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Section 5 - Maintenance

90-864839061 NOVEMBER 2006

Page 67

Owner/Operator Responsibilities

It is the operator's responsibility to perform all safety checks, to ensure that all lubrication

and maintenance instructions are complied with for safe operation and to return the unit to

an authorized Mercury MerCruiser dealer for a periodic checkup.
Normal maintenance service and replacement parts are the responsibility of the owner/

operator and as such, are not considered defects in workmanship or material within the

terms of the warranty. Individual operating habits and usage contribute to the need for

maintenance service.
Proper maintenance and care of your power package will ensure optimum performance

and dependability and will keep your overall operating expenses at a minimum. See your

authorized Mercury MerCruiser dealer for service aids.

Dealer Responsibilities

In general, a dealer's responsibilities to the customer include predelivery inspection and

preparation such as:
• Ensure that the boat is properly equipped.
• Prior to delivery, make certain that the Mercury MerCruiser power package and other

equipment are in proper operating condition.

• Make all necessary adjustments for maximum efficiency.
• Familiarize 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

Avoid product damage, injury, or death from electrical shock, fire or explosion. Always

disconnect both battery cables from the battery before servicing the power package.

!

WARNING

Fuel vapors can be present in the engine compartment. Avoid injury or power package

damage caused by fuel vapors or explosion. Always ventilate the engine compartment

prior to servicing the power package.

IMPORTANT: Refer to the maintenance schedule for complete listing of all scheduled

maintenance to be performed. Some listings can be done by owner/operator, while others

should be performed by an authorized Mercury MerCruiser dealer. Before attempting

maintenance or repair procedures not covered in this manual, it is recommended that a

Mercury MerCruiser Service Manual be purchased and read thoroughly.

NOTE: Maintenance points are color coded for ease of identification. See the decal on

engine for identification.

Maintenance Point Color Codes

Blue

Coolant

Yellow

Engine Oil

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Summary of Contents for 496 MAG Bravo

Page 1: ...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 be insta...

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 2006 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...0 hours of engine run time 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...

Page 4: ... 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 chemicals known to the state of California to cause cancer birth defects or other reproductive harm ...

Page 5: ...abel 15 Owner Responsibility 16 Emission Certification Star Label 16 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal 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 Mou...

Page 6: ... 56 Bottom Of Boat 56 Cavitation 56 Ventilation 56 Elevation And Climate 57 Propeller Selection 57 Getting Started 57 20 Hour Break In Period 57 After Break In Period 58 End of First Season Checkup 58 Section 4 Specifications Fuel Requirements 60 Fuel Ratings 60 Using Reformulated Oxygenated Gasolines USA Only 60 Gasolines Containing Alcohol 60 Engine Oil 61 Engine Specifications 496 61 Engine Spe...

Page 7: ...03 Corrosion Information 103 Maintaining Ground Circuit Continuity 103 Anodes and MerCathode System Locations 103 Checking the Quicksilver MerCathode System 104 Power Package Exterior Surfaces 105 Boat Bottom Care 105 Anti fouling Paint 105 Sterndrive Surface Care 107 Flushing the Power Package 108 Flushing Attachments 108 Sterndrive Water Pickups 109 Alternative Water Pickups 111 The SeaCore Powe...

Page 8: ...Does Not Operate Motor Does Not Operate 133 Power Trim Does Not Operate Motor Operates But Sterndrive Unit Does Not Move 133 Section 8 Customer Assistance Information Owner Service Assistance 136 Local Repair Service 136 Service Away From Home 136 Stolen Power Package 136 Attention Required After Submersion 136 Replacement Service Parts 136 Parts And Accessories Inquiries 137 Resolving A Problem 1...

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

Page 10: ...urned 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 clai...

Page 11: ...ing 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 s...

Page 12: ...ed 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 Limited Warranty for Standard Models which do not include Horizon Sterndrive and Inboard Models MX 6 2 Black Scorpion Tow Sport Models or SeaCor...

