Mercury mercruiser User Manual

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Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President - Mercury Marine, Fond du Lac, WI USA...
Page 2 Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
Page 3: Read This Manual Thoroughly
We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Page 4 WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
Page 5: Table Of Contents
Independent States, Middle-East, and Africa..5 Warranty Registration Outside The United States And 3 Year Limited Warranty Against Corrosion Canada..............2 (Worldwide).............6 Mercury, MerCruiser Limited Warranty United States, Warranty Coverage And Exclusions......7 Canada and Europe (Gasoline Fueled Products General Exclusions From Warranty....8 Only)................3 Section 2 - Getting to Know Your Power Package Lanyard Stop Switch..........12...
Page 6 High-Speed And High-Performance Boat Conditions Affecting Operation......46 Operation..............43 Weight Distribution (Passengers and Gear) Passenger Safety In Pontoon Boats And Deck Inside the Boat..........46 Boats..............43 Bottom Of Boat..........46 Boats Having An Open Front Deck....43 Cavitation............46 Boats With Front-Mounted, Raised Pedestal Ventilation.............
Page 7 Section 8 - Customer Assistance Information Owner Service Assistance........118 Parts And Accessories Inquiries....119 Local Repair Service........118 Resolving A Problem........119 Service Away From Home......118 Mercury Marine Service Offices......119 Stolen Power Package........118 Ordering Literature..........120 Attention Required After Submersion.....118 United States and Canada......120 Replacement Service Parts......118 Outside The United States and Canada..120...
Page 8 Page iv 90-864839060 MAY 2006...
Page 9: Section 1 - Warranty
Warranty Registration Outside The United States 3 Year Limited Warranty Against Corrosion And Canada............2 (Worldwide)............6 Mercury, MerCruiser Limited Warranty United Warranty Coverage And Exclusions..... 7 States, Canada and Europe (Gasoline Fueled General Exclusions From Warranty ....8 Products Only)............3...
Page 10: Transfer Of Warranty
1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information.
Page 11: Mercury, Mercruiser Limited Warranty United States, Canada And Europe (Gasoline Fueled Products Only)
Mercury, MerCruiser Limited Warranty United States, Canada and Europe (Gasoline Fueled Products Only) WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for either two (2) years from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
Page 12 If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
Page 13: Mercury Mercruiser Limited Warranty
Mercury MerCruiser Limited Warranty (Confederation of Independent States, Middle-East, and Africa WHAT IS COVERED: Mercury Marine warrants its products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for either one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
Page 14: Year Limited Warranty Against Corrosion (Worldwide)
If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
Page 15: Warranty Coverage And Exclusions
COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented.
Page 16: General Exclusions From Warranty
8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. 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.
Page 17 Section 1 - Warranty 15. Use of fuels and lubricants which are not suitable for use with or on the product. Refer to the Maintenance section. 16. 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.
Page 18 Section 1 - Warranty Notes: Page 10 90-864839060 MAY 2006...
Page 19: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Lanyard Stop Switch........... 12 Dual Helm Station Transfer......22 Instrumentation........... 13 Synchronizing Dual Helms Prior To Station System View ..........13 Transfer ..........
Page 20: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position). 74608 Stop switch Clips to the operator...
Page 21: Instrumentation
System View H O M E 5650 Your power package may be connected to the Mercury SC5000 SmartCraft System View display. The display monitors and reports information ranging from basic operating data to engine alarm data. The SC5000 System View Display is a comprehensive boat information center. System View allows the boat operator to receive a wealth of critical operational information, displayed clearly and instantly at the helm on the LCD display.
Page 22: Digital Gauges
Section 2 - Getting to Know Your Power Package Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, battery voltage, fuel consumption and engine operating hours.
Page 23: Remote Controls (Non-Dts Models)
Remote Controls (Non-DTS Models) Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.
Page 24: Console Mount Features
Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.
Page 25: Zero Effort Features
IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.
Page 26: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features 3409 Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.
