or fuel tank vent line Flame arrestor plugged with foreign material EFI System Fault Not using 91 Octane fuel Throttle not fully open Damaged or improper propeller Excessive bilge water Boat overloaded or load improp erly distributed Boat bottom fouled or damaged Flame arrestor dirty Engine overheating Ignition or EFI System fault Water inlet valve closed if so equipped Alternator drive belt loose broken or in poor condition Seawater pickup pump drive belt loose broken or in poor condition Water pickup obstructed Kinked collapsed or broken hose Faulty thermostat Transmission fluid cooler and or engine oil cooler plugged with foreign material Remed Check fuel pressure if below specification Have your dealer replace pump Fill fuel tank Service ignition system Replace filters Inspect fuel for water or other contaminants If contaminated drain tank and flush
65. s normal wear and a variety of other causes that affect the product are not covered Warranty is limited to defects in material or workmanship but only when the consumer sale is made in the country to which distribution is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have Warranty Does Not Apply To The Following Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection with normal services Damage caused by neglect lack of maintenance accident abnormal operation or improper installation or ser vice or freezing temperatures Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reason able access must be provided to the product for warranty service Customer must deliver product to an Autho rized Dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by otherthan an Authorized Dealer may be covered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in area who can perform the work
66. some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power As we cannot possibly know of and advise the boating public of all conceivable boat motor types and or poor operating practices the final decision of whether to use a lanyard stop switch rests with you the own er driver We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine and boat in an emergency 4 CA281 Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions e Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squad ron 3 The Red Cross and 4 your state or provincial boating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT We strongly recommend that all powerboat operators attend one of these courses You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of s
67. tain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Parts and Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local Authorized Dealer The dealer has the necessary information to order parts and accessories for you should he not have them in stock Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory Mer cury Marine does not sell to unauthorized dealers or retail customers When inquiring on parts and accessories the dealer requires the motor model and serial number s to order the correct parts 68 Resolving a Problem Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser Any problems with ser vice sales warranty or operation of your MerCruiser power package will be resolved by your dealer He also is your primary source of information on your boat power package and trailer Should there be a misunderstanding or if your problem has not been resolved to your satisfaction please follow these steps STEP ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Misunderstandings or complaints can be quickly resolved by the dealer If you are unable to obtain satisfaction contact the dealership s owner STEP TWO IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE
68. till exists In some cases a gear ratio change to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the en gine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less than its recommended RPM This will result in further loss of horsepower at the propeller with another de crease in boat speed This secondary loss however can be somewhat regained by switching to a lower pitch pro peller that allows the engine to again run at recommended RPM For boaters to realize optimum engine performance under changing weather conditions it is essential that the en gine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging de
69. tion e Check fuel system sight tube for evidence of fuel If fuel is present contact your Authorized MerCruiser Dealer for repairs 54 CC464 Troubleshooting Trouble Possible Cause Starter motor e Battery switch turned off if so won t crank en equipped e Turn switch on gine or cranks it very slowly Engine won t start or is hard to start Remote control not in neutral position Open circuit breaker or blown fuse Loose or dirty electrical connec tions or damaged wiring Bad battery Improper starting procedure Empty fuel tank or fuel shut off valve closed if so equipped Faulty fuel pump Engine flooded Faulty ignition system com ponent Clogged fuel filters Contaminated fuel Fuel line or tank vent line kinked or clogged EFI System Fault Position control lever properly Lever MUST BE EXACTLY in neutral Check and reset circuit breaker or replace fuse Check all associated electrical connections and wires especially battery cables Referto wiring diagram following Clean and tighten faulty connection Repair or replace wiring Test and replace if bad Review starting procedure under Operation Instructions Fill tank or open valve Check fuel pump pressure Do not attempt to start engine for at least 5 min utes then follow the procedure for starting a flooded engine found in the Operation sec tion of this manual Service ignition system Replace filter
