MerCruiser 350 Magnum MPI Operation & Maintenance Manual Download Page 2

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CC142

IDENTIFICATION RECORD

PLEASE RECORD THE FOLLOWING INFORMATION:

Engine Model, Horsepower

Engine Serial Number

Transmission Models

Transmission Serial Number

Propeller Number

Pitch

Diameter

Hull Identification Number (HIN)

Purchase Date

Boat Manufacturer

Boat Model

Length

Serial Numbers

The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your MerCruiser
power package. When contacting your Authorized MerCruiser Dealer about service, always specify model and
serial numbers.

(NOTE: The numbers seen on illustrations are reference for numbered items above)

74192

Summary of Contents for 350 Magnum MPI

Page 1: ...OPERATION MAINTENANCE MANUAL 1995 Brunswick Corporation 350 Magnum MPI Tournament Ski 90 806906960 595 ...

Page 2: ...ntification Number HIN Purchase Date 6 Boat Manufacturer Boat Model Length Serial Numbers The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers 2 1 3 2 4 5 NOTE The numbers seen on illustrations are reference for numbered item...

Page 3: ...len Power Package 10 Replacement Service Parts 10 Do It Yourself Maintenance Suggestions 11 Diagnosing EFI Problems 11 20 Hour Break In Period 12 After Break In Period 12 20 Hour Checkup 12 Operation 14 Instrumentation 15 Audio Warning 17 Electrical System Overload Protection 19 Remote Controls Panel Mounted 21 Starting Shifting And Stopping 22 Operation Chart 23 Specifications 24 Fuel Recommendat...

Page 4: ...5 Warranty Coverage 66 Warranty Does Not Apply To The Following 66 Transferable Warranty 67 Direct Sale By Owner 67 Q Guard Product Protection Plan 68 United States and Canada Only 68 Owner Service Assistance 68 Local Repair Service 68 Service Away From Home 68 Parts and Accessories Inquiries 68 Resolving a Problem 69 Service Centers 70 Customer Service Literature 71 General Maintenance Parts 72 E...

Page 5: ...companied by the Inter national Hazard Symbol may be used to alert the installer user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special in structions while performing the service plus comm...

Page 6: ...yard moves far enough away from the operator s position to activate the switch This would occur if the operator falls or moves within the boat a sufficient distance from the operator s position This type of accident is most likely in certain types of boats such as low sided boats and high performance boats It is also likely as a result of poor operating practices such as sitting on the back of the...

Page 7: ...roof storage containers 6 Manual bilge pump and extra drain plugs compass and map or chart of area 7 Spare operating equipment batteries bulbs fuses etc 8 Transistor radio 9 Drinking water Know signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you expect to return Passenger boarding Stop the engine whenever passengers are boarding unload...

Page 8: ...ts or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed Always slow down and exercise extreme...

Page 9: ... coming 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 bottom should be observed Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts the water Straight and smooth fore and a...

Page 10: ...s speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less tha...

Page 11: ...at the MerCruiser power package and other equipment are in proper operating condition Make all necessary adjustments for maximum efficiency Familiarize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat At the time of delivery the dealer should provide you with a copy of a Predelivery Inspection Checklist Your selling dealer should fill out...

Page 12: ...result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks if they existed Marine engines are expected to operate at or near full throttle for most of t...

Page 13: ...able to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or request the repair procedure It is difficult fo...

Page 14: ...kcase with correct oil see SPECIFICATIONS CA211 After Break In Period To help extend the life of your MerCruiser power package the following recommendations should be considered Use a propeller that allows the engine to operate at or near the top of the maximum RPM range See Specifica tions section when at full throttle with a normal boat load Operation at 3 4 throttle setting or lower is recommen...

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Page 16: ...14 CC93 Operation 70514 70515 70516 70523 70517 70522 70518 70521 70519 1 2 3 4 5 6 7 8 9 ...

Page 17: ...tes boat speed 2 Tachometer indicates engine RPM 3 Oil Pressure Gauge indicates engine oil pressure 4 Battery Meter indicates battery voltage 5 Water Temperature Gauge indicates engine operating temperature 6 Fuel Gauge indicates fuel tank volume 7 Hour Meter records engine running time 8 Bilge Blower Switch must be operated for five minutes to ventilate bilge 9 Ignition Switch allows operator to ...

Page 18: ...16 CC180 70516 1 2 3 72957 70518 ...

