MerCruiser 350 MAG MPI User Manual Download Page 82

Page: 82 / 150

Section 5 - Maintenance

Page 74

90-864195070 JUNE 2007

1. Remove the cap from the heat exchanger and observe the fluid level.

6101

a -

Heat exchanger cap

2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the

coolant level is low, contact your authorized Mercury MerCruiser dealer.

3. Install the cap onto the heat exchanger.
IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the

filler neck.
4. With the engine at normal operating temperature, check the coolant 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 cooling system with an ethylene glycol antifreeze

solution suitable to the lowest temperature to which the engine will be exposed.

Summary of Contents for 350 MAG MPI

Page 1: ...x II ISO 8846 SAE J1171 SAE J1191 SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust when installed in a recreational craft in accordance with the manufacturers supplied instructions will meet the exhaust emissions requirements of the directive mentioned above This engine must not be put into service until the recreational craft in which it is to...

Page 2: ...printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2007 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...ime in order to verify and make a record of compliance with applicable standards and regulations All Mercury Marine product sold as new receives the applicable limited warranty coverage whether the engine participated in one of the test programs described above or not Read This Manual Thoroughly IMPORTANT If you don t understand any portion of this manual contact your dealer for a demonstration of...

Page 4: ...ver 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 WARNING The engine exhaust from this product contains...

Page 5: ...on Star Label 17 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal MPI 20 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Lanyard Stop Switch 22 Instrumentation 23 System View 23 Digital Gauges 24 Analog Gauges 25 Remote Controls Non DTS Models 25 Remote Controls 25 Panel Mount Features 26 Console Mount Features 27 Remote ...

Page 6: ... Hour Break In Period 55 After Break In Period 55 End of First Season Checkup 56 Section 4 Specifications Fuel Requirements 58 Fuel Ratings 58 Using Reformulated Oxygenated Gasolines USA Only 58 Gasolines Containing Alcohol 58 Engine Oil 59 Engine Specifications MPI 59 Engine Specifications 59 Fluid Specifications MPI 60 Fluid Specifications 60 Engine 60 Alpha Sterndrive 61 Bravo Sterndrives 61 Po...

Page 7: ...8 Corrosion Protection 99 Corrosion Information 99 Maintaining Ground Circuit Continuity 100 Anodes and MerCathode System Locations 100 Checking the Quicksilver MerCathode System 101 Power Package Exterior Surfaces 102 Boat Bottom Care 102 Anti fouling Paint 102 Sterndrive Surface Care 104 Flushing the Power Package 105 Flushing Attachments 105 Sterndrive Water Pickups 106 Alternative Water Pickup...

Page 8: ...e play Or Makes Unusual Sounds 136 Steering Wheel Turns Hard Or Jerky 136 Power Trim Does Not Operate Motor Does Not Operate 137 Power Trim Does Not Operate Motor Operates But Sterndrive Unit Does Not Move 137 Section 8 Customer Assistance Information Owner Service Assistance 140 Local Repair Service 140 Service Away From Home 140 Stolen Power Package 140 Attention Required After Submersion 140 Re...

Page 9: ...harts 8 Consumer Application Warranty Chart 9 Commercial Application Warranty Chart 10 Government Application Warranty Chart 11 Mercury Installation Quality Certification Program 11 California Emissions Limited Warranty 12 What Is Covered 12 Duration Of Coverage 13 How To Obtain Warranty Coverage 13 What Mercury Will Do 14 What Is Not Covered 14 Components Of The Emission Control System 14 Disclai...

Page 10: ...ned to him for warranty service The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required You may change your address at any time including at time of warranty claim ...

Page 11: ...g the warranty registration card and its relationship to warranty claim processing refer to the International Warranty See Table of Contents NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event of a safety recall notification under the Federal Boat Safety Act Transfer of Warranty The limited warranty is transferable to a sub...

Page 12: ...2 Black Scorpion Tow Sport Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations SeaCore Sterndrive Model Coverage The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Standard Model Coverage The L...

Page 13: ...per 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 wit...

Page 14: ...wing 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 inclu...

Page 15: ...Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dea...

Page 16: ...t our option repairing a corroded part replacing such part or parts with new or Mercury Marine certified remanufactured 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 provide Mercury Mari...

Page 17: ...r 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 3 years 3 years all Tow Sports 3 years 4 years South Pacific 1 year 3 years 1 year 1 year 1 year 3 years 1 year 1 year 3 yea...

