MerCruiser 3.0 TKS User Manual Download Page 105

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Section 7 - Troubleshooting

90-8M0053372

eng

NOVEMBER 2010

Page 97

Section 7 - Troubleshooting

Table of Contents

Starter Motor Will Not Crank Engine, Or Cranks Slow......... 98

Engine Will Not Start Or Is Hard To Start............................. 98

Engine Runs Rough, Misses or Backfires............................ 98

Poor Performance................................................................ 98

Excessive Engine Temperature............................................ 99

Insufficient Engine Temperature........................................... 99

Low Engine Oil Pressure...................................................... 99

Battery Will Not Recharge.................................................... 99

Remote Control Is Difficult to Move, Has Excessive Play, or

Makes Unusual Sounds...................................................... 100

Steering Wheel Jerks or Is Difficult to Turn........................ 100

Power Trim Does Not Operate (Motor Does Not Operate). 100

Power Trim Does Not Operate (Motor Operates but

Sterndrive Unit Does Not Move)......................................... 100

Summary of Contents for 3.0 TKS

Page 1: ... 68 EC Directive 88 77 EC Conformity assessment module used for noise emissions A Aa G H Other Community Directives applied Electromagnetic Compatibility Directive 2004 108 EC Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle z or sterndrive with integral exhaust Diesel 2 stroke Inboard engine Petrol 4 stroke Identification of Engines Covered by This Declarat...

Page 2: ...r designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin USA Printed in USA 2009 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Bravo Two Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort VesselView Zeus Axi...

Page 3: ...e dangers warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special instruction...

Page 4: ......

Page 5: ...20 Engine Serial Number Decal 20 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Lanyard Stop Switch 21 Instrumentation 22 Remote Controls 23 Panel Mount Features 23 Console Mount Features 24 Power Trim 24 Single Engine Trim Trailer 25 Dual Engine Trim Trailer 25 Electrical System Overload Protection Carbureted Engines 25 Audio Warning System 28 Testing The Audi...

Page 6: ...e Cable 61 Shift Cable Typical 61 Sterndrive Unit and Transom Assembly 62 Sterndrive U Joint Shaft Splines and O Rings Sterndrive Unit Removed 62 Engine Coupler 62 Driveshaft Extension Models 63 Propellers 64 Propeller Repair 64 Alpha Propeller Removal 64 Alpha Propeller Installation 64 Bravo One Propeller Removal 65 Bravo One Propeller Installation 65 Bravo Two Propeller Removal 66 Bravo Two Prop...

Page 7: ...ll Not Recharge 99 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 100 Steering Wheel Jerks or Is Difficult to Turn 100 Power Trim Does Not Operate Motor Does Not Operate 100 Power Trim Does Not Operate Motor Operates but Sterndrive Unit Does Not Move 100 Section 8 Customer Assistance Information Owner Service Assistance 102 Local Repair Service 102 Service Away From...

Page 8: ...Page iv 90 8M0053372 eng NOVEMBER 2010 ...

Page 9: ...ernment Applications 8 Mercury MerCruiser Warranty Charts 9 Consumer Application Warranty Chart 9 Commercial Application Warranty Chart 10 Government Application Warranty Chart 11 Emission Control Warranty Information 11 Important Information 11 Emission Control Information Label 12 Owner Responsibility 13 California Emissions Limited Warranty 13 What Is Covered 13 Duration of Coverage 13 How to O...

Page 10: ...sure that your warranty coverage begins promptly your selling dealer should fill out the warranty registration card completely and mail it to the distributor responsible for administering the warranty registration and claim program for your area The warranty registration card identifies your name and address product model and serial numbers date of sale type of use and the selling distributor s an...

Page 11: ...iser boatbuilder customers who have achieved higher manufacturing standards It is the first and only comprehensive manufacturer installation certification program in the industry The program has three goals 1 To enhance overall product quality 2 To improve the boat ownership experience 3 To enhance overall customer satisfaction The certification process is designed to review all facets of manufact...