Page 27: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features - Single Engine 3410 Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 28: Slim Binnacle Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features - Single Engine START STOP 14637 Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 29: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features- Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch Arrow trackpad Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw...
Page 30: Synchronizing Dual Engines
Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine. Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5°...
Page 31: Synchronizing Dual Helms Prior To Station Transfer
Section 2 - Getting to Know Your Power Package 3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STATION SELECT STATION SELECT 3433...
Page 32: Power Trim
Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
Page 33: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
Page 34: Trim Delta
Section 2 - Getting to Know Your Power Package Trim Delta Trim delta controls the distance between the individual adjacent drive angles when trimming. The trim delta limit is preset, and will not allow extreme drive angle differences that could damage tie bars. If the maximum trim delta limit is met, the drive furthest in the trim process "up or down", will stop trimming until the adjacent drive is back within the delta limit.
Page 35 Section 2 - Getting to Know Your Power Package 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. mc74907-1 3.
Page 36: Audio Warning System
Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
Page 37: Testing The Audio Warning System
When the alarm has sounded, do not operate engine except to avoid a hazardous situation. If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System 1.
Page 38: Emissions Information
A tamper-resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, FEL (emission level), date of manufacture (month, year), and the engine displacement.
Page 39: Owner Responsibility
Beginning January 1, 2003, one Three-Star label will be included with each factory-certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three-Star Ultra Low Emission rating. The Three-Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards.
Page 40 Section 2 - Getting to Know Your Power Package One Star - Low emission The one-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines.
Page 41 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........34 While You Are Cruising ........ 42 Be Alert To Carbon Monoxide Poisoning... 35 While Boat Is Stationary ....... 42 Good Ventilation ........... 36 High-Speed And High-Performance Boat Operation Poor Ventilation ...........
Page 42: Safe Boating Suggestions
Know and obey all nautical rules and laws of the waterways. • Mercury MerCruiser strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency.
Page 43: Be Alert To Carbon Monoxide Poisoning
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.
Page 44: Good Ventilation
Section 3 - On The Water Good Ventilation Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 45: Operation Chart
Section 3 - On The Water OPERATION CHART Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Observe all gauges to Observe all gauges to check condition of Turn ignition key to the Install bilge drain plug. check condition of engine. If engine.
Page 46: Stopping The Engine
If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer.
Page 47: Freezing Temperature Operation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 48: Starting And Stopping The Engine
NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 49: Stopping The Engine
Section 3 - On The Water CAUTION Avoid damage to the drive system. Shifting the drive system at RPMs greater than engine idle speed may cause internal damage to the drive system. Shift the drive system only when the engine is at idle RPM. STOPPING THE ENGINE 1.
Page 50: Trailering The Boat
If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer.
Page 51: High-Speed And High-Performance Boat Operation
For additional information, refer to Hi-Performance Boat Operation booklet (90-849250-R2) from your dealer, distributor or Mercury Marine. Passenger Safety In Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers.
Page 52: Wave And Wake Jumping
Section 3 - On The Water Wave And Wake Jumping WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.
Page 53: Drive Unit Impact Protection
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 54: Conditions Affecting Operation
Section 3 - On The Water CAUTION Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be sucked into the water inlets restricting or shutting off the water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water.
Page 55: Elevation And Climate
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. Refer to Mercury Marine's web page http:// www.mercurymarine.com/everything_you_need_to_know_about_propellers6. Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load.
Page 56: After Break-In Period
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year-round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
Page 57: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........50 Engine Oil............51 Fuel Ratings ..........50 Engine Specifications......... 52 Using Reformulated (Oxygenated) Gasolines Fluid Specifications..........52 (USA Only) ........... 50 Sterndrives ........... 52 Gasolines Containing Alcohol ...... 50 Engine ............
Page 58: Fuel Requirements
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand.
Page 59: Engine Oil
To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of the following oils listed in the order of recommendation: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC-W rated, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC-W rated oil.
