MerCruiser 350 Magnum EFI GEN+ Alfa One Operation And Maintenance Manual Download Page 5

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Maintenance

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Maintenance Aids

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Maintenance Chart

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Checking Fluid Levels

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Changing Fluids

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Water Separating Fuel Filter

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Fuel Pump Sight Tube Inspection

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Lubrication

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Propeller

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Flushing Cooling System

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Seawater Pump Impeller

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Drive Belts

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Corrosion And Corrosion Protection

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Emissions

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Changing Positive Crankcase Ventilation Valve (PCV)

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Emissions Testing

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Miscellaneous Maintenance

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Battery

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Bottom Of Boat

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Inspection And Maintenance

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Cold Weather or Extended Storage

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Power Package Lay Up

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Draining Instructions

101

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Battery Winter Storage

104

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Power Package Recommissioning

104

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Troubleshooting

105

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Warranty Information

112

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Owner Warranty Registration

112

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International Owner Registration

113

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Warranty Policies

114

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Mercruiser Limited Warranty - Gasoline Engines

114

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Mercruiser International Warranty - Gasoline Engines

116

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3 Year Limited Warranty Against Corrosion Failure

118

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Warranty Coverage

120

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Transferable Warranty

123

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Q-Guard Product Protection Plan

124

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Owner Service Assistance

125

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Service Centers

128

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Customer Service Literature

130

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General Maintenance Parts

131

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Literature Order Form

133

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Summary of Contents for 350 Magnum EFI GEN+ Alfa One

Page 1: ...E MANUAL 1995 Brunswick Corporation 5 7L EFI 5 7LX EFI 350 Magnum EFI Gen Alpha One OPERATION MAINTENANCE MANUAL 1995 Brunswick Corporation 90 806582963 196 5 7L EFI 5 7LX EFI 350 Magnum EFI Gen Alpha One 90 806582963 196 ...

Page 2: ... Authorized MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation...

Page 3: ...1 CA365 71352 74849 ABC12345Z123 19 48 12345 71345 5 6 7 1 2 2 3 4 4 1 2 3 4 5 6 7 74031 3 71718 ...

Page 4: ...7 Emissions Information 18 Attention Required After Submersion 18 Trailering Boat 18 Launching And Boat Operation Care 19 Stolen Power Package 19 Replacement Service Parts 20 Do It Yourself Maintenance Suggestions 21 Diagnosing EFI Problems 22 20 Hour Break In Period 23 After Break In Period 23 20 Hour Checkup 24 Operation 27 Instrumentation 27 Audio Warning System 29 Electrical System Overload Pr...

Page 5: ...ntenance 95 Cold Weather or Extended Storage 97 Power Package Lay Up 97 Draining Instructions 101 Battery Winter Storage 104 Power Package Recommissioning 104 Troubleshooting 105 Warranty Information 112 Owner Warranty Registration 112 International Owner Registration 113 Warranty Policies 114 Mercruiser Limited Warranty Gasoline Engines 114 Mercruiser International Warranty Gasoline Engines 116 3...

Page 6: ...any boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation and Maintenance Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our MerCruiser products We sincerely hope your b...

Page 7: ...structions while per forming the service plus common sense operation are major acci dent prevention measures WARNING WARNING Hazards or unsafe practices which could result in severe personal injury or death CAUTION CAUTION Hazards or unsafe practices which could result in mi nor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for pro...

Page 8: ...ble so as to minimize the likelihood of lanyard entangle ment with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If for any reason it is desired to have a shorter functional lanyard this may be accomplished by using up length in th...

Page 9: ...d cause any or all of the following poten tially hazardous situations 1 Loss of balance and falling forward of unstable boat passen gers a particular concern in bow rider type boats 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking While activation of the lanyard stop switch will result in immedi ate power shut down a boat can continu...

Page 10: ...y Information booklet It lists regional sources of safety cruising and local naviga tion and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made Check safety equipment on boa...

Page 11: ... refer to your boat capacity plate When in doubt contact your dealer or the boats manufac turer Know your boat s operating and loading limitations Make sure everyone in the boat is properly seated Don t allow anyone to sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat any whe...