Page 12: ...on Inboard Models and Vazer 100 Sterndrive Models The Limited Warranty for Horizon Inboard Models and Vazer 100 Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for non certified installations Coverage for SeaCore Sterndrive Models The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certif...

Page 13: ... proper maintenance What Mercury Marine Will Do Mercury Marine s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury Marine product Mercury Marine reserves the right to improve or modify products from time to time...

Page 14: ...h towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal or replacement of boat partitions or other material in order to gain access to the product are not covered by this warranty No individual or entity i...

Page 15: ...y is limited to at our option repairing a corroded part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage The customer must pr...

Page 16: ...ed Warranty by Certification Status of Boat Manufacturer Commercial Limited Corrosion Warranty Not Certified Installation Quality Certified 4 3 TKS 5 0 TKS 5 7 TKS The Americas excluding Brazil 1 year 1 year 1 year Brazil 2 years 2 years 2 years Europe Middle East Africa 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours Australia New Zealand Japan South Pacific Other Asia Warranty for Go...

Page 17: ...years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years Mexico 1 year 3 years 1 year 1 year 1 year 4 years 1 year 1 year 1 year 4 years Europe 2 years 3 years 2 years 2 years 3 years 4 years 3 years 3 years 3 years 4 years Japan 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year Australia and New Zealand 2 years 3 years 3 years 3 years all Tow Sports 2 years 3 years ...

Page 18: ...ear 1 year 1 year 1 year Europe 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zeal...

Page 19: ...w Zealand 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none South Pacific 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Asia excludin g Japan South Pacific ...

Page 20: ...A or California emission control regulations ECI Label Standard of Compliance REFER TO THE OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS FAMILY XXXXXXX XXXX EMISSION CONTROLINFORMATION NOT FOR SALE IN CALIFORNIA THIS MARINE ENGINE COMPLIES WITH U S EPA EXHAUST REGULATIONS FOR 2009 XXXXXXXX SERIAL XX XXXX g kWh FEL DOM MMM YYYY DISP X XL ECIEPA 0575 42010 Indicates a marine engine c...

Page 21: ...e regulations provides this limited warranty for the emission control systems see the components of the emission control system listed following and further warrants that the inboard or sterndrive engine was designed built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Hea...

Page 22: ...anner inconsistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see Specifications alteration or removal ...

Page 23: ...ck of receipts or your failure to ensure the performance of all scheduled maintenance As the inboard or sterndrive engine owner you should however be aware that Mercury Marine may deny you warranty coverage if your inboard or sterndrive engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your inboard or sterndrive eng...

Page 24: ...t is labeled on the hull with one of the following star labels The symbol for Cleaner Marine Engines means 1 Cleaner air and water for a healthier lifestyle and environment 2 Better fuel economy burns up to 30 40 less gas and oil than conventional carbureted two stroke engines saving money and resources 3 Longer emission warranty protects consumer for worry free operation Beginning January 1 2003 ...

Page 25: ...utboard marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission 42146 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emissi...

Page 26: ...Section 1 Warranty Notes Page 18 90 8M0053372 eng NOVEMBER 2010 ...

Page 27: ... 20 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Lanyard Stop Switch 21 Instrumentation 22 Remote Controls 23 Panel Mount Features 23 Console Mount Features 24 Power Trim 24 Single Engine Trim Trailer 25 Dual Engine Trim Trailer 25 Electrical System Overload Protection Carbureted Engines 25 Audio Warning System 28 Testing The Audio Warning System 28 2 ...

Page 28: ...r decal is located on the engine cover 26301 Serial numbers and maintenance color codes decal The engine serial number is also stamped in the engine block Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number gear ratio model number and bar code are embedded in the ground plate on the port side of the sterndrive 33533 Bravo sterndrive information on ground plate The ...