Page 60: Engine Specifications
Section 4 - Specifications Engine Specifications Models 496 MAG 496 MAG HO Horsepower Kilowatts Displacement 8.1 L (496 cid) 4400-4800 4600-5000 Specified WOT RPM Range Idle rpm in Neutral 103 kPa (15 psi) Minimum Oil Pressure @ Idle 207 kPa (30 psi) Minimum Oil Pressure @ 2000 rpm Thermostat 71°...
Page 61 Section 4 - Specifications All Models Capacity Fluid Type Mercury/Quicksilver Synthetic Blend MerCruiser Engine 8.5 liters (9 U.S. qt.) Engine Oil (With Filter) Oil 25W-40 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water Seawater Cooling System Mercury Extended Life Coolant/Antifreeze or Extended Closed Cooling System 18 liters (19 U.S.
Page 62 Section 4 - Specifications Notes: Page 54 90-864839060 MAY 2006...
Page 63 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......56 Changing ............67 Dealer Responsibilities........56 Power Trim Fluid..........69 Maintenance............56 Checking ............69 Do It Yourself Maintenance Suggestions... 57 Filling ............69 Inspection............57 Changing ............
Page 64: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...
Page 65: Do It Yourself Maintenance Suggestions
Transmission (Inboard models only) Do It Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 66: Maintenance Schedule - Sterndrive Models
Scheduled Maintenance NOTE: Only perform maintenance which applies to your particular power package. AFTER THE INITIAL 20 HOUR BREAK-IN PERIOD To help extend the life of your Mercury MerCruiser power package, the following is reccommended: • Change the engine oil and filter.
Page 67: Every 200 Hours Or 3 Years
Section 5 - Maintenance • Driveshaft extension models: Lubricate the driveshaft U-joints, and tailstock input and output bearings. EVERY 200 HOURS OR 3 YEARS • Inspect the U-joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U-joint splines and cross bearing, if equipped with a grease fitting.
Page 68: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat.
Page 69: Changing Oil And Filter
3. Replace the fill cap. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W-40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.
Page 70: Engine Oil Drain Pump
Section 5 - Maintenance 4. Place the oil drain hose in a suitable container. 5. Remove the drain plug from the oil drain hose. 6. After oil has drained completely, install the drain plug in the oil drain hose. 7. Push the hose through bilge drain and install the plug. ENGINE OIL DRAIN PUMP 1.
Page 71: Power Steering Fluid
OK range. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W-40 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.
Page 72: Filling
Section 5 - Maintenance 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add the specified fluid to bring the fluid level up to the proper range.
Page 73: Filling
92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat.
Page 74: Filling
If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Page 75: Changing
Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 8530 Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
Page 76 Sealing washer IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air-free stream of lubricant flows from oil vent hole.
Page 77: Power Trim Fluid
Power Trim and Steering Fluid Power trim pump 92-802880A1 3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. 90-864839060 MAY 2006 Page 69...
Page 78: Cleaning The Flame Arrestor
Section 5 - Maintenance Cleaning The Flame Arrestor WARNING Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Be careful when cleaning flame arrestor; ensure that ignition is off. Do not smoke or allow sources of spark or open flame in area when cleaning flame arrestor.
Page 79: Changing Water Separating Fuel Filter
Wipe up any spilled fuel immediately. Ensure that no fuel leaks exist before closing the engine hatch. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped.
Page 80 Section 5 - Maintenance 6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap. 8837 Cool Fuel Module Fuel filter element Cool Fuel Module harness Filter cup Filter cap...
Page 81: Lubrication
21. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Steering System CAUTION Do not grease the steering cable while its extended.
Page 82 3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92-883725K01 Oil SAE25W-40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 83: Throttle Cable
Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92-883725K01 Oil SAE25W-40 guide contact surfaces Shift Cable - Typical 1. Lubricate the pivot points and the guide contact surfaces.
Page 84: Sterndrive Unit And Transom Assembly
Section 5 - Maintenance Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun. mc77068-1 Gimbal bearing grease fitting Tube Ref No. Description Where Used Part No. U-joint and Gimbal Bearing Gimbal bearing 92-802870A1 Grease...