Page 12: ...should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal inju...

Page 13: ...e allowing people to swim or be in the water near your boat WARNING Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CA283 High speed And High performance Boat Operation If your boat i...

Page 14: ...ming off plane Shifting weight to front bow will Improve ease of planing Improve rough water ride At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum speed the following conditions of the boat bot tom should be observed A Clean free of barnacles and marine growth B Free of distortion nearly flat where it contacts the water C Straight and smooth fore a...

Page 15: ...und the propeller resulting in propeller speedup and a re duction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ring C A damaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing D Drive unit installed too high on transom CA294 Propeller Selection IMPORTANT Instal...

Page 16: ...he recommended range the propel ler must be changed to prevent loss of performance and possible en gine damage On the other hand operating an engine above the rec ommended operating RPM range will cause higher than normal wear and or damage Generally there is a 200 300 RPM change between propeller pitches After initial propeller selection the following common problems may require that the propelle...

Page 17: ...is speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an en gine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propel ler will in effect become too large Consequently the engine oper ates at less...

Page 18: ...timum performance and dependability and will keep your overall op erating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include prede livery inspection and preparation such as Make sure that the boat is properly equipped Prior to delivery make certain that the MerCruiser power package...

Page 19: ...it to return to original operating position preventing loss of steering control and engine overspeed Use extreme caution when operating in shallow water or where un derwater objects are known to be present Use extreme care to pre vent striking submerged object while operating in REVERSE No im pact protection is provided in REVERSE If drive unit should strike a submerged object stop engine as soon ...

Page 20: ...that must be supplied by the boat owner op erator is the exhaust elbow test probes These test probes should have been provided with your power package They should be carried aboard your boat at all times Refer to Emis sions Testing procedure found later in this manual CA18 Attention Required After Submersion Before recovery contact a MerCruiser Dealer After recovery immediate service by an Authori...

Page 21: ...In this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the preceding paragraph In any of these situations water entering the engine could cause se vere damage to internal parts Refer to Attention Required After Submersion CA21 Stolen Power Package If your power package is stolen immediately advise the local author...

Page 22: ... most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard auto motive engine For example one of the most important and probably the least sus pected special replacement part is the cylinder ...

Page 23: ...are aware of the precautions Cautions and Warn ings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you or der the service manual for that model The service manual out lines the correct procedures to follow It is written for the trained mechanic so there may be procedures you don t understand Do not attempt repairs if you do not under...

Page 24: ...our power package He has qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on your power package Have him winterize it in the fall and service it before the boating season This will reduce the possibility of any problems occurring during your boating season when you want trouble free boating pleasure CB129 Diagnosing EFI Problems Your Authoriz...

Page 25: ...ble 5 min utes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operat ing temperature Frequently check crankcase oil level Add oil if needed It is nor mal for oil consumption to be high during break in period After 20 hour break in period drain crankcase oil and replace oil filter see MAINTENANCE Fill crankcase with cor...

Page 26: ...le cable adjustments lubricate and inspect for loose damaged or missing parts Steering System Lubricate and inspect for loose damaged or missing parts Inspect all drive belts Check engine alignment Include proper lubrication of U joint and splined shaft Complete Engine Exhaust System Inspect externally for dam age and deterioration check all hose clamps for adequate tight ness Retorque gimbal ring...

Page 27: ...THIS PAGE IS INTENTIONALLY BLANK 25 CA175 ...

Page 28: ...26 CA26 70514 70515 70516 70523 70517 70522 70518 70521 70520 70519 1 2 3 4 5 6 7 8 9 10 ...

Page 29: ...gine RPM 3 Oil Pressure Gauge Indicates engine oil pressure 4 Battery Meter Indicates battery voltage 5 Water Temperature Gauge Indicates engine operating tempera ture 6 Fuel Gauge Indicates fuel tank volume 7 Power Trim Gauge Indicates drive unit angle trim up out and down in 8 Hour Meter Records engine running time 9 Bilge Blower Switch Must be operated for five minutes before starting engine to...