Page 29: ...ing with serial number stamping a Transom assembly serial Number 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 a Stop switch b Lanyard c Clips to the operator Accidental ejections such as falling overboard are more likely to occur in low sided sport bo...

Page 30: ... from being struck by the boat Always properly connect the operator to the stop switch using a lanyard Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front...

Page 31: ...y disengaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the neutral position and should only be used to assist in starting the engine 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 Refer to Lan...

Page 32: ...tructions provided with remote control for complete adjustment instructions Power Trim Switch See Power Trim section for detailed power trim operating procedures Trailer Switch Used to raise drive unit for trailering launching beaching or shallow water operation See Power Trim for detailed trailer switch operation Power Trim Power trim allows the operator to adjust the sterndrive angle while under...

Page 33: ...ols also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only Dual Engine Trim Trailer NOTICE If using external tie bars raising or lowering the drives independently of each other can damage the drive and steering systems If using an external tie bar raise and lower all drives together as a unit Dual engine applications may have a single integral button ...

Page 34: ...llow lever will appear Reset the yellow lever after testing or if tripped by pushing the yellow lever back into the housing Yellow lever style circuit breaker typical a Yellow lever shown tripped b Red test button 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 A 15 amp acce...

Page 35: ...ng happens and circuit breaker is not tripped mc70525 1 5 The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump The trim pump may also have an in line circuit protection device in the power trim positive lead near the battery switch or battery connection a 20 amp spade fuse b 110 amp fuse 6 The Quicksilver Three Button Power Trim Control ...

Page 36: ...ning system will sound with a continuous horn if one of the following occurs Engine oil pressure too low Engine temperature too hot Sterndrive oil level too low NOTICE A continuous horn indicates a critical fault Operating the engine during a critical fault can damage components If the warning horn emits a continuous beep do not operate the engine unless avoiding a hazardous situation If the alarm...

Page 37: ...ilge Pump 34 Protecting People in the Water 34 While You Are Cruising 34 While Boat Is Stationary 34 High Speed and High Performance Operation 34 Passenger Safety in Pontoon Boats and Deck Boats 34 Boats Having an Open Front Deck 34 Boats With Front Mounted Raised Pedestal Fishing Seats 35 Wave and Wake Jumping 35 Impact with Underwater Hazards 35 Drive Unit Impact Protection 36 Operating with Low...

Page 38: ...ing Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal Law requires that there be a U S Coast Guard approved life jacket personal flotation device correctly sized and readily accessible for every person on board plus a throwable cushion or ring We strongly ad...

Page 39: ...here is complete loss of the boat Seek further assistance from local law enforcement Be Alert to Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards sterndrives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxide is a deadly gas that is odorless colorless...

Page 40: ...ttery switch to the OFF position Turn battery switch on Check shift and throttle control operation Close fuel shut off valve Operate bilge blowers Check steering operation Close seacock if equipped Open fuel shut off valve Flush cooling system if in saltwater Open seacock if equipped Drain bilge Close the drain system Place sterndrive unit in full down in position Check the engine oil Perform all ...

Page 41: ... for a long period of time allow the engine to cool at idle speed for 3 to 5 minutes 2 Turn ignition key to the OFF position Starting the Engine After It Has Been Stopped While In Gear IMPORTANT Avoid stopping the engine if the sterndrive unit is in gear If the engine does stop refer to the following procedure 1 Push and pull repeatedly on the remote control handle until handle returns to the neut...

Page 42: ...he water is near your boat Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat High Speed and High Performance 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 demonstr...

Page 43: ...wever when this activity is done with enough speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water The primary concern is the boat changing direction while in the midst of the jump In such cases the landing may cause the boat to violently veer in a new direction Such a sharp change in direction or turn can cause o...

Page 44: ...of the power package or could affect control of the boat If continued operation is necessary do so at greatly reduced speeds WARNING Operating a boat or engine with impact damage can result in product damage serious injury or death If the vessel experiences any form of impact have an authorized Mercury Marine dealer inspect and repair the vessel or power package Drive Unit Impact Protection The po...