Page 18: ... 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 Zealand 1 year or 500 hours 1 year or 500 hours 1 year or...

Page 19: ...ours 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 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 y...

Page 20: ...rtification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and fo...

Page 21: ...d warranty provides coverage for the components of the emissions control systems of new 2003 2008 model year inboard and sterndrive engines for 2 years from either the date the product is first sold or first put into service whichever occurs first Emission related normal maintenance items such as spark plugs and filters that are on the warranted parts list see following are warranted up to their f...

Page 22: ...or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses a...

Page 23: ... Owner Service Assistance for contact information California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board is pleased to explain the emission control system warranty on your 2003 model year1 and later inboard or sterndrive engine In California new inboard and sterndrive engines must be designed built and equipped to meet the State s str...

Page 24: ...m You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine dealer authorized to service the product as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities refer to Owner Service Assistance for contact information Emission Con...

Page 25: ...ication standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Emission Certification Star Label Your boat 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 environ...

Page 26: ... that meet the Air Resources Board s Personal Watercraft and Outboard 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 A SS D mc79571 1 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission ...

Page 27: ... Panel Mount Features 26 Console Mount Features 27 Remote Controls DTS Models 27 Remote Controls 27 Panel Mount Features 28 Console Mount Features Single Engine 29 Slim Binnacle Console Mount Features Single Engine 30 Console Mount Features Dual Engine 31 Synchronizing Dual Engines 32 Dual Helm Station Transfer 32 Synchronizing Dual Helms Prior To Station Transfer 33 Zero Effort Features 33 Power ...

Page 28: ...serial numbers Engine Serial Number Decal MPI The serial number decal is located on the engine cover 25903 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 sterndrive serial number gear ratio model number and bar code is embedded in the ground plate located on the port side of the Bra...

Page 29: ...ck cover This is used as a permanent reference for authorized MerCruiser Dealers 25907 a Bravo sterndrive serial number stamping a Serial number stamping Bravo Transom Serial Number The Bravo transom serial number is stamped in the U bolt plate of the Bravo transom assembly 25904 a Bravo transom assembly U bolt plate a Transom assembly serial Number ...

Page 30: ...operator s position as in accidental ejection from the operator s position 74608 RUN a b c 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 boats bass boats high performance boats Accidental ejections can also occur from poor operating practices sitting on the seat or gunwale at planing speeds standing at pla...

Page 31: ...under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected WARNING If the operator falls out of the boat stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat Always properly connect ...

Page 32: ...ed and fuel to destination information When a problem is detected with the engine or system the System View will alert the operator to the potential problem by displaying the alarm message in the information window located at the bottom of the view screen If the problem can cause immediate engine damage the Engine Guardian System will respond to the problem by limiting engine power Immediately red...

Page 33: ...e d Voltmeter e Water temperature gauge f Fuel gauge g Hour meter h Bilge blower switch i Ignition switch j Power trim gauge Speedometer Indicates boat speed Tachometer Indicates engine RPM Oil Pressure Gauge Indicates engine oil pressure Voltmeter Indicates battery voltage Water Temperature Gauge Indicates engine operating temperature Fuel Gauge Indicates quantity of fuel in tank Hour meter Recor...

Page 34: ...ting 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 Lanyard Stop Switch for information on the use of this switch Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neut...

Page 35: ...sed to adjust the effort required to move the remote control handle Refer to instructions 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 Remo...

Page 36: ...shing back to increase speed Shift Lock Pressing the shift lock allows the engine to shift The shift lock must always be pressed when moving the control handle out of the neutral position Trim Tilt Switch if equipped Refer to Power Trim Throttle Only Button Allows engine throttle advancement without shifting the engine The throttle only button can be depressed only when the remote control is in th...

Page 37: ...ngine is in neutral gear position NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the gear switch Select Key Selects System View on screen options and confirms data entries Arrow Trackpad Navigates through System View on screen function messages Throttle Only Station Select Key Allows engine throttle advancement without shifting the ...

Page 38: ...ight is illuminated when the engine is in neutral gear position NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the gear switch Stop Start Button Allows the boat operator to start or stop the engine without using the ignition key Throttle Only Station Select Key Allows engine throttle advancement without shifting the engine The throt...

Page 39: ...tion NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the gear switch Select Key Selects System View on screen options and confirms data entries Arrow Trackpad Navigates through System View on screen function messages Sync Light The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system Thro...