Page 30: ...28 CB218 70516 2 1 3 71987 70518 ...

Page 31: ...rning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred When the buzzer sounds with the engine running stop engine im mediately Investigate cause and correct it if possible If cause can not be determined consult your Authorized MerCruiser Dealer IMPORTANT Warning buzzer will sound for 2 seconds when ig nition key is turned to RUN positio...

Page 32: ...30 CB294 70525 70528 70527 70526 1 6 5 4 3A 3B 71583 3C 71585 2 7 72852 ...

Page 33: ...r If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 3 There are three fuses located in the fuel injection system electrical box These fuses control various EFI circuits A Fuel Pump Fuse 15 Amp B ECM Injector Fuse 10 Amp C ECM Battery Fuse 15 Amp 4 A 20 amp fuse may be located in ignition switch I terminal lead to protect electrical...

Page 34: ...32 CB181 1 4 5 2 3 6 7 ...

Page 35: ...ing procedures 4 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 5 Lanyard Stop Switch Turns ignition Off whenever the opera tor when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at the front of this manual for safet...

Page 36: ...34 CB183 1 4 2 6 3 2 4 3 1 6 5 5 ...

Page 37: ...depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control han dle cover must be removed to adjust This will help prevent Creep of the remote control handle Turn screw Clockwise to increase ten sion and Counte...

Page 38: ...36 CB185 3 4 70537 71339 1 2 ...

Page 39: ... be increased or decreased 3 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread screw all the way out 4 DETENT Screw controls the effort needed to move control han dle out of NEUTRAL To increase tension turn screw clockwise to decrease turn screw counterclockwise Do not thread scre...

Page 40: ...38 CA34 71338 1 3 TO 5 DEGREES ...

Page 41: ...mance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the wa ter Trimming Drive Unit UP OUT Can Lower the bow Generally increase top speed Increase clearance over submerged objects or a shallow bottom Cause boat to accelerate and plane off slower In excess cause boat porpoising bouncing or propeller ventila tion Cause engine overheating if trimmed UP OUT t...

Page 42: ...40 CB187 1 3 2 6 4 5 73976 73977 ...

Page 43: ...er Position Press button until drive unit reaches desired height 2 Trim Up Out Press UP on Trim switch until drive unit reaches de sired trim position 3 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position CB189 POWER TRIM OPERATION CONSOLE MOUNT REMOTE CONTROL SINGLE ENGINE VERSION 4 Trailer Position Press button until drive unit reaches desired height 5 Trim Up Ou...

Page 44: ...42 CB190 4 2A 1 1 2B 3 73978 73979 ...

Page 45: ...n until drive unit reach es desired height for trailering drive units 2 Two Button Trim Control Dual Buttons in Handle used to control both drive units from the handle Press UP on button s to trim drive unit UP OUT Press down on button s to trim drive unit DOWN IN A Forward Trim Button Used to trim the port drive unit B Rear Trim Button Used to trim the starboard drive unit 3 Three Button Trim Con...

Page 46: ...44 CB192 70540 70540 70540 1 2 3 ...

Page 47: ...release button s and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Simultaneously press the UP button top along with the UP OUT button center until drive unit reaches desired trail er position 2 Trim Drive Unit UP OUT Press center UP OUT button until drive unit reaches desired trim position 3 Trim Drive Unit IN DOWN P...

Page 48: ...t pump or engine damage Do not operate starter motor continuously for more than 30 seconds Never shift drive unit unless engine is at Idle RPM 1 Perform the following as appropriate A Check all items listed in OPERATION CHART B Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual C Place drive unit in full down in position D Place control handle i...

Page 49: ...ediately and determine cause H Be sure charging system is functioning correctly I Observe power package for fuel oil water and exhaust leaks J To shift drive unit into gear move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shift to REVERSE After shifting drive unit advance throttle to de sired setting K To shift drive unit out of gear move control sh...