Page 13: ...e purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any covered repair The purchaser in that case shall pay for all related transportation charges and travel time If the service provided is not covered by this warranty the purchaser shall pay for all related labor and material and any other e...

Page 14: ...nt noncommercial use purchaser upon proper re registration of the product Warranty coverage is terminated for used product repossessed from a retail customer purchased at auction from a salvage yard or from an insurance company that obtained the product as a result of an insurance claim Condition That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail cu...

Page 15: ... to distribute the product in the country in which the sale occurred and then only after the pre delivery inspection process specified by Mercury Marine is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation Maintenance Warranty manual must be in use on the boat and rou...

Page 16: ...Non Certified Boat Brand Certified Boat Brand All Boat Brands Region Standard SeaCore Horizon 6 2 Scorpion Standard SeaCore Horizon 6 2 Scorpion Standard and Horizon SeaCore USA and Canada 1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years Latin America 1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years Mexico 1 year 3 years 1 year 1 year 1 yea...

Page 17: ... 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year ...

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

Page 19: ...Certification 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 ...

Page 20: ...ted 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...

Page 21: ...er 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 associa...

Page 22: ...d 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 stringent anti smog standards Mercury Marine must warrant the emission control system on your inboard or sterndrive engine for the periods of time listed below provided there has be...

Page 23: ...nty 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 Control Information Label A tamper resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser ...

Page 24: ...ification 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 envir...

Page 25: ...es 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 emissio...

Page 26: ...Section 1 Warranty Notes Page 18 90 864839061 NOVEMBER 2006 ...

Page 27: ...ole Mount Features 27 Zero Effort Features 28 Remote Controls DTS Models 28 Remote Controls 28 Panel Mount Features 29 Console Mount Features Single Engine 30 Slim Binnacle Console Mount Features Single Engine 31 Console Mount Features Dual Engine 32 Synchronizing Dual Engines 33 Dual Helm Station Transfer 33 Synchronizing Dual Helms Prior To Station Transfer 34 Zero Effort Features 34 Power Trim ...

Page 28: ...nd serial numbers Engine Serial Number Decal The serial number decal is located on top of the engine 25902 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: ...back 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: ...e 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 p...

Page 31: ... 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 Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connec...

Page 32: ...peed 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 r...

Page 33: ...uge 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 Rec...

Page 34: ...arting 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 ne...

Page 35: ...handle Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Control Handle Tension Adjustment Screw not visible This screw is used to adjust the effort...

Page 36: ...ing the throttle lever back Achieve minimum RPM idle by placing the throttle lever in its full aft position Trim Tilt Switch Refer to Power Trim Remote Controls DTS Models Remote Controls IMPORTANT Your boat must be equipped with a Mercury Marine electronic remote control Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated ...

Page 37: ...pushing 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 ...

Page 38: ... 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 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 th...

Page 39: ... light 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 thr...

Page 40: ...sition 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 Th...

Page 41: ...control 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 eng...

Page 42: ...e 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 ...

Page 43: ...terndrive unit raised Severe damage to the sterndrive unit may result if unit is raised beyond the gimbal ring support flanges 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 bottom C...

Page 44: ...e bar and sterndrives could occur Always raise or lower the sterndrive units evenly Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only Trim without Key Trim without key is a...

Page 45: ...nd corrected before replacing the fuse or resetting the circuit breaker NOTE In an emergency when the engine must be operated and the cause for the high current draw cannot be located and corrected turn off or disconnect all accessories connected to the engine and instrumentation wiring Reset the circuit breaker If the breaker remains open the electrical overload has not been eliminated Further ch...

Page 46: ...side of the engine These fuses protect various Electronic Fuel Injection EFI circuits mc77602 1 4 The main power and fuel pump relays are located next to the fuses and control voltage to the engine with the ignition key in the ON position mc77602 2 5 A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical system Check for blown fuse if the ignition key is turn...