Page 45: ...n the propeller Ventilation Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed up and a reduction in boat speed Air bubbles strike the propeller blade and cause erosion of the blade surface If allowed to continue eventual blade failure breakage will occur Excessive ventilation is usually caused by Drive unit trimmed out too f...

Page 46: ...his break in period the following rules must be observed Do not operate below 1500 RPM for extended periods of time for the first 10 hours Shift into gear as soon as possible after starting and advance the 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 the first 10 hours During the next 10 ...

Page 47: ...Specifications Table of Contents Fuel Requirements 40 Fuel Ratings 40 Using Reformulated Oxygenated Gasolines USA Only 40 Gasolines Containing Alcohol 40 Engine Oil 40 Engine Specifications 41 4 3 TKS 41 5 0 TKS 42 5 7 TKS 42 Fluid Specifications 43 Sterndrives 43 Engine 43 4 ...

Page 48: ...he gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specific recommendations on the boat s fuel system components fuel tanks fuel lines and fittings Be aware that gasolines containing alcohol may increase Corrosion of metal parts Deterioration of rubber or plastic parts Fuel permeation through the rubber fuel lines Difficulty startin...

Page 49: ...cted in accordance with SAE J1228 ISO 8665 Crankshaft Power All measurements are taken with the engine at normal operating temperature RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures Oil pressure must be checked with the engine at normal operating temperature NOTE Oil pressure specifications are for reference and may vary IMPORTANT Do not...

Page 50: ... idle 10 BTDC Firing order 1 8 4 3 6 5 7 2 Minimum battery rating 375 CCA 475 MCA 90 Ah Spark plug type AC Platinum AC 41 993 AC Platinum AC 41 101 Spark plug gap 1 5 mm 0 060 in 5 7 TKS NOTE Performance specifications are obtained and corrected in accordance with SAE J1228 ISO 8665 Crankshaft Power All measurements are taken with the engine at normal operating temperature RPM range is measured us...

Page 51: ...n the listed capacity Use the dipstick to determine the exact quantity of oil or fluid required Listed capacities are approximate 4 3 TKS Models Capacity Fluid Type Engine oil with filter 3 8 L 4 US qt Mercury MerCruiser Full Synthetic Engine Oil 20W 40 NMMA FC W rated Seawater cooling system 14 1 L 15 US qt Propylene glycol and purified water Closed cooling system 19 L 20 US qt Mercury Extended L...

Page 52: ...Section 4 Specifications Notes Page 44 90 8M0053372 eng NOVEMBER 2010 ...

Page 53: ...ging 57 Cleaning the Flame Arrestor 57 Positive Crankcase Ventilation Valve PCV 58 Changing 58 Changing the Water Separating Fuel Filter 59 Lubrication 59 Steering System 59 Throttle Cable 61 Shift Cable Typical 61 Sterndrive Unit and Transom Assembly 62 Sterndrive U Joint Shaft Splines and O Rings Sterndrive Unit Removed 62 Engine Coupler 62 Driveshaft Extension Models 63 Propellers 64 Propeller ...

Page 54: ... product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components WARNING Fuel vapors trapped in the engine compartment may be an irritant cause difficulty breathing or may ignite resulting in a fire or explosion Always ven...

Page 55: ...rts hoses and clamps tighten or replace as necessary Check plug leads and electrical leads for damage Remove and inspect the propeller If badly nicked bent or cracked contact your authorized Mercury MerCruiser dealer Repair nicks and corrosion damage on power package exterior finish Contact your authorized Mercury MerCruiser dealer Maintenance Schedule Sterndrive Models Routine Maintenance NOTE On...

Page 56: ... extension models Lubricate the driveshaft U joints and tailstock input and output bearings Every 150 hours or annually whichever occurs first All Bravo models except 496 Lubricate the engine coupler Every 300 hours or 3 years Check the engine mounts for tightness and torque if necessary Check the electrical system for loose damaged or corroded fasteners Inspect the condition of the spark plugs sp...