Page 50: ... if so equipped Check for fuel oil wa ter fluid and exhaust leaks etc Turn bat tery switch OFF if so equipped Operate bilge blowers if so equipped Check shift and throttle control op eration Close fuel valve Open fuel shutoff valve Check steering operation Close sea cock if so equipped Open seacock if so equipped Flush cool ing system if in saltwa ter area Place drive unit in full down in position...

Page 51: ...soline CA291 USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol also These Reformulated Gasolines are acceptable for use in your Mer Cruiser en...

Page 52: ...cted for leakage soften ing hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine oper ation Because of possible adverse effects of alcohol in gasoline it is rec ommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alco hol is unknown increased inspection frequenc...

Page 53: ...ankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not avail able a multiviscosity 20W 40 SG or CD or as a second but less preferable choice 20W 50 SG or CD may be used IMPORTANT The use of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oils or oils which contain solid additives are specificall...

Page 54: ...Idle 160 F 71 C Thermostat 5 7L EFI 220 164 4200 4600 RPM 280 1 256 2 209 1 191 2 9 4 1 Propshaft Kilowatts BSO SAV Rating Propshaft Horsepower BSO SAV Rating 350 Mag EFI Gen 1 Power Rated in Accordance with NMMA National Marine Manufacturers Association rating procedures 2 Power Rated in Accordance with BSO SAV rating procedures This rating procedure is used to certify that the engine complies wi...

Page 55: ...tery Rating AC MR43T Champion RV15YC4 NGK BR6FS 8 BTDC 1 8 4 3 6 5 7 2 12 Volt Negative Ground Electrical System 65 Amps Alternator Rating 5 7LX EFI 350 Mag EFI Gen AC MR43LTS Champion RS9YC NGK BPR6ESS 045 in 1 1mm 1 Timing must be set using a special procedure as outlined in the appropriate Service Manual Timing cannot be properly set using the conventional method ...

Page 56: ...l Capacity w Reservoir Seawater Cooling System 2 15 U S Quarts 14 1 L Approximately 64 fl oz 1892ml Drive Unit Oil Capacity 1 Approx 5 5 U S Quarts 5 2 L 5 7L EFI 350 Mag EFI Gen 1 Always use dipstick to determine exact quantity of oil required 2 Seawater Cooling System capacity information is for winterization use only ...

Page 57: ...hly NOTE Maintenance points are color coded for ease of identifica tion See the decal on engine for identification Maintenance Aids 1 Power Steering System Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid ATF 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Exposed portion of Steering Cable and Pro...

Page 58: ...stem Coolant 50 50 mixture of ethylene glycol antifreeze must meet GM specification 1825 M and tap water Areas where temperatures generally do not go below 32 F 0 C rust inhibitor and tap water is acceptable 11Gasoline Stabilizer Quicksilver Gasoline Stabilizer for Marine Engines 12Grease Fittings on Drive Shaft Extension Models Quicksilver U Joint and Gimbal Bearing Grease ...

Page 59: ...R OPERATOR Weekly TASK Engine Crankcase Oil Check level Power Steering Fluid Check level Stern Drive Unit Oil Check level Battery Check level and inspect for damage Fuel Pump Sight Tube Check that no fuel is present Power Trim Pump Oil Check level Anodes Inspect for erosion Gear Housing Water Pickups Check for ma rine growth or debris INTERVAL ...

Page 60: ... All Inspect condition and check tension Propeller Shaft Lubricate Power Package Exterior Surfaces Spray with rust preventative Power Package Exterior Surfaces Clean and paint Cooling System Flush seawater section INTERVAL Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichever Occurs First Once a Year Saltwater ...

Page 61: ...sitive Crankcase Venti lation PCV Valve Change 350 Mag Model Stern Drive unit Oil Change Gimbal Ring Clamping Screws Retorque to 50 55 lb ft 67 74 N m Rear Engine Mounts Check torque to 35 40 lb ft 47 54 N m Gimbal Bearing Lubricate Cooling System Clean inspect Every 100 Hours of Operation or Once Yearly Whichever Occurs First TASK INTERVAL At First 20 Hours of Operation Whenever Insufficient Seaw...