Page 47: ...im Control Panel is further protected by a 20 amp in line fuse mc70527 1 8 The Quicksilver MerCathode System has a 20 amp in line fuse in the wire which connects to the positive terminal on controller If the fuse is blown the system will not operate resulting in a loss of corrosion protection mc79977 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning S...

Page 48: ... engine power when a potential problem is sensed by the ECM Engine Guardian monitors Oil pressure Coolant temperature Seawater pressure Engine overspeed Exhaust Manifold Temperature 8 1 liter 496 cid engines only Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails For example if the water inlet becomes partially blocked Engin...

Page 49: ...Section 2 Getting to Know Your Power Package 90 864839061 NOVEMBER 2006 Page 41 In addition depending on the gauge package there will be warning icons and fault messages on the dash mounted gauges ...

Page 50: ...Section 2 Getting to Know Your Power Package Notes Page 42 90 864839061 NOVEMBER 2006 ...

Page 51: ...ng the Engine 50 Stopping the Engine 51 Throttle Only Operation 51 Trailering the Boat 52 Freezing Temperature Operation 52 Drain Plug and Bilge Pump 52 Protecting People In The Water 52 While You Are Cruising 52 While Boat Is Stationary 52 High Speed And High Performance Boat Operation 53 Passenger Safety In Pontoon Boats And Deck Boats 53 Boats Having An Open Front Deck 53 Boats With Front Mount...

Page 52: ...y 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 si...

Page 53: ...r 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 in...

Page 54: ... 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 to launching boat ...

Page 55: ...r boat builder Listen for Audio Warning Alarm to sound when the ignition switch is in the ON position Starting and Stopping the Engine NOTE Only perform those functions applicable to your power package STARTING THE ENGINE 1 Check all items listed in the Operation Chart 2 Place the remote control handle in neutral CAUTION Overheating from insufficient cooling water will cause engine and drive syste...

Page 56: ...nd pull repeatedly on the remote control handle until handle returns to the neutral idle position This may take several tries if the power package was operating above idle RPM when the engine stopped 2 After the handle returns to the neutral idle position resume normal starting procedures Throttle Only Operation 1 Refer to Remote Controls section for remote control features 2 Move the control leve...

Page 57: ...r boat from a steep ramp enter the water slowly Do not use the lanyard stop switch to shut off the engine above idle speed When coming off plane if a large following wave may roll over the boat s transom apply a short light burst of throttle to minimize the wave action against the stern of the boat Do not come off plane quickly and then shut off the engine Also avoid shifting into reverse while on...

Page 58: ...starting process When the start button is pushed the DTS system signals the engine PCM to start the engine If the engine does not start the starting process times out after eight seconds or when the engine reaches 400 RPM Attempting to start the engine with the engine already running will turn the engine off 3 Turn ignition key to RUN position 4 Turn the ignition key switch to the START position t...

Page 59: ...ral mode the DTS Control System will not allow the engine speed to increase above 3500 RPM Zero effort remote controls Zero effort remote controls have seperate throttle control and shift control levers Advancing the throttle control lever beyond the idle position while the shift control lever is in the neutral position will cause engine speed to increase but only up to the maximum neutral engine ...

Page 60: ...on boats are normally equipped with a drain plug and or a bilge pump It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package Components on your engine will be damaged if submerged Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty Protecting People In The Water While You Are Cr...

Page 61: ...sharp change of boat direction could throw them over the front of boat Falling over the front of the boat between the two pontoons will position them to be run over Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or p...

Page 62: ...oat to launch off of a wave or wake If the bow of your boat pitches down far enough while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occupants flying forward The boat may also veer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution wh...

Page 63: ...is necessary do so at greatly reduced speeds WARNING Avoid serious injury or death from loss of boat control Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts Have the power package thoroughly inspected and any necessary repairs made Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protecti...