Page 57: ...on not to spill oil coolant or other fluids into the environment when using or servicing your boat Be aware of the local restrictions governing the disposal or recycling of waste and contain and dispose of fluids as required Checking 1 Stop the engine Allow approximately 5 minutes for the oil to drain into the oil pan The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reins...

Page 58: ...cified engine oil to bring the level up to but not over the full or OK range mark on the dipstick Recheck oil level 3 Replace the fill cap Engine Model Engine Oil Capacity Fluid type 4 3 TKS 3 8 liters 4 U S qt Mercury Full Synthetic MerCruiser Oil 20W 40 5 0 TKS 4 25 liters 4 5 U S qt 5 7 TKS Changing Oil and Filter Refer to the Maintenance schedule for the change interval Engine oil should be ch...

Page 59: ...o the dipstick tube a Typical oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the crankcase oil pump onto an appropriate container and using the handle pump until the crankcase is empty 5 Remove the pump 6 Install the dipstick Changing Filter 1 Remove and discard oil filter 2 Coat sealing ring on new filter with engine oil and install 3 Tighten oil filter securely following filt...

Page 60: ...l with engine cold should be within the cold range a Power steering pump b Cold range c Warm range 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 Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid ATF to bring the...

Page 61: ...t level in the coolant recovery bottle 5 The coolant level should be between the ADD and FULL marks 6102 6 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine Fill the closed cool...

Page 62: ...ds into the environment when using or servicing your boat Be aware of the local restrictions governing the disposal or recycling of waste and contain and dispose of fluids as required Checking NOTE Oil level will fluctuate during operation Oil level should be checked with the engine cold before starting 1 Check the gear lube oil level Keep the oil level within the recommended operating range If an...

Page 63: ...drive unit refer to Changing Changing 1 Remove the gear lube monitor from the bracket a 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 a Oil fill drain screw b Sealing was...

Page 64: ...2 858064K01 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndrive unit 8 Install the oil vent screw and sealing washer 9 Continue to pump gear lubricant into the gear lube monitor circuit until the gear lubricant appears in the gear lube monitor 10 Fill the monitor so that the oil level is in the operating range Do not overfill Ensure that the rubber gasket is inside...

Page 65: ...level to the bottom of the filler neck Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074K01 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 Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive Ensure that the...

Page 66: ...sary 8 Install the flame arrestor sealing washer and locknut Torque the flame arrestor locknut to specification Description Nm lb in lb ft Flame arrestor nut 12 106 9 Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover Positive Crankcase Ventilation Valve PCV Changing NOTE We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with...

Page 67: ...g on the new filter with engine oil Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Filter sealing ring 92 883725K01 6 Thread filter onto bracket and tighten securely by hand Do NOT use a filter wrench a Fuel filter base b Sealing ring c Fuel filter 7 Open fuel supply valve if equipped 8 Ensure that engine compartment is properly ventilated 9 Supply cooli...

Page 68: ...o 34 Special Lubricant 101 Steering cable grease fitting 92 802865Q02 2 Turn the steering wheel until the steering cable is fully extended Lightly lubricate the exposed part of the cable a Extended steering cable Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Steering cable 92 802865Q02 3 Lubricate the steering pin a Steering pin Tube Ref No Description Where Used Part No Synt...

Page 69: ...Throttle Cable 1 Lubricate the pivot points and the guide contact surfaces a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 Shift Cable Typical 1 Lubricate the pivot points and the guide contact surfaces a Pivot points b Guide contact surfaces Tube Ref N...

Page 70: ...cation refer to Propellers Sterndrive U Joint Shaft Splines and O Rings Sterndrive Unit Removed 1 Coat sterndrive U joint O rings and driveshaft splines with grease a Driveshaft splines b U joint O rings 3 Tube Ref No Description Where Used Part No 91 Engine Coupler Spline Grease Driveshaft splines and U joint O rings 92 802869A 1 2 For propeller shaft lubrication refer to Propellers Engine Couple...