Page 40: ...ntrol of the engine operation The active light is illuminated at the remote control station that is in control of the engine WARNING Avoid serious injury or death from loss of boat control The boat operator should never leave the active station while engine is in gear Helm transfer should only be attempted while both stations are manned One person helm transfer should only be performed while engin...

Page 41: ...nearing match position Once the light stays on continuously the handles are matched and the button can be released Transfer process is complete and the new station is now in control If the button is held for over 10 seconds the station transfer is cancelled Zero Effort Features c a b 5656 a Shift ever b Throttle lever c Trim tilt switch Shift Lever Shift functions are controlled by the movement of...

Page 42: ...en trimming with a single ram trim system and never trim out beyond the unit s side support flanges while the boat is underway or at engine speeds above 1200 RPM For best performance trim the sterndrive unit so that the boat bottom is at a 3 5 angle to the water 3 5 mc79528 Trimming sterndrive unit up out can Generally increase top speed Increase clearance over submerged objects or a shallow botto...

Page 43: ...PM 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 to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit S...

Page 44: ...r Reset the yellow lever after testing or if tripped by pushing the yellow lever back into the housing b a 22529 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 Four fuses are located o...

Page 45: ...appens 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 b 9208 a 20 amp spade fuse b 110 amp fuse 6 The Quicksilver Three Button Power Trim Con...

Page 46: ...oo 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 sounds stop the engine immediately Investigate cause and correct it if possible If the cause cannot be determined contact your authorized Mercury MerCrui...

Page 47: ...ecurrence of the problem you should contact an authorized dealer The ECM stores the fault and with this information the technician will be able to more rapidly diagnose problems Warning Horn Signals Most faults will cause the warning horn circuit to activate How the warning horn activates depends on how serious the problem is There are four warning horn states Caution horn signal varies with produ...

Page 48: ...Section 2 Getting to Know Your Power Package Notes Page 40 90 864195070 JUNE 2007 ...

Page 49: ... the Engine 47 Stopping the Engine 48 Throttle Only Operation 49 Trailering the Boat 49 Freezing Temperature Operation 50 Drain Plug and Bilge Pump 50 Protecting People In The Water 50 While You Are Cruising 50 While Boat Is Stationary 50 High Speed And High Performance Boat Operation 50 Passenger Safety In Pontoon Boats And Deck Boats 51 Boats Having An Open Front Deck 51 Boats With Front Mounted...

Page 50: ...for minor repairs Anchor and extra anchor line Manual bilge pump and extra drain plugs Drinking water Transistor radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board Watch for sign...

Page 51: ...er skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier who was 61 m 200 ft in front of you in 5 seconds 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 to the skier The operator should always have the down skier i...

Page 52: ...e boat is moored in a confined space b Mooring close to another boat with its engine operating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim angle of the bow too high b Operating the boat with no forward hatches open station wagon effect Basic Boat Operation Non DTS Models Launching and Boat Operation IMPORTANT Install bilge drain plug prior...

Page 53: ...e engine to overheat Provide a sufficient supply of water at the water inlets during operation WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes 3 Turn ignition key to START Release key when engine starts and allow switch to...

Page 54: ... neutral idle position resume normal starting procedures Throttle Only Operation 1 Refer to Remote Controls section for remote control features 2 Move the control lever to the idle neutral position 3 Depress and hold the throttle only button and move the control lever to the idle forward or idle reverse position 4 Advancing the control lever beyond the idle forward or idle reverse position will ca...

Page 55: ...engine If not normal stop engine Observe all gauges to check condition of engine If not normal stop engine Turn ignition key to the OFF position Open engine hatch Check for fuel oil water fluid and exhaust leaks Listen for the audio alarm Turn battery switch to the OFF position Turn battery switch on Check shift and throttle control operation Close fuel shut off valve Operate bilge blowers Check s...

Page 56: ...ttempts a Push the throttle only button and position the remote control handle or throttle lever to the 1 4 throttle position b Turn the ignition key to start Release key when the engine starts and allow the switch to return to the on position 6 If the engine does not start after step 5 a Move the remote control handle throttle lever to the full throttle position then return to 1 4 throttle b Turn...

Page 57: ...o loss of boat control Always place the throttle control lever in the idle position before moving the shift control lever into forward or reverse gear position Panel Mount and Console Mount Remote Controls Panel mount and console mount remote controls are equipped with a throttle only button To activate throttle only mode 1 Refer to Remote Controls section for remote control features 2 Move the co...

Page 58: ...ds 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving even coasting and the gear shift is in neutral 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 WARNING A spinning prope...