Page 64: ...ere it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when the boat is docked This growth must be removed before operation it may clog the water inlets and cause the engine to overheat Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object such as a gear housing or a propeller Cavitation permits the propeller ...

Page 65: ...opeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal...

Page 66: ...sure that propeller allows the engine to operate at or near the top of the specified WOT RPM range Refer to Specifications and Maintenance when at full throttle with a normal boat load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at WOT RPM Change the engine oil and oil filter Refer to Maintenance Change the transmission oil and filter Refer to Mainten...

Page 67: ...formulated Oxygenated Gasolines USA Only 60 Gasolines Containing Alcohol 60 Engine Oil 61 Engine Specifications 496 61 Engine Specifications 61 Fluid Specifications 496 62 Fluid Specifications 62 Engine 62 Bravo Sterndrives 62 Power Assisted Steering and Power Trim Fluids 63 Approved Power Assisted Steering Fluids 63 Approved Power Trim Fluids 63 4 ...

Page 68: ...se 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 system components on your Mercury MerCruiser engine will withst...

Page 69: ...icksilver 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 ...

Page 70: ...s 496 Fluid Specifications IMPORTANT All capacities are approximate fluid measures Engine IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines Always use the dipstick to determine the exact quantity of oil or fluid required All Models Capacity Fluid Type Engine oil with filter 8 5 liters 9 U S qt Mercury Quicksilver S...

Page 71: ...ROVED POWER ASSISTED STEERING FLUIDS Description Part Number Power Trim and Steering Fluid 92 858074K01 Dexron III Automatic Transmission Fluid Obtain Locally APPROVED POWER TRIM FLUIDS Description Part Number Power Trim and Steering Fluid 92 858074K01 SAE Engine Oil 10W 30 Obtain locally SAE Engine Oil 10W 40 ...

Page 72: ...Section 4 Specifications Notes Page 64 90 864839061 NOVEMBER 2006 ...

Page 73: ...aning The Flame Arrestor 81 Cleaning The IAC Muffler 82 Water Separating Fuel Filter 496 83 Water Separating Fuel Filter 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 Unit Removed 89 Engine Coupler 89 Engine Coupler 90 Drivesha...

Page 74: ...Section 5 Maintenance Page 66 90 864839061 NOVEMBER 2006 ...

Page 75: ...e 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 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 ...

Page 76: ...e 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 the repair proc...

Page 77: ... 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 the following is reccommended Change the engine oil and filter Change the sterndrive lube EVERY 100 HOURS OR ANNUALLY WHICHEVER OCCURS F...

Page 78: ... damaged 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...

Page 79: ... 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 8481 a a Dipstick tube IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dipstick 3...

Page 80: ...hetic Blend MerCruiser Engine Oil 25W 40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval Engine oil should be changed before placing the boat in storage IMPORTANT Change engine oil when the engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended engine oil refer to Specifications EASY ENGINE OIL DRAIN SYSTEM NOTE...

Page 81: ...rain 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 crankcase oil pump onto an appropriate container and using the handle pump until the crankcase is empty 5 Remove the pump 6 Install the dipstick...

Page 82: ...aise the level from the add mark to the top of the OK range All Models Capacity Fluid Type Engine Oil With Filter 8 5 liters 9 U S Quart Mercury Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 7 Start the engine run the engine for three minutes and check for leaks Stop the engine Allow approximately 5 minutes for the oil to drain into the oil pan The boat must be at rest in the water Powe...

Page 83: ...Power steering fluid does not require changing unless it becomes contaminated with water or debris Contact your authorized Mercury MerCruiser dealer Engine Coolant Checking WARNING Allow the engine to cool down before removing the coolant pressure cap A sudden loss of pressure could cause hot coolant to boil and discharge violently After the engine has cooled turn the cap 1 4 turn to allow any pre...