Page 71: ...upler and shaft splines can be lubricated without removing the sterndrive unit Apply lubricant from a typical hand operated grease gun until a small amount of grease begins to push out The Perm a Lube U joints do not require lubrication Driveshaft Extension Models 1 Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10 12 pumps of grease from a typical...

Page 72: ...ller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval IMPORTANT If reusing tab washer carefully inspect tabs for cracks or other damage Replace tab washer if condition is questionable a Propeller shaft b Thrust hub c Flo Torq II drive hub d Propeller e Drive sleeve f Locking tab was...

Page 73: ...ler shaft Bravo One Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval IMPORTANT If reusing tab washer carefully inspect tabs for cracks or other damage Replace tab washer if condition i...

Page 74: ... Place wood block between propeller blade and anti ventilation plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer spline washer propeller and thrust hub off propeller shaft Bravo Two Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller the drive or drive components A...

Page 75: ...the anti ventilation plate 1 Place wood block between propeller blades and anti ventilation plate to prevent rotation 2 Remove the bolt and washers securing the propeller shaft anode 3 Remove the propeller shaft anode a Propeller b Propeller shaft nut c Propeller shaft anode d Propeller shaft anode screw e Flat washer f Star washer 4 Turn aft propeller shaft nut 37 mm 1 7 16 in counterclockwise to...

Page 76: ...iption Where Used Part No 34 Special Lubricant 101 Propeller shaft 92 802865Q02 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C Marine Lubricant with PTFE Propeller shaft 92 802859A 1 3 Align splines and place propeller on propeller shaft 4 Install and torque the propeller nut Check propeller at least every 20 hours of operation and retorque as needed Description Nm lb in lb ft Forw...

Page 77: ...sing the propeller shaft anode screw and washers Torque the screw Description Nm llb in lb ft Propeller shaft anode screw 38 mm 0 3125 18 x 1 5 in long 27 20 Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death Turn off the engine and remove the ignition key before adjusting tension or inspecting belts With a seawater pump Without a seawater ...

Page 78: ...d 2 Turn the adjustment stud and loosen the belt 3 If a new serpentine drive belt is required remove the old belt and install a new belt onto the pulleys 4 Put a wrench on the adjustment stud 16 mm 5 8 in locking nut 5 Use a 8 mm 5 16 in socket and tighten adjusting the stud to adjust the belt deflection 6 Using one of the 2 methods following check for correct deflection a Push down with moderate ...

Page 79: ...ousing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive unit and to the engine during operation Flushing Attachments Flushing Device 91 44357Q 2 9192 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the engine Dual Water Pick up Flush Gearcase Seal Kit 91 881150K 1 9194 Blocks off t...

Page 80: ...unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate b Remove propeller c Install the appropriate flushing attachment over the water inlet holes in the gear housing 6 Connect hose between flushing attachment and water source 7 With sterndrive unit in normal operating position open the...

Page 81: ...rom the water source to the water inlet of the seawater pump NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 7 With sterndrive unit in normal operating position open the water source fully 8 Place the remote control in neutral idle speed position and star...

Page 82: ...ent when handling or servicing batteries Corrosion Protection NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion Do not use any cleaning equipment such as brushes or high pressure washers to clean the MerCathode assembly a MerCathode reference electrode b Do not paint c Do not pressure wash Whenever two or more dissimilar metals like those found on the sterndr...

Page 83: ...d some models have a MerCathode System as standard equipment 1 Gearcase anodic plate 2 Ventilation plate anode 3 Gimbal mounted anodic block 4 MerCathode System 5 Anode kit 6 Trim cylinder anodes 7 Bearing carrier anodes Alpha only 8 Propshaft Anode Bravo III standard IMPORTANT Replace sacrificial anodes if eroded 50 percent or more The following sacrificial anodes are installed at different locat...