Page 19: ...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 immediately Investigate cause and correct it if pos sible If cause cannot be determined consult your Authorized MerCruiser Dealer IMPORTANT Warning buzzer will sound for 2 seconds when ignition key is turned to RUN position ...

Page 20: ...18 CC254 70525 1 4 3A 3B 71583 3C 71585 2 72852 ...

Page 21: ...an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or disconnect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 3 There are three fuses located in the fuel injection system electric...

Page 22: ...20 CC166 1 3 2 4 5 73866 ...

Page 23: ...fety warning on the use of this switch 4 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the ten sion on the control handle This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 5 Control Handle Operation of the shift and throttle are controlled...

Page 24: ...n as engine starts return throttle to the idle position 4 Turn ignition key to START Release key when engine starts and allow switch to return to RUN position 5 Check oil pressure gauge immediately after engine starts If oil pressure is not within specified range see SPECIFICATIONS stop engine immediately and determine cause 6 After engine has warmed up check water temperature gauge to ensure that...

Page 25: ...ine Turn ignition key OFF Turn battery switch ON if so equipped Check for fuel oil water fluid and exhaust leaks etc Operate bilge blowers if so equipped Check shift and throttle control operation Close fuel valve if so equipped Open fuel shutoff valve if so equipped Check steering operation Close seacock if so equipped Open seacock if so equipped Flush cooling system if in a saltwater area Perfor...

Page 26: ...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 MerCruiser eng...

Page 27: ...ected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration re quires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency ...

Page 28: ...ovide maximum protection we strongly recommend the use of Quicksilver 4 Cycle Marine Engine Oil If not available a good grade straight weight detergent automotive oil of correct viscosity with an API classification of SG CD II may be used The chart below is a guide to crankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not av...

Page 29: ...kPa Oil Pressure 2000 RPM 4 psi 28 kPa Min Oil Pressure Idle 160 F 71 C Thermostat 1 Power Rated in Accordance with NMMA Procedure Using Marine Engine Rating Code SAE J1228 Technically Identical to ISO 3046 and ICOMIA 28 83 2 Engine Rated with Velvet Drive 1 1 In Line Transmission Power Output with Other Transmissions Will Be Less 3 Engine is equipped with an RPM Rev Limiter This limiter is design...

Page 30: ...ring Order Recommended Battery 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 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 350 MAGNUM MPI TOURNAMENT SKI ...

Page 31: ...pacity w New Filter 15 Qts 14 2L Seawater Cooling System2 Transmission1 Velvet Drive 1 1 2 Qts 1 9L 1Always use dipstick to determine exact quantity of oil required 2Seawater Cooling System capacity information is for winterization use only 350 MAGNUM MPI TOURNAMENT SKI ...

Page 32: ...30 CC233 Maintenance 71459 1 2 2 4 5 3 6 74192 5 ...

Page 33: ...ry before working around electrical system components to prevent injury to yourself or damage to electrical system IMPORTANT Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be per formed Some listings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempting maintenance or repair procedures not covered in thi...

Page 34: ...Oil Check level Seawater Strainer Check and clean Water Pickups Check for marine growth or debris Cooling System flush seawater section Drive Belts inspect condition and check tensions Power Package Exterior Surfaces clean and paint Battery Check level and inspect for damage Power Package Exterior Surfaces spray with Quicksilver Corrosion Guard Before Use and Whenever Insufficient Seawater Flow is...

Page 35: ...ation or Once Yearly Whichever Occurs First After first 20 hours then every 100 hours of operation thereafter 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 At First 20 Hours of Operation 20 Hour Checkup NOTE 1 Seawater Pickup Pump Disassemble and Inspect Whenever Insufficient Seawater Flow ...

Page 36: ...34 CC224 3 70543 2 4 5 71419 73749 74176 74192 ...

Page 37: ...evel is below ADD 4 Remove oil filler cap Add specified oil to bring level up to but not over FULL mark on dipstick IMPORTANT Do not overfill crankcase oil CHECKING TRANSMISSION FLUID IMPORTANT Engine must be run at 1500 RPM for 2 minutes immediately prior to checking level 5 Borg Warner Transmissions Stop engine and quickly check fluid level by turning T handle counterclockwise to remove dipstick...

Page 38: ...36 CC225 3 2 1 73684 71344 ON OFF 74176 74195 ...