Page 59: ... deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water mc79555 1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in ...

Page 60: ... reduce injury or impact damage from striking a floating or underwater object is control the boat speed Under these conditions boat speed should be kept to a maximum speed of 24 to 40 km h 15 to 25 MPH Striking a floating underwater object may result in an infinite number of situations Some of these situations could result in the following The boat could move suddenly in a new direction Such a sha...

Page 61: ... to be present No impact protection is provided in reverse use extreme care to prevent striking submerged objects while operating in reverse IMPORTANT Impact protection system cannot be designed to ensure total protection from impact damage under all conditions Operating With Low Water Inlets In Shallow Water mc75827 1 a a Low Water Inlets NOTICE Operating in shallow water can cause severe engine ...

Page 62: ... 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 fa...

Page 63: ...perating in a higher elevation causes a loss of RPM Operating with a dirty boat bottom causes a loss of RPM Operating with increased load additional passengers pulling skiers causes a loss of RPM For better acceleration such as is needed for water skiing use the next lower pitch propeller When not pulling skiers do not operate at full throttle when using the lower pitch propeller Getting Started 2...

Page 64: ...d oil filter Refer to Maintenance Change the transmission oil and filter Refer to Maintenance ZF Transmission models 1 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 ...

Page 65: ...xygenated Gasolines USA Only 58 Gasolines Containing Alcohol 58 Engine Oil 59 Engine Specifications MPI 59 Engine Specifications 59 Fluid Specifications MPI 60 Fluid Specifications 60 Engine 60 Alpha Sterndrive 61 Bravo Sterndrives 61 Power Assisted Steering and Power Trim Fluids 61 Approved Power Assisted Steering Fluids 61 Approved Power Trim Fluids 61 4 ...

Page 66: ... should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank The fuel s...

Page 67: ...ksilver Synthetic Blend NMMA FC W rated 4 cycle oil 2 MerCruiser Quicksilver 25W40 NMMA FC W rated oil 3 A NMMA FC W rated oil 4 MerCruiser Quicksilver 4 cycle 25W40 non FC W rated oil 5 A good grade straight weight detergent automotive oil per the operating chart below NOTE The use of non detergent oils multi viscosity oils other than as specified non FC W rated synthetic oils low quality oils or...

Page 68: ...d Alternator rating 65 amp Recommended battery rating Non DTS models minimum 750 CCA 950 MCA or 180 Ah Recommended battery rating DTS models minimum 800 CCA 1000 MCA or 190 Ah Spark plug type AC Platinum AC 41 993 Spark plug gap 1 5 mm 0 060 in Fluid Specifications MPI Fluid Specifications IMPORTANT All capacities are approximate fluid measures Engine IMPORTANT It may be necessary to adjust oil le...

Page 69: ...er Alpha Sterndrive NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Alpha One 1892 ml 64 oz High Performance Gear Lubricant Bravo Sterndrives NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Bravo One 2736 ml 92 1 2 oz High Performance Gear Lubricant Bravo Two 3209 ml 108 1 2 oz Bravo Three 2972 ml 100 1 2 oz Power Assisted Steering and Power Trim Fluid...

Page 70: ...Section 4 Specifications Notes Page 62 90 864195070 JUNE 2007 ...

Page 71: ...ame Arrestor 81 Positive Crankcase Ventilation Valve PCV 82 Changing 82 Water Separating Fuel Filter MPI 82 Water Separating Fuel Filter 82 GEN II Models 83 Removal 83 Installation 83 GEN III Models 84 Removal 84 Installation 85 Lubrication 85 Steering System 85 Throttle Cable 87 Shift Cable Typical 88 Sterndrive Unit and Transom Assembly 88 Sterndrive U joint Shaft Splines And O rings Sterndrive ...

Page 72: ...Section 5 Maintenance Page 64 90 864195070 JUNE 2007 Alternative Water Pickups 108 The SeaCore Power Package Flushing Procedure 109 Models Using The Sterndrive Water Pickup 109 ...

Page 73: ...arize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Predelivery Inspection Checklist Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product Maintenance WARNING Performing service or maintenance without first disconnec...

Page 74: ...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 to request t...

Page 75: ...and the wiring connections are secure Clean the gauges 1 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 we reccommend the following Change the engine oil and filter Change the sterndrive lube EVERY 100 HOURS OR ANNUALLY WHICHEVER OCCURS FIRS...