Page 85: Engine Coupler
Section 5 - Maintenance NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated Bravo Models - every 50 hours; Alpha Models - every 150 hours. 6212 6213 Alpha drive coupler Bravo drive coupler Grease fitting Tube Ref No.
Page 86: Driveshaft Extension Models
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo One Propeller Removal WARNING Avoid Injury: Remote Control must be in neutral and ignition key removed from switch before removing and/or installing propeller.
Page 87: Bravo One Propeller Installation
Section 5 - Maintenance Bravo One Propeller Installation CAUTION Avoid injury and propeller damage or sterndrive damage, or both, caused by a loose propeller or propellers. The propeller may become loose during normal operation. Periodically throughout the boating season and at the maintenance intervals specified, the propeller nut or nuts must be checked for tightness.
Page 88: Bravo Two Propeller Removal
Section 5 - Maintenance 7. Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.
Page 89: Bravo Three Propeller Removal
Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft 92-802867A1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon 3. Align splines and place propeller on propeller shaft. 4. Install spline washer and tab washer. 5.
Page 90: Bravo Three Propeller Installation
Section 5 - Maintenance 6. Turn front propeller shaft nut 70 mm (2-3/4 in.) counterclockwise to remove nut. 7. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304...
Page 91 Section 5 - Maintenance 1. Slide forward thrust hub onto propeller shaft with tapered side toward propeller hub (toward end of shaft). 2. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No.
Page 92: Serpentine Drive Belt
Section 5 - Maintenance Description lb. in. lb. ft. Propeller shaft anode screw 38 mm (0.3125-18 x 1.5 in.) long Serpentine Drive Belt WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt. 8118 Belt Routing Diagram Idler pulley...
Page 93: Replacing
Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the limits. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION The belt tensioner assembly contains a high tension spring. Rapid release of the tensioner, or allowing the tensioner to snap back quickly, could injure the operator or cause product damage.
Page 94: Flushing The Power Package
The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Bravo models equipped with closed cooling require dual water pickups and must be equipped with a through the hull or through the transom pickup in addition to the sterndrive water inlets.
Page 95: Flushing Attachments
9194 Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
Page 96 Section 5 - Maintenance 2. On Alpha closed cooled models with the sterndrive seawater inlet blocked: Flushing water will need to be supplied to the sterndrive unit and to the engine. Refer to Alternative Water Pickups. 3. On Bravo closed cooled models using the sterndrive seawater inlet and a through the hull or through the transom alternative water pickup: Flushing water will need to be supplied to only the sterndrive unit by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet...
Page 97: Alternative Water Pickups
Section 5 - Maintenance 11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. 12. Slowly return throttle to idle speed position. 13. Stop engine. 14. Shut off water and remove flushing attachment. 15.
Page 98: Battery
Section 5 - Maintenance 5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine or boat. 6147 6. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.
Page 99: Multiple Efi Engine Battery Precautions
Section 5 - Maintenance WARNING Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine. Do not recharge a weak battery in the boat. Remove battery and recharge in a ventilated area away from fuel vapors, sparks or flames. WARNING Batteries contain acid which can cause severe burns.
Page 100: Corrosion Protection
Section 5 - Maintenance Corrosion Protection CAUTION Improper boat-cleaning procedures can cause product damage. Washing the MerCathode assembly, especially with a brush or high-pressure washer, will damage the MerCathode assembly making it unable to inhibit galvanic corrosion. When cleaning the boat, do not use a brush or a high-pressure washer to wash the MerCathode assembly found on the bottom of the transom assembly.
Page 101 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti-Corrosion Anode Kit and/or a MerCathode System be installed (some models have a MerCathode System as standard equipment).
Page 102 MerCathode System - Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. Page 94...
Page 103 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. 6206 MerCathode controller MerCathode assembly Anode Kit (if equipped) - Mounted to the boat transom. 5642 Trim Cylinder Anodes - Mounted on each trim cylinder. 5643 Trim cylinder anodes 90-864839060 MAY 2006...