Page 84: ... cap from the coolant recovery bottle and inspect the gasket Replace the gasket if necessary IMPORTANT This closed cooling system flows coolant at a high rate Higher idle speeds increase dispersion of trapped air into the system making it more difficult to purge trapped air Operate at idle during filling and air purging when specified 2 Fill to the full mark with the specified coolant Tube Ref No ...

Page 85: ...ar 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 operating range Do not...

Page 86: ...ar 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 87: ...e 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 802854A1 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndrive unit...

Page 88: ... 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 Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074...

Page 89: ... 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 engine s electrical system In either case the ECM could shut off When the voltage returns to the range that the ECM requires the ECM will reset itself and the engine will operate n...

Page 90: ...letely 8482 a a Flame arrestor 4 Install flame arrestor Tighten the flame arrestor clamp 5 Install the engine cover Cleaning The IAC Muffler WARNING Avoid gasoline fire or explosion Gasoline is extremely flammable and highly explosive under certain conditions Be careful when cleaning IAC muffler ensure that ignition is off Do not smoke or allow sources of spark or open flame in area when cleaning ...

Page 91: ...ater Separating Fuel Filter WARNING Avoid serious injury or death from a gasoline fire or explosion gasoline is extremely flammable and highly explosive under certain conditions When servicing the fuel system components ensure that the engine is cool the ignition switch is in the off position and that the lanyard stop switch if equipped is in the off position Do not smoke or allow spark or open fl...

Page 92: ...off 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...

Page 93: ...ing screw Description Nm lb in lb ft 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 CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes durin...

Page 94: ...rom 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 802865A1 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 ...

Page 95: ...o 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...

Page 96: ... MerCruiser 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 Fo...

Page 97: ...gine coupler splines through 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 Use...

Page 98: ...ery 150 hours a 6212 Bravo drive coupler a Grease fitting Tube Ref No Description Where Used Part No 91 Engine Coupler Spline Grease Coupler 92 802869A1 NOTE Bravo Models The coupler and shaft splines can be lubricated without removing the sterndrive unit Apply lubricant from a typical hand operated grease gun until a small amount of grease begins to push out Driveshaft Extension Models 1 Lubricat...

Page 99: ...Remote Control must be in neutral and ignition key removed from switch before removing and or installing propeller WARNING A rotating propeller can cause injury Place a block of wood between the anti ventilation plate and the propeller to protect hands from the propeller blades and to prevent the propeller from rotating when removing or installing the propeller nut BRAVO ONE MODELS NOTE Bravo One ...

Page 100: ... Wood block b Propeller c Propeller nut under socket 3 Turn the propeller shaft nut counterclockwise and remove the nut 4 Slide the propeller and the attaching hardware from the propeller shaft a b c d e f g 5301 Bravo One models a Propeller shaft splines b Forward thrust hub c Flo Torque II drive hub d Propeller e Drive sleeve adapter f Tab washer g Propeller nut ...

Page 101: ...els a Propeller shaft b Propeller hub insert with snubbers c Propeller d Thrust washer e Washer f Washer g Propeller nut BRAVO TWO MODELS 1 Straighten the bent tabs of the tab washer on the propeller shaft e c d b a 4750 a Prop b Tab washer c Drive sleeve adapter d Tab bent down e Propeller nut ...

Page 102: ...opeller shaft nut counterclockwise to remove nut 4 Slide the propeller and attaching hardware from the propeller shaft 8566 a b c f d e Bravo Two a Propeller shaft splines b Forward thrust hub c Propeller d Spline washer e Tab washer f Propeller nut BRAVO THREE MODELS 1 Place a block of wood between the propeller blade and the sterndrives anti ventilation plate 2 Remove the bolt and washers securi...

Page 103: ...peller shaft 6 Use the Propeller Nut Tool turn the front propeller shaft nut counterclockwise and remove the nut Propeller Nut Tool 91 805457T 1 10677 Aids in the removal and installation of the front propeller nut 7 Slide the propeller and the thrust hub off the propeller shaft e f a b c d 5304 g h i j Bravo Three a Aft propeller nut b Aft propeller c Aft propeller thrust hub d Front propeller nu...