Page 76: ...amaged or corroded fasteners Check the cooling system and the exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn components Clean the seawater section of the closed cooling system Clean inspect and test the pressure cap Inspect the exhaust system components and verify that the flapper valves are not missing o...

Page 77: ...ain into the oil pan The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reinstall fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NOTE Ensure that dipstick is installed with oil level indication marks facing the rear of the engine flywheel end a 6095 a Dipstick tube IMPORTANT Add the specified engine oil to bring the level up to but not over the fu...

Page 78: ...apacity Fluid type 4 3L 262 cid 3 8 liters 4 U S qt Mercury Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 5 0L 305 cid 4 25 liters 4 5 U S qt 5 7L 350 cid Changing Oil and Filter Refer to the Maintenance schedule for the change interval Engine oil should be changed before placing the boat in storage IMPORTANT Change engine oil when the engine is warm from operation Warm oil flows more f...

Page 79: ...ain 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 Loosen the oil filter to vent the system 2 Remove the dipstick 3 Install the oil pump onto the dipstick tube mc70571 1 a c b a Typical oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the ...

Page 80: ...to but not over the full or OK range NOTE Adding 0 95 liters 1 quart of engine oil will raise the level from the add mark to the top of the OK range Engine Model Engine Oil Capacity Fluid type 4 3L MPI 3 8 liters 4 U S qt Mercury Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 5 0 MPI 350 MAG MPI MX 6 2 MPI 5 7L 350 cid 4 25 liters 4 5 U S qt 7 Start the engine run the engine for three mi...

Page 81: ...uid or Dexron III Automatic Transmission Fluid ATF to bring the fluid level up to the proper level Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steering system 92 858074K01 3 Reinstall the fill cap dipstick Changing Power steering fluid does not require changing unless it becomes contaminated with water or debris Contact your authorized Mercury MerCruiser deal...

Page 82: ...ntil it seats on the filler neck 4 With the engine at normal operating temperature check the coolant 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 antif...

Page 83: ...emove the fill cap from the coolant recovery bottle 2 Fill to the FULL line with the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 3 Install the fill cap onto the coolant recovery bottle Changing Contact your authorized Mercury MerCruiser dealer Drive Unit Oil NOTICE Discharge of oil coolant or other engine drive...

Page 84: ...osed cooled models a Gear lube monitor Filling IMPORTANT If more than 59 ml 2 fl oz of High Performance Gear Lubricant is required to fill the monitor a seal may be leaking Damage to the sterndrive unit may occur due to lack of lubrication Contact your authorized Mercury MerCruiser dealer 1 Remove the gear lube monitor cap 2 Fill the monitor with the specified fluid so that the oil level is in the...

Page 85: ... 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 mc79506 1 b a Oil fill drain screw b Sealing washer ...

Page 86: ...r 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 Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Sterndrive unit 92 858064K01 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndrive...

Page 87: ...terndrive is cool and the engine is shut down Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive unit in full down in position 2 Observe the oil level Level must be between the MIN and MAX lines on the reservoir a b 7876 a Reservoir b MIN and MAX lines 3 Fill as necessary with the specified fluid Tube Ref No Des...

Page 88: ...red to supply any charging current EFI Electronic Control Module ECM The ECM requires a stable voltage source During multiple engine operation an onboard electrical device may cause a sudden drain of voltage at the engine s battery The voltage may go below the ECM s minimum required voltage Also the alternator on the other engine may now start charging This could cause a voltage spike in the engin...

Page 89: ...b c d e f a Engine cover knob b Engine cover c Nuts flame arrestor d Cover mount bracket e Flame arrestor f Crankcase ventilation hose 4 Clean the flame arrestor with warm water and a mild detergent 5 Inspect the flame arrestor for holes cracks or deterioration Replace if necessary 6 Allow the flame arrestor to air dry completely before use 7 Clean the crankcase ventilation hose with warm water an...

Page 90: ...the valve cover Water Separating Fuel Filter MPI Water Separating Fuel Filter WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attemp...

Page 91: ...rt No 80 SAE Engine Oil 30W Water separating fuel filter sealing ring Obtain Locally 2 Thread filter onto the mounting bracket and tighten securely by hand Do not use a filter wrench 3 Open fuel supply valve if equipped 4 Ensure that engine compartment is properly ventilated NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a suf...

Page 92: ...f position 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 7 Unseat the filter assembly by grasping the filter assembly handle and pulling upward Do not remove the filter assembly from the Cool Fuel Module at this time 8 Allow any fuel that may be in the filter assembly to d...