Page 39: ... connected near the engine thermo stat housing Remove fitting from end of hose Lower hose into appropriate container and allow oil to drain When oil has drained completely reinstall fitting in end of hose and and secure hose to engine using the attached clip 2 Turn oil filter counterclockwise to left remove and discard old oil filter and old sealing ring Coat sealing ring on new filter with motor ...

Page 40: ...38 CC226 3 2 4 70659 71457 1 74174 1 74183 ...

Page 41: ...nd linkages must position transmission shift lever so that it is fully in the forward and reverse gear detent positions with the lever over the letter F on transmission case when propelling boat forward IMPROPER POSITIONING OF SHIFT LEVER MAY CAUSE TRANSMIS SION TO FAIL Damage caused to transmission as a result of improper shift lever positioning will not be covered by Velvet Drive Transmission Wa...

Page 42: ...40 CC232 1 71170 71118 3 74192 ...

Page 43: ...estarted to prevent contaminated water from flowing back into engine To prevent silt and or salt buildup in cooling system flush with freshwater at specified intervals 1 Disconnect water inlet hose Lower hose from aft end of seawater pickup pump 2 Using appropriate connector connect hose between connector and water tap Partially open water tap about 1 2 maximum Place remote control in NEUTRAL idle...

Page 44: ...42 CC231 Maintenance continued 1 70562 2 71349 74192 ...

Page 45: ...ernator drive belt and seawater pickup pump drive belt If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 2 Seawater Pump Drive Belt Inspect drive belt for excessive wear or da...

Page 46: ...44 CC374 2A 2 70573 1 73694 1B 1A 3 74637 ...

Page 47: ...and highly explo sive under certain conditions Be sure ignition key is OFF Do not smoke or allow spark or open flame in area when changing fuel filter Wipe up any spilled fuel immediately Make sure no fuel leaks exist before closing engine hatch 2 Remove water separating fuel filter by turning counterclockwise and sealing ring from mounting bracket and discard Coat sealing rings on new filter with...

Page 48: ...46 CC69 1 71449 70140 70057 2 3 4 5 6 2 3 4 6 5 TYPICAL FRONT MOUNT TYPICAL REAR MOUNT ...

Page 49: ...t After alignment is correct tighten securely 3 Adjusting Nut Turning nut clockwise lowers engine IMPORTANT Both front mounts or rear mounts adjusting nuts must be turned equally to keep engine level from side to side 4 Clamping Screw s and Nut s Loosen to allow sideways movement of engine After alignment is correct tight en securely NOTE Some rear mounts have two clamping screws and nuts on each ...

Page 50: ...THIS PAGE IS INTENTIONALLY BLANK 48 ...

Page 51: ...ng are explosive When charging batteries be sure battery compartment or area where batteries are located is well vented Battery electrolyte is a corro sive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body im mediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible CC71 Bottom Of Boat To maintain maxi...

Page 52: ...50 CC228 3B 74179 ...

Page 53: ...move the vapor separator tank plug in the following procedure Also hold a clean shop towel over the plug when removing it to help avoid fuel spraying on the engine 3 Prepare fuel system for extended storage as follows A Allow engine to cool down B Remove plug from top of vapor separator tank C Add approximately 1 fluid ounce 30 ml of Quicksilver 2 Cycle Outboard Oil to fuel in the vapor separator ...

Page 54: ...52 CC229 71170 7 71758 8 2A 3 6 4 71334 2B 74165 74140 ...

Page 55: ...It may be necessary to lift or bend hoses to allow water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow engine to start Loosen hose clamps and disconnect the following hoses 6 From engine circulating pump 7 From seawater pickup pump both hoses After cooling system has drained completely coat drain plug threads with Quicksilver Perfect...

Page 56: ...ical system damage will result Install fully charged battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Secure each cable clamp when connecting Coat terminal connections with a battery terminal anti corrosion agent Perform all checks in OPERATION CHART in the BEFORE STARTING column CAUTION Refer to precautions listed under FLUSHING COOLING SYSTEM before ...

Page 57: ...to start Improper starting procedure Empty fuel tank or fuel shut off valve closed if so equipped Faulty fuel pump Engine flooded Faulty ignition system com ponent Clogged fuel filters Contaminated fuel Fuel line or tank vent line kinked or clogged Review starting procedure under Operation Instructions Fill tank or open valve Check sight tube for fuel Have your dealer re place pump if fuel is pres...