Page 84: ...node Mounted on the front of the gearcase a Anode Drive Mounted Anodic Block if equipped Mounted to underside of gimbal housing 5640 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 a 620...

Page 85: ...wash a MerCathode controller b MerCathode assembly Anode Kit if equipped Mounted to the boat transom 5642 Trim Cylinder Anodes Mounted on each trim cylinder a Trim cylinder anodes Bearing Carrier Anode Alpha and Bravo One Located in front of the propeller between the front side of the propeller and the gear housing a Bearing carrier anode 6206 a b a 5643 a 5644 ...

Page 86: ...int may be applied to boat hull and boat transom but you must observe the following IMPORTANT Do NOT paint anodes or MerCathode System reference electrode and anode as this will render them ineffective as galvanic corrosion inhibitors IMPORTANT If anti fouling protection is required for boat hull or boat transom copper or tin base paints if not prohibited by law can be used If using copper or tin ...

Page 87: ...nual Single Point Drain System 83 Three Point Manual Drain System 83 Multi Point Drain MPD System 83 Air Actuated Single Point Drain System 84 Boat in the Water 84 Boat out of the Water 86 Manual Single Point Drain System 88 Boat in the Water 88 Boat out of the Water 89 Three Point Manual Drain System 89 Boat in the Water 89 Boat out of the Water 90 Multi Point Drain MPD System 91 Boat out of the ...

Page 88: ...r for Marine Engines added to any fuel remaining in the tank Refer to Fuel Requirements for additional information 3 Flush the cooling system Refer to the Maintenance section IMPORTANT In order to run the engine as required in the remainder of the storage preparation procedure water must be supplied to the engine as described in the flushing procedure 4 Provide cooling water to the engine as done ...

Page 89: ...or Carburetor 92 858081K03 g Turn ignition key to OFF position 2 Refer to Flushing the Power Package and appropriately remove the water supply the the seawater pickup pump 3 Clean the flame arrestor and crankcase ventilation hoses and reinstall 4 Lubricate all items listed in the Lubrication section 5 On models with closed cooling systems Test coolant to ensure that it will withstand the lowest te...

Page 90: ...es or extended storage Ensure 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 recommendations Drain System Identification Air Actuated Single Point Drain System Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators S...

Page 91: ...ual Single Point Drain System a Blue handle b Blue drain plug location Three Point Manual Drain System a Blue drain plug Multi Point Drain MPD System a Side of cylinder block b Bottom of exhaust manifolds b a b 6128 a a 6126 10226 M110050 932356 72 b a a b 6129 ...

Page 92: ...or remove and plug the water inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lock pump on the fitting a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green in...

Page 93: ... Manual Drain System instructions a Port side drain location b Starboard side drain location 9 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 10 Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump Do not allow engine to start 11 Reinstall the blue drain plug in the thermostat hous...

Page 94: ...r NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Place the boat on a lever surface to ensure complete draining of system 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lock pump...

Page 95: ...h opening If not use the Three Point Manual Drain System instructions a Port side drain location b Starboard side drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump Do not allow engine to start 10 Remove the air pump f...

Page 96: ...orce the handle as this will create new threads 3 Immediately remove the blue drain plug from the side of the thermostat housing This must be removed within 30 seconds to properly vent the cooling system a Blue handle b Blue drain plug location 4 Visually verify that water is draining If water does not drain remove the blue drain plug from the distribution housing and drain manually a Drain locati...

Page 97: ... a Blue handle 3 Visually verify that water is draining If water does not drain remove the blue drain plug from the distribution housing and drain manually a Drain location orange or red b Blue drain plug 4 Allow the system to drain for a minimum of five minutes We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained 5 Clos...

Page 98: ...he drain system open while transporting the boat or performing other maintenance to ensure that all water is drained 7 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 8 Before launching the boat or starting the engine close the drain system by installing the four blue drain plugs 9 Open the seacock if equippe...