Page 93: ...Filter assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness to the engine wiring harness 8 Properly ventilate the engine compartment NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a sufficient supply of water at the water inlets during operation 9 Supply cooling water to t...

Page 94: ... a typical hand operated grease gun 6221 a a Steering cable grease fitting Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Steering cable grease fitting 92 802865Q02 2 Turn steering wheel until steering cable fully extended Lightly lubricate the exposed part of cable a 6222 a Extended steering cable Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Steering ca...

Page 95: ...Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie bar pivot points 92 883725K01 5 Upon first starting engine turn steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway Throttle Cable 1 Lubricate the pivot points and the guide contact surfaces a b a 5577 a Pivot points b Guide contact surfaces Tube Ref No Description W...

Page 96: ...erCruiser Engine Oil SAE25W 40 Shift cable pivot points guide contact surfaces 92 883725K01 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 a a Gimbal bearing grease fitting Tube Ref No Description Where Used Part No 42 U joint and Gimbal Bearing Grease Gimbal bearing 92 802870A1 2 For ...

Page 97: ... grease fittings on coupler by applying approximately 8 10 pumps of grease from a typical hand operated grease gun 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 a 6213 a 6212 Alpha drive coupler Bravo drive coupler a Grease fitting Tube Ref No Description Where Used Part No 91 Engine Coupler ...

Page 98: ...ease fitting engine end grease fitting driveshaft grease fittings 92 802870A1 Propellers Propeller Repair Some damaged propellers can be repaired Contact your authorized Mercury MerCruiser dealer Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the...

Page 99: ...nut 1 Apply a liberal coat of one of the following lubricants to the propeller shaft Tube Ref No Description 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 Teflon Propeller shaft 92 802859A1 2 Slide thrust hub onto propeller shaft with stepped side toward propeller hub 3 Install Flo Torq ...

Page 100: ...tral and engage the lanyard stop switch to prevent the engine from starting 1 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 drive sleeve propeller and thrust hub off propeller shaft Bravo One Propeller Installation NOTICE Operating the engine wit...

Page 101: ...ter with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyar...

Page 102: ...b ft Propeller nut1 81 60 6 Bend 3 tabs on the tab washer down into the grooves in spline washer After the first use bend the 3 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 Bravo Three Propeller Removal WARNING Rotating propellers can cause serious injury or death Never o...

Page 103: ...ockwise to remove nut 5 Slide propeller and thrust hub off propeller shaft 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 e f a b c d 5304 g h i j a Rear propeller nut b Rear propeller c Rear propeller thrust hub d Front...

Page 104: ...rd 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 34 Special Lubricant 101 Propeller shaft 92 802865Q02 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C Marine Lubricant with Teflon Propeller shaft 92 802859A1 3 Align splines and place propeller on propeller shaft 4 Install and torque the propel...

Page 105: ...ker 271 to the threads of the propeller shaft anode screw a b d c f e 5303 a Propeller b Propeller shaft nut c Propeller shaft anode d Propeller shaft anode screw e Flat washer f Star washer Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Propeller shaft threads 92 809819 12 Secure the propeller shaft anode to the propeller shaft using the propeller shaft anode screw and wash...

Page 106: ...tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the belt width may be acceptable Longitudinal cracks in the direction of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys mc75130 1 ...

Page 107: ...EWTONE N E W T O N E b a 14980 a Kent Moore Tension Gauge b Serpentine belt 7 While holding the adjustment stud at the correct belt tension tighten the 16 mm 5 8 in locking nut a b 6119 a 16 mm 5 8 in locking nut b 8 mm 5 8 in adjusting stud 8 Operate the engine for a short period of time and recheck the belt adjustment Corrosion Protection Corrosion Information Whenever two or more dissimilar met...

Page 108: ...and MerCathode System Locations IMPORTANT Replace sacrificial anodes if eroded 50 percent or more The following sacrificial anodes are installed at different locations on your power package These anodes help protect against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package MerCathode System Electrode assembly replaces the Anode blo...

Page 109: ... to the electrode harness 20340 Anode kit if equipped Mounted to the boat transom 20341 Trim cylinder anodes Mounted on each of the trim cylinders 20342 Bearing carrier anode Bravo One Located in front of the propeller between the front side of the propeller and the gear housing 20343 Propshaft anode Bravo Three Located behind the aft propeller 20344 Checking the Quicksilver MerCathode System The ...