Page 58: ...an flame arrestor Inspect cable and linkages for binding ob struction or loose fasteners Replace Drain and check for cause of entry Reduce load or redistribute load more evenly Clean or repair as necessary Clean flame arrestor Excessive engine temperature Engine overheating Ignition or EFI System fault See Excessive engine temperature Refer to Engine runs rough misses and or backfires Water inlet ...

Page 59: ...r replace if damaged Maintain fluid level Inspect shift linkages and shift lever positioning Straighten hoses or replace if damaged Turn off non essential accessories Excessive trans mission fluid temperature or slipping trans mission Loose or dirty electrical connec tions or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty con...

Page 60: ...58 CC163 Water Flow Diagram 73854 ...

Page 61: ...Power for a Fused Accessory Panel May Be Taken from This Connection Load Must Not Exceed 40 Amps Panel Ground Wire Must Be Connected to Instrument Terminal That Has an 8 Gauge BLACK Ground Harness Wire Connected to it NOTE 3 Taped back BROWN WHITE wire may be used for an accessory LOAD MUST NOT EXCEED 5 AMPS 73371 NOTE 1 2 BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PUR...

Page 62: ...ction Circuit C Instrumentation Senders 1 Harness Connector To EFI System Harness 2 Positive Power Wire To EFI System Harness 3 Auxiliary Tachometer Lead BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK 1 2 3 A B C 90 Amp Fuse ...

Page 63: ...e 10 Amp ECM Injector Ignition Knock Module 18 Harness Connector To Starting Charging Harness 19 Harness Connector To Lanyard Stop Switch Optional 20 Harness Connector For Dual Engine Data Link Cable 21 Positive Power Wire To Engine Circuit Breaker 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 BLK BLACK BLU BLUE BRN BROWN GRN GREEN GRY GRAY ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WH...

Page 64: ...out the Warranty Registration Card completely and mails it to the dis tributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and address product model and serial number s date of sale type of use and the selling distributor s dealer s code number name and address The distributor...

Page 65: ... Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho rized to service the Purchaser s product If purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Company We shall then arrange for the inspection and repair provided such service is covered under this warranty Purchaser shall pay for all related ...

Page 66: ...tributor shall then arrange for the inspection and repair provided such service is covered under this warranty Pur chaser shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Any Product or parts shipped by purchaser for inspection...

Page 67: ...LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU V This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state or country to country VI Other details of this warranty are contained in paragraphs IV V and VI of the United States and Canada Product Warranty and paragraphs III IV V and VI of the International Product Warranty contained in this man...

Page 68: ...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 per formed at this facility All incidental and or consequential damages storage charges telephone or rental charges of any type incon venience or loss of time or income are the owner s responsibility Use of other than Quicksilver replacement parts when ...

Page 69: ... 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 70: ...ur engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for MerCruiser stern drives and inboards Service Away From Home If you are away from your local dealer and the need arises for service contact the nearest Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cann...

Page 71: ...Propeller pitch and or part number Normal use and approximate gross load Please bear in mind that Service Centers resolve all problems through the dealership using the dealer s facili ties equipment and personnel This is the reason we request you use the preceding steps in sequence when you have a problem or complaint Our experience has shown that this is the most expedient and successful proce du...

Page 72: ...ga 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 4822 Verviers Belgium Telephone 0 87 32 32 11 Fax 32 87 31 19 65 ...

Page 73: ... Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 Customer Service Literature English language publications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Marine Power International Service Center for further i...

Page 74: ... Wire Set 816608A68 Thermostat 160 F 807252 2 Thermostat Gaskets 27 47510 27 53045 1 Alternator Belt 57 48120A1 Water Pump Belt 57 13457T Water Separating Filter 35 807172 Quicksilver Motor Oil 92 816096A12 Storage Seal 92 86145A12 Valvtane Plus 92 17955A12 Gasoline Stabilizer For Marine Engines 92 817529A12 Fuel System Cleaner 92 17885A12 Corrosion Guard Spray 92 815869A12 ...

Page 75: ...nd disassembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance 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 M...

Page 76: ...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 74 METHOD OF PAYMENT NO CASH OR C O D Personal Check Cashiers Check Money Order Visa MasterCard ...

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MerCruiser 350 Magnum MPI, Operation & Maintenance Manual

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