Page 99: ...tly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 6 Before launching the boat or starting the engine close the drain system by installing the three blue drain plugs Multi Point Drain MPD System Boat out of the Water 1 Place the boat on a level surface to ensure complete draining of the system 2 Remove the blue drain plugs from the follow...

Page 100: ...n 6 Storage Page 92 90 8M0053372 eng NOVEMBER 2010 c Water circulating pump hose a Drain plug d Fuel cooler to thermostat housing hose a Drain plug e Check valve a Drain plug if equipped a 6143 a 6144 a 6131 ...

Page 101: ... to start 5 After the cooling system has been drained completely install the drain plugs reconnect the hoses and tighten all hose clamps securely Boat in the Water 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the blue drain plugs from the following locations If necessary clean out the drain holes using a stiff piece of wire Do so until the entire system is drain...

Page 102: ... Blue drain plugs 4 Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 5 Before launching the boat or starting the engine close the drain system by installing the blue drain plugs 6 Open the seacock if equipped or unplug and reconnect the water inlet hose before operating the engine Draining the Sterndrive N...

Page 103: ...l of water and the battery is fully charged and in good operating condition It should be clean and free of leaks Follow the battery manufacturer s instructions for storage Recommissioning the Power Package 1 Ensure that all cooling system hoses are connected properly and hose clamps are tight CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electr...

Page 104: ...Section 6 Storage Notes Page 96 90 8M0053372 eng NOVEMBER 2010 ...

Page 105: ...es or Backfires 98 Poor Performance 98 Excessive Engine Temperature 99 Insufficient Engine Temperature 99 Low Engine Oil Pressure 99 Battery Will Not Recharge 99 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 100 Steering Wheel Jerks or Is Difficult to Turn 100 Power Trim Does Not Operate Motor Does Not Operate 100 Power Trim Does Not Operate Motor Operates but Ster...

Page 106: ... Faulty ignition system component Service the ignition system Clogged fuel filter Replace fuel filter Stale or contaminated fuel Drain fuel tank Fill with fresh fuel Fuel line or tank vent line kinked or clogged Replace kinked lines or blow out lines with compressed air to remove obstruction Faulty wire connections Check wire connections TKS fuse blown Check TKS fuse Replace the fuse if blown Engi...

Page 107: ... Repair Seawater discharge restricted or plugged Clean exhaust elbows Insufficient Engine Temperature Possible Cause Remedy Faulty thermostat Replace Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase Check and add oil Excessive oil in crankcase causing it to become aerated Check and remove required amount of oil Check for cause of excessive oil improper filling Diluted or...

Page 108: ...ition Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all parts and fasteners if any are loose or missing see authorized Mercury MerCruiser dealer immediately Contaminated power steering fluid See authorized Mercury MerCruiser dealer Power Trim Does Not Operate Motor Does Not Operate Possible Cause Remedy Blown fuse...

Page 109: ...ce Assistance 102 Local Repair Service 102 Service Away From Home 102 Stolen Power Package 102 Attention Required after Submersion 102 Replacement Service Parts 102 Parts and Accessories Inquiries 102 Resolving a Problem 102 Mercury Marine Service Offices 103 Ordering Literature 103 United States and Canada 103 Outside the United States and Canada 104 8 ...

Page 110: ... full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standard automotive engine For example one of the most important special replacement parts is the cylinder head gasket Marine engines c...

Page 111: ...Victoria 3164 Australia 32 87 32 32 11 32 87 31 19 65 Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium 954 744 3500 954 744 3535 Mercury Marine Latin America Caribbean 11650 Interchange Circle North Miramar FL 33025 U S A 81 53 423 2500 81 53 423 2510 Mercury Marine Japan 283 1 Anshin cho Hamamatsu Shizuoka 435 0005 Japan 65 6546 6160 65 6546 7789 Mercury Marine Sin...

Page 112: ...nter for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature Print or type your mailing address which be used as your shipping label and include your order and payment Mail to Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 USA ...

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