Page 110: ...Care To achieve maximum performance and fuel economy the boat bottom must be kept clean Accumulation of marine growth or other foreign matter can greatly reduce boat speed and increase fuel consumption To ensure best performance and efficiency periodically clean the boat bottom in accordance with manufacturer s recommendations In some areas it may be advisable to paint the bottom to help prevent m...

Page 111: ... in UNPAINTED area on transom of the boat around these items 8107 b a a Painted boat transom b Minimum 40 mm 1 1 2 in unpainted area around transom assembly NOTE Sterndrive and transom assembly can be painted with a good marine paint or an anti fouling paint that DOES NOT contain copper or any other material that could conduct electrical current Do not paint drain holes anodes the MerCathode syste...

Page 112: ...ver ground wire d Ground wire between the gimbal ring and bell housing e Stainless steel hoses f Ground wire between the gimbal housing and trim cylinder g Ground wire between the gimbal ring and gimbal housing We recommend the following maintenance items to help keep your sterndrive corrosion free Maintain a complete paint covering on the sterndrive Check the finish regularly Prime and paint nick...

Page 113: ...ng the Power Package Your boat could come equipped with a combination of any of three different types of water pickups through the hull through the transom and through the sterndrive 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 Br...

Page 114: ...and the flush seal kit 881150K 1 and side pickups require the flushing attachment 44357Q 2 5752 5773 Dual Water Pickup Side Pickup NOTE Flushing is needed only for salty brackish mineral laden or polluted water applications Flushing is recommended after each outing for best results NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine resulting in engine ...

Page 115: ...ving a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting 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 in normal operating position open the water source fully 8 Place the remote control in the...

Page 116: ...position WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting b Remove propeller c Install the appropriate flushing attachment over the water inlet holes in the gear housing 3 Con...

Page 117: ...lushing Procedure NOTE Flushing is needed only for salt brackish mineral laden or polluted water applications Flushing is recommended after each outing for best results IMPORTANT Flushing the SeaCore power package with the boat and sterndrive in the water is less effective Flushing the SeaCore power package is most effective when performed with the boat and sterndrive out of the water such as on a...

Page 118: ...quipped with an alternative water pickup and not equipped with a seacock disconnect the water hose from the alternative water pickup and plug both ends excluding the Bravo sterndrive 4 Ensure that the inlet water hose from the sterndrive to the engine is connected 5 Remove the quick connect fitting from the parts bag supplied with the engine 6 Attach the quick connect fitting to a water hose 18487...

Page 119: ...ontrol in neutral idle speed position and start engine NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a sufficient supply of water at the water inlets during operation 11 Operate the engine at idle speed in neutral gear Do not exceed 1200 RPM 12 Monitor the engine temperature while operating the engine 13 Flush the engine for ...

Page 120: ...nect fitting water hose end b Water hose 19 Retain the quick connect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access IMPORTANT Do not store the quick connect fitting in the flush socket on the engine Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem Damages due to ...

Page 121: ...er installed in the flush socket a Dust cover b Flush socket IMPORTANT If the unit is to be stored in the water the seacock should remain closed until time of usage If unit is to be stored out of the water open the seacock 21 Open the seacock if equipped or reconnect the alternative water inlet source prior to operating the engine ...

Page 122: ...Section 5 Maintenance Notes Page 114 90 864195070 JUNE 2007 ...

Page 123: ...ain System 119 Manual Single Point Drain System 119 Three Point Manual Drain System 119 Multi Point Drain MPD System 120 Air Actuated Single Point Drain System 120 Boat in the Water 120 Boat out of the Water 122 Manual Single Point Drain System 124 Boat in the Water 124 Boat out of the Water 125 Three Point Manual Drain System 126 Boat in the Water 126 Boat out of the Water 128 Multi Point Drain M...

Page 124: ...eeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations Preparing Power Package for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 If t...

Page 125: ... the full down position 11 Store boat with drive unit in full down in position 12 Store the battery according to the manufacturer s instructions ENGINE AND FUEL SYSTEM PREPARATION WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the...

Page 126: ...en damaging the engine or causing the boat to sink Remove the boat from the water or close the seacock disconnect and plug the seawater inlet hose and ensure the bilge pump is operating before draining Do not operate the engine with the drain system open CAUTION Water can enter the bilge when the drain system is open damaging the engine or causing the boat to sink Remove the boat from the water or...

Page 127: ... DRAIN SYSTEM 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators MANUAL SINGLE POINT DRAIN SYSTEM b a b 6128 a Blue handle b Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM a a 6126 a Blue drain plug ...