Page 104: Painting Your Power Package
Section 5 - Maintenance Bearing Carrier Anode (Bravo One) - Located in front of the propeller, between the front side of the propeller and the gear housing. 5644 Bearing carrier anode Propshaft Anode (Bravo Three) - Located behind the aft propeller. 5821 Propshaft anode In addition to the corrosion protection devices, the following steps should be taken to inhibit...
Page 105 Section 5 - Maintenance • Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1-1/2 in.) unpainted area on transom of the boat around these items.
Page 106 Section 5 - Maintenance Notes: Page 98 90-864839060 MAY 2006...
Page 107 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....100 Boat in the Water ......... 103 Preparing Power Package for Storage..100 Boat out of the Water ......105 Engine and Fuel System Preparation . . 101 Manual Drain System........107 Draining the Seawater System......
Page 108: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION Seawater that is trapped in or remains in the cooling system seawater section during cold weather or winter storage can freeze resulting in cooling system or engine damage.
Page 109: Engine And Fuel System Preparation
Section 6 - Storage ENGINE AND FUEL SYSTEM PREPARATION WARNING Avoid serious injury or death from a gasoline fire or explosion; gasoline is extremely flammable and highly explosive under certain conditions. When servicing the fuel system components ensure that the engine is cool, the ignition switch is in the off position, and that the lanyard stop switch, if equipped, is in the off position.
Page 110: Drain System Identification
Section 6 - Storage CAUTION Excess water in the bilge can damage the engine or cause the boat to sink. When the drain system is open excess water can enter the bilge. Do not operate the engine with the drain system open. IMPORTANT: Only drain the seawater section of the closed cooling system.
Page 111: Manual Drain System
Section 6 - Storage MANUAL DRAIN SYSTEM 17255 Blue drain plug locations Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1.
Page 112 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 113: Boat Out Of The Water
Section 6 - Storage 13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 114 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 115: Manual Drain System
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 116: Boat Out Of The Water
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 117: Battery Storage
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.
Page 118 Section 6 - Storage 2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect cables. Tighten each cable clamp securely when connecting. 3. Coat the terminal connections with a battery terminal anti-corrosion agent. 4. Perform all the checks in the before starting column of the Operation Chart. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage.
Page 119: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 112 Low Engine Oil Pressure........114 Diagnosing DTS Problems....... 112 Battery Will Not Come Up On Charge....114 Engine Guardian System........112 Remote Control Operates Hard, Binds, Has Starter Motor Will Not Crank Engine, Or Cranks Excessive Free-play Or Makes Unusual Sounds Slow..............
Page 120: Diagnosing Efi Problems
Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 121: Engine Runs Rough, Misses And/Or Backfires
Section 7 - Troubleshooting Possible Cause Remedy Have EFI System checked by an authorized Mercury EFI system fault. MerCruiser dealer. Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Clogged fuel filter. Replace filter. Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.
Page 122: Insufficient Engine Temperature
Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level.
Page 123: Power Trim Does Not Operate (Motor Does Not Operate)
Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Does Not Operate) Possible Cause Remedy Replace fuse. Fuses may be located near the dash trim switch, at the trim pump, in the positive (red) Blown fuse. power trim battery lead near the battery switch, or a combination of these.
Page 124 Section 7 - Troubleshooting Notes: Page 116 90-864839060 MAY 2006...
Page 125: Section 8 - Customer Assistance Information
Parts And Accessories Inquiries ..119 Local Repair Service ........118 Resolving A Problem ........119 Service Away From Home ......118 Mercury Marine Service Offices ....119 Stolen Power Package ....... 118 Ordering Literature..........120 Attention Required After Submersion ..118 United States and Canada ......
Page 126: Owner Service Assistance
These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance. 1. Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser sterndrives and inboards.
Page 127: Parts And Accessories Inquiries
Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If additional assistance is required, take these steps: 1.
Page 128: Ordering Literature
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

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