70. tonation This of course enhances overall reliability and durability of the engine CA13 Important Information Operation And Maintenance OWNER OPERATOR RESPONSIBILITIES Itis the operator s responsibility to perform all safety checks to ensure that all lubrication and maintenance instruc tions are complied with for safe operation and to return the unit to an Authorized MerCruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the responsibility of the owner operator and as such are not considered defects in workmanship or material within the terms ofthe 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 MerCruiser Dealer for service aids CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation such as e Make sure that the boat is properly equipped e Prior to delivery make certain that the MerCruiser power package and other equipment are in proper operating condition 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
71. tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal opera tion or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Oper ation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or prepar ing for racing or other competitive activity or operating with a racing type lower unit or 5 Alteration or removal of parts or 6 Water entering engine cylinder s through exhaust system or carburetor s Reasonable access must be provided to the Product for warranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replacement of boat partitions or material because of boat design for necessary access to the Product Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho rized to service the Product If purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Marine Power Service Center or distributor The Marine Power Service Center or distributor shall then arrange for the inspection and repair provided such service is covered under this warranty Pur chaser shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purc
72. u acer Pate 21 Starting Shifting And Stopping s s s epe e Ca eee dee d re eset bo 22 Operation CHAR o ern a a OCA E A OR A E at Des we ee RAP an E Ra OR RR 23 506611162110135 ecc 24 Fuel Recommendations u 23 u XE a ME RE ee Ra d RR 24 Seacock Size Recommendation 42 recens tud a NE a et 26 Sea Strainer Recommendation 4 uiuis erem een e wed eee MEA Re UR VaL ne 26 Crankcase Olii aa Aer ii aks eas ERU SR Pad att te eu Le e eh eae 26 Engine SDecITICallOFiS na tor ey metu IN CU EN CR isis 27 Tune up SpecifICallOnS urn dr a ee bete a we G 28 CAPAC ISS tarot nana SS AS ro Da bt OMAR e ads Ge ated atta tb Ae las 29 8 cr a a Se pe A aa coh ae Say 30 EFI System Maintenance Precautions occ nennen ernennen nen 31 Maintenance Rr dueis zu na ee aR 31 Maintenance Schedules cu 666666266660000 ee er ee Re 32 Checking Fmd Levels nat a a er uo ee 35 Changing Fluids D ie aa ae en are 37 a re Be aE has ES EEE en ame Ber pup hS 39 Flushing Cooling System aus ars E ete ERE RR xU ERU Oe a a eee eek 41 seawater Pump Impeller cse aiar erene DERI ext is a a RES 41 Dive Belts nen ae traces resur at ehr ee a a 43 Sight TUBE IrisDBCIIDI a Re a ee qu ee aE EE 45 Water Sepa
73. ulty connections Repair or re place damaged wiring Replace and or adjust Test battery Lubricate Check all linkages If any are loose or missing SEE YOUR DEALER IMMEDIATELY Remove obstruction Straighten cable or have your dealer replace cable if damaged beyond repair 57 58 Water Flow Diagram A SEAWATER INLET EXHAUST ELBOW SEAWATER PICKUP PUMP THERMOSTAT 7 HOUSING T 4 P GO ro qm FLUID COOLER EXHAUST MANIFOLD ENGINE CIRCULATING e PUMP CC117 Wiring Diagrams Quicksilver Instrumentation Refer to gauge manufacturer s instructions for specific connections NOTE 1 Connect Wires Together with Screw and Hex Nut Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection NOTE 2 Power for a Fused Accessory Panel May Be Taken from This Connection Load Must Not Exceed 40 Amps Panel Ground Wire Must Be Connected to Instrument Terminal That Has an 8 Gauge BLACK Ground Harness Wire Connected to it NOTE 3 Taped back BROWN WHITE wire may be used for an accessory LOAD MUST NOT EXCEED 5 AMPS BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK AUDIO WARNING BUZZER Oil Pressure Water Temperature To Engine Harness YEL RED M E N z 59 CC2
74. ures not covered in this manual it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly CC445 Maintenance Products 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 per formed Some listings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempting maintenance or repair procedures not covered in this manual it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly A CAUTION Avoid damage to transmission The transmission on your MerCruiser product is filled with Dexron Ill trans mission fluid at the factory Do not mix other transmission fluids with Dexron Ill transmission fluid 1 Velvet Drive Transmission Dexron Transmission Fluid 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Crankcase Oil Quicksilver 4 Cycle Marine Engine Oil Refer to SPECIFICATIONS for alternatives and oil rec ommendations for varying ambient temperatures 5 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard 6 Gasoline Stabilizer Quicksilver Gasoline Stabilizer for Marine Engines 31 00424 Maintenanc
75. ypes of corrosion damage must be provided by using such systems as the Quicksilver MerCathode System and or Galvanic Isolator These certain types of corrosion damage are damage due to stray electrical currents on shore power connections nearby boats submerged metal or improper application of cop per base anti fouling paint If anti fouling protection is required Tri Butyl Tin Adipate TBTA base anti fouling paints are recommended on MerCruiser boating applications In areas where Tri Butyl Tin Adipate base paints are prohibited by law copper base paints can be used on the boat hull and transom Do not apply paint to the MerCruiser drive unit or transom assembly In addition care must be taken to avoid an electrical interconnection between the MerCruiser Product and the paint Corrosion damage that results from the improper application of copper base paint will not be covered by this limited warranty TRANSFER OF WARRANTY This Limited Warranty is transferable to subsequent purchasers for the remainder of the unused portion of the 3 year limited warranty 65 Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The table explains some of the types of services that are not covered by warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship Installation errors accident

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