Page 128: ...ing a 6131 a Check valve if equipped 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 Close the seacock if equipped 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 I...

Page 129: ...green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 7 Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger This must be removed within 30 seconds to properly vent the cooling system 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug loc...

Page 130: ... 12 Remove the air pump from the air manifold and return it to the mounting bracket 13 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 14 Before launching the boat pull up on the manual release valve Verify that the green indicators are no longer extended a 6135 a Green indicat...

Page 131: ...he fitting 8293 b d e a c 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 indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Ai...

Page 132: ... the air manifold and return it to the mounting bracket 11 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 12 Before launching the boat pull up on the manual release valve Verify that the green indicators are no longer extended a 6135 a Green indicators Manual Single Point Drai...

Page 133: ...e 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 6 Reinstall the blue drain plug in the thermostat housing 7 Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug if removed The handle is fully seated when no red is visib...

Page 134: ...stem to drain for a minimum of five minutes Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained 5 Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug The handle is fully seated when no red is visible Do not overtighten handle as this will c...

Page 135: ...erify that water is draining from each opening 6 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 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...

Page 136: ... system open while transporting the boat or while performing other maintenance to ensure that all water is drained 5 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 6 Prior to launching the boat or starting the engine close the drain system by installing the three blue drain plugs Multi Point Drain MPD System...

Page 137: ...ction 6 Storage 90 864195070 JUNE 2007 Page 129 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 138: ...is procedure is needed only for salty brackish mineral laden or polluted water applications and for freezing temperatures or extended storage 1 Insert a small wire repeatedly to make sure that vent holes water drain holes and passages are unobstructed and open b a d e f c 6146 Sterndrive Water Drain Holes a Speedometer pitot tube b Trim tab cavity vent hole c Trim tab cavity drain passage d Gear h...

Page 139: ... Follow the battery manufacturer s instructions for storage Power Package Recommissioning 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 electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it las...

Page 140: ...Section 6 Storage Notes Page 132 90 864195070 JUNE 2007 ...

Page 141: ... Start 134 Engine Runs Rough Misses And Or Backfires 135 Poor Performance 135 Excessive Engine Temperature 135 Insufficient Engine Temperature 136 Low Engine Oil Pressure 136 Battery Will Not Come Up On Charge 136 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 136 Steering Wheel Turns Hard Or Jerky 136 Power Trim Does Not Operate Motor Does Not Operate 137 Power...

Page 142: ...ne protection If Guardian System has been activated reduce throttle speed The horn will turn off when throttle speed is within the allowable limit Consult an authorized Mercury MerCruiser dealer for assistance Starter Motor Will Not Crank Engine Or Cranks Slow Possible Cause Remedy Battery switch turned off Turn the switch on Remote control not in neutral position Position the control lever in neu...

Page 143: ...Drain and check for cause of entry Boat overloaded or load improperly distributed Reduce load or redistribute load more evenly Flame arrestor dirty Clean the flame arrestor Boat bottom fouled or damaged Clean or repair as necessary Ignition problem See Engine Runs Rough Misses or Backfires Engine overheating See Excessive Engine Temperature EFI System fault Have EFI System checked by an authorized...

Page 144: ...d tighten faulty connections Repair or replace damaged wiring Faulty alternator Test alternator output replace if necessary Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fasteners Lubricate Obstruction in shift or throttle linkages Remove obstruction Loose or missing shift and throttle...

Page 145: ...tery lead near the battery switch or a combination of these Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not Operate Motor Operates But Sterndrive Unit Does Not Move Possible Cause Remedy Trim pump oil level low Fill pump with oil D...

Page 146: ...Section 7 Troubleshooting Notes Page 138 90 864195070 JUNE 2007 ...

Page 147: ...ssistance 140 Local Repair Service 140 Service Away From Home 140 Stolen Power Package 140 Attention Required After Submersion 140 Replacement Service Parts 140 Parts And Accessories Inquiries 141 Resolving A Problem 141 Mercury Marine Service Offices 141 Ordering Literature 142 United States and Canada 142 Outside The United States and Canada 142 8 ...

Page 148: ...ge Replacement Service Parts WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with U S Coast Guard rules to minimize risk of fire or explosion Do not use replacement electrical or fuel system components that do not comply with these rules When servicing the electrical and fuel systems properly install and tighten all components...

Page 149: ... manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the service office Your name...

Page 150: ...ed 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 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center fo...

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