Page 104: ...er nut a b c 4826 a Wood block b Propeller c Propeller nut under socket BRAVO ONE MODELS IMPORTANT Use the correct rotation propeller The propeller rotation MUST match the direction of rotation of the propeller shaft 1 Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft spline...

Page 105: ...Bravo One XR models a Propeller shaft b Propeller hub insert with snubbers c Propeller d Thick washer e Washer f Washer g Propeller nut NOTE The propeller torque stated is a minimum torque value Description Nm lb in lb ft Bravo One propeller nut 75 55 Then align tabs with grooves NOTE Bravo One XR models do not use the tab washer 4 Models equipped with the tab washer Continue to tighten the propel...

Page 106: ... Quicksilver lubricants Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft splines 92 802865A1 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A1 94 Anti Corrosion Grease Propeller shaft splines 92 802867A1 NOTE Anti corrosion grease is for salt water applications only 2 Install the propeller with the attaching hardware as shown 3 Torque the ...

Page 107: ... Special Lubricant 101 Propeller shaft splines 92 802865A1 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A1 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A1 NOTE Anti corrosion grease is for salt water applications only 2 Slide forward thrust hub onto propeller shaft with tapered side toward propeller hub 3 Align splines and place front propeller o...

Page 108: ...in lb ft Bravo Three rear propeller nut 81 60 8 Install propeller shaft anode and screw and torque e f a b c d 5304 g h i j Bravo Three a Rear propeller nut b Rear propeller c Rear propeller thrust hub d Front propeller nut e Front propeller f Front propeller thrust hub g Propeller shaft anode screw h Flat washer i Star washer j Propeller shaft anode Description Nm lb in lb ft Propeller shaft anod...

Page 109: ...ension 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 R...

Page 110: ...ontains a high tension spring Rapid release of the tensioner or allowing the tensioner to snap back quickly could injure the operator or cause product damage Relieve the spring tension slowly to avoid injury or product damage 1 Use a breaker bar and appropriate socket to hold back the tensioner and relieve the belt tension Rotate the tensioner away from belt until it stops Remove the belt from the...

Page 111: ...t chemically active or anodic to erode This is known as galvanic corrosion For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts Marine Corrosion Protection Guide 90 881813003 Maintaining Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the eng...

Page 112: ...using The MerCathode controler is mounted on the engine or on the boat transom The controler harness connects 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 Props...

Page 113: ...m 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...

Page 114: ...ransom 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 system or items specified by the boat manufacturer CAUTION Improper boat cleaning procedure...

Page 115: ...lever 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 ni...

Page 116: ...ants containing graphite on or near the aluminum in saltwater Do not paint trim tabs or the mounting surface Flushing 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 a...

Page 117: ... 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 CAUTION If flushing the engine with the boat in the water seawater can flow into the engine causing damage The water inlet must be closed when flushing the engine 1 On seawater cooled models Proceed to Ste...

Page 118: ... With the sterndrive in normal operating position open the water source fully 7 Place the remote control in the neutral idle speed position and start engine CAUTION Avoid engine damage from overheating If the engine is operated above 1500 RPM during flushing suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat 8 Depress the throttle only b...

Page 119: ...Contact with moving drive components and the propeller can cause personal injury or death To avoid possible injury remove the propeller and ensure that no people or animals are in the area of the drive unit while flushing b Remove propeller c Install the appropriate flushing attachment over the water inlet holes in the gear housing 3 Connect hose between flushing attachment and water source 4 Clos...

Page 120: ...or to operating engine The SeaCore Power Package Flushing 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...

Page 121: ... equipped 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 184...

Page 122: ...control in neutral idle speed position and start engine CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes 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 f...

Page 123: ...onnect 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 t...