Page 62: ...rical System Check for loose or damaged wiring Cooling System Hoses and Clamps Inspect for damage and deteriora tion Check clamps for tightness Continuity Circuit Check components for loose connections bro ken or frayed wires TASK INTERVAL Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichev er Occurs First Salt...

Page 63: ...s for tightness Ignition System Check timing and adjust if needed Fuel filters Replace Steering Head and Remote Control Inspect and lubricate Quicksilver MerCathode System Test output Throttle Body Inspect Drive Unit Bellows and Clamps Inspect TASK INTERVAL Once a Year Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Day...

Page 64: ...62 CA187 71341 1 2 4 4 71448 70543 70546 70545 3 74107 ...

Page 65: ...vel must be between FULL and ADD If oil level is below ADD 3 Remove oil filler cap Add specified oil to bring level up to but not over FULL mark on dipstick IMPORTANT Do not overfill crankcase oil CA55 CHECKING POWER STEERING PUMP FLUID Stop engine and position drive unit Straight back 4 Remove FILLCAP DIPSTICK and observe level Add specified fluid if required Reinstall FILLCAP DIPSTICK IMPORTANT ...

Page 66: ...64 CA189 71345 2 A 70979 2 B 70551 1 74107 ...

Page 67: ...ill monitor a seal may be leaking Damage to drive unit may occur due to lack of lubrica tion Contact your Authorized MerCruiser Dealer for service CB41 CHECKING POWER TRIM PUMP FLUID Place drive unit in full down in position 2 Remove fill cap from reservoir and observe oil level Level must be up to but not over bottom of filler neck Add Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor...

Page 68: ...66 CA201 71345 1 2 2 70571 71344 74025 3 ...

Page 69: ...th engine at normal operating temperature remove dipstick In stall Quicksilver Crankcase Oil Pump onto dipstick tube Insert hose end of crankcase oil pump into an appropriate container and using pump handle pump until crankcase is empty Remove crankcase oil pump 2 Turn oil filter counterclockwise to left remove and discard old oil filter and old sealing ring Coat sealing ring on new filter with mo...

Page 70: ...68 CA190 71345 70021 70569 1 2 3 74107 ...

Page 71: ...iately by your Authorized MerCruiser Dealer Lower drive unit so anti ventilation plate is level Fill drive unit through OIL FILL DRAIN hole with Specified Gear Lube until an air free stream of lubricant flows from OIL VENT hole Remove tube from OIL FILL DRAIN hole Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 3 Fill gear lube monitor with Specified Gear Lube When oil sta...

Page 72: ...70 CB221 71345 50681 70573 1 2 2 73752 ...

Page 73: ...r oil Thread filter clockwise onto bracket and tighten securely by hand Do not use a filter wrench Start and run engine Check filter connection for gasoline leaks If leaks exist recheck filter installation If leaks continue stop engine im mediately and contact your Authorized MerCruiser Dealer WARNING Make sure no leaks exist before closing engine hatch CB220 Fuel Pump Sight Tube Inspection 2 The ...

Page 74: ...72 CA70 4 5 71357 71359 1 3 71903 71904 71901 2 ...

Page 75: ...ntrol NOTE If steering cable does not have grease fitting inner wire of cable cannot be greased 2 With steering cable fully extended lubricate exposed part of cable with Special Lubricant 101 3 Lubricate steering system pivot points with SAE 30W motor oil On dual engine boats lubricate all pivot points including tie bar pivot points with SAE 30W motor oil CA72 SHIFT CABLE 4 Lubricate pivot points ...

Page 76: ...74 CA74 6 70558 71569 8 ...

Page 77: ...pped with a sealed engine coupler and Perm a Lube U joints The sealed coupler and shaft splines can be lubricated without removing the drive unit The Perm a Lube U joints do not require lubrication The engine coupler is lubricated with Quicksilver Engine Coupler Spline Grease Contact your Authorized MerCruiser Dealer for this service CAUTION Speedometer water hose must be disconnected from drive u...

Page 78: ...76 CA76 1 2 70560 ...

Page 79: ...oving propeller nut CAUTION Periodically check propeller nut for tightness during boating season A minimum of 55 lbs ft 75 N m torque is required CA78 REMOVAL 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 spline washer continuity washer propell...

Page 80: ...78 CA80 4 5 6 7 8 70134 ...

Page 81: ...th stepped side toward pro peller hub 6 Align splines and place propeller and thrust hub on propeller shaft 7 Place continuity washer spline washer and tab washer onto shaft 8 Install propeller nut Tighten nut securely A minimum of 55 lbs ft 75 N m torque is required Bend three tabs on tab washer down into grooves in spline washer After first use bend the three tabs straight retighten propeller nu...

Page 82: ...80 CA202 1 2 3 70565 71353 70564 71354 4 ...

Page 83: ...IL ER position install flushing attachment and lower drive unit to full down in position 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 With drive unit in normal operating position partially open water tap about 1 2 maximum Place remote control in NEUTRAL idle speed positron and start eng...

Page 84: ...82 CA89 5 1 3 2 6 4 71351 70562 71349 70563 ...

Page 85: ...ur Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage 2 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 3 Power Steering Pump Drive Belt Inspect drive belt for excessive wear or damage 4 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 5 Seawater...

Page 86: ...84 CA204 71335 70578 70577 70576 70033 4 2 3 5 1 73919 ...

Page 87: ...re 1 Universal Anodic Plate serves as a sacrificial anode Remove plug from drive shaft housing to access attaching screw and insert 1 2 inch socket Unthread attaching screw and remove univer sal anodic plate Do not remove screw Install new anodic plate and tighten screw securely Install plug 2 Anodic Plate serves as a sacrificial anode Unscrew both at taching screws and remove Install a new anodic...

Page 88: ...86 CA162 71958 71957 1 2 B ...

Page 89: ...tighten securely CA164 2 Propeller Anode is located in front of the propeller between the front side of the propeller and the gear housing Refer to Propeller section in this manual for propeller removal and installation To re place the propeller anode A Remove propeller B Remove two screws from anode C Install new anode and tighten securely D Reinstall propeller ...

Page 90: ...88 CA93 1 2 71176 3 ...

Page 91: ...observe the following 2 Avoid any electrical interconnection between the MerCruiser Product Anodic Blocks or MerCathode System and the paint by al lowing a minimum of 1 1 2 in 40mm UNPAINTED area on transom of the boat around these items 3 Painting Drive Unit or Transom Assembly Drive unit and tran som assembly should be painted with a good quality marine paint or an anti fouling paint that DOES N...

Page 92: ...90 CA359 1 74807 74820 ...

Page 93: ...e valve is tightly seated in valve cover CA361 Emissions Testing The 350 Magnum EFI Gen engine can be equipped with special de sign features and special tuning to minimize the emission output from the engine If the kit has been installed your engine complies with Stage 1 Bodensee and Swiss Regulations You should follow Recommended maintenance schedules particularly as to the igni tion system Prope...

Page 94: ...92 CA362 71926 4 3 74819 ...

Page 95: ... Remove plugs from both exhaust elbows 3 Install exhaust elbow adapter fittings into elbows Apply Loctite Pipe Sealant with Teflon to threads that go into elbow Tighten it se curely 4 Insert exhaust probes into fittings and tighten securely The testing agency will connect their adapters and test equipment to the probes to conduct the test Once the test is complete remove the test probes and fittin...

Page 96: ...ries also produce hy drogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmo sphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an ex plosion which may shatter the battery and could cause blind ness or other serious injury Safety glasses and rubber gloves are recommende...

Page 97: ...n CA105 Inspection And Maintenance Inspect power package often and at regular intervals to help main tain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts Check for loose damaged or missing parts hoses and clamps tight en or replace as required Check plug leads and electrical le...

Page 98: ...THIS PAGE IS INTENTIONALLY BLANK 96 CA175 ...

Page 99: ...seawater pickup pump as pump im peller may be damaged and subsequent overheating damage to engine or stern drive unit may result IMPORTANT Before starting engine a water source must be at tached to the seawater intake openings in gear housing Follow all warnings and flushing attachment procedures stated in FLUSHING COOLING SYSTEM 1 Run engine sufficiently to bring it up to normal operating tempera...

Page 100: ...98 CA192 3B 74107 ...

Page 101: ...ator tank E Shut off the fuel supply to the engine s fuel pump F Start and run engine at idle speed until the vapor separator tank and fuel injection system are empty and engine stops 4 Fill fuel tank s with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat gasoline Follow instructions on container 5 If boat is to be...

Page 102: ...100 CB232 2 2 74158 71332 3 ...

Page 103: ... result in trapped water causing freeze and or corro sion damage to engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from cylinder block as follows A Port Side from cylinder block B Starboard Side from Y fitting Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sen sor in the upper hole of t...

Page 104: ...102 CA193 5 7 8 71334 71216 74108 6 ...

Page 105: ...eawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is rec ommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 7 Make sure gear housing water drain holes are open 8 For additional assurance against freezing and rust remove ther mostat cover and...

Page 106: ...l system damage will result 2 Install fully charged battery Clean battery cable clamps and ter minals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat terminal connections with a battery terminal anti corrosion agent 4 Perform all checks in OPERATION CHART in the BEFORE STARTING column CAUTION Refer to FLUSHING COOLING SYSTEM before starting en...

Page 107: ...neu tral position Open circuit breaker or blown fuse Loose or dirty electrical connections or damaged wiring Bad battery Turn switch on Position control lever in neutral Check and reset circuit breaker or replace fuse Check all electrical con nections and wires espe cially battery cables Clean and tighten faulty connection Test and replace if bad ...

Page 108: ...ked or clogged EFI System fault Read starting procedure Fill tank or open valve Check sight tube for fuel Have Authorized Mer Cruiser Dealer replace pump if fuel is present Do not attempt to start en gine for at least 5 minutes Refer to STARTING PRO CEDURES Service ignition system Replace filter If contaminated drain tank Fill with fresh fuel Replace kinked lines or blow out lines with com pressed...

Page 109: ... system checked 107 Engine Runs Rough Misses And Or Backfires Possible Cause Remedy Idle speed too low Faulty ignition system com ponent Clogged fuel filters Stale or contaminated fuel Kinked or clogged fuel line or fuel tank vent line Flame arrestor plugged with foreign material EFI system fault Have EFI system checked by an Authorized Mer Cruiser Dealer Service ignition system Replace filters If...

Page 110: ...oor condition Seawater pickups ob structed Faulty thermostat Faulty seawater pickup pump Seawater discharge re stricted or plugged Open Replace and or adjust belt Remove obstruction Replace Repair Clean exhaust elbows Insufficient Engine Temperature Possible Cause Remedy Faulty Thermostat Replace ...

Page 111: ...ade and vis cosity oil Determine cause for dilution excessive id ling faulty fuel pump etc Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery Loose or dirty electrical connections or damaged wiring Alternator drive belt loose or in poor condition Unacceptable battery con dition Turn off non essential ac cessories Check all associated elec trical connection...

Page 112: ...ized MerCruiser Dealer immediately Remove obstruction Straighten cable or have dealer replace cable if damaged beyond repair Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level Drive belt loose or in poor condition Insufficient lubrication on steering system compo nents Loose or missing steering fasteners or parts Contaminated power steering fluid Refill sy...

Page 113: ...eplace fuse Check all associated elec trical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move Possible Cause Remedy Trim pump oil level low Drive unit binding in gimbal ring Fill pump with oil Check for obstruction ...

Page 114: ...anty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service dur ing this period present the temporary registration card to the deal er He will...

Page 115: ...aler may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registra tion Card from your distributor dealer If you receive a plas...

Page 116: ...orkman ship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of mainte nance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other competi...

Page 117: ... Warranty claims will not be accepted without presentation of the Warranty Registration Card VI Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workman ship as covered by this Warranty We reserve the ri...

Page 118: ...val of parts or 6 Water entering engine cylinder s through exhaust system or carbure tor s III Reasonable access must be provided to the Product for war ranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replace ment of boat part...

Page 119: ...l be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obli gation to modify any Product previously manufactured VII ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS...

Page 120: ...of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below II This warranty shall become effective upon receipt of a com pleted standard Product warranty registration card and shall re main effective for a period of three years from the date of pur chase III This...

Page 121: ...ghts and you may also have other legal rights which vary from state to state or country to country VI Other details of this warranty are contained in paragraphs IV V and VI of the United States and Canada Product Warranty and paragraphs III IV V and VI of the International Product Warranty contained in this manual which paragraphs are in corporated herein by reference Mercury Marine products are b...

Page 122: ...on damage that results from the improper application of copper base paint will not be covered by this limited warranty TRANSFER OF WARRANTY This Limited Warranty is transferable to subsequent purchasers for the remainder of the unused portion of the 3 year limited warranty Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warrant...

Page 123: ...sted by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an Authorized Dealer may be cov ered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work perfo...

Page 124: ...here lead is thrown out of commutator because of ex cess cranking Valve or valve seat grinding required because of wear Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material block ing inlets or power package being mounted too high Use of fuels and lubricants which are not suitable for use with or on the product Our limited warr...

Page 125: ...a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 A new Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file There is no charge ...

Page 126: ...ion Plan provides cov erage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q Guard Product Protection Plan is the only Factory Plan available for your engine Two three or four year term plans can be purchased up to 180 days after the original engine purchase date See your participating MerCruiser dealer for complete program ...

Page 127: ...uthorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Parts And Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accesso ries should be directed to your local Author...

Page 128: ...P ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Misunderstandings or complaints can be quickly resolved by the dealer If you are unable to obtain satisfaction contact the dealer ship s owner STEP TWO IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN CONTACT YOUR NEAREST MERCRUISER SERVICE CENTER Provide the following important information Your name address and...

Page 129: ... SOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT United States MERCRUISER 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 Canada Contact Nearest Regional Service Center Other Countries Contact the Nearest Marine Power International Service Center The customer service representatives will review all the facts in volved If they feel some further action can be taken they wil...

Page 130: ...uga Ontario L4Y 2C2 Canada Telephone 905 270 4481 Fax 905 270 4510 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 11 Fax 32 87 31 19 65 ...

Page 131: ...Fax 61 3 791 5880 ASIA Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 ...

Page 132: ...d P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Ma rine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s ...

Page 133: ...Thermostat Gaskets 27 47510 27 53045 1 27 47510 27 53045 1 Alternator Belt 57 48120A1 57 48120A1 Power Steering Belt 57 37619T 57 37619T Water Pump Belt 57 74271T 57 74271T Water Separating Filter 35 807172 35 807172 Quicksilver Motor Oil 92 816096A12 92 816096A12 Storage Seal 92 86145A12 92 86145A12 Valvtane Plus 92 17955A12 92 17955A12 Gasoline Stabilizer for Marine Engines 92 817529A12 92 81752...

Page 134: ... Drain Screw 10 14834 Drain Screw O Ring 19183 Vent Screw 10 79953 Vent Screw O ring 12 19183 Drive Mounting Gasket 27 64818A3 Drive Mounting O ring 27 35982 Trim Pump 20 Amp Fuse 88 79091 Trim Pump 10 Amp Fuse 88 79023A10 Water Pump Impeller 47 43026 2 Water Pump Cover Gasket 27 817227 Water Pump Base Gasket 27 43033 1 2 4 C Marine Lubricant with Teflon 92 825407A3 U Joint and Gimbal Bearing Grea...

Page 135: ...sembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Manual Part Number Official Use Only Qty Price Each Total Price Service Manual Engine 90 30 00 Service Manual Drive 90 30 00 Service Manual Remote Control 90 30 00 Parts Manual En...

Page 136: ...se Return with Payment to Mercury Marine Attn Publications Dept P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print or Type This is your Shipping Label Name Address City State Zip METHOD OF PAYMENT NO CASH OR C O D Personal Check Cashiers Check Money Order Visa MasterCard ...

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