Page 124: ...over 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 125: ...reparation 119 Draining the Seawater System 119 Drain System Identification 120 Air Actuated Single Point Drain System 120 Manual Drain System 121 Air Actuated Single Point Drain System 121 Boat in the Water 121 Boat out of the Water 123 Manual Drain System 125 Boat in the Water 125 Boat out of the Water 126 Draining the Sterndrive 126 Battery Storage 127 Power Package Recommissioning 127 6 ...

Page 126: ...hol is not available Fuel tanks should be drained as low as possible and Mercury Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to Fuel Requirements for additional information 3 Flush the cooling system Refer to the Maintenance section 4 Supply cooling water to engine Refer to the Maintenace section 5 Operate the engine sufficiently to bring it up ...

Page 127: ...eatment and Stabilizer Concentrate Tube Ref No Description Where Used Part No 115 Premium Plus 2 cycle TC W3 Outboard Oil Fuel system 92 802824A1 124 Fuel System Treatment Stabilizer Fuel system 802875A1 2 Allow the engine to cool down IMPORTANT Immediately wipe up any fuel spills or sprays 3 Close the fuel shut off valve if equipped Disconnect and plug the fuel inlet fitting if not equipped with ...

Page 128: ...NT The boat must be as level as possible to ensure complete draining of the cooling system Your power package is equipped with a drain system Refer to Drain System Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure Drain System Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM b c a 82...

Page 129: ...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 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lock pump on the fitting 8293 b d e a c a Actuator fitting b Green indicators c Manua...

Page 130: ...de drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit by pulling the fuse marked CD 10 Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump Do not allow engine to start 11 Remove...

Page 131: ...E WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Place the boat on a lever surface to ensure complete draining of system 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to loc...

Page 132: ...side drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit by pulling the fuse marked CD 10 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump Do not allow engine to start 11 Remove t...

Page 133: ...a 17255 a a Blue drain plug locations 3 Verify that water is draining from each opening 4 Allow the system to drain for a minimum of five minutes Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained 5 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit b...

Page 134: ...n 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 5 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit by pulling the fuse marked CD 6 Crank the engine over slightly with starter motor to purge any water trapped in the...

Page 135: ... the cooling system with propylene glycol mixed to the manufacturer s recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturers instructions be used in the seawater section of the cooling system for freezing temperatures or ...

Page 136: ...ch cable clamp securely when connecting 3 Coat the terminal connections with a battery terminal anti corrosion agent 4 Perform all the checks in the before starting column of the Operation Chart CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes during operation 5 Start the engine...

Page 137: ...To Start 130 Engine Runs Rough Misses And Or Backfires 131 Poor Performance 131 Excessive Engine Temperature 131 Insufficient Engine Temperature 132 Low Engine Oil Pressure 132 Battery Will Not Come Up On Charge 132 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 132 Steering Wheel Turns Hard Or Jerky 132 Power Trim Does Not Operate Motor Does Not Operate 133 Pow...

Page 138: ...gine 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 n...

Page 139: ...r 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 authoriz...

Page 140: ...and 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 thrott...

Page 141: ...attery 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...

Page 142: ...Section 7 Troubleshooting Notes Page 134 90 864839061 NOVEMBER 2006 ...

Page 143: ... Assistance 136 Local Repair Service 136 Service Away From Home 136 Stolen Power Package 136 Attention Required After Submersion 136 Replacement Service Parts 136 Parts And Accessories Inquiries 137 Resolving A Problem 137 Mercury Marine Service Offices 137 Ordering Literature 138 United States and Canada 138 Outside The United States and Canada 138 8 ...

Page 144: ...gned manufactured or installed To minimize risks of fire or explosion electrical ignition and fuel system components on Mercury Marine power products are designed and manufactured to comply with numerous international directives federal regulations voluntary standards and product installation instructions Use or installation of replacement electrical ignition or fuel system components which do not...

Page 145: ...es 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 na...

Page 146: ...ited 